MIM magnet

Abstract

The invention relates to an MIM magnet. Examples provide a magnet for an electronic device. The magnet may be formed as a monolithic structure using metal injection molding. The magnet may be referred to as a neodymium magnet. That is, they may be formed of neodymium, iron and boron. The magnet may include a plurality of easy axes, wherein the plurality of easy axes are not parallel.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 540,775, filed on September 27, 2023, entitled “MIM Magnet,” and U.S. Non-Provisional Application No. 18 / 896,214, filed on September 25, 2024, entitled “MIM Magnet,” which are incorporated herein by reference in their entirety. Background Art

[0003] The number of commercially available electronic devices of various types has increased dramatically over the past few years, and the rate of introduction of new electronic devices shows no sign of slowing down. Electronic devices such as tablet computers, laptop computers, all-in-one computers, desktop computers, smart phones, storage devices, wearable computing devices, portable media players, portable computing devices, navigation systems, monitors, audio devices, remote controls, adapters, etc. have become ubiquitous.

[0004] These electronic devices often include magnets for a variety of reasons. Magnets can be used to attach two electronic devices together. Magnets can be used to attach an electronic device to an accessory. Magnets can be used to secure one part of an electronic device to another part of an electronic device.

[0005] More specific examples may include magnets that can hold an audio device in a case for charging. Other magnets can hold a case in a closed position. Magnets can be used on smartphones to attach and align wallets, battery packs, chargers, camera adapters, and other accessories. Magnets can be used to attach tablet computers to keyboards and other input devices.

[0006] But these magnets can take up space in their electronic devices. Using this space can require increasing the size of the electronic device housing the magnets, reducing the functionality of the electronic device, or both.

[0007] In addition, conventional magnet manufacturing may result in the generation of unused resources. For example, excess material may be cut away to produce a magnet with a specific shape or form factor. While these resources can be recycled or reused, additional resources are required to do so.

[0008] Therefore, what are needed are magnets that are stronger, smaller, or both, and easier to manufacture, as well as methods and apparatus that can manufacture magnets with reduced amounts of resources. Summary of the invention

[0009] Thus, embodiments of the present invention may provide magnets that are stronger, smaller, or both, and easier to manufacture, as well as methods and apparatus that can manufacture magnets with a reduced amount of resources.

[0010] Exemplary embodiments of the present invention can provide a monolithic magnet having a stronger magnetic field than a combination of magnets. The magnet can be formed as a single piece using metal injection molding or other processes. The magnet can be a neodymium magnet. That is, the magnet can be formed of neodymium, iron and boron (NdFeB or NIB). In these and other embodiments of the present invention, other materials, such as rare earth materials, can be used. Samarium cobalt, manganese bismuth or other materials can be used. Ferrite materials can also be used.

[0011] Conventional magnets for electronic devices can be formed by several magnets attached together. Each of the individual magnets may include an easy axis formed in one direction. The combination of magnets can be arranged proximally and fixed together, for example using epoxy or other adhesives, retainers, magnetic shields or other structures. But this may be inefficient and may result in large magnetic structures. Therefore, embodiments of the present invention may provide a monolithic magnet that may include an easy axis that can be positioned in three dimensions. Using such a monolithic magnet can be more efficient. This efficiency can reduce the size of the required magnet, thereby saving resources. This can reduce the volume required for the magnet in the electronic device, can provide a stronger magnetic field, or a combination of these. This efficiency can also reduce excess or unwanted magnetic flux around the magnet and the electronic device, thereby providing some protection for magnetically stored information (such as information on a credit card).

[0012] These and other embodiments of the present invention can provide magnets that are easy to manufacture. For example, the magnet can be formed by metal injection molding or other molding processes. While forming the magnet, multiple magnets can be used to strengthen the multiple magnetic pole directions in the magnet. That is, while forming the magnet, multiple magnets can be placed around the molded part. The multiple magnets can be permanent magnets, pole pieces, electromagnets, or a combination of these and other magnetic structures. Multiple magnets can cause the magnetic domains on the outer surface of the grains in the same magnet to be pinned in different directions, so that the easy axis of the magnet has a curvature. This allows a single magnet to mimic multiple magnets positioned proximally to each other.

[0013] The use of metal injection molding processes can save resources required to form magnets for electronic devices. Conventional magnets can be formed by starting with a block of magnetic material and then removing excess magnetic material until a magnet with a desired form factor is retained. Excess material can be recycled, but the recycled material needs further processing before reuse, and this further processing may require additional resources. Therefore, these and other embodiments of the present invention can utilize metal injection molding or other molding when forming magnets. Only enough magnetic material required for the actual magnet is used, and smaller excess parts, such as gate residues and parting lines, are used to save resources. Smaller excess parts, such as gate residues and parting lines, can be trimmed from the finished magnet and can be easily reused without further processing or with only a small amount of processing when making additional magnets, which can further save resources.

[0014] These and other embodiments of the present invention can provide various types of magnets. For example, embodiments of the present invention can provide magnets with shapes that may not be achieved using conventional methods. Embodiments of the present invention can provide a monolithic magnet with adjacent surfaces that intersect to form one of an acute angle or an obtuse angle. This is particularly useful when mounting the magnet in a small space of a small electronic device, such as an earbud or other electronic device.

[0015] Embodiments of the present invention may provide a magnet that replaces a plurality of magnets. The plurality of magnets that are replaced may include a curved surface. The easy axis direction of each of the plurality of magnets may be orthogonal to the curved surface. Embodiments of the present invention may provide a monolithic magnet having an easy axis direction that forms at least about a 180 degree turn in the magnet.

[0016] Embodiments of the present invention may provide a magnet that replaces a magnet having a first polarity at a first side, a second polarity at a second side, and no magnetic polarity at the center. Embodiments of the present invention may provide a monolithic magnet having a first easy axis direction in a first direction at a first side, and a second easy axis direction in a second direction at a second side. The middle of the monolithic magnet may also have a third easy axis direction having a polarity pointing in a third direction, wherein the third direction is from the second side to the first side. The first easy axis direction and the second easy axis direction may converge at one of an acute angle or an obtuse angle. The third easy axis direction in the middle of the magnet may allow the monolithic magnet to be more efficient and therefore have a stronger magnetic field, a smaller size, or a combination thereof. These different easy axis directions may provide non-parallel and non-anti-parallel polarities.

[0017] Embodiments of the present invention may provide a magnet that replaces an array of magnets. The monolithic magnet may include an array of segments having different easy axes, wherein each segment provides a first polarity or a second polarity facing a surface of an electronic device, and wherein each row in the array includes a segment providing a first polarity and a segment having a second polarity facing the surface, and each column in the array includes a segment having a first polarity and a segment having a second polarity facing the surface.

[0018] Embodiments of the present invention may use a monolithic magnet to simulate a Halbach array (or implement the functionality of such an array).These embodiments may provide a monolithic magnet in which the magnetic field strength on a first side of the magnet is stronger than the magnetic field on a second side of the magnet.

[0019] These and other embodiments of the present invention can provide magnets of other shapes. For example, embodiments can provide conventional bar magnets. Such bar magnets can be manufactured more efficiently because commercially available bar magnets may not be available in the exact dimensions required, and therefore material still needs to be removed to form the bar magnets. In addition, embodiments can provide stronger magnets that are commercially available. Other shapes such as plus or "X" shaped magnets, ring magnets, "S" shaped magnets, horseshoe magnets, or other shaped magnets can be formed using embodiments of the present invention.

