Magnet with multiple disks

Abstract

A magnet comprising a center disk having a center disposed as a center of the magnet, a face of the center disk being substantially perpendicular to a central axis of the magnet. The magnet further comprises a first plurality of outer disks disposed in a bundled rod configuration around the center disk, a face of each of the first plurality of outer disks being substantially perpendicular to the central axis of the magnet, wherein each disk of the center disk and the first plurality of outer disks is electrically insulated from each other disk.

Description

[0001] This application claims the benefit of U.S. Provisional Application No. 62 / 912,969, filed on October 9, 2019, which is incorporated herein by reference in its entirety. Technical Field

[0002] The present invention relates generally to magnets, and more specifically to magnets that can be used in the energy transfer elements of a power converter. Background Technology

[0003] Electronic devices operate using electricity. Switching-mode power converters are commonly used to power many modern electronic devices due to their high efficiency, small size, and light weight. Conventional wall outlets provide high-voltage alternating current (AC). In a switching-mode power converter, the high-voltage AC input is converted by energy transfer elements to provide a well-regulated direct current (DC) output. During operation, switches are used to provide the desired output by changing the duty cycle, the switching frequency, or the number of pulses per unit time of the switches in the switching-mode power converter.

[0004] Energy transfer elements used in switch-mode power converters typically comprise a coil of wire wound around a core of a magnetically active material, such as ferrite or steel. For energy transfer elements such as transformers, the element may also include a structure called a bobbin, which supports the wire coil and provides a region for the core to be inserted, allowing the coil to wrap around it. The core provides a path for the magnetic field generated by the current flowing through the coil. A discrete region of non-magnetically active material, often referred to as a gap, is typically present in the path of the magnetic field provided by the core. The length of this gap can be chosen to manage the energy distribution within the energy transfer element. This non-magnetically active material is typically air, and the gap is often referred to as an air gap, but it can contain other non-magnetically active materials such as paper or varnish. The energy transfer element may also include a magnet, such as a permanent magnet, used with the core to provide a flux density offset to the magnetically active material core. This magnet can be inserted into the air gap of the energy transfer element. However, due to the varying magnetic field of the energy transfer element, the magnet may be susceptible to eddy currents. Eddy currents can generate undesirable power dissipation within the magnet. Attached Figure Description

[0005] Non-limiting and non-exhaustive embodiments of the invention are described with reference to the following figures, wherein, unless otherwise stated, the same reference numerals refer to the same parts in all the various views.

[0006] Figure 1A This is a perspective view of a composite disc magnet with a circular disk according to an embodiment of the present disclosure.

[0007] Figure 1B This is based on the implementation scheme of this disclosure in the presence of a changing magnetic field. Figure 1A A perspective view of a single disk of a composite disk magnet.

[0008] Figure 1C It is an implementation plan based on the contents of this disclosure. Figure 1A An example of a composite disk magnet is shown in perspective view of its outer boundary.

[0009] Figure 1D It is an embodiment of the present disclosure with insulating filler. Figure 1A A plan view of a composite disc magnet.

[0010] Figure 1E The implementation scheme based on this disclosure can be used to create Figure 1A A perspective view of a composite disc magnet with a bundled rod structure consisting of circular rods.

[0011] Figure 2A This is a perspective view of a composite disk magnet with a hexagonal disk according to an embodiment of the present disclosure.

[0012] Figure 2B This is based on the implementation scheme of this disclosure in the presence of a changing magnetic field. Figure 2A A perspective view of a single hexagonal disk of a composite disk magnet.

[0013] Figure 2C It is an implementation plan based on the contents of this disclosure. Figure 2A An example of a composite disk magnet is shown in perspective view of its outer boundary.

[0014] Figure 2D It is an embodiment of the present disclosure with insulating filler. Figure 2A A plan view of a composite disc magnet.

[0015] Figure 2E The implementation scheme based on this disclosure can be used to create Figure 2A A perspective view of a composite disc magnet with a hexagonal rod binding structure.

[0016] Figure 3A This is a plan view of a composite disc magnet with a triangular disk according to an embodiment of the present disclosure.

[0017] Figure 3B This is a plan view of another embodiment of a composite disc magnet with a triangular disk according to the embodiments of this disclosure.

[0018] Figure 3C This is a plan view of a composite disc magnet with circular discs of different sizes, according to an embodiment of the present disclosure.

[0019] Figure 4A This is a flowchart of one embodiment of creating a composite disc magnet according to the implementation of the present disclosure.

[0020] Figure 4B This is a flowchart of another embodiment of creating a composite disc magnet according to the implementation of this disclosure.

[0021] Figure 5A This is a perspective view of a core with an air gap according to an embodiment of this disclosure.

[0022] Figure 5B It is an implementation plan based on the contents of this disclosure. Figure 5A A plan view of the core.

[0023] Figure 5C It is an embodiment of the present disclosure having a composite disk magnet Figure 5A An exploded view of the core.

[0024] Figure 6A This is a perspective view of a substrate and multiple disks according to an embodiment of the present disclosure.

[0025] Figure 6B It is an implementation plan based on the contents of this disclosure. Figure 6A A plan view of the substrate and an example composite disc magnet.

[0026] Figure 6C It is an implementation plan based on the contents of this disclosure. Figure 6A A plan view of the substrate and an example tiled disc magnet.

[0027] Figure 7 This is a flowchart of an embodiment of creating a composite disk magnet or a tiled magnet on a substrate according to the implementation of this disclosure.

[0028] Figure 8A This is a perspective view of an example core with an air gap according to an embodiment of this disclosure.

[0029] Figure 8B This is a perspective view of another example core with an air gap according to an embodiment of this disclosure.

[0030] Figure 8C This is a plan view of an example composite disc magnet on a square central column according to an embodiment of the present disclosure.

[0031] Figure 8D This is a plan view of an example tiled disc magnet on a square central column according to an embodiment of the present disclosure.

[0032] Figure 8E This is a plan view of another example composite disc magnet on a square central column according to an embodiment of the present disclosure.

[0033] Figure 8F This is a plan view of another example tiled disc magnet on a square central column according to an embodiment of the present disclosure.

[0034] In all the views of the accompanying drawings, corresponding reference characters indicate corresponding parts. Those skilled in the art will understand that the elements in the drawings are illustrated for simplicity and clarity and are not necessarily drawn to scale. For example, the scale of some elements in the drawings may be exaggerated relative to others to aid in understanding the various embodiments of the invention. Furthermore, common but easily understood elements that are useful or necessary in commercially viable embodiments are generally not depicted to facilitate viewing of these various embodiments of the invention less obstructively. Detailed Implementation

[0035] In the following description, numerous specific details are set forth to provide a thorough understanding of the invention. However, it will be apparent to those skilled in the art that the specific details are not required to practice the invention. In other instances, well-known materials or methods have not been described in detail to avoid obscuring the invention.

[0036] Throughout this specification, references to "one embodiment," "an embodiment," "one example," or "an example" mean that a specific feature, structure, or characteristic described in connection with that embodiment or example is included in at least one embodiment of the invention. Therefore, the phrases "one embodiment," "an embodiment," "one example," or "an example" appearing in various places throughout this specification do not necessarily refer to the same embodiment or example. Furthermore, specific features, structures, or characteristics can be combined in any suitable combination and / or sub-combination in one or more embodiments or examples. Specific features, structures, or characteristics can be included in integrated circuits, electronic circuits, combinational logic circuits, or other suitable components that provide the described functionality. Additionally, it should be understood that the accompanying drawings are for illustrative purposes to those skilled in the art and are not necessarily drawn to scale.

[0037] Energy transfer elements can utilize magnets to provide flux density shifts to a core of magnetically active material. The time-varying magnetic field of an energy transfer element used with a switch-mode power converter generates an electric field that drives eddy currents within the magnet. Although permanent magnets can have a relative permeability close to 1 when magnetized and are therefore considered non-magnetically active, the material can have relatively high conductivity that allows for non-negligible currents in the presence of an electric field. Eddy currents in conductive materials can generate power losses in the energy transfer element. Previous solutions have included stacked magnets, where sheets or slices of magnets are assembled into larger blocks. For stacked magnets, the sheets or slices are typically assembled such that the faces of the sheets or slices are parallel to the direction of the magnetic field. Embodiments of this disclosure include composite disk magnets or tiled disk magnets that can reduce power losses caused by eddy currents.

[0038] Embodiments of this disclosure include a composite disk magnet in which multiple disks are attached to each other within the outer boundary of the composite disk magnet. Each disk may include a magnetically active material that is initially unmagnetized and then magnetized after assembly to create a composite permanent magnet. In one embodiment, the face of each disk is a plane perpendicular to the central axis of the composite disk magnet. Furthermore, the face of each disk is perpendicular to the intended magnetic field. In one embodiment, the top or bottom surface of the disk may be considered a "face," and both the top and bottom surfaces are planes perpendicular to the central axis. The outer surface of each disk, such as the top surface, the bottom surface, and the surface coupling the top surface to the bottom surface, may be coated with an electrically insulating material. The coating prevents conduction between each disk. The gaps between the disks may be filled with an electrically insulating material to the outer boundary of the composite disk magnet. The shape of the disks may be variable, such as circular, hexagonal, triangular, pie-shaped, etc. Furthermore, the multiple disks may have equal or variable dimensions. In one embodiment, the composite disk magnet may include seven circular disks of equal diameter, wherein the diameter of each individual circular disk is approximately one-third the diameter of the outer boundary of the composite disk magnet. In another embodiment, the composite disk magnet may include seven hexagonal disks of equal size within the outer boundary of the composite disk magnet. Furthermore, the composite disk magnet may be assembled individually or assembled onto a substrate.

