Screen Printed Magnetic Sheet Production via Layer Merging
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Solution Overview
Problem
The existing methods for producing magnetic sheets for electrical machines are complex due to the logistical and manufacturing challenges of handling and processing large numbers of individual components, particularly in thermal processing and pre- and post-treatment steps.
Innovation Solution
A method involving screen printing to create a three-dimensional structure by layering green bodies with a release layer, followed by heat treatment and removal of separating layers to produce planar individual components, allowing for simultaneous processing and reduced thermal steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual magnetic sheets are produced and processed separately, then each sheet can be manufactured with precise control, but the logistical complexity and handling effort increase significantly
Solution Approach 1:
The patent combines multiple individual magnetic sheets into a single integrated green body structure before sintering. This merging approach allows all sheets to be processed simultaneously as one unit, eliminating the need for separate handling, transport, and processing of thousands of individual components, thereby reducing logistical complexity while maintaining manufacturing precision through controlled sintering
Solution Approach 2:
The patent introduces release layers between individual magnetic sheets within the integrated green body. These release layers allow the sheets to be segmented and separated after sintering into individual components, enabling precise control and independent handling of each sheet while having been processed together as a unified structure
2Strength
If each green body is heat-treated and sintered individually, then each magnetic sheet achieves proper densification and mechanical strength, but the processing time and thermal energy consumption increase
Solution Approach 1:
The patent merges multiple green bodies into a single integrated green body that undergoes one unified sintering process. This allows all magnetic sheets to be densified and strengthened simultaneously in a single thermal treatment cycle, reducing total processing time and thermal energy consumption compared to processing each sheet individually while still achieving the required mechanical strength
3Reliability
If thousands of individual magnetic sheets are handled separately, then each component can be inspected and quality-controlled independently, but the handling effort and storage requirements become unmanageable
Solution Approach 1:
The patent combines thousands of individual magnetic sheets into a single integrated green body with manageable dimensions. This merging makes the entire assembly easy to handle, transport, store, and process as one unit, while the internal structure with release layers still allows for quality control and inspection of individual sheets after separation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies handling and processing, reduces logistical complexity, and enhances stacking accuracy and mechanical strength of the magnetic sheets, while maintaining good magnetic properties.
Implementation Method 1
Printing a green body of a first layer using a screen printing process
Implementation Method 2
Heat-treating the three-dimensional structure at a temperature at which a sintering process of the individual layers of the green bodies occurs
Data Source
Figure 1a~2
Figure 3a~3d
Figure 4
AI summary
The invention relates to a method for producing a three-dimensional structure (2) from planar individual components (3, 4), comprising the following steps: a) printing a green body (6) of a first layer (8) using a screen printing process (10), b) applying a separating layer (12) to the green body (6) of the first layer (8), c) printing a second green body (6) of a second layer (14) onto the separating layer (12), d) repeating steps a) to c) until the three-dimensional structure (2) is in a green state (16), e) heat treatment (26) of the three-dimensional structure (2) at a temperature at which a sintering process of the green bodies (6) of the individual layers (8, 14) occurs, f) removing the separating layer (12) so that the three-dimensional structure (2) is formed.