[0020] Embodiments of the present invention may provide a monolithic magnet having different easy axis directions at different locations. In addition, embodiments may provide a monolithic magnet having one polarity direction throughout the magnet. Such magnets may be manufactured more efficiently because commercially available magnets may not be available in the exact dimensions required, and thus material still needs to be removed to form a magnet having one polarity direction. In addition, embodiments may provide stronger magnets that are commercially available.

[0021] Various embodiments of the present invention may include one or more of these and other features described herein.The nature and advantages of the present invention may be better understood by referring to the following detailed description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1A and Figure 1B A magnet according to an embodiment of the present invention is shown;

[0023] Figure 2A A set of magnets is shown, and Figure 2B An integral magnet according to an embodiment of the present invention is shown, which can replace Figure 2A A magnet group;

[0024] Figure 3 shows a monolithic magnet according to an embodiment of the present invention;

[0025] Figure 4A A set of magnets is shown, and Figure 4B An integral magnet according to an embodiment of the present invention is shown, which can replace Figure 4A A magnet group;

[0026] Figure 5A shows a magnet, and Figure 5B An integral magnet according to an embodiment of the present invention is shown, which can improve Figure 5A magnet;

[0027] Fig. 6A An electronic device including a plurality of magnet groups is shown, and Figure 6B It shows that you can replace Fig. 6A A plurality of integral magnets of a magnet group in the magnet group;

[0028] Fig. 7A A Halbach array formed by a plurality of magnets is shown, and Figure 7B A monolithic magnet implemented as a simulated Halbach matrix is ​​shown, which can replace Fig. 7A magnet;

[0029] Figure 8 A molding system that can be used to manufacture an integrally molded magnet according to an embodiment of the present invention is shown;

[0030] Fig. 9 shows the processes involved in manufacturing a magnet according to an embodiment of the present invention;

[0031] Fig.10 A method of manufacturing a magnet according to an embodiment of the present invention is shown;

[0032] Fig.11 shows a configuration of coils that may be used during the manufacture of a magnet according to an embodiment of the present invention;

[0033] Fig.12 shows a configuration of coils that may be used during manufacture of a magnet according to an embodiment of the present invention; and

[0034] Fig.13 A configuration of coils that may be used during the manufacture of a magnet according to an embodiment of the present invention is shown. DETAILED DESCRIPTION

[0035] Figure 1A and Figure 1BShown is a monolithic magnet according to an embodiment of the present invention. Magnet 100 may include several curved surfaces, acute surfaces, obtuse surfaces, tapered surfaces and other non-orthogonal surfaces and intersections of surfaces. For example, magnet 100 may include curved surface 140. Magnet 100 may include surface 110 and surface 150 that may intersect to form an acute angle. Surface 120 and surface 130 may intersect to form an obtuse angle. Magnet 100 may also include surface 110, surface 120 and surface 150 that may intersect at tapered point 112. These different profiles may be provided using metal injection molding or other techniques provided by embodiments of the present invention. These profiles are extremely difficult or impossible to machine out of a block.

[0036] The easy axis (not shown) can be in different directions in different parts of the magnet 100. Therefore, the magnetic pole direction of the magnet 100 can be non-linear. For example, the magnetic pole direction can enter the surface 130 and leave the surface 160, which can be non-opposite sides. The magnetic pole direction can be orthogonal or perpendicular to the curvature of the surface 140. That is, the easy axes at different locations of the magnet 100 can be non-parallel. In these and other embodiments of the present invention, the magnet can have a polar direction. For example, the magnet 100 can be formed to have a polar direction.

[0037] The monolithic magnet 100 can be formed by metal injection molding or other molding processes. Using metal injection molding or other molding processes can provide a monolithic magnet 100 with shapes, features and nonlinear or non-parallel magnetic field characteristics, which may be impossible or difficult to manufacture in other ways, especially in mass production. The monolithic magnet 100 can be referred to as a neodymium magnet. That is, the magnet 100 can be formed by neodymium, iron and boron (NdFeB). In these and other embodiments of the present invention, other materials such as rare earth materials, such as samarium cobalt, manganese bismuth or other materials can be used. Ferrite materials can also be used. Powdered neodymium, iron and boron (NdFeB) can be formed by grinding crystal NdFeB and combined with a binder to produce a feedstock. The feedstock can be heated and injected into a mold. A magnetic field can be applied to the mold to strengthen the non-parallel easy axis. The molded magnet can be debonded, that is, the binder can be removed. The molded magnet can be sintered, and then the result can be used in electronic devices. Portions of the molded magnet, such as gate remnants and parting lines, can be removed before or after sintering and reused as feedstock. The molded magnet can include voids or open areas within its volume. For example, the monolithic magnet 100 can include 2%, 3%, 4%, or other percentages of voids.

[0038] During the molding process, a magnetic field may be applied to the magnet 100 to strengthen the nonlinear magnetic pole direction of the magnet 100. That is, a magnetic field may be applied to the magnet 100 during the molding process to strengthen the nonlinear easy axis of the magnet 100. These magnets may be permanent magnets, magnetic elements such as pole pieces, electromagnets, or other structures capable of delivering or generating a magnetic field, or a combination of these. Figure 8 Examples are shown in . The figure below shows examples of other magnets that can have nonlinear or non-parallel easy axes.

[0039] Figure 2A A set of magnets is shown, and Figure 2B An integral magnet according to an embodiment of the present invention is shown, which can replace Figure 2A of magnet groups. Figure 2A A set of magnets 200 is shown, the set of magnets including magnet 210, magnet 212, magnet 214, and magnet 216. Magnet 210, magnet 212, magnet 214, and magnet 216 can be held together and supported by base 230 and base 232. Magnet 210, magnet 212, magnet 214, magnet 216, base 230, and base 232 can be held together using an adhesive or other material. Magnet 210 can include an easy axis direction 220 approximately orthogonal to surface 211. Magnet 212 can include an easy axis direction 222 approximately orthogonal to surface 213. Magnet 214 can include an easy axis direction 224 approximately orthogonal to surface 215. Magnet 216 can include an easy axis direction 226 approximately orthogonal to surface 217.

[0040] Magnets 210 and 212 may have poles of a first polarity that may be positioned such that they are at least approximately orthogonal to surfaces 211 and 213, respectively. Magnets 214 and 216 may have poles of a second polarity that may be positioned such that they are at least approximately perpendicular to surfaces 215 and 217, respectively. The easy axis of each of magnets 210, 212, 214, and 216 may be oriented in its easy axis direction, easy axis direction 220, easy axis direction 222, easy axis direction 224, and easy axis direction 226.

[0041] Figure 2B An integral magnet according to an embodiment of the present invention is shown, which can replace Figure 2A The monolithic magnet 240 may include a curved surface 242 having a first portion 244 and a second portion 246. The easy axis directions 250 may be substantially orthogonal to the portion 246 of the surface 242, and they may be substantially orthogonal to the portion 244 of the surface 242. This may result in the portion 246 of the surface 242 having a first polarity and the portion 244 of the surface 242 having a second polarity.

