Supercar Motor Self-Bonding Iron Core Solution: Our Factory's Technological Breakthroughs and Performance Innovation Practice

I. Material Breakthroughs: Independently Control Core Substrates to Lay a Solid Foundation for Supercar Iron Core Performance

Supercar motors need to maintain low loss and high stability when operating at high speeds above 20000rpm, which puts strict requirements on iron core materials. Our factory abandons the passive limitation of external procurement, achieves dual breakthroughs in substrate localization and coating customization, builds a unique material competitive advantage, ensures the quality and performance of iron cores from the source, and meets the extreme working conditions of supercar motors.

1. Independent Supply of Ultra-Thin Silicon Steel for Ultimate Eddy Current Loss Suppression

   We fully understand that eddy current loss is proportional to the square of the silicon steel sheet thickness. The strict standards for high-frequency loss of supercar motors make ultra-thin silicon steel a core necessity. After years of technological research, our factory has realized the independent production and supply of 0.05-0.1mm ultra-thin silicon steel. Compared with traditional silicon steel sheets of more than 0.2mm, it can limit the eddy current path to a narrower space. Combined with the insulation effect of the coating, it directly reduces eddy current loss by 15%-30%. Relying on independent supply capacity, we can flexibly adjust the magnetic permeability and iron loss parameters of silicon steel sheets according to the customized needs of supercar customers, without being restricted by the specifications of external suppliers, and accurately match the performance requirements of each supercar motor.

2. Custom R&D of High-Temperature Resistant Coatings to Adapt to Extreme Working Conditions of Supercars

   When supercar motors output peak power, the iron core temperature often exceeds 200℃. Ordinary coatings are prone to thermal attenuation and bonding failure, which seriously affects motor stability. Our factory has developed a customized self-adhesive coating with a temperature resistance of up to 220℃. By precisely controlling the B-stage reaction degree and curing parameters of the coating, we ensure that the iron core can still maintain sufficient vertical tensile force in high-temperature environments, and the bonding strength is much higher than that of traditional riveted structures. At the same time, the coating has dual characteristics of insulation and thermal conductivity: the uniform film layer of 2-8μm can effectively block inter-sheet circulation, fill the lamination gap to improve axial thermal conductivity, make the iron core temperature rise more uniform, avoid magnetic performance degradation caused by local overheating, and fully adapt to the extreme working environment of supercar motors.



3. Adaptive Processing of Special Alloys to Expand the Performance Boundary of Supercar Motors

   To meet the higher power density requirements of supercar motors, in addition to conventional silicon steel processing, our factory can also provide processing services for self-bonding iron core products of special soft magnetic alloys such as 1J22 and 1J50. Taking 1J22 iron-cobalt alloy as an example, its saturation magnetic flux density can reach 2.4T, which is more than 40% higher than that of ordinary silicon steel. Combined with the high lamination factor of our self-bonding process (more than 97%), it can increase the power density of motors of the same volume by more than 30%, helping supercar motors break through performance limits and achieve stronger power output.

II. Process Innovation: Full-Chain Automated Production, Balancing Performance and Processing Efficiency

Traditional riveting and welding processes not only damage the insulation layer of silicon steel sheets, but also are difficult to adapt to ultra-thin substrates and complex structures, which cannot meet the high precision and high performance requirements of supercar iron cores. Based on the core advantages of processing and manufacturing, our factory has achieved dual breakthroughs in the performance and production efficiency of self-bonding iron cores through full-chain process innovation, built a standardized, refined and automated production system, and ensured that each product meets the supercar-level quality standards.

1. Full-Surface Bonding Replaces Mechanical Fastening to Eliminate Performance Shortcomings

   Our factory adopts a fully automated production process of "coating - slitting - punching - integral forming". Through high-temperature and high-pressure curing process, the laminations form a seamless integrated structure, which completely replaces the "point connection" of traditional riveting and welding, and eliminates iron core performance loss from the processing level. Compared with traditional processes, this technology has three core advantages:

   No performance loss:

   Avoid damage to the silicon steel sheet coating by rivets and welding scars, no magnetic circuit distortion caused by mechanical connection points, reducing hysteresis loss by more than 10%.

   Leap in structural strength:

   The bonding strength can reach 2-4N/mm², which is more than 10 times that of traditional welding structures, ensuring no lamination loosening risk when the iron core rotates at a high speed of 20000rpm.

   Lightweight efficiency:

   Remove fasteners such as end plates and pressure rings, reduce the iron core weight by 8%-12%, and achieve an overall weight reduction of more than 40% with ultra-thin substrates, directly optimizing the unsprung mass and cruising range of supercars, and conforming to the lightweight development trend of supercars.

2. Independent R&D of Customized Equipment to Adapt to Complex Structure Processing Needs

   Supercar motors often adopt iron cores with special structures, which have extremely high requirements for the irregularity and refinement of iron cores. Conventional processing equipment is difficult to meet the needs. Our factory has independently developed an integrated forming and curing equipment for self-adhesive iron cores, equipped with replaceable tooling molds and precise pressure-temperature control modules, realizing the customized production of small iron cores below 10mm to large irregular iron cores of 600mm. It can flexibly adapt to the motor layout needs of different supercar models, solve the pain points of poor adaptability and insufficient precision of traditional processing equipment, and ensure that each irregular iron core meets the design standards.

3. Low-Stress Processing Technology to Maintain the Intrinsic Performance of Materials

   We fully understand that the high temperature of traditional welding and the mechanical force of riveting will cause plastic deformation of silicon steel sheets, resulting in magnetic performance degradation and affecting the energy efficiency of supercar motors. To this end, our self-bonding process avoids high-temperature welding and mechanical stamping stress throughout the process. Through the toughness buffer of the semi-cured coating and uniform pressure curing, the original magnetic performance of the silicon steel sheet is maximally retained. Test data shows that the performance degradation rate of the self-bonding iron core produced by our factory due to processing is less than 5%, while the degradation rate of traditional processes often exceeds 15%, which effectively ensures the extreme energy efficiency of supercar motors and provides core support for the "second-level acceleration" of supercars.

III. Scene Adaptation: Precisely Connect with Supercar Needs to Highlight Our Factory's Processing Strength

The extreme pursuit of "acceleration burst, handling stability and operation quietness" by supercars is highly consistent with the performance advantages of our self-bonding iron cores. As a professional processing factory, we have always been customer-oriented, accurately matching the core needs of supercar motors, and providing a full range of iron core solutions for the supercar field with customized processing capabilities and stable product quality.

1. Leap in Power Density: Supporting Supercar "Second-Level Acceleration"

   The 100km acceleration of supercars often needs to break through 2.0 seconds, relying on the instantaneous output of kilonewton-meter torque by the motor, and power density is the core constraint factor. Through the combined processing scheme of "ultra-thin substrate + high lamination factor + special alloy", our factory can increase the motor power density by more than 35%, effectively supporting the instantaneous power output of supercar motors, helping supercars achieve extreme acceleration performance, and highlighting our factory's technical strength in the field of iron core processing.

2. NVH Optimization: Achieving Supercar "Quiet Performance"

   Magnetostriction and lamination loosening are the main sources of motor noise, and supercars have extremely high requirements for cockpit quietness. The full-surface bonding structure of our self-bonding iron core completely eliminates inter-layer gaps, reducing vibration caused by magnetostriction by more than 22% and magnetostriction noise by 10dB. Test results show that the motor noise of supercar motors equipped with our self-bonding iron cores is less than 55 decibels at a speed of 120km/h. Combined with the vehicle acoustic package design, it achieves a "balance between performance and quietness" and meets the high-end riding needs of supercars.



3. Customized Response: Adapting to Supercar Multi-Motor Architecture

   Modern supercars mostly adopt distributed drive architecture, and the motor layout is strictly limited by the chassis space, which has extremely high requirements for the irregular and modular design of iron cores. Our self-bonding solution does not need to consider the symmetrical arrangement of rivets, and can flexibly realize irregular and modular iron core design. At the same time, relying on the fully automated production line, it realizes the rapid response of small-batch customized orders, accurately meets the needs of supercars for "limited production and personalized configuration", and provides flexible and efficient processing services for supercar manufacturers.

Conclusion: Ingenious Manufacturing Creates Core Competitiveness of Supercar Iron Cores

As a factory focusing on motor iron core processing, we have always adhered to technological innovation and quality first. Our factory's self-bonding iron core solution is not a breakthrough in a single technology, but a systematic project of "material localization + process customization + scene adaptation". Through the independent R&D of 0.05mm/0.1mm(10JNEX900 Supercore silicon) ultra-thin silicon steel and high-temperature resistant coatings, we solve the problems of high-frequency loss and high-temperature stability of supercar motors; through full-surface bonding and automated equipment, we achieve dual improvements in iron core structural strength and design freedom; finally, through NVH optimization and customized response, we accurately match the extreme demands of supercars for "performance, handling and quietness".

Relying on full-chain independent processing capabilities, strict quality control system and rapid customized response capabilities, our factory has become a core supplier of supercar motor iron cores, using professional processing strength to help supercar motors break through performance boundaries and provide solid iron core manufacturing support for the performance revolution in the supercar field. In the future, we will continue to deepen technological R&D, optimize processing processes, and empower the high-quality development of the supercar motor industry with better products and more efficient services.