[0039] Embodiments of this disclosure also include tiled disk magnets, wherein multiple disks are attached to a substrate in a desired pattern. However, in these embodiments, the tiled disks may not necessarily be in contact with each other. Each disk may include a magnetically active material that is initially unmagnetized and then magnetized after assembly onto the substrate to create a composite permanent magnet. In one embodiment, the face of each disk is a plane perpendicular to the central axis of the substrate. Furthermore, the face of each disk is perpendicular to the desired magnetic field.

[0040] Figure 1A A perspective view of a composite disk magnet 100 having disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g is shown. Each of disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g is circular in shape and may include magnetically active material for creating a permanent magnet. In other words, the face of each disk 102a, 102b, 102c, 102d, 102e, 102f, and 102g is generally circular. Or, in other words, the top and bottom surfaces of each disk 102a, 102b, 102c, 102d, 102e, 102f, and 102g are generally circular. As shown, these top and bottom surfaces are planar. Each circular disk 102a, 102b, 102c, 102d, 102e, 102f, and 102g has a diameter d1 108 and a thickness Z 104. In other words, the top and bottom surfaces of each disk 102a, 102b, 102c, 102d, 102e, 102f, and 102g have a diameter d1 108. Disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g are assembled about axis A 116. In other words, disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g are assembled such that the plane of the surface of each disk 102a, 102b, 102c, 102d, 102e, 102f, and 102g is perpendicular to axis A 116. In the illustrated embodiment, the top and bottom surfaces of disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g can be considered as the surfaces of the disks. Axis A 116 can be the central axis of the composite disk magnet 100 and can also represent the intended direction of an external magnetic field to which the composite disk magnet 100 can be exposed. In embodiments of the composite disk magnet, disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g touch or otherwise contact their adjacent disks. Thus, in one embodiment, disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g are coated with an electrically insulating material to prevent current conduction between disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g.

[0041] Figure 1AThe illustrated embodiment exemplifies seven disks. The outer rows each comprise two disks (102a, 102b and 102f, 102g), while the middle row comprises three disks (102c, 102d and 102e). Disk 102d is shown as the central disk for the composite disk magnet 100, wherein disks 102a, 102b, 102c, 102e, 102f and 102g substantially surround disk 102d. In the illustrated embodiment, disk 102d contacts or otherwise touches disks 102a, 102b, 102c, 102e, 102f and 102g.

[0042] In one embodiment, disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g comprise magnetic materials such as neodymium iron boron (NdFeB), samarium cobalt (SmCo), alnico (AlNiCo), or nickel boron (NiB). Disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g may also comprise ceramic or ferrite materials. Furthermore, in one embodiment, disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g comprise a conductive magnetic material uniformly mixed with an electrically insulating binder. Each of disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g can be formed by compression bonding or sintered bonding. However, it should be understood that other forms of adhesive can be used.

[0043] In one embodiment of the assembly, the assembly begins with individual disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g. Initially, disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g are not magnetized. The individual disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g may be coated with an insulating material and then glued or otherwise attached together. If the initial thickness of disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g is greater than the target thickness Z, then disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g can undergo a process similar to wafer backgrinding to reduce their thickness. The gaps in the composite disk magnet 100 can optionally be filled with an insulating material. Once assembled, the composite disk magnet 100 is magnetized. In another embodiment, individual disks can be mounted to a substrate or other desired surface instead of being glued together. For this embodiment, a pick-and-place machine can be used to mount individual disks to the substrate. This machine can apply adhesive drops in a suitable pattern and place individual disks on the adhesive drops to form the composite disk magnet 100. In one embodiment, the substrate may be part of a ferrite core for an energy transfer element.

[0044] In relation to Figure 1E In another embodiment of the assembly, further illustrated, the assembly begins with multiple individual rods. In one embodiment, the length or thickness of the rod is greater than the thickness of the disk. It should be understood that a disk can be considered a shortened rod. In one embodiment, a rod can be considered a disk when its length is its minimum dimension. Initially, the individual rods of magnetic material are not magnetized. The individual rods may be coated with an insulating material and then glued or otherwise attached together in the rod bundle configuration 101. The rod bundle configuration 101 may then be sliced ​​to a thickness Z 104 to produce the composite disk magnet 100. The gaps in the composite disk magnet 100 may optionally be filled with an insulating material. Once assembled, the composite disk magnet 100 is magnetized.

[0045] Figure 1BA perspective view of a single disk 102 of a composite disk magnet 100 is illustrated. Disk 102 is an embodiment of any one of disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g. The surface of disk 102 is generally circular. For the illustrated embodiment, the time-varying magnetic field is shown as perpendicular to the circular surface of disk 102. The time-varying magnetic field (dB / dt) can be generated externally and independently of the composite disk magnet 100, such as a magnetic field generated by the current in the energy transfer element of a power converter. The time-varying magnetic field (dB / dt) generates a corresponding electric field that drives charge carriers—called eddy currents—through the material. Eddy currents I caused by the time-varying magnetic field (dB / dt) D 106 is shown flowing clockwise around the surface of disk 102 and also clockwise around the side surface of disk 102. (Return to Reference) Figure 1A The time-varying magnetic field will generate corresponding eddy currents in each of disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g. The smaller diameter of each individual disk 102a, 102b, 102c, 102d, 102e, 102f, and 102g increases the effective resistivity of the composite disk magnet 102 compared to the resistivity derived from a magnet formed from a single disk of the same size as the composite disk magnet 102. As the effective resistivity increases, the power loss originating from the composite disk magnet 102 should be less than the power loss originating from a magnet formed from a single disk of the same size as the composite disk magnet 102.

[0046] Figure 1CAnother perspective view of a composite disk magnet 100 having disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g is illustrated, the disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g being housed within an outer boundary 112 (shown as dashed lines) of the composite disk magnet 100. In one embodiment, the outer boundary 112 is generally circular. However, it should be understood that the outer boundary 112 can have different shapes. As mentioned above, each disk 102a, 102b, 102c, 102d, 102e, 102f, and 102g has a circular surface. Or in other words, each disk 102a, 102b, 102c, 102d, 102e, 102f, and 102g has a planar circular top and bottom surface. The composite disc magnet 100 and each of the discs 102a, 102b, 102c, 102d, 102e, 102f, and 102g are shown as having a thickness Z 104. Discs 102a, 102b, 102c, 102d, 102e, 102f, and 102g also have a diameter d 1108. Disc 102d is located at the center of the composite disc magnet 100 and is surrounded by discs 102a, 102b, 102c, 102e, 102f, and 102g.

[0047] Figure 1D A plan view of a composite disk magnet 100 having disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g is shown, the disks being housed within an outer boundary 112 (shown as bold lines) of the composite disk magnet 100. The plan view shown can be viewed along axis A 116. Figure 1D In one embodiment, axis A 116 will emerge from the page. In one implementation, outer boundary 112 is generally circular. Disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g also have a diameter d1 108. The composite disk magnet 100 has a total diameter d M 110. In one embodiment, the diameter d of the composite disc magnet 100 M 110 is roughly three times the diameter d1 108 of disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g. However, it should be understood that in disks with diameter d... M Smaller or larger disks can be used within the circle, which can change the number of disks within the outer boundary 112. Furthermore, in a circle with a diameter d... M Various sizes of disks can be used inside the circle, such as those related to... Figure 3CAs shown. Optionally, the composite disc magnet 100 may also include an insulating filler 114. As shown, the gaps between each disc 102a, 102b, 102c, 102d, 102e, 102f, and 102g and the outer boundary 112 may be filled with the insulating filler 114. The material used for the insulating filler 114 may be electrically insulating. In one embodiment, the insulating filler 114 may comprise the same or similar material as the adhesive used to bond the discs 102a, 102b, 102c, 102d, 102e, 102f, and 102g together. For example, cyanoacrylates (e.g., super glues) such as Loctite 414 may be used for the adhesive, insulating coating, and insulating filler 114.

[0048] Figure 1E A perspective view of a binding rod construction 101 having circular rods 102a', 102b', 102c', 102d', 102e', 102f', and 102g' is shown, which can be used for... Figure 1A , Figure 1B , Figure 1C and Figure 1DOne embodiment of the construction of the composite disc magnet 100 shown is illustrated. Individual rods 102a', 102b', 102c', 102d', 102e', 102f', and 102g' correspond to similarly numbered discs 102a, 102b, 102c, 102d, 102e', 102f, and 102g, and are aggregated and glued or otherwise attached together in a bundled rod construction. In one embodiment, a bundled rod construction may refer to the aggregation of two or more rods together within a boundary such as the outer boundary 112 shown above. Each rod 102a', 102b', 102c', 102d', 102e', 102f', and 102g' may be formed by compression bonding or sintering bonding. As shown, each of the bars 102a', 102b', 102c', 102d', 102e', 102f', and 102g' is generally cylindrical in shape. The lengths of the bars 102a', 102b', 102c', 102d', 102e', 102f', and 102g' are generally parallel to the axis A116. Furthermore, the lengths of the bars 102a', 102b', 102c', 102d', 102e', 102f', and 102g' are greater than the thickness Z 104. Similar to the above, bar 102d' is the central bar of this structure and is surrounded by bars 102a', 102b', 102c', 102e', 102f', and 102g'. In one embodiment, rods 102a', 102b', 102c', 102d', 102e', 102f', and 102g' are coated with an electrically insulating material. To assemble the composite disc magnet 100, the binding rod structure 101 can be sliced ​​along a plane 120 perpendicular to axis A 116. The distance between the slices can be approximately equal to the thickness Z 104 to produce the composite disc magnet 100. When sliced ​​along plane 120, the cross-sectional view of the binding rod structure 101 can be approximately... Figure 1D The diagram shows a plan view of the composite disc magnet 100. It should be understood that a disc can be considered a shortened rod. In embodiments, a rod can be considered a disc when its length is its minimum dimension.