[0042] Magnet 240 may have a pole of a first polarity that may be positioned at least approximately normal to portion 244 of surface 242. Magnet 240 may have a pole of a second polarity that may be positioned at least approximately normal to portion 246 of surface 242. The polarity of magnet 240 may follow a curve that may be oriented in the direction of easy axis direction 250.

[0043] The magnet 240 may be a monolithic magnet. That is, the magnet 240 may be formed as a single piece. Figure 2A 200 and 210 , but a base (not shown) may be used to secure magnet 240 in place in an electronic device. In addition, since magnet 240 is a unitary magnet, no adhesive or other material is required to attach portions of the magnet together. This can reduce the number of parts required to manufacture an electronic device, and can simplify its assembly, save resources, and reduce rework. This can also result in a smaller unitary magnet 240, which saves space compared to magnet set 200. This space saving can allow an electronic device including unitary magnet 240 to be smaller, can allow the electronic device to include more functionality, or both. Although easy axis directions 250 are shown as converging, unitary magnet 240 can include divergent easy axis directions.

[0044] The magnet 240 can be formed by metal injection molding or other molding processes. The magnet 240 can be referred to as a neodymium magnet. That is, the magnet 240 can be formed of neodymium, iron and boron. In these and other embodiments of the present invention, other materials such as rare earth materials, such as samarium cobalt, manganese bismuth or other materials, can be used. Ferrite materials can also be used. Powdered neodymium, iron and boron (NdFeB) can be formed by grinding crystal NdFeB and combined with a binder to produce a feedstock. The feedstock can be heated and injected into a mold. A magnetic field can be applied to the mold to strengthen the non-parallel easy axis. The molded magnet can be debonded, that is, the binder can be removed. The molded magnet can be sintered, and then the result can be used in an electronic device. Parts of the molded magnet, such as gate residues and parting lines, can be removed before or after sintering and reused as feedstock. The molded magnet can include voids or open areas within its volume. For example, the monolithic magnet 240 can include 2%, 3%, 4% or other percentages of voids.

[0045] During the forming process, a magnetic field may be applied to the magnet 240 to strengthen the nonlinear magnetic pole direction of the magnet 240. That is, a magnetic field may be applied to the magnet 240 during the forming process to strengthen the nonlinear easy axis of the magnet 240. The magnetic field may be generated using permanent magnets, pole pieces, electromagnets, or a combination of these and other magnetic structures. Figure 8An example is shown in FIG. In this example, the easy axis direction 250 can be enhanced in various ways during the manufacturing process. For example, electromagnets having windings around a U-shaped core can be positioned on the front and back sides of the magnet 240 ( Figure 2B The U-shaped core follows the contour of the desired easy axis direction 250 (as viewed from the front side in FIG. 2 ). The current flowing through the windings can strengthen the magnetic domains in the magnet 240 to align in a curved manner to produce the desired easy axis direction 250.

[0046] Figure 3 An integral magnet according to an embodiment of the present invention is shown. The magnet 300 may have a first side 310 along the outer periphery and a second side 320 along the inner periphery. The magnet 300 may have an arc shape. In this example, the magnet 300 may have a semicircular shape, but in other examples, the magnet 300 may be smaller than a semicircle or larger than a semicircle, for example, the magnet 300 may be a full circle instead. The magnet 300 may be one of two magnets that may be put together to form a complete circle. A pair of semicircular magnets may be used in each of two compatible electronic devices to provide an attachment mechanism between the electronic devices. For each pair of semicircular magnets, the easy axis direction may be different. The following figure shows an example.

[0047] Figure 4A A set of magnets is shown, and Figure 4B An integral magnet according to an embodiment of the present invention is shown, which can replace Figure 4A of magnet groups. Figure 4A A set of magnets 400 is shown, which includes magnets 430, magnets 432, magnets 434, and magnets 436. Magnets 430, magnets 432, magnets 434, and magnets 436 can be held together using a base, shield or other structure, adhesive (such as epoxy) or other structure, material, or combination of structures or materials. Magnets 432, magnets 434, and magnets 436 can have an outer edge 410 along an outer perimeter and an inner edge 420 along an inner perimeter.

[0048] Magnet 430 may have easy axis directions 440. Like the other easy axis directions shown in this example, easy axis directions 440 may be parallel to each other and may extend from outer edge 410 to inner edge 420. Magnet 432 may have easy axis directions 442, which may also be parallel to each other. Similarly, magnet 434 may have parallel easy axis directions 444, and magnet 436 may have parallel easy axis directions 446. The parallel easy axis directions may tend to converge at the center of the circle defined by the arc formed by magnet group 400, but actual convergence is not achievable because the easy axis directions are parallel to each other within each magnet. Therefore, embodiments of the present invention may provide a monolithic magnet to replace magnet group 400. Monolithic magnets may have easy axis directions that converge at the center point of the circle defined by the arc formed by the monolithic magnets. Figure 4B An example is shown in .

[0049] Figure 4B An integral magnet according to an embodiment of the present invention is shown, which can replace Figure 4A Because magnet 450 is a unitary magnet, magnet 450 does not need to be held together using a base, shielding, epoxy, or other material, thereby simplifying the assembly process of an electronic device that houses integral magnet 450. Some of these or other materials can be used to secure integral magnet 450 in place in an electronic device. Integral magnet 450 can be more efficient, thereby allowing integral magnet 450 to be smaller. This reduced size can save space in the electronic device, allow additional functionality to be included in the electronic device, or a combination of both.

[0050] The integrated magnet 450 can have an outer edge 460 along an outer periphery and an inner edge 470 along an inner periphery. The easy axis directions 448 can extend in a direction from the outer edge 460 to the inner edge 470. The easy axis directions 448 can converge at a center 490 of a circle defined by the arc of the integrated magnet 450. This can help increase the magnetic properties of the magnet 450 in the first electronic device and other integrated magnets such as the integrated magnet 550 (e.g., Figure 5B The attraction between the magnets (shown) of the integral magnet 450 can have a true radial rather than polygonal polarity orientation, which can increase electromagnetic efficiency.

[0051] The integral magnet 450 can have poles of a first polarity that can be located along an outer edge 460 of the magnet 450. The integral magnet 450 can have poles of a second polarity that can be located along an inner edge 470 of the magnet 450. The magnet 450 can generate field lines that can be oriented along an easy axis direction 448.

[0052] The monolithic magnet 450 can be formed by metal injection molding or other molding processes. The magnet 450 can be referred to as a neodymium magnet. That is, the magnet 450 can be formed by neodymium, iron and boron. In these and other embodiments of the present invention, other materials such as rare earth materials, such as samarium cobalt, manganese bismuth or other materials can be used. Ferrite materials can also be used. Powdered neodymium, iron and boron (NdFeB) can be formed by grinding crystal NdFeB and combined with a binder to produce a feedstock. The feedstock can be heated and injected into a mold. A magnetic field can be applied to the mold to strengthen the non-parallel easy axes. Figure 8 An example is shown in . The molded magnet can be debonded, that is, the binder can be removed. The molded magnet can be sintered, and the result can then be used in an electronic device. Portions of the molded magnet, such as gate residues and parting lines, can be removed before or after sintering and reused as feedstock. The molded magnet can include voids or open areas within its volume. For example, the monolithic magnet 450 can include 2%, 3%, 4%, or other percentages of voids.

