The manufacturing logic of injection molding magnetic rotor originates from the composite synergistic effect of permanent magnet material and polymer matrix. This structure, which evenly disperses magnetic powder particles in a thermoplastic matrix, realizes the integrated molding of magnetic circuit system and mechanical carrier through injection molding process. The magnetic domain orientation technology is completed under the action of the gradient magnetic field in the mold flow channel, so that permanent magnetic materials such as NdFeB can complete the preferential crystal growth in the molten state.
The ratio of thermosetting binder and rare earth magnetic powder determines the balance between magnetic energy product and mechanical strength, and the formation of cross-linked structure simultaneously solidifies the magnetic powder distribution network. Rheological parameter control ensures that the melt maintains the orientation stability of magnetic particles during the filling process, avoiding magnetic pole displacement caused by shear thinning. The anisotropic magnetic properties of injection molding magnetic rotor are spatially modulated through multi-layer superposition injection molding process to meet the distribution requirements of complex electromagnetic fields.
The conductive shielding layer of overmolding suppresses eddy current loss. This electromagnetic insulation property makes injection molding magnetic rotor suitable for high-frequency drive scenarios. The elimination of residual stress relies on the precise control of the mold temperature field to ensure the dimensional stability of the magnet during cooling and shrinkage. The intrinsic damping characteristics of the composite material reduce the risk of resonance when the injection molding magnetic rotor rotates at high speed, and the magnetic circuit closure design reduces leakage flux through geometric topology optimization.