[0049] Figure 2AA perspective view of a composite disk magnet 200 having disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g is shown. It should be understood that the composite disk magnet 200 and its corresponding disks are similar to the composite disk magnet 100 and its corresponding disks discussed above, and can be made of similar materials and assembled in a similar manner. However, one difference is that each of disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g is hexagonal in shape. In other words, the faces of each disk 202a, 202b, 202c, 202d, 202e, 202f, and 202g are substantially hexagonal. Or in other words, the top and bottom surfaces of each disk 202a, 202b, 202c, 202d, 202e, 202f, and 202g are generally hexagonal. Furthermore, the top and bottom surfaces are generally planar. Each disk 202a, 202b, 202c, 202d, 202e, 202f, and 202g is generally the same size and has a thickness Z 104. Disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g are assembled around axis A 216 such that the plane of the surface of each disk 202a, 202b, 202c, 202d, 202e, 202f, and 202g is perpendicular to axis A 116. As shown, the bottom and top surfaces of disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g can be considered as surfaces. Axis A 216 can be the central axis of the composite disk magnet 200 and can also represent the intended direction of an external magnetic field to which the composite disk magnet 200 can be exposed. In embodiments of the composite disk magnet 200, disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g touch or otherwise contact their adjacent disks. Thus, in one embodiment, disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g are coated with an electrically insulating material to prevent current conduction between disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g.

[0050] Figure 2A The illustrated embodiment exemplifies seven hexagonal disks. The outer rows each comprise two disks (202a, 202b and 202f, 202g), while the middle row comprises three disks (202c, 202d and 202e). Disk 202d is shown as the central disk for the composite disk magnet 200, with disks 202a, 202b, 202c, 202e, 202f and 202g generally surrounding disk 202d. Furthermore, disk 202d contacts or otherwise touches disks 202a, 202b, 202c, 202e, 202f and 202g.

[0051] In one embodiment, disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g comprise magnetic materials such as neodymium iron boron (NdFeB), samarium cobalt (SmCo), alnico (AlNiCo), or nickel boron (NiB). Disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g may also comprise ceramic or ferrite materials. Furthermore, in one embodiment, disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g comprise a conductive magnetic material uniformly mixed with an electrically insulating adhesive. Each of disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g can be formed by compression bonding or sintering bonding.

[0052] In one embodiment of the assembly, the assembly begins with individual disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g. Initially, disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g are not magnetized. The individual disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g may be coated with an insulating material and then glued or otherwise attached together. If the initial thickness of disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g is greater than the target thickness Z, then disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g can undergo a process similar to wafer thinning to reduce their thickness. The gaps in the composite disk magnet 200 can optionally be filled with an insulating material. Once assembled, the composite disk magnet 200 is magnetized. In another embodiment, individual disks can be mounted to a substrate or other desired surface instead of being glued together. For this embodiment, a pick-and-place machine can be used to mount individual disks to the substrate. This machine can apply adhesive drops in a suitable pattern and place individual disks on the adhesive drops to form the composite disk magnet 200. In one embodiment, the substrate may be part of a ferrite core for an energy transfer element.

[0053] In relation to Figure 2EIn another embodiment of the assembly, further illustrated, the assembly begins with multiple individual rods. Initially, the individual rods are not magnetized. The individual rods may be coated with an insulating material and then glued or otherwise attached together in the bundled rod configuration 201. It should be understood that a disc can be considered a shortened rod. In the embodiment, a rod can be considered a disc when its length is its minimum dimension. The bundled rod configuration 201 can then be sliced ​​to a thickness Z 104 to produce a composite disc magnet 200. The gaps in the composite disc magnet 200 may optionally be filled with an insulating material. Once assembled, the composite disc magnet 200 is magnetized.

[0054] Figure 2B A perspective view of a single hexagonal disk 202 of a composite disk magnet 200 is shown. Disk 202 is an embodiment of any one of disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g. The face of disk 202 is generally hexagonal. A time-varying magnetic field (dB / dt) is shown perpendicular to the hexagonal face of disk 202. The time-varying magnetic field (dB / dt) can be generated externally and independently of the composite disk magnet 200, such as a magnetic field generated by the current in the energy transfer element of a power converter. The time-varying magnetic field (dB / dt) generates a corresponding electric field that drives charge carriers—called eddy currents—through the material. Eddy currents I caused by the time-varying magnetic field (dB / dt) D 106 is shown flowing clockwise around the surface of disk 202 and along the side of disk 202. (Return to Reference) Figure 2A The time-varying magnetic field will generate corresponding eddy currents in each of disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g. The smaller diameter of each individual disk 202a, 202b, 202c, 202d, 202e, 202f, and 202g increases the effective resistivity of the composite disk magnet 202 compared to the resistivity of a magnet with a single disk of the same size as the composite disk magnet 202. With the increase in effective resistivity, the power loss originating from the composite disk magnet 202 should be less than the power loss originating from a magnet formed from a single disk of the same size as the composite disk magnet 202.

[0055] Figure 2CAnother perspective view of a composite disk magnet 200 having disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g is illustrated, with disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g housed within an outer boundary 112 (shown as dashed lines) of the composite disk magnet 200. In one embodiment, the outer boundary 112 is generally circular. However, it should be understood that the outer boundary 112 can have different shapes. As mentioned above, each disk 202a, 202b, 202c, 202d, 202e, 202f, and 202g has a hexagonal face. Or in other words, each disk 202a, 202b, 202c, 202d, 202e, 202f, and 202g has a planar hexagonal top and bottom surface. The composite disc magnet 200 and each of the discs 202a, 202b, 202c, 202d, 202e, 202f, and 202g are shown as having a thickness Z 104. Disc 202d is located at the center of the composite disc magnet 200 and is surrounded by discs 202a, 202b, 202c, 202e, 202f, and 202g.

[0056] Figure 2D A plan view of a composite disk magnet 200 having disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g is shown, the disks being housed within an outer boundary 112 (shown as bold lines) of the composite disk magnet 200. The plan view shown can be viewed along axis A 216. Figure 2DIn one embodiment, axis A 216 will emerge from the page. In one implementation, the outer boundary 112 is generally circular. As shown, seven hexagonal disks are housed within the outer boundary 112. Disks 202a, 202b, 202c, 202d, 202e, 202f, and 202g are generally the same size and are sized such that the outer disks 202a, 202b, 202c, 202e, 202f, and 202g reach the outer boundary 112. However, it should be understood that smaller or larger disks can be used within the outer boundary 112, which can change the number of disks within the outer boundary 112. Optionally, the composite disk magnet 200 may also include insulating filler 114. As shown, the gaps between each disk 202a, 202b, 202c, 202d, 202e, 202f, and 202g and the outer boundary 112 may be filled with insulating filler 114. The material used for insulating filler 114 may be electrically insulating. In one embodiment, insulating filler 114 may comprise the same or similar material as the adhesive used to bond discs 202a, 202b, 202c, 202d, 202e, 202f, and 202g together. For example, cyanoacrylates (e.g., super glues) such as Loctite 414 may be used for the adhesive, insulating coating, and insulating filler 114.

[0057] Figure 2E A perspective view of a binding rod construction 201 having hexagonal rods 202a', 202b', 202c', 202d', 202e', 202f', and 202g' is shown, which can be used for... Figure 2A , Figure 2B , Figure 2C and Figure 2DOne embodiment of the construction of the composite disc magnet 200 shown is illustrated. Individual rods 202a', 202b', 202c', 202d', 202e', 202f', and 202g' correspond to similarly numbered discs 202a, 202b, 202c, 202d, 202e, 202f, and 202g, and are aggregated and glued or otherwise attached together in a bundled rod construction. In one embodiment, a bundled rod construction may refer to the aggregation of two or more rods together within a boundary such as the outer boundary 112 shown above. Each rod 202a', 202b', 202c', 202d', 202e', 202f', and 202g' may be formed by compression bonding or sintering bonding. As shown, each of the bars 202a', 202b', 202c', 202d', 202e', 202f', and 202g' is generally hexagonal in shape. The lengths of bars 202a', 202b', 202c', 202d', 202e', 202f', and 202g' are also generally parallel to axis A 216. Furthermore, the lengths of bars 202a', 202b', 202c', 202d', 202e', 202f', and 202g' are greater than the thickness Z 104. Similar to the above, bar 202d' is the central bar of the binding bar structure and is surrounded by bars 202a', 202b', 202c', 202e', 202f', and 202g'. In one embodiment, rods 202a', 202b', 202c', 202d', 202e', 202f', and 202g' are coated with an electrically insulating material. To assemble the composite disc magnet 200, the binding rod structure 201 can be sliced ​​along a plane 220 perpendicular to axis A 216. The distance between the slices can be approximately the thickness Z 104 to produce the composite disc magnet 200. When sliced ​​along plane 220, the cross-sectional view of the binding rod structure 201 can be approximately... Figure 2D The diagram shows a plan view of the composite disc magnet 200. It should be understood that a disc can be considered a shortened rod. In the embodiments, the rod can be considered a disc when its length is its minimum dimension.

[0058] Figure 3A , Figure 3B and Figure 3C A plan view illustrating an alternative embodiment of a composite disc magnet with individual discs of different shapes is shown. Figure 3A Examples of composite disk magnets 300 with triangular disks 302a, 302b, 302c, 302d, 302e, 302f, 302g, and 302h are shown. It should be understood that the composite disk magnet 300 with triangular disks is similar to the composite disk magnets and corresponding disks discussed above, and can be made of similar materials and assembled in a similar manner. For Figure 3AIn the illustrated embodiment, each of disks 302a, 302b, 302c, 302d, 302e, 302f, 302g, and 302h is triangular in shape. In other words, the surface (bottom or top surface) of each disk 302a, 302b, 302c, 302d, 302e, 302f, 302g, and 302h is generally triangular. Each disk 302a, 302b, 302c, 302d, 302e, 302f, 302g, and 302h is generally the same size and has a thickness. Each disk 302a, 302b, 302c, 302d, 302e, 302f, 302g, and 302h is assembled around the center point of the composite disk magnet 300 such that the triangular disks 302a, 302b, 302c, 302d, 302e, 302f, 302g, and 302h radiate from that center point. The disks 302a, 302b, 302c, 302d, 302e, 302f, 302g, and 302h are housed within the outer boundary 112 of the composite disk magnet 300. In the illustrated embodiment, the outer boundary 112 is generally circular. However, it should be understood that other shapes may be used for the outer boundary 112. In an embodiment of the composite disc magnet 300, discs 302a, 302b, 302c, 302d, 302e, 302f, 302g, and 302h touch or otherwise contact their adjacent discs. Each disc 302a, 302b, 302c, 302d, 302e, 302f, 302g, and 302h may be coated with an electrically insulating material to prevent current conduction between the discs. Furthermore, the gaps between the individual discs and the outer boundary 112 may be filled with an insulating filler 114.

[0059] Figure 3BAn example of a composite disk magnet 301 having disc-shaped disks 302i, 302j, 302k, 302l, 302m, 302n, 302o, and 302p is shown. It should be understood that the composite disk magnet 301 with disc-shaped disks is similar to the composite disk magnets and corresponding disks discussed above, and can be made of similar materials and assembled in a similar manner. The face (bottom or top surface) of each disk 302i, 302j, 302k, 302l, 302m, 302n, 302o, and 302p is generally disc-shaped. Each disk 302i, 302j, 302k, 302l, 302m, 302n, 302o, and 302p is substantially the same size and has the same thickness, and is assembled around the center point of the composite disk magnet 301 such that the disks 302i, 302j, 302k, 302l, 302m, 302n, 302o, and 302p radiate from the center point. In embodiments of the composite disk magnet 301, disks 302i, 302j, 302k, 302l, 302m, 302n, 302o, and 302p touch or otherwise contact their adjacent disks. Each disk 302i, 302j, 302k, 302l, 302m, 302n, 302o, and 302p may be coated with an electrically insulating material. However, with Figure 3A Unlike the composite disc magnet 300 shown, the outer boundary 312 of the composite disc magnet 301 is defined by the edges of the discs 302i, 302j, 302k, 302l, 302m, 302n, 302o and 302p.

[0060] Figure 3C This is a plan view of a composite disk magnet 305 comprising circular disks 102a, 102b, 102c, 102d, 102e, 102f, 102g, 102h, 102i, 102j, 102k, 102l, and 102m of different sizes. It should be understood that the composite disk magnet 305 with circular disks of various sizes is similar to the composite disk magnets and corresponding disks discussed above, and can be made of similar materials and assembled in a similar manner. Furthermore, the composite disk magnet 305 is similar to... Figure 1A , Figure 1B , Figure 1C , Figure 1D and Figure 1E The composite disc magnet 100 is discussed. However, at least one difference is that the composite disc magnet 305 also includes discs 102h, 102i, 102j, 102k, 102l and 102m.

[0061] In one embodiment, the surfaces of disks 102a, 102b, 102c, 102d, 102e, 102f, 102g, 102h, 102i, 102j, 102k, 102l, and 102m are generally circular. Furthermore, disks 102a, 102b, 102c, 102d, 102e, 102f, 102g, 102h, 102i, 102j, 102k, 102l, and 102m may also have a thickness Z. As shown, disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g are generally the same size, having a diameter d1 108. The composite disk magnet 305 also includes disks 102h, 102i, 102j, 102k, 102l, and 102m, which are substantially the same size and have a diameter d2 318. In one embodiment, the diameter d2 318 is smaller than the diameter d1 108. The outer boundary 112 of the composite disk magnet 305 is shown as generally circular. However, it should be understood that other shapes may be used for the outer boundary 112. Disks 102a, 102b, 102c, 102d, 102e, 102f, 102g, 102h, 102i, 102j, 102k, 102l, and 102m are accommodated within the outer boundary 112 of the composite disk magnet 305. The composite disk magnet 305 has a total diameter d M 110. In one embodiment, the diameter d of the composite disc magnet 205 M 110 is approximately three times the diameter d1 108 of disks 102a, 102b, 102c, 102d, 102e, 102f, and 102g. In embodiments of the composite disk magnet 305, disks 102a, 102b, 102c, 102d, 102e, 102f, 102g, 102h, 102i, 102j, 102k, 102l, and 102m touch or otherwise contact their adjacent disks. In one embodiment, disks 102a, 102b, 102c, 102d, 102e, 102f, 102g, 102h, 102i, 102j, 102k, 102l, and 102m are coated with an electrically insulating material. Furthermore, the composite disk magnet 305 may also include an insulating filler 114 (shown in dashed lines). As shown, the gaps between each of the disks 102a, 102b, 102c, 102d, 102e, 102f, 102g, 102h, 102i, 102j, 102k, 102l, and 102m and the outer boundary 112 can be filled with insulating filler 114. The material used for the insulating filler 114 can be electrically insulating. Although circular disks are shown, it should be understood that disks of various sizes and other shapes can be accommodated within the outer boundary 112 of the composite disk magnet.

[0062] Figure 4AProcess 401 is illustrated as an example assembly for a composite disc magnet according to an embodiment of this disclosure. Specifically, process 401 illustrates an assembly beginning with a single pre-cut disc. The order in which some or all of the process boxes appear in process 401 should not be considered limiting. Rather, those skilled in the art who benefit from this disclosure will understand that some of the process boxes may be performed in a variety of orders not illustrated, or even in parallel.

[0063] The assembly begins at frame 400 and proceeds to frame 405, where individual discs are assembled. Once assembled, the process proceeds to frame 410, where the perimeter of the individual discs is coated with an insulating material. In one embodiment, the insulating coating may comprise the same or similar material as the adhesive used to bond the discs. For example, cyanoacrylates (e.g., super glue) such as Loctite 414 may be used as the adhesive, insulating coating, and insulating filler. In some embodiments, the insulating coating may comprise a varnish, such as clear nail polish, or a polymer film, such as parylene. Furthermore, example processes for coating the discs may include the individual application of an insulating material or a suitable insulating material via chemical vapor deposition using appropriate tools.

[0064] At frame 415, individual discs are assembled into a bundled bar configuration of the desired shape. In one embodiment, the bundled bar configuration may refer to the aggregation of individual discs within an outer boundary, wherein the face of each disc is substantially perpendicular to the central axis of the composite disc magnet. For example, the desired shape may be circular, and thus the outer boundary of the composite disc is circular. Other shapes may include hexagons, squares, rectangles, etc. In one embodiment, the individual discs may be fastened together with glue or other adhesive materials. For this embodiment, a sheet of paper having the outline of outer boundary 112 may be covered with a transparent polyester film (Mylar) sheet. The individual discs may be arranged within outer boundary 112 in a bundled bar configuration of the desired shape on top of the transparent polyester film sheet, and then filled with an adhesive such as cyanoacrylate. Furthermore, the individual discs may be arranged such that the face of each disc is parallel to the transparent polyester film sheet, and the direction of the central axis of the resulting composite disc magnet will be outward from the page. Once the adhesive has cured, the discs can be removed from the polyester film sheet, and excess adhesive can be trimmed. In another embodiment, as per [reference to...] Figure 7As will be discussed further, individual discs can be mounted onto a substrate or other desired surface instead of being initially glued together. For this embodiment, a pick-and-place machine can be used to mount individual discs onto the substrate. This machine can apply adhesive drops in a suitable pattern and place the individual discs onto the drops. If the individual discs are at the desired thickness Z, the process can continue. However, if the individual discs are thicker than the desired thickness Z, the individual discs constructed from bundled rods can be scraped or ground to the desired thickness Z. In one embodiment, a composite disc magnet can be placed onto a substrate and then scraped or ground to the desired thickness Z. In one embodiment, the substrate can be part of a ferrite core for an energy transfer element. Furthermore, the composite disc magnet can be trimmed before or after magnetization.

[0065] At frame 420, the gap may optionally be filled with an insulating material to the outer boundary of the desired shape of the composite disk. At frame 425, the composite disk with the binding rod structure is magnetized.

[0066] Figure 4B Process 403 is illustrated, which is an example assembly for a composite disc magnet according to an embodiment of the present disclosure. Specifically, process 403 illustrates the assembly of a composite disc magnet from a... Figure 1E and Figure 2E The assembly begins with the individual bars shown. The order in which some or all of the process boxes appear in process 403 should not be considered limiting. Rather, those skilled in the art who benefit from this disclosure will understand that some of the process boxes may be executed in a variety of orders not illustrated, or even in parallel.

[0067] The assembly begins at frame 430 and proceeds to frame 435, where individual rods are assembled. Once assembled, the process proceeds to frame 440, where the perimeter of the individual rods is coated with an insulating material. In one embodiment, the insulating material coating may comprise the same or similar material as the adhesive used to bond the rods. For example, cyanoacrylates (e.g., super glue) such as Loctite 414 may be used as the adhesive, insulating coating, and insulating filler. In some embodiments, the insulating coating may comprise a varnish, such as clear nail polish, or a polymer film, such as parylene. Furthermore, an example process for coating the disc may comprise the individual application of an insulating material or a suitable insulating material via chemical vapor deposition using appropriate tools.

[0068] At box 445, a bundled bar configuration is formed by aggregating individual bars into a desired shape. In one embodiment, the bundled bar configuration may refer to an aggregation of individual bars within an outer boundary. Regarding... Figure 1E and Figure 2EAn embodiment of the bundled bar construction is shown. For example, the desired shape of the resulting composite disc magnet can be circular, and thus the individual bars are assembled in the bundled bar construction such that the outer boundary of the cross-section is substantially circular. The individual bars can be fastened together with glue or other adhesive materials.

[0069] At box 450, the binding rod is cut into a composite disk of the binding rod construction. The binding rod may be cut to a desired thickness Z, or cut to a thickness greater than the desired thickness Z and then trimmed to the desired thickness Z. It should be understood that the disk can be considered a shortened rod. In the embodiment, the rod can be considered a disk when its length is its minimum dimension. The “length” of the disk is then considered as the thickness. At box 455, the gap may optionally be filled with an insulating material to the outer boundary of the desired shape of the composite disk. At box 460, the composite disk of the binding rod construction is magnetized.

[0070] Figure 5A , Figure 5B and Figure 5C Various views of the chip 522 are shown. Figure 5A An example of a perspective view is shown. Figure 5B A plan view is shown, and Figure 5C An exploded view of core 522 is shown. Furthermore, Figure 5C An exploded view of a core 522 having a composite disk magnet 100 is illustrated. It should be understood that the composite disk magnet 100 is similar to the composite disk magnets discussed in this disclosure, and other embodiments of composite disk magnets can be utilized. Furthermore, elements similarly named and numbered can be coupled and function as described above. In one embodiment, the core 522 is used as a power transfer element in a switch-mode power converter. The power transfer element typically comprises a coil of wire wound around a portion of the core 522, which is a magnetically active material such as ferrite or steel. The core 522 provides a path for the magnetic field generated by the current flowing through the coil of wire. Figure 5A , Figure 5B and Figure 5C The core 522 shown includes a first portion 524 and a second portion 526. The first portion 524 includes side posts and a central post 525. Similarly, the second portion 526 also includes side posts and a central post 527. The central posts 525 and 527 are shown as cylindrical. In other words, the faces of the central posts 525 and 527 are generally circular. A central axis A 516 is shown passing through both the central posts 525 and 527. Furthermore, the circular faces of the central posts 525 and 527 are generally perpendicular to axis A 516. Figure 5A , Figure 5B and Figure 5C The orientation of axis A 516 shown is generally similar to that of axis A discussed above. Figure 5CIn this embodiment, axis A 516 passes through the central disk of the composite disk magnet 100 and is perpendicular to the surface of the central disk. Thus, the composite disk magnet 100 is aligned with the central posts 525 and 527 of the core 522.

[0071] In one embodiment, Figure 5A , Figure 5B and Figure 5C The core 522 shown is a magnetic core with circular central posts 525, 527. In the assembled energy transfer element, the central posts 525, 527 pass through a spool holding a wire coil surrounding the posts. A first portion 524 mates with a second portion 526. The assembled parts are held in place using mechanical clamps or tape, and then the assembly is sealed with varnish. As shown, an air gap 528 exists between the central posts 525 of the first portion 524 and the central posts 527 of the second portion 526. It should be understood that this air gap can be between any one or both of the side posts of the first portion 524 and any one or both of the side posts of the second portion 526. In one embodiment, a composite disc magnet 100 can be inserted into the air gap 528 between the first portion 524 and the second portion 526 of the core 522. The composite disc magnet can provide a flux density shift in the magnetic path to the core 522. In another embodiment, and as will be discussed below, a flat disc magnet can be inserted into the air gap 528 to provide flux density offset within the magnetic path to the core 522.

[0072] Figure 6A A perspective view of a substrate having disks 602a, 602b, 602c, 602d, 602e, 602f, and 602g is illustrated. In one embodiment, the substrate is a surface or medium on which a composite disk magnet and / or individual disks are applied. For the illustrated embodiment, any one of the central posts 525, 527 of the first portion 524 and the second portion 526 of the core 522 can be considered as the substrate. As will be discussed further, disks 602a, 602b, 602c, 602d, 602e, 602f, and 602g can be attached to any one of the central posts 525, 527. Disks 602a, 602b, 602c, 602d, 602e, 602f, and 602g can be assembled together as a composite disk magnet and / or a tiled disk magnet.

[0073] Figure 6B This is a plan view of disks 602a-1, 602b-1, 602c-1, 602d-1, 602e-1, 602f-1, and 602g-1 assembled as composite disk magnets 600 on a substrate such as center post 525 or center post 527. Disks 602a-1, 602b-1, 602c-1, 602d-1, 602e-1, 602f-1, and 602g-1 are... Figure 6AAn embodiment of disks 602a, 602b, 602c, 602d, 602e, 602f, and 602g is shown. As shown, Figure 6B The plan view is along axis A 616. Figure 6B The view shown is similar to Figure 1D A view of the composite disc magnet 100 is shown. The discs of the composite disc magnet 600 are housed within an outer boundary 112, and each disc touches or otherwise contacts its adjacent disc. Furthermore, discs 602a-1, 602b-1, 602c-1, 602d-1, 602e-1, 602f-1, and 602g-1 are attached to each other. In one embodiment, individual discs 602a-1, 602b-1, 602c-1, 602d-1, 602e-1, 602f-1, and 602g-1 are composite disc magnets because individual discs can maintain a desired pattern without additional support from the substrate or other surfaces. As shown, the outer boundary 112 can also be the outer edge of the substrate, such as the edge of the central post 525 or central post 527. Disks 602a-1, 602b-1, 602c-1, 602d-1, 602e-1, 602f-1, and 602g-1 are fixed on top of center post 525 or center post 527 and within outer boundary 112. Disks 602a-1, 602b-1, 602c-1, 602d-1, 602e-1, 602f-1, and 602g-1 are shown as being of substantially the same size; however, it should be understood that smaller or larger disks may be used within outer boundary 112.

[0074] for Figure 6B In the illustrated embodiment, disks 602a-1, 602b-1, 602c-1, 602d-1, 602e-1, 602f-1, and 602g-1 are coated with an electrically insulating material and can substantially contact adjacent disks. In one example assembly, disks 602a-1, 602b-1, 602c-1, 602d-1, 602e-1, 602f-1, and 602g-1 can be assembled together to form a composite disk magnet 600 and then placed on a substrate (center post 525 or center post 527). In another example assembly, disks 602a-1, 602b-1, 602c-1, 602d-1, 602e-1, 602f-1, and 602g-1 can be individually placed on the substrate (center post 525 or center post 527) using a device such as a pick-and-place machine. Optionally, the gaps between disks 602a-1, 602b-1, 602c-1, 602d-1, 602e-1, 602f-1 and 602g-1 and the outer boundary 112 can be filled with an electrically insulating filler.

[0075] Figure 6CThe disks 602a-2, 602b-2, 602c-2, 602d-2, 602e-2, 602f-2, and 602g-2 are also plan views of disks 602a-2, 602b-2, 602c-2, 602d-2, 602e-2, 602f-2, and 602g-2 assembled together on a substrate such as center post 525 or center post 527 as a tiled disk magnet 607. Disks 602a-2, 602b-2, 602c-2, 602d-2, 602e-2, 602f-2, and 602g-2 are... Figure 6A An embodiment of disks 602a, 602b, 602c, 602d, 602e, 602f, and 602g is shown. As shown, Figure 6C The plan view is along axis A616. Figure 6C and Figure 6B There are many similarities; however, at least one difference is that the individual disks 602a-2, 602b-2, 602c-2, 602d-2, 602e-2, 602f-2, and 602g-2 do not contact any of their neighboring disks. Because disks 602a-2, 602b-2, 602c-2, 602d-2, 602e-2, 602f-2, and 602g-2 do not contact each other, they may optionally be coated with an electrically insulating material. In one embodiment, the tiled disk magnet 607 may include multiple disks (such as disks 602a-2, 602b-2, 602c-2, 602d-2, 602e-2, 602f-2, and 602g-2) and a substrate. It should be understood that the individual disks of the tiled disk magnet may comprise materials similar to those of the individual disks of a composite disk magnet; however, the individual disks of the tiled disk magnet do not necessarily contact their neighboring disks. In an example assembly, disks 602a-2, 602b-2, 602c-2, 602d-2, 602e-2, 602f-2, and 602g-2 can be individually placed onto the substrate (center post 525 or center post 527) using a device such as a pick-and-place machine. This pick-and-place machine can align disks 602a-2, 602b-2, 602c-2, 602d-2, 602e-2, 602f-2, and 602g-2 so that they do not contact each other. In other words, disks 602a-2, 602b-2, 602c-2, 602d-2, 602e-2, 602f-2, and 602g-2 can be tiled onto the substrate and can be referred to as tiled disk magnets 607. Optionally, the gaps between disks 602a-2, 602b-2, 602c-2, 602d-2, 602e-2, 602f-2 and 602g-2 and the outer boundary 112 can be filled with an electrically insulating filler.

[0076] In one embodiment, a single disk can be considered a composite disk magnet if it can maintain a tiled pattern without a substrate. For example, individual disks 602a-2, 602b-2, 602c-2, 602d-2, 602e-2, 602f-2, and 602g-2 may not touch or otherwise contact their adjacent disks, but the electrically insulating filler allows the individual disks to maintain the desired pattern. Thus, individual disks 602a-2, 602b-2, 602c-2, 602d-2, 602e-2, 602f-2, and 602g-2 can be considered composite disk magnets.

[0077] Figure 7 Process 700 is illustrated as an example assembly of a composite disk magnet or a tiled disk magnet onto a portion of a substrate, such as a core. The order in which some or all of the process boxes appear in process 700 should not be considered limiting. Rather, those skilled in the art who benefit from this disclosure will understand that some of the process boxes may be performed in a variety of orders not illustrated, or even in parallel.

[0078] The assembly begins at frame 701 and proceeds to frame 705, where individual discs and substrates are assembled. Once assembled, the process proceeds to frame 710, where an adhesive is applied to the substrate to form the desired pattern for the individual discs. In other words, an adhesive is applied to the substrate to form the desired pattern for composite disc magnets or tiled disc magnets. Examples of adhesives may include cyanoacrylates (e.g., super glue) such as Loctite 414, however, other adhesives may also be used.

[0079] At frame 715, individual discs are mounted and adhered to the substrate in a desired pattern. For this embodiment, a pick-and-place machine can be used to mount the individual discs to the substrate. This machine can apply adhesive drops in a desired pattern and place the individual discs on the adhesive drops. In one embodiment, the adhesive can be placed in a desired pattern such that the individual discs are in contact with each other or otherwise touch each other to form a composite disc magnet. In another embodiment, the adhesive can be placed in a desired pattern such that the individual discs are not in contact with each other or otherwise touch each other to form a tiled disc magnet. The perimeter of the individual discs can be coated with an electrically insulating material. In one embodiment, the coating of the electrically insulating material can include the same or similar material as the adhesive used to bond the discs to the substrate. In some embodiments, the insulating coating can include a varnish, such as clear nail polish, or a polymer film, such as parylene. Furthermore, example processes for coating the discs can include the individual application of an insulating material or a suitable insulating material via chemical vapor deposition using appropriate tools. However, the discs can be placed such that they are not in contact with each other or otherwise touch each other, and in this case, the insulating coating can be optional. If the individual disk is at the desired thickness Z, the process can continue. However, if the individual disk is thicker than the desired thickness Z, the individual disk can be scraped or ground to the desired thickness Z. In one embodiment, the individual disk can be scraped or ground before or after being placed on the substrate.

[0080] At frame 720, the gaps may optionally be filled with an insulating material. In one embodiment, the gaps between the disks may be filled with an insulating material. In another embodiment, the gaps may be further filled to the outer boundary of the substrate. At frame 725, the disks are magnetized.

[0081] Figure 8A A perspective view of another example core 830 is shown. Core 830 is another example core that can be used as an energy transfer element in a switch-mode power converter. Figure 8A The core 830 shown includes a first portion 832 and a second portion 834. The first portion 832 includes side posts and a central post 833. Similarly, the second portion 834 also includes side posts and a central post 835. It should be understood that core 830 has many similarities to core 522; however, at least one difference is that the faces of the central posts 833 and 835 are generally square. A central axis 816 is shown passing through both central posts 833 and 835, and the square faces of the central posts 833 and 835 are generally perpendicular to axis A 816. Figure 8A The core 830 shown is an EE core with square central pillars 833 and 835. It can be used with... Figure 5A , Figure 5B and Figure 5CThe core with a circular central post is assembled in the same manner. As shown, an air gap 528 exists between the central post 833 of the first portion 832 and the central post 835 of the second portion 834. In one embodiment, a composite disc magnet or a flat disc magnet may be inserted into or otherwise placed in the air gap 528 between the first portion 832 and the second portion 834 of the core 830.

[0082] Figure 8B A perspective view of another example core 840 is shown. Core 840 is another example core that can be used as an energy transfer element in a switch-mode power converter. Figure 8B The shown core 840 includes a first portion 842 and a second portion 844. Core 840 is similar to... Figure 8A The core 830 is shown; however, at least one difference is that the first portion 842 of the core 840 does not have a side post or a center post. As shown, the first portion 842 may be a bar. The second portion 844 includes a side post and a center post 845. Figure 8B The core 840 shown is an EI core with a square central post 845. It can be used with... Figure 5A , Figure 5B and Figure 5C The core with the circular central post is assembled in the same manner. As shown, an air gap 528 exists between the central post 845 and the first part 842. In one embodiment, a composite disc magnet or a flat disc magnet can be inserted into the air gap 528 between the central post of the second part 844 and the first part 842.

[0083] Figure 8C It is placed in Figure 8A and Figure 8B A plan view of individual circular disks 802a-1, 802b-1, 802c-1, 802d-1, 802e-1, 802f-1, 802g-1, 802h-1, and 802i-1 assembled together on the surfaces of the central pillars 833, 835, or 845 as a composite disk magnet 850. As shown, Figure 8CThe plan view is along axis A 816. Disks 802a-1, 802b-1, 802c-1, 802d-1, 802e-1, 802f-1, 802g-1, 802h-1, and 802i-1 are housed within outer boundary 812 and touch or otherwise contact their adjacent disks. Furthermore, disks 802a-1, 802b-1, 802c-1, 802d-1, 802e-1, 802f-1, 802g-1, 802h-1, and 802i-1 are attached to each other. In one embodiment, individual disks 802a-1, 802b-1, 802c-1, 802d-1, 802e-1, 802f-1, 802g-1, 802h-1, and 802i-1 can be considered as composite disk magnets because individual disks can maintain the desired pattern without additional support from the substrate or other surfaces. In one embodiment, the outer boundary 812 can also be the outer edge of the face of the central post 833, 835, or 845. As shown, the outer edge 812 is generally square. Disks 802a-1, 802b-1, 802c-1, 802d-1, 802e-1, 802f-1, 802g-1, 802h-1, and 802i-1 are shown as being of substantially the same size; however, it should be understood that smaller or larger disks may be used within the outer boundary 812.

[0084] for Figure 8C In the illustrated embodiment, disks 802a-1, 802b-1, 802c-1, 802d-1, 802e-1, 802f-1, 802g-1, 802h-1, and 802i-1 are coated with an electrically insulating material and can substantially contact adjacent disks. In one example assembly, disks 802a-1, 802b-1, 802c-1, 802d-1, 802e-1, 802f-1, 802g-1, 802h-1, and 802i-1 can be assembled together to form a composite disk magnet 850, which is then placed on a substrate (center post 833, 835, or 845). In another example assembly, disks 802a-1, 802b-1, 802c-1, 802d-1, 802e-1, 802f-1, 802g-1, 802h-1, and 802i-1 can be individually placed onto the substrate (center post 833, 835, or 845) using equipment such as a pick-and-place machine. Optionally, the gap between disks 802a-1, 802b-1, 802c-1, 802d-1, 802e-1, 802f-1, 802g-1, 802h-1, and 802i-1 and the outer boundary 812 can be filled with an electrically insulating filler.

[0085] Figure 8D It is also placed in Figure 8A and Figure 8BThe central pillars 833, 835, or 845 are assembled together as individual circular disks 802a-2, 802b-2, 802c-2, 802d-2, 802e-2, 802f-2, 802g-2, 802h-2, and 802i-2 on the surface and as a flat disk magnet 860. It should be understood that disks 802a-2, 802b-2, 802c-2, 802d-2, 802e-2, 802f-2, 802g-2, 802h-2, and 802i-2 and... Figure 8C Disks 802a-1, 802b-1, 802c-1, 802d-1, 802e-1, 802f-1, 802g-1, 802h-1, and 802i-1 have many similarities and are therefore numbered accordingly. As shown, Figure 8D The plan view also follows axis A816. However, at least one difference is that the individual disks 802a-2, 802b-2, 802c-2, 802d-2, 802e-2, 802f-2, 802g-2, 802h-2, and 802i-2 do not contact any adjacent disks. In one embodiment, the tiled disk magnet 860 may include multiple disks (such as disks 802a-2, 802b-2, 802c-2, 802d-2, 802e-2, 802f-2, 802g-2, 802h-2, and 802i-2) and a substrate. Because disks 802a-2, 802b-2, 802c-2, 802d-2, 802e-2, 802f-2, 802g-2, 802h-2, and 802i-2 do not contact each other, the electrical insulating coating of each disk can be optional. In the illustrated embodiment, disks 802a-2, 802b-2, 802c-2, 802d-2, 802e-2, 802f-2, 802g-2, 802h-2, and 802i-2 are placed at the outer boundary 812; however, it should be understood that a gap may exist between the outer boundary 812 and the disks.

[0086] In an example assembly, disks 802a-2, 802b-2, 802c-2, 802d-2, 802e-2, 802f-2, 802g-2, 802h-2, and 802i-2 can be individually placed onto the substrate (center post 833, 835, or 845) using a device such as a pick-and-place machine. This pick-and-place machine will align disks 802a-2, 802b-2, 802c-2, 802d-2, 802e-2, 802f-2, 802g-2, 802h-2, and 802i-2 so that they do not contact each other. In other words, disks 802a-2, 802b-2, 802c-2, 802d-2, 802e-2, 802f-2, 802g-2, 802h-2, and 802i-2 can be laid flat on a substrate and can be referred to as a laid disk magnet 860. Optionally, the gap between disks 802a-2, 802b-2, 802c-2, 802d-2, 802e-2, 802f-2, 802g-2, 802h-2, and 802i-2 and the outer boundary 812 can be filled with an electrically insulating filler.

[0087] In one embodiment, a single disk can be considered a composite disk magnet if it can maintain a tiled pattern without a substrate. For example, individual disks 802a-2, 802b-2, 802c-2, 802d-2, 802e-2, 802f-2, 802g-2, 802h-2, and 802i-2 may not touch or otherwise contact their adjacent disks, but the electrically insulating filler allows the individual disks to maintain the desired pattern. Thus, individual disks 802a-2, 802b-2, 802c-2, 802d-2, 802e-2, 802f-2, 802g-2, 802h-2, and 802i-2 can be considered composite disk magnets.

[0088] Figure 8E It is placed in Figure 8A and Figure 8BA plan view of another embodiment of a composite disk magnet 870 comprising individual circular disks 802j-1, 802k-1, 802l-1, 802m-1, 802n-1, 802o-1, and 802p-1 on the square face of a central post 833, 835, or 845. Disks 802j-1, 802k-1, 802l-1, 802m-1, 802n-1, 802o-1, and 802p-1 are housed within an outer boundary 812 and contact or otherwise touch their adjacent disks. Furthermore, disks 802j-1, 802k-1, 802l-1, 802m-1, 802n-1, 802o-1, and 802p-1 are attached to each other, allowing the disks to maintain a desired pattern without the need for a substrate. The patterns of the individual disks are more irregular than the previously shown patterns. Disks 802m-1, 802n-1, 802o-1, and 802p-1 are generally patterned as squares and are of similar size. Disks 102a and 102c are of similar size and are larger than disks 102d, 102e, 102f, and 102g. Furthermore, disks 802j-1 and 802l-1 are placed between outer boundary 812 and disks 802m-1 and 802n-1, or between outer boundary 812 and disks 802n-1 and 802p-1, respectively. Disk 802k-1, as shown, is larger than disks 802j-1 and 802jl-1 and is placed between outer boundary 812 and disk 802n-1. Thus, Figure 8E and Figure 8F The example composite disc magnets 870 and / or tiled magnets 880 shown have discs of various sizes and irregular patterns. For Figure 8E In the embodiments shown, disks 802j-1, 802k-1, 802l-1, 802m-1, 802n-1, 802o-1, and 802p-1 are coated with an electrically insulating material and can substantially contact adjacent disks.

[0089] Figure 8F It is also placed in Figure 8A and Figure 8B Plan view of the individual circular disks 802j-2, 802k-2, 802l-2, 802m-2, 802n-2, 802o-2, and 802p-2 assembled together on the surface of the central pillar 833, 835, or 845 as a flat disc magnet 880. It should be understood that... Figure 8F Disks 802j-2, 802k-2, 802l-2, 802m-2, 802n-2, 802o-2, and 802p-2 and Figure 8EDisks 802j-1, 802k-1, 802l-1, 802m-1, 802n-1, 802o-1, and 802p-1 share many similarities and are correspondingly numbered. However, at least one difference is that individual disks 802j-2, 802k-2, 802l-2, 802m-2, 802n-2, 802o-2, and 802p-2 do not contact any of their neighboring disks. Because disks 802j-2, 802k-2, 802l-2, 802m-2, 802n-2, 802o-2, and 802p-2 do not contact each other, the insulating coating used for each disk can be optional. In one embodiment, the flat disc magnet 880 may include a plurality of discs (such as discs 802j-2, 802k-2, 802l-2, 802m-2, 802n-2, 802o-2 and 802p-2) and a substrate.

[0090] The above description of the illustrative embodiments of the invention, including those described in the abstract, is not intended to be exhaustive or to limit the precise forms disclosed. Although specific embodiments and examples of the invention have been described herein for illustrative purposes, various equivalent modifications are possible without departing from the broader spirit and scope of the invention. Indeed, it should be understood that specific examples of voltage, current, frequency, power range values, time, etc., are provided for illustrative purposes, and other values ​​may be employed in other embodiments and examples according to the teachings of the invention.

[0091] Although the invention is defined in the claims, it should be understood that the invention may be defined alternatively according to the following embodiments:

[0092] Example 1. A magnet, comprising: a central disk having a center configured as the center of the magnet, the face of the central disk being substantially perpendicular to the central axis of the magnet; and a first plurality of outer disks disposed around the central disk in a binding rod configuration, each of the first plurality of outer disks having a face substantially perpendicular to the central axis of the magnet, wherein the central disk and each of the first plurality of outer disks are electrically insulated from each other disk.

[0093] Example 2. The magnet according to Example 1, wherein the thickness of the central disk is substantially the same as the thickness of each of the first plurality of outer disks.

[0094] Example 3. The magnet according to Example 1 or 2, wherein the size of the central disk is substantially the same as the size of each of the first plurality of outer disks.

[0095] Example 4. The magnet according to any one of Examples 1 to 3, wherein the shape of the central disk and the shape of each of the first plurality of outer disks are substantially the same.

[0096] Example 5. A magnet according to any one of Examples 1 to 4, wherein the shape is generally circular.

[0097] Example 6. A magnet according to any one of Examples 1 to 5, wherein the shape is generally hexagonal.

[0098] Example 7. A magnet according to any one of Examples 1 to 6, wherein the central disk and each of the first plurality of outer disks are within the outer boundary of the magnet.

[0099] Example 8. A magnet according to any one of Examples 1 to 7, wherein there is a gap between the central disk and each of the first plurality of outer disks and between each of the first plurality of outer disks and the outer boundary, and the gap is filled with an insulating filler.

[0100] Example 9. A magnet according to any one of Examples 1 to 8, wherein the outer boundary, the central disk, and each of the first plurality of outer disks are generally circular in shape, and wherein the diameter of the outer boundary is greater than the diameter of the central disk and each of the first plurality of outer disks.

[0101] Example 10. A magnet according to any one of Examples 1 to 9, wherein the diameter of the outer boundary is three times the diameter of the central disk and three times the diameter of each of the first plurality of outer disks.

[0102] Example 11. The magnet according to any one of Examples 1 to 10 further includes:

[0103] The second plurality of outer disks are arranged around the central disk in a binding rod configuration having the central disk and each of the first plurality of outer disks, the face of each of the second plurality of outer disks being substantially perpendicular to the central axis of the magnet, and each of the first plurality of outer disks and each of the second plurality of outer disks being electrically insulated from each other disk.

[0104] Example 12. A magnet according to any one of Examples 1 to 11, wherein the outer boundary, the central disk, each of the first plurality of outer disks and each of the second plurality of outer disks are substantially circular in shape, wherein: the diameter of the outer boundary is greater than the diameter of the central disk and greater than the diameter of each of the first plurality of outer disks and greater than the diameter of each of the second plurality of outer disks, and the diameter of the central disk and the diameter of each of the first plurality of outer disks are greater than the diameter of each of the second plurality of outer disks.

[0105] Example 13. The magnet according to any one of Examples 1 to 12, wherein the central disk, each of the first plurality of outer disks and each of the second plurality of outer disks are coated with an insulating material.

[0106] Example 14. The magnet according to any one of Examples 1 to 13, wherein the central disk and each of the first plurality of outer disks are coated with an insulating material.

[0107] Example 15. A magnet includes: an outer boundary; and a first plurality of disks disposed within the outer boundary in a binding rod configuration, wherein the surface of each of the first plurality of disks is substantially perpendicular to the central axis of the magnet, and wherein each of the first plurality of disks is electrically insulated from each other of the first plurality of disks.

[0108] Example 16. The magnet according to Example 15, wherein each of the first plurality of disks has a substantially the same thickness.

[0109] Example 17. The magnet according to Example 15 or 16, wherein each of the first plurality of disks is substantially the same size.

[0110] Example 18. The magnet according to any one of Examples 15 to 17, wherein each of the first plurality of disks has a substantially identical shape.

[0111] Example 19. A magnet according to any one of Examples 15 to 18, wherein the shape is generally circular.

[0112] Example 20. A magnet according to any one of Examples 15 to 19, wherein the shape is generally hexagonal.

[0113] Example 21. A magnet according to any one of Examples 15 to 20, wherein the shape is generally triangular.

[0114] Example 22. A magnet according to any one of Examples 15 to 21, wherein the shape is generally disc-shaped.

[0115] Example 23. A magnet according to any one of Examples 15 to 22, wherein a gap exists between each of the first plurality of disks and the outer boundary, and the gap is filled with an insulating filler.

[0116] Example 24. The magnet according to any one of Examples 15 to 23, wherein the first plurality of disks comprises at least two different shapes.

[0117] Example 25. The magnet according to any one of Examples 15 to 24 further includes a second plurality of disks disposed within the outer boundary in the binding rod configuration, wherein the face of each of the second plurality of disks is substantially perpendicular to the central axis, and wherein each of the second plurality of disks and each of the first plurality of disks is electrically insulated from each other disk.

[0118] Example 26. A magnet according to any one of Examples 15 to 25, wherein each of the first plurality of disks is substantially the same size, and each of the second plurality of disks is substantially the same size, wherein the size of each of the first plurality of disks is different from the size of each of the second plurality of disks.

[0119] Example 27. The magnet according to any one of Examples 15 to 26, wherein each of the first plurality of disks and each of the second plurality of disks is coated with an insulating material.

[0120] Example 28. The magnet according to any one of Examples 15 to 27, wherein each of the first plurality of disks is coated with an insulating material.

[0121] Example 29. A method for constructing a composite disk magnet, comprising: assembling a plurality of disks of magnetizable material; coating the perimeter of the plurality of disks with an insulating material; attaching the plurality of disks to each other in a desired shape, wherein the surfaces of the plurality of disks are substantially perpendicular to the central axis of the composite disk magnet; and magnetizing the plurality of disks.

[0122] Example 30. The method according to Example 30 further includes trimming the thickness of each of the plurality of disks.

[0123] Example 31. The method according to Example 29 or 30 further includes filling the gap between the outer boundaries of the plurality of disks and the composite disk magnet with an insulating filler.

[0124] Example 32. The method according to any one of Examples 29 to 31, wherein attaching the plurality of disks into the desired shape further includes attaching the plurality of disks into the desired shape on a substrate.

[0125] Example 33. A method for constructing a composite disk magnet, comprising: assembling a plurality of rods of magnetizable material; coating the periphery of the plurality of rods with an insulating material; attaching the plurality of rods to each other such that the cross-sections of the plurality of rods are of a generally desired shape, wherein the cross-sections of the plurality of rods are generally perpendicular to the central axis of the composite disk magnet; cutting the plurality of rods into composite disk slices of a thickness; and magnetizing the composite disk slices.

[0126] Example 34. The method according to Example 33 further includes filling the gap between the outer boundaries of the composite disc slice and the composite disc magnet with an insulating filler.

[0127] Example 35. The method according to Example 33 or 34 further includes adjusting the thickness of the composite disc slice.

[0128] Example 36. A method for constructing a magnet on a substrate, comprising: assembling a plurality of disks of magnetizable material; assembling a substrate; placing an adhesive material onto the substrate in a desired pattern; attaching the plurality of disks to the adhesive material of the desired pattern onto the substrate, wherein the faces of the plurality of disks are substantially perpendicular to the central axis of the magnet; and magnetizing the plurality of disks.

[0129] Example 37. The method according to Example 36 further includes coating the perimeter of the plurality of disks with an insulating material.

[0130] Example 38. The method according to Example 36 or 27 further includes adjusting the thickness of the plurality of disks.

[0131] Example 39. The method according to any one of Examples 36 to 38 further includes filling the gap between the outer boundaries of the plurality of disks and the substrate with an insulating filler.

[0132] Example 40. The method according to any one of Examples 36 to 39, wherein attaching the plurality of disks to the substrate further includes attaching the plurality of disks using a pick-and-place machine.

[0133] Example 41. An energy transfer element for a power converter, comprising: a composite disc magnet including a first plurality of discs, each of the first plurality of discs having a face substantially perpendicular to the central axis of the composite disc magnet; and a core of magnetically active material, the core comprising: a first portion; a second portion; and an air gap between the first portion and the second portion, the composite disc magnet being accommodated in the air gap between the first portion and the second portion of the core.

[0134] Example 42. The energy transfer element according to Example 41 further includes a wire coil.

[0135] Example 43. The energy transfer element according to Example 41 or 42 further includes a spool.

[0136] Example 44. According to any one of Examples 41 to 43, the first plurality of disks are arranged around the central axis of the composite disk magnet in a binding rod configuration and each of the plurality of disks is electrically insulated from each other disk.

[0137] Example 45. An energy transfer element according to any one of Examples 41 to 44, wherein each of the first plurality of disks has a substantially the same thickness.

[0138] Example 46. An energy transfer element according to any one of Examples 41 to 45, wherein each of the first plurality of disks is substantially the same size.

[0139] Example 47. The energy transfer element according to any one of Examples 41 to 46, wherein each of the first plurality of disks has a substantially identical shape.

[0140] Example 48. The energy transfer element according to any one of Examples 41 to 47, wherein the second portion of the core further includes a central post, and the composite disc magnet is substantially positioned on the central post and within the outer boundary of the central post.

[0141] Example 49. The energy transfer element according to any one of Examples 41 to 48, wherein the gap between each of the first plurality of disks and the outer boundary is filled with an insulating filler.

[0142] Example 50. The energy transfer element according to any one of Examples 41 to 49, wherein each of the first plurality of disks is coated with an insulating material.

[0143] Example 51. A tiled disc magnet, comprising: a substrate having a surface; and a plurality of discs disposed on the surface of the substrate, wherein the face of each of the plurality of discs is substantially parallel to the surface of the substrate and each of the plurality of discs does not contact any other disc.

[0144] Example 52. A flat disc magnet according to Example 51, wherein each of the plurality of discs has a substantially the same thickness.

[0145] Example 53. A flat disc magnet according to Example 51 or 52, wherein each of the plurality of discs is substantially the same size.

[0146] Example 54. A flat disc magnet according to any one of Examples 51 to 53, wherein the size of at least one of the discs is not substantially the same as the size of another disc of the plurality of discs.

[0147] Example 55. A flat disc magnet according to any one of Examples 51 to 54, wherein each of the plurality of discs has a substantially identical shape.

[0148] Example 56. A flat disc magnet according to any one of Examples 51 to 55, wherein the shape is generally circular.

[0149] Example 57. A flat disc magnet according to any one of Examples 51 to 56, wherein the shape is generally hexagonal.

[0150] Example 58. A tiled disc magnet according to any one of Examples 51 to 57, wherein the plurality of discs are within the outer boundary of the tiled disc magnet.

[0151] Example 59. A flat disc magnet according to any one of Examples 51 to 58, wherein the gaps between the plurality of discs are filled with an insulating filler.

[0152] Example 60. A flat disc magnet according to any one of Examples 51 to 59, wherein the plurality of discs comprises at least two shapes.

[0153] Example 61. A flat disc magnet according to any one of Examples 51 to 60, wherein each of the plurality of discs is coated with an insulating material.

Claims

1. A method for assembling a composite disc magnet, the composite disc magnet comprising: A central disk having a center set as the center of the magnet, the surface of the central disk being substantially perpendicular to the central axis of the magnet, and The first plurality of outer disks are arranged around the central disk in a binding bar configuration and are glued or otherwise attached together, wherein each disk is a shortened bar, and the face of each of the first plurality of outer disks is substantially perpendicular to the central axis of the magnet, wherein the central disk and each of the first plurality of outer disks are electrically insulated from each other disk and coated with an insulating material, the method comprising: It begins with a plurality of individual rods of magnetizable material, wherein the length of each rod is greater than the thickness of the disk, wherein initially, the plurality of individual rods of magnetizable material are not magnetized; The individual rods are coated with the insulating material; The individual rods are then glued or otherwise attached together in the binding rod construction; The binding rod structure is then cut to a certain thickness to produce a composite disc; and Once the composite disc magnet is assembled, the composite disc magnet is magnetized.

2. The method of claim 1, wherein the thickness of the central disk is substantially the same as the thickness of each of the first plurality of outer disks.

3. The method of claim 1, wherein the size of the central disk is substantially the same as the size of each of the first plurality of outer disks.

4. The method of claim 1, wherein the shape of the central disk and the shape of each of the first plurality of outer disks are substantially the same.

5. The method of claim 4, wherein the shape is generally circular.

6. The method of claim 4, wherein the shape is generally hexagonal.

7. The method of claim 1, wherein the central disk and each of the first plurality of outer disks are within the outer boundary of the magnet.

8. The method of claim 7, wherein a gap exists between the central disk and each of the first plurality of outer disks and between each of the first plurality of outer disks and the outer boundary, and the gap is filled with an insulating filler.

9. The method of claim 7, wherein the outer boundary, the central disk, and each of the first plurality of outer disks are substantially circular in shape, and wherein the diameter of the outer boundary is greater than the diameter of the central disk and each of the first plurality of outer disks.

10. The method of claim 9, wherein the diameter of the outer boundary is three times the diameter of the central disk and three times the diameter of each of the first plurality of outer disks.

11. The method according to claim 7, wherein the composite disc magnet further comprises: The second plurality of outer disks are arranged around the central disk in the binding rod configuration having the central disk and each of the first plurality of outer disks, the face of each of the second plurality of outer disks being substantially perpendicular to the central axis of the magnet, and each of the first plurality of outer disks and each of the second plurality of outer disks being electrically insulated from each other disk.

12. The method of claim 11, wherein the outer boundary, the central disk, each of the first plurality of outer disks, and each of the second plurality of outer disks are substantially circular in shape, wherein: The diameter of the outer boundary is greater than the diameter of the central disk and greater than the diameter of each of the first plurality of outer disks, and greater than the diameter of each of the second plurality of outer disks. The diameter of the central disk and the diameter of each of the first plurality of outer disks are greater than the diameter of each of the second plurality of outer disks.

13. The method of claim 11, wherein the central disk, each of the first plurality of outer disks, and each of the second plurality of outer disks are coated with an insulating material.

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