[0053] During the molding process, a magnetic field can be applied to the magnet 450 to strengthen the nonlinear magnetic pole direction of the magnet 450. That is, a magnetic field can be applied to the magnet 450 during the molding process to strengthen the nonlinear easy axis of the monolithic magnet 450. The magnetic field can be generated using permanent magnets, pole pieces, electromagnets, or a combination of these and other magnetic structures. In this example, the easy axis direction 448 can be strengthened in various ways during the manufacturing process. For example, the first polarity of the magnet can be positioned in the center 490 of the circle defined by the arc of the magnet 450. The second polarity of the magnet can be placed along the outer edge 460 of the magnet 450. This can generate a magnetic field that can align the grains of the magnet 450 during molding so that the finished magnet 450 has an easy axis direction 448.

[0054] Figure 5A shows a magnet, and Figure 5B An integral magnet according to an embodiment of the present invention is shown, which can improve Figure 5A of magnets. Figure 5A A magnet 500 is shown. The magnet 500 can be supported by a shield 505 or other structure. The magnet 500 can have a first end 510 and a second end 520. The magnet 500 can have a non-magnetized portion 530 between the first end 510 and the second end 520. The first end 510 can have an easy axis direction that produces a polarity 540, and the second end 520 can have an easy axis direction that produces a polarity 542. The polarity 540 and the polarity 542 can be parallel. That is, the polarity 540 produced by the easy axis direction and the polarity 542 produced by the easy axis direction can be non-convergent.

[0055] The easy axis of the first end 510 may be in the same direction as the easy axis of the second end 520. The magnetic pole directions of the first end 510 and the second end 520 may be in opposite directions. The first end 510 may have a magnetic pole of a first polarity at a surface 512, and the second end 520 may have a magnetic pole of a second polarity at a surface 522.

[0056] Portion 530 of magnet 500 is not magnetized, or at least not strongly magnetized. For example, first end 510 of magnet 500 may be magnetized in a first direction, while the other end 520 of magnet 500 may be magnetized in a second opposite direction. Portion 530 is not magnetized in view of the limitations of the magnetizer. To complete the path of the magnetic flux of magnet 500, shield 505 may be used.

[0057] More specifically, magnet 500 may be one of a group of magnets forming an arc. This may be combined with magnet group 400 (eg, Figure 4A That is, magnet 500 may have the same or similar properties as magnet 400 (as shown). Figure 4A The first circular magnet may be formed by a magnet group 500 and placed in a first electronic device (not shown). The second electronic device (not shown) may include two magnets 450 (such as Figure 4B ). Magnetic flux from the first end 510 of the magnet 500 can pass through the shield 505, thereby bypassing the non-magnetized portion 530, and pass through the other end 520 of the magnet 500. The magnetic flux can pass from the outer edge 460 of the monolithic magnet 450 to the inner edge 470 and back to the first end 510 of the magnet 500.

[0058] Therefore, magnet 500 may have several limitations. Multiple magnets 500 are required to form a semicircular arc. In addition, the non-magnetized portion 530 reduces the effectiveness of magnet 500 and reduces the strength of the magnetic field of magnet 500. Due to the presence of non-magnetized portion 530, a shield may need to be used with magnet 500 to generate a sufficient magnetic field to attach two electronic devices together. Therefore, embodiments of the present invention can provide a monolithic magnet, each of which can form a semicircular magnet and does not include a non-magnetized portion, so a shield is not required. Examples are shown in the following figure.

[0059] Figure 5B An integral magnet according to an embodiment of the present invention is shown, which can improve Figure 5A of magnets. Figure 5AAn integral magnet 500 is shown. When assembled into an electronic device, the magnet 500 can be supported by a shield, a plastic housing, or other structure. The magnet 500 can have a first end 560 and a second end 570. The magnet 500 can have a transverse magnetized portion 580 between the first end 560 and the second end 570. The first end 560 can have an easy axis direction that produces a polarity 590, and the second end 570 can have an easy axis direction that produces a polarity 594. The portion 580 can have an easy axis direction that produces a polarity 592 extending from the first end 560 to the second end 570. The easy axis direction that produces the polarity 590 and the easy axis direction that produces the polarity 592 can be non-parallel easy axis directions. That is, the easy axis direction that produces the polarity 540 and the easy axis direction that produces the polarity 542 can be converging easy axis directions.

[0060] The easy axis of the first end 560 may be in a different direction than the easy axis of the second end 570. The magnetic pole directions of the first end 560 and the second end 570 may be substantially opposite directions, but not parallel and converging. The first end 560 may have a magnetic pole of a first polarity at a surface 562, and the second end 570 may have a magnetic pole of a second polarity at a surface 572.

[0061] With the portion 530 of the magnet 500 (such as Figure 5A 500). For example, a first end 560 of the magnet 550 may be magnetized in a first direction, while the other end 570 of the magnet 550 may be magnetized in a second, opposite direction that is slightly closer. The portion 580 may be magnetized in a direction from the first end 560 to the second end 570. This may complete the path of the magnetic flux of the magnet 550 without the need for a shield.

[0062] More specifically, magnet 550 may be a unitary magnet forming an arc (e.g., a semicircle), but the profile of magnet 500 may be larger or smaller than a semicircle. This may be similar to magnet 450 (e.g., Figure 4B That is, magnet 550 may have the same or similar properties as magnet 450 (as shown). Figure 4B The first circular magnet may be formed by a magnet group 550 and placed in a first electronic device (not shown). The second electronic device (not shown) may include a magnet group 550 formed by two magnets 450 (such as Figure 4BThe magnetic flux from the first end 560 of the magnet 550 can pass through the portion 580 without the need for a shield, and through the other end 570 of the magnet 550. The magnetic flux can pass from the outer edge 460 of the integral magnet 450 to the inner edge 470, and back to the first end 560 of the magnet 550. In this way, the integral magnet 450 and the integral magnet 550 can form a strong magnetic attraction between the first electronic device and the second electronic device.

[0063] The monolithic magnet 550 can be formed by metal injection molding or other molding processes. The magnet 550 can be referred to as a neodymium magnet. That is, the magnet 550 can be formed by neodymium, iron and boron. In these and other embodiments of the present invention, other materials such as rare earth materials, such as samarium cobalt, manganese bismuth or other materials can be used. Ferrite materials can also be used. Powdered neodymium, iron and boron (NdFeB) can be formed by grinding crystal NdFeB and combined with a binder to produce a feedstock. The feedstock can be heated and injected into a mold. A magnetic field can be applied to the mold to strengthen the non-parallel easy axes. Figure 8 An example is shown in . The molded magnet can be debonded, that is, the binder can be removed. The molded magnet can be sintered, and the result can then be used in an electronic device. Portions of the molded magnet, such as gate residues and parting lines, can be removed before or after sintering and reused as feedstock. The molded magnet can include voids or open areas within its volume. For example, the monolithic magnet 550 can include 2%, 3%, 4%, or other percentages of voids.

[0064] During the molding process, a magnetic field can be applied to the magnet 550 to strengthen the nonlinear magnetic pole direction of the magnet 550. That is, a magnetic field can be applied to the magnet 550 during the molding process to strengthen the nonlinear easy axis of the monolithic magnet 550. The magnetic field can be generated using permanent magnets, pole pieces, electromagnets, or a combination of these and other magnetic structures. In this example, the easy axis directions that produce polarities 590, 592, and 594 can be enforced in various ways during the manufacturing process. For example, an electromagnet can be placed above the magnet 550, where the electromagnet can be bent to follow the semicircular profile of the magnet 550. The resulting magnetic field can be around the magnet 550, which can align the grains of the magnet 550 during molding so that the finished magnet 550 has an easy axis direction that produces polarities 590, 592, and 594.

[0065] Fig. 6A An electronic device including a plurality of magnet groups is shown, and Figure 6B It shows that you can replace Fig. 6A Multiple integral magnets in a magnet group. Fig. 6AA magnet array 610 is shown having a plurality of magnets 620 with a first pole facing a bottom surface of the electronic device 600 (as shown) and a plurality of magnets 630 with a second pole facing a bottom surface of the electronic device 600. Each row in the magnet array 610 may include one or more magnets with a first pole and one or more magnets with a second pole facing the bottom of the electronic device 600. Each column in the magnet array 610 may include one or more magnets with a first pole and one or more magnets with a second pole facing the bottom of the electronic device 600. The magnet array 610 may be used to attach a second electronic device (not shown) to the electronic device 600. For example, the second electronic device may include a set of magnets with opposite poles that attract the magnet array 610, thereby attaching the electronic device 600 to the second electronic device.

[0066] The magnet array 610 can be assembled by combining nine magnets together manually or by machine. In either case, the process can be time consuming and result in loss of yield. Mistakes may result in the need for rework and consumption of resources. Therefore, embodiments of the present invention can replace the nine magnets used to form the magnet array 610 with a single integral magnet. Examples are shown in the following figure.

[0067] Figure 6B It shows that you can replace Fig. 6A In this example, the integral magnet 650 can be used to replace the magnet array 610 (such as Fig. 6A 640). The integral magnet may have a plurality of segments 660 having a first magnetic pole and a plurality of segments 670 having a second magnetic pole, the second magnetic pole facing the bottom surface of the electronic device 640 (as shown). Each row of segments in the magnet 650 may include one or more segments 660 having a first magnetic pole and one or more segments 670 having a second magnetic pole facing the bottom of the electronic device 640. Each column in the magnet array 610 may include one or more segments 660 having a first magnetic pole and one or more segments 670 having a second magnetic pole facing the bottom of the electronic device 640. The integral magnet 650 may be used to attach a second electronic device (not shown) to the electronic device 640. For example, the second electronic device may include a set of magnets having opposite magnetic poles that attract the integral magnet 650, thereby attaching the electronic device 640 to the second electronic device.

[0068] Using integral magnet 650 can simplify the manufacture of electronic device 640. For example, a set of magnets does not need to be aligned and fixed to each other as in magnet array 610. In addition, integral magnet 650 can be smaller, thereby saving space in electronic device 640, and making electronic device 640 smaller, including more functions, or both. This can reduce assembly time, improve yield, reduce rework, and save resources.

[0069] The monolithic magnet 650 can be formed by metal injection molding or other molding processes. The magnet 650 can be referred to as a neodymium magnet. That is, the magnet 650 can be formed of neodymium, iron and boron. In these and other embodiments of the present invention, other materials such as rare earth materials, such as samarium cobalt, manganese bismuth or other materials, can be used. Ferrite materials can also be used. Powdered neodymium, iron and boron (NdFeB) can be formed by grinding crystal NdFeB and combined with a binder to produce a feedstock. The feedstock can be heated and injected into a mold. A magnetic field can be applied to the mold to strengthen the non-parallel easy axis. The molded magnet can be debonded, that is, the binder can be removed. The molded magnet can be sintered, and then the result can be used in an electronic device. Parts of the molded magnet, such as gate residues and parting lines, can be removed before or after sintering and reused as feedstock. The molded magnet can include voids or open areas within its volume. For example, the monolithic magnet 650 can include 2%, 3%, 4% or other percentages of voids.

[0070] During the molding process, a magnetic field may be applied to the magnet 650 to reinforce the non-linear magnetic pole orientation of the magnet 650 . Figure 8 An example is shown in . That is, a magnetic field can be applied to magnet 650 during the molding process to strengthen the different polarities of monolithic magnet 650. The magnetic field can be generated using permanent magnets, pole pieces, electromagnets, or a combination of these and other magnetic structures. In this example, the poles of segment 660 and segment 670 can be strengthened in various ways during the manufacturing process. For example, multiple magnets can be placed above and below magnet 650 (where downward is entering Figure 6B 650). The magnets below magnet 650 may have the same pattern as shown for magnet 650 facing the bottom side (not shown) of magnet 650. The magnets above magnet 650 may have the opposite polarity pattern facing the top side (shown here) of magnet 650. The resulting magnetic field may align the grains of magnet 650 during forming so that the finished magnet 650 has segments 660 and segments 670 with the desired polarity.

[0071] Fig. 7A A Halbach array formed by a plurality of magnets is shown, and Figure 7B A monolithic magnet implemented as a simulated Halbach matrix is ​​shown, which can replace Fig. 7A of magnets. Fig. 7A A Halbach array 700 is shown formed of a plurality of magnets, including magnet 710, magnet 712, magnet 714, magnet 716, and magnet 718. The magnets of the Halbach array 700 may be positioned so that their polarities generated by the easy axis directions rotate from left to right in a counterclockwise manner (as shown). For example, magnet 710 may have an easy axis direction that produces a polarity 740 that extends horizontally in a rightward direction (as shown). Magnet 712 may have an easy axis direction that produces a polarity 742 that is rotated 90 degrees counterclockwise to an upward direction relative to the polarity 740 of magnet 710. Magnet 714 may have a polarity 744 that is rotated 90 degrees counterclockwise relative to the polarity 742 of magnet 712. Similarly, magnet 716 may have a polarity 746 that is rotated 90 degrees counterclockwise relative to polarity 744 of magnet 714 , and magnet 718 may have a polarity 748 that is rotated 90 degrees counterclockwise relative to polarity 746 of magnet 716 .

[0072] The arrangement of the Halbach array 700 can produce an easy axis direction 720 on the top side that is stronger than the easy axis direction 730 on the bottom side. That is, the magnetic field from the bottom of the Halbach array 700 can be rerouted to the top side. This can effectively increase the magnetic field at the top of the Halbach array 700. It can also reduce the stray flux at the bottom of the Halbach array 700.

[0073] It may be difficult to manufacture the Halbach array 700. For example, the various magnets may need to be held in place relative to each other using a base or other substrate. This may be difficult because the magnets in the Halbach array 700 may strongly repel each other. The magnets may be held together using an adhesive such as an epoxy or other material. Due to the mutual repulsion of the magnets in the Halbach array 700, a stronger adhesive may need to be used. The use of these materials will reduce the efficiency and field strength of the Halbach array 700. To compensate, the magnets can be made larger, but this will increase the space occupied by the Halbach array 700 in the electronic device and may increase the amount of resources consumed in its manufacturing process. Therefore, embodiments of the present invention may replace multiple magnets used to form the Halbach array 700 with a single integral magnet. An example is shown in the figure below.

[0074] Figure 7B shows a monolithic magnet implemented as a simulated Halbach array, which can replace Fig. 7A The use of an integral magnet 750 can eliminate or reduce the repulsion of the magnet and the difficulty in manufacturing the Halbach array 700 (such as Fig. 7AThe complexity that arises from the need for a strong adhesive when the magnet 750 is placed in a plurality of positions (as shown). The Halbach array 755 can be implemented as a monolithic magnet 750. Note that the magnet 750 can be referred to as a Halbach array 755 herein even if it is implemented as a single magnet rather than an array of magnets. The monolithic magnet 750 can include several parts having different easy axes that produce different polarity directions. That is, each of the several parts can have a different direction as their easy axis direction. The grains of the monolithic magnet 750 can be positioned so that their polarity rotates from left to right in a counterclockwise manner. For example, a segment 780 of the monolithic magnet 750 can have a polarity 790 extending horizontally in a rightward direction (as shown). Segment 782 can have a polarity 792 that is rotated 90 degrees counterclockwise to an upward direction relative to the polarity 790 of segment 780. Segment 784 can have a polarity 794 that is rotated 90 degrees counterclockwise relative to the polarity 792 of segment 782. Similarly, segment 786 may have a polarity 796 that is rotated 90 degrees counterclockwise relative to polarity 794 of segment 784 , and segment 788 may have a polarity 798 that is rotated 90 degrees counterclockwise relative to polarity 796 of segment 786 .

[0075] The arrangement of the segments in the integral magnet 750 can produce a stronger magnetic field 760 on the top side than the magnetic field 770 on the bottom side. That is, the magnetic field 770 from the bottom of the integral magnet 750 can be rerouted to the top side. This can effectively increase the magnetic field 760 at the top of the integral magnet 750. It can also reduce stray flux at the bottom of the integral magnet 750.

[0076] Using the integral magnet 750 for the Halbach array 755 can simplify the manufacture of electronic devices. For example, a set of magnets does not need to be aligned and fixed to each other as in the Halbach array 700 (e.g., Fig. 7A ). This can reduce assembly time, increase yields, reduce rework, and conserve resources. The monolithic magnet 750 can be more efficient, allowing the Halbach array 755 to be smaller than the Halbach array 700, which can allow the electronics to be smaller, include more functionality, or both.

[0077] The monolithic magnet 750 can be formed by metal injection molding or other molding processes. The monolithic magnet 750 can be referred to as a neodymium magnet. That is, the magnet 750 can be formed by neodymium, iron and boron. In these and other embodiments of the present invention, other materials such as rare earth materials, such as samarium cobalt, manganese bismuth or other materials can be used. Ferrite materials can also be used. Powdered neodymium, iron and boron (NdFeB) can be formed by grinding crystal NdFeB and combined with a binder to produce a feedstock. The feedstock can be heated and injected into a mold. A magnetic field can be applied to the mold to strengthen the non-parallel easy axes. Figure 8An example is shown in . The molded magnet can be debonded, that is, the binder can be removed. The molded magnet can be sintered, and the result can then be used in an electronic device. Portions of the molded magnet, such as gate residues and parting lines, can be removed before or after sintering and reused as feedstock. The molded magnet can include voids or open areas within its volume. For example, the monolithic magnet 750 can include 2%, 3%, 4%, or other percentages of voids.

[0078] During the forming process, a magnetic field can be applied to the magnet 750 to reinforce the nonlinear magnetic pole orientation of the magnet 750. That is, a magnetic field can be applied to the magnet 750 during the forming process to reinforce the different polarities of the monolithic magnet 750. The magnetic field can be generated using permanent magnets, pole pieces, electromagnets, or a combination of these and other magnetic structures. In this example, the easy axis can be reinforced in various ways during the manufacturing process. For example, multiple magnets arranged in a Halbach array can be placed on the top and bottom sides of the monolithic magnet 750 (with downward being the direction of entry). Figure 6B The magnets on the side of the monolithic magnet 750 can have the same pattern as shown for the monolithic magnet 750. During molding, the resulting magnetic field can align the grains of the monolithic magnet 750 so that the finished monolithic magnet 750 has the desired rotational polarity.

[0079] These and other integral magnets can be formed by metal injection molding or other molding processes. The use of metal injection molding or other molding processes can provide integral magnets with shapes, features and non-linear or non-parallel magnetic field characteristics that may be impossible or difficult to manufacture in other ways, especially in mass production. These and other integral magnets can be neodymium magnets. These and other integral magnets can be formed of neodymium, iron and boron. In these and other embodiments of the present invention, other materials such as rare earth materials, such as samarium cobalt, manganese bismuth or other materials can be used. Ferrite materials can also be used.

[0080] In these and other embodiments of the present invention, powdered neodymium, iron, and boron can be combined with a binder to produce a feedstock. The feedstock can be heated and injected into a mold. A magnetic field can be applied to the mold to strengthen the non-parallel easy axes. The molded magnet can be debonded, that is, the binder can be removed. The molded magnet can be removed from the mold before debonding. The molded magnet can be sintered, and the result can then be used in an electronic device. The molded magnet can also be removed from the mold before sintering. Portions of the molded magnet, such as gate residues and parting lines, can be removed before or after sintering and reused as feedstock. The molded magnet can include voids or open areas within its volume. For example, the monolithic magnet 100 can include 2%, 3%, 4%, or other percentages of voids.

[0081] During the forming process, a magnetic field may be applied to the magnet to strengthen the nonlinear magnetic pole direction of the formed magnet. That is, a magnetic field may be applied to the magnet 100 during the forming process to strengthen the nonlinear easy axis of the magnet 100. These magnets may be permanent magnets, magnetic elements such as pole pieces, electromagnets, or other structures capable of delivering or generating a magnetic field, or a combination of these. The following figure shows an example of this process.

[0082] Figure 8 A molding system that can be used to make a monolithic molded magnet according to an embodiment of the present invention is shown. Molding system 800 can include a mold 810 having a top portion 812 and a bottom portion 814. Top portion 812 and bottom portion 814 can form a cavity 816 and a gate 818. Coils 830 and 832 can be included in mold 810, or can be formed or placed around mold 810.

[0083] During the manufacturing process, powders are made by grinding neodymium, iron and boron (NdFeB), which may be crystals. The powdered neodymium, iron and boron may be combined with a binder to produce a feedstock. The feedstock may be heated and injected into a cavity 816 in a mold 810 through a gate 818 to form a magnet 820. An electric current may flow in either or both of the coils 830 and 832 to produce a magnetic field 834. The field lines of the magnetic field 834 may be non-parallel. The magnetic field 834 may exist while the magnet 820 is formed. The easy axis of the magnet 820 may follow the field lines of the magnetic field 834. The magnetic field 834 may be generated by the coils 830 and 832 or other coils, permanent magnets, magnets, magnetic elements such as pole pieces, electromagnets, or other structures capable of conveying or generating a magnetic field, or a combination of these.

[0084] After forming the magnet 820, the binder can be removed by a debonding process. The debonding process leaves gaps in the magnet 820. These gaps can be removed by sintering the magnet 820. Excess parts on the magnet 820, such as the parting line (not shown) between the top part 812 and the bottom part 814 of the gate portion 822 and the mold 810, can be removed by, for example, trimming. In these and other embodiments of the present invention, the magnet 820 can be removed from the mold 810 during the debonding process and the sintering process. When the magnet 820 is in the mold 810, the magnetic field 834 can be generated by either or both of the coil 830 and the coil 832. Alternatively, the magnetic field 834 can be generated by a permanent magnet, a magnet, a magnetic element such as a pole piece, an electromagnet, or other structures capable of conveying or generating a magnetic field, or a combination of these. During these processes, the magnetic field 834 can be a constant or variable magnetic field.

[0085] In this example, a mixture of powdered neodymium, iron and boron (NdFeB) can be permanently formed by grinding crystalline NdFeB and combined with a binder to produce a feedstock for injection into mold 810. In these and other embodiments of the present invention, other materials, such as rare earth materials, can be used. Samarium cobalt, manganese bismuth or other materials can be used. Ferrite materials can also be used.

[0086] Mold 810 can be formed by various materials that do not react with the feed used. For example, mold 810 can be formed by steel, stainless steel, cast iron, iron or other materials. Any one or both of coil 830 and coil 832 can be in mold 810, for example, mold 810 can be formed or assembled around coil 830 and coil 832. Any one or both of coil 830 and coil 832 can be positioned around mold 810 alternatively. Although two coils, i.e. coil 830 and coil 832, are shown in this example, molding system 800 can include one, three, four, five or more than 5 coils. In addition, although coil 830 and coil 832 are shown as parallel, coil 830 and coil 832 can have other spatial relationships, for example, they can be tilted, orthogonal, offset or have other spatial relationships.

[0087] Coil 830 and coil 832 can share the same current, or they can have a separate current, and the current can have the same or different direction, duration and magnitude. Any one or both of these currents can be constant or variable, that is, their magnitude can change over time. Any one or both of these currents can be turned on for a period of time, which is at least the majority of the time required for the molding process. Any one or both of these currents can be turned on in one or more short durations with a relatively large magnitude, or a combination of longer and shorter durations of this current can be used during the molding process. Coil 830 and coil 832 can be connected to a current source (not shown) in series or in parallel. Coil 830 and coil 832 can each be connected to a separate current source.

[0088] After the magnet 820 is formed, the binder may be removed and the magnet 820 sintered. An example is shown in the following figure.

[0089] Fig. 9914. The process involved in manufacturing a magnet according to an embodiment of the present invention is shown. During manufacturing, powder 910 can be made by grinding neodymium, iron, and boron (NdFeB), which can be crystalline, into a powder that can be composed primarily of individual grains. Neodymium, iron, and boron powder 910 can be combined with a binder 912 to produce feedstock 920. Binder 912 can be formed of a polymer, such as polyphenylene sulfide (PPS), polyamide or nylon, polyvinyl butyral, rubber. Powder 910 and binder 912 can be mixed and granulated in process 914 to produce feedstock 920 for molding. Feedstock 920 can be heated and then injection molded into a mold, such as mold 810 ( Figure 8 As shown), to form the magnet 820 (both in Figure 8 ). During the molding process 930, the mold 810 may be in a magnetic field, such as magnetic field 834 (id). Magnetic field 834 may be a constant or variable magnetic field. Magnetic field 834 may generate current in either or both of coils 830 and 832, and may be present during some or all of the molding process. Magnetic field 834 may be generated by one or more short current pulses in either or both of coils 830 and 832. Magnetic field 834 may be generated by coils 830 and 832 or other coils, permanent magnets, magnets, magnetic elements such as pole pieces, electromagnets, or other structures capable of conveying or generating a magnetic field, or a combination of these.

[0090] After molding, the molded material can be debonded in a debonding process 940. The debonding process 940 can be a thermal debonding. The debonding process 940 can alternatively be a catalytic debonding process, in which the molded material is debonded in a gaseous acidic environment, where the acid is nitric acid, oxalic acid, or other acid. The debonding process 940 can be performed with a solvent, such as acetone, heptane, or other ketones.

[0091] After the debinding process 940, the result, which may be referred to as the prototype 950, may be sintered in a sintering process 960 to produce a finished product 970. The sintering process may remove some or all of the voids created during the debinding process 940. In these and other embodiments of the present invention, the magnet 820 may include 2%, 3%, 4%, or other percentages of voids. The molded material may be removed from the mold 810 for the debinding process 940 and the sintering process 960.

[0092] After the sintering process 960, the grains of the finished product 970 can remain aligned, thereby forming the desired easy axis. The sintering process 960 can remove some or all of the magnetism of the finished product 970. At this point, the finished product 970 can be magnetized to complete the magnet 820. Alternatively, the finished product 970 can be placed in an electronic device while it is still demagnetized and easy to operate. Once installed, the finished product 970 can be magnetized to complete the magnet 820. In these and other embodiments of the present invention, the finished product 970 can be magnetized at other times after sintering to complete the magnet 820.

[0093] During the forming process, coil 830 and coil 832 can share the same current, or they can have separate currents, and the currents can have the same or different directions, durations, and magnitudes. Either or both of these currents can be constant or variable, that is, their magnitudes can change over time. Either or both of these currents can be turned on for a period of time that is at least a majority of the time required for the forming process. Either or both of these currents can be turned on for one or more short durations at a relatively large magnitude, or a combination of longer and shorter durations of such currents can be used during the forming process.

[0094] Fig.10 A method for manufacturing a magnet according to an embodiment of the present invention is shown. In step 1010, a feedstock containing a mixture of neodymium, iron and boron, and a binder can be provided. Neodymium, iron and boron can be a powder formed by grinding crystalline NdFeB into a powder mainly composed of a single grain. The powder can be combined with a binder and then mixed and granulated to form the feedstock. In action 1020, the feedstock can be heated. In action 1030, a magnetic field can be applied to the mold. The magnetic field can be generated by one or more coils, permanent magnets, magnets, magnetic elements such as pole pieces, electromagnets, or other structures capable of conveying or generating a magnetic field, or a combination of these. In action 1040, the feedstock can be injected into the mold. In these and other embodiments of the present invention, the feedstock can be injected into the mold, and then the magnetic field is applied, or these two events can occur simultaneously or nearly simultaneously.

[0095] In act 1050, some or all of the binder material may be removed from the molded magnet. In act 1060, the molded magnet may be sintered. In act 1070, the sintered magnet may be trimmed. The sintered magnet may be magnetized at this time or later, or the sintered magnet may be placed in an electronic device and then magnetized. Placing the sintered magnet in an electronic device before magnetization may make the sintered magnet easier to handle.

[0096] Fig.111 shows a configuration of coils that can be used during the manufacture of magnets according to embodiments of the present invention. In this example, molding system 1100 can include magnet 1110 and coil 1120. Magnet 1110 can be formed in a mold, such as mold 810 (e.g., Figure 8 11), while current is run in coil 1120 to generate magnetic field 1122. Coil 1120 can generate magnetic field 1122, which can align the easy axis of the magnet in a radial manner when forming magnet 1110. For example, magnetic field 1122 can be as follows Figure 4B The easy axis direction 448 shown is shown to enforce the easy axis direction in a radial, non-parallel manner.

[0097] The current in the coil 1120 may have a long duration extending during some or all of the forming process. The current in the coil 1120 may be one or more short pulses, or these different types of current waveforms may be combined. The current in the coil 1120 may vary in magnitude over time. During some of the forming processes in the entire forming process as described above, the current in the coil 1120 may exist and form a magnetic field 1122.

[0098] Fig.12 1 shows a configuration of coils that can be used during the manufacture of a magnet according to an embodiment of the present invention. In this example, molding system 1200 can include magnet 1210, coil 1220, and coil 1222. Magnet 1210 can be formed in a mold, such as mold 810 (e.g., Figure 8 ), while current is run in coils 1220 and 1222 to generate magnetic field 1224. Coils 1220 and 1222 can generate magnetic field 1224, which can align the easy axis of magnet 1210 in a divergent, non-parallel manner when formed.

[0099] Coil 1220 and coil 1222 can carry the same or different currents. The current can flow in the same or opposite directions. Any one or both of the currents in coil 1220 and coil 1222 can have a long duration extending during some or all of the forming processes in the forming process. Any one or both of the currents in coil 1220 and coil 1222 can be one or more short pulses, or these different types of current waveforms can be combined. The magnitude of any one or both of the currents in coil 1220 and coil 1222 can vary over time. During some of the forming processes in all the forming processes as described above, any one or both of the currents in coil 1220 and coil 1222 can exist and form a magnetic field 1224. Any one or both of coil 1220 and coil 1222 can be connected in series or in parallel to a current source (not shown). Any one or both of coil 1220 and coil 1222 can be connected to a corresponding separate current source.

[0100] Fig.13 1 shows a configuration of coils that can be used during the manufacture of magnets according to embodiments of the present invention. In this example, molding system 1300 can include magnet 1310 and coil 1320. Magnet 1310 can be molded in a mold such as mold 810 (e.g., Figure 8 1320) is formed, and current is run in the coil 1320 to generate a magnetic field 1322. The coil 1320 can generate a magnetic field 1322, which can align the easy axis of the magnet into a Halbach array when the magnet 1310 is formed. For example, the magnetic field 1322 can strengthen the Figure 7B The polarities 790 to 798 are shown arranged in the easy axis direction of the Halbach array.

[0101] The coils 1320 can each carry the same or different currents. The current can flow in all directions. One or more of the currents in the coils 1320 can have a long duration extending during some or all of the forming processes in the forming process. One or more of the currents in the coils 1320 can be one or more short pulses, or these different types of current waveforms can be combined. One or more of the currents in the coils 1320 can vary in magnitude over time. During some of the forming processes in all of the forming processes described above, one or more of the currents in the coils 1320 can exist and form a magnetic field 1224. One or more coils 1320 can be connected in series or in parallel to a current source (not shown). One or more coils 1320 can each be connected to a corresponding separate current source.

[0102] These and other embodiments of the present invention can provide magnets of other shapes. For example, an embodiment can provide conventional bar magnets. Such bar magnets can be manufactured more efficiently because commercially available bar magnets may not be available in the exact dimensions required, and therefore material still needs to be removed to form the bar magnets. In addition, embodiments can provide stronger magnets that are commercially available. Other shapes, such as plus or "X" shaped magnets. These magnets can have a first polarity at two adjacent ends, or they can have a first polarity at two opposite ends and a second polarity at the remaining end. Ring magnets, "S" shaped magnets, horseshoe magnets, or other shaped magnets can also be formed using embodiments of the present invention.

[0103] Embodiments of the present invention may provide a monolithic magnet having different easy axis directions at different locations. In addition, embodiments may provide a monolithic magnet having one polarity direction throughout the magnet. Such magnets may be manufactured more efficiently because commercially available magnets may not be available in the exact dimensions required, and thus material still needs to be removed to form a magnet having one polarity direction. In addition, embodiments may provide stronger magnets that are commercially available.

[0104] It is understood that the use of personally identifiable information should be subject to privacy policies and practices that are generally recognized to meet or exceed industry or government requirements for maintaining user privacy. Specifically, personally identifiable information data should be managed and processed to minimize the risk of unintentional or unauthorized access or use, and the nature of the authorized use should be clearly stated to users.

[0105] For the purpose of illustration and description, the above description of the embodiment of the present invention is presented. It is not intended to be exhaustive, nor is it intended to limit the present invention to the precise form, and many modifications and variations are possible according to the above teachings. This embodiment is selected and described to fully illustrate the principle of the present invention and its practical application, so that other technical personnel in the field can make full use of the present invention in various embodiments and in the case of various modifications suitable for the specific purpose envisioned. Therefore, it should be understood that the present invention is intended to cover all modifications and equivalents within the scope of the following claims.

Claims

1. An electronic device, comprising: a magnet formed as a unitary structure, wherein the magnet comprises a first portion and a second portion, The first portion has a first easy axis, and the second portion has a second easy axis, and the first easy axis and the second easy axis are not parallel. 2 . The electronic device according to claim 1 , wherein the magnet is formed by metal injection molding. The electronic device according to claim 2 , wherein the magnet is a rare earth magnet.

4. The electronic device according to claim 2, wherein the magnet is formed of neodymium, iron and boron. The electronic device of claim 4 , wherein the magnet comprises at least one curved surface.

6. The electronic device of claim 5, wherein the magnet comprises at least 2% voids.

7. An electronic device, comprising: a magnet formed as a unitary structure, wherein the magnet comprises a first portion and a second portion, wherein the first portion has an easy axis direction along a first axis, The second portion has an easy axis direction along a second axis, Wherein the first axis and the second axis intersect.

8. The electronic device according to claim 7, wherein the magnet is formed by metal injection molding.

9. The electronic device of claim 8, wherein the magnet is formed of neodymium, iron, and boron.

10. The electronic device of claim 9, wherein the magnet is shaped as an arc of a circle, the circle having a center, and wherein the first axis and the second axis intersect at the center of the circle.

11. The electronic device of claim 10, wherein the magnet comprises at least 2% voids.

12. An electronic device, comprising: A magnet is formed into a unitary structure using metal injection molding, wherein the magnet is formed of neodymium, iron and boron, the magnet includes multiple easy axes, and the multiple easy axes are not parallel.

13. The electronic device of claim 12, wherein adjacent surfaces of the magnets form one of an acute angle or an obtuse angle.

14. The electronic device of claim 12, wherein the easy axis direction of the magnet enters the first surface, rotates at least 180 degrees, and exits the first surface.

15. The electronic device of claim 14, wherein the first surface is curved.

16. The electronic device of claim 12, wherein a first side of the magnet has an easy axis orientation in a first direction, a second side of the magnet has an easy axis orientation in a second direction, and a middle of the magnet has an easy axis orientation in a third direction, Wherein the third direction is from the second side of the magnet to the first side of the magnet, and the first direction and the third direction converge into one of an acute angle or an obtuse angle.

17. The electronic device of claim 12, wherein the surface of the magnet comprises an array of easy-axis direction groups, wherein each easy-axis direction group has a first polarity or a second polarity, wherein each row in the array comprises a group of easy-axis directions having the first polarity and a group of easy-axis directions having the second polarity.

18. The electronic device of claim 17, wherein each column in the array includes a set of easy-axis directions having the first polarity and a set of easy-axis directions having the second polarity.

19. The electronic device of claim 12, wherein the magnets emulate a Halbach array.

20. The electronic device of claim 19, wherein the strength of the magnetic field on the first side of the magnet is stronger than the strength of the magnetic field on the second side of the magnet.

21. An electronic device, comprising: A magnet is formed as a unitary structure using metal injection molding, wherein the magnet is formed of neodymium, iron, and boron, wherein the magnet has a single easy axis direction.

22. The electronic device of claim 21, wherein adjacent surfaces of the magnets form one of an acute angle or an obtuse angle.

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