Magnetic steel preparation process and motor

Abstract

The invention provides a magnetic steel preparation process and a motor, and the magnetic steel preparation process comprises the steps: obtaining a plurality of magnetic material sheets with a preset magnetization direction, and stacking and fixing the plurality of magnetic material sheets together according to a preset sequence to obtain a large assembly; cutting the large combination body to obtain a plurality of small combination bodies; performing surface process treatment on the small assembly; and magnetizing the small assembly subjected to the surface process treatment to obtain the target magnetic steel. According to the invention, the large combination body with a large size is cut into the small combination bodies with small sizes, so that a large number of target magnetic steel can be obtained, and the assembly cost of the target magnetic steel is reduced; and the size of each small assembly can be accurately controlled through a cutting process, so that the size precision of the target magnetic steel is improved, the preparation process is not influenced by repulsive force between the magnetic steel, the phenomenon that the magnetic steel pops up is not easy to occur, and the assembly difficulty is reduced.

Description

[Technical Field]

[0001] This invention belongs to the field of motor technology, and particularly relates to a manufacturing process for a magnet and a motor. [Background Technology]

[0002] In related technologies, the magnets in the magnetic circuit systems of vibration motors and VCM (Voice Coil Motor) motors are made by first magnetizing multiple small magnets and then bonding and assembling them together to obtain the finished magnet. However, because the finished magnet is made by splicing together multiple small magnets, the assembly cost is high, and the forces between some of the small magnets are repulsive, making assembly difficult and resulting in poor dimensional accuracy of the finished magnet.

[0003] Therefore, it is necessary to provide a new manufacturing process for magnets. [Summary of the Invention]

[0004] The purpose of this invention is to provide a magnet manufacturing process and a motor that can solve the technical problems of high assembly cost and poor dimensional accuracy of finished magnets in related technologies.

[0005] The technical solution of the present invention is as follows:

[0006] A manufacturing process for a magnetic steel includes the following steps:

[0007] Obtain multiple magnetic material sheets with preset magnetization directions;

[0008] The multiple magnetic material sheets are stacked and fixed together in a preset order to obtain a large assembly.

[0009] The large assembly is cut to obtain multiple smaller assemblies with preset sizes;

[0010] The small assembly is subjected to surface processing.

[0011] The small assembly that has undergone the surface treatment is magnetized to obtain the target magnet.

[0012] Optionally, before stacking and fixing the plurality of magnetic material sheets together in a preset order, a pretreatment step is further included, the pretreatment step including:

[0013] Each magnetic material sheet is electroplated.

[0014] Phosphating is performed on the electroplated magnetic material sheet.

[0015] The phosphated magnetic material sheet is then coated with resin to complete the pretreatment step.

[0016] Optionally, before stacking and fixing the plurality of magnetic material sheets together in a preset order, a pretreatment step is further included, the pretreatment step including:

[0017] Each magnetic material sheet is subjected to acid washing to complete the pretreatment step.

[0018] Optionally, the stacking and fixing method is adhesive fixing or welding fixing.

[0019] Optionally, the plurality of magnetic material sheets are neodymium iron boron sheets.

[0020] Optionally, the welding and fixing method is as follows:

[0021] Soldering is performed by adding tin-containing solder between adjacent magnetic material sