Segmented Rotor Core Blocks for Uniform Resin Injection
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Solution Overview
Problem
Existing methods for manufacturing rotor cores with embedded permanent magnets face challenges in ensuring uniform resin injection and proper alignment of core blocks, leading to inefficiencies and potential performance issues due to unfilled spaces and magnetic flow disruptions.
Innovation Solution
The method involves forming a rotor core by stacking two core blocks with resin injection portions and gate marks on opposite ends, allowing for uniform resin injection and alignment, with the core blocks being designed to maintain a consistent stack state through specific burr and identification code placement, ensuring efficient resin distribution and magnetic flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single core block with long resin injection portion is used, then the rotor core can be manufactured in one piece, but the resin injection becomes non-uniform and unfilled spaces occur
Solution Approach 1:
The rotor core is divided into multiple core blocks, each with its own resin injection portion. This segmentation allows resin to be injected uniformly into each shorter portion, avoiding the non-uniform injection that occurs in long single-piece cores. The core blocks are subsequently stacked to form the complete rotor core.
2Reliability
If gate marks are formed on the resin injection portions, then resin filling can be monitored, but the gate marks may disrupt magnetic flow in the rotor core
Solution Approach 1:
The gate marks are extracted from the inner circumferential surface of the rotor core and placed on the outer circumferential surfaces of the core blocks. This relocation allows resin filling verification to be performed without the gate marks being present in the magnetic field path, thereby eliminating magnetic flow disruption while maintaining the ability to monitor resin filling.
3Strength
If the rotor core is manufactured as a single long piece, then structural integrity is maintained, but production efficiency decreases due to manufacturing difficulties
Solution Approach 1:
The rotor core is segmented into multiple core blocks that can be manufactured independently through resin injection molding. This segmentation significantly improves manufacturing efficiency by allowing parallel production of multiple blocks. The blocks are then stacked with burr portions providing alignment, maintaining structural integrity while enabling efficient production.
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 approach results in a more efficient resin distribution, reducing unfilled spaces and magnetic flow disruptions, thereby enhancing the performance and output of the rotor core.
Implementation Method 1
injecting a molten resin into a first resin injection portion... such that a first solidified resin is provided in the first resin injection portion
Data Source
AI summary
A core product includes a first core block and a second core block. The first core block includes: a first block body including a first end surface and a second end surface, and a first resin injection portion; a first solidified resin provided in the first resin injection portion; and a first gate mark integrated with the first solidified resin and protruding outward more than the first end surface. The second core block includes: a second block body including a third end surface and a fourth end surface, and a second resin injection portion; a second solidified resin provided in the second resin injection portion; and a second gate mark integrated with the second solidified resin and protruding outward more than the fourth end surface. The first core block and the second core block are stacked such that the second end surface and the third end surface face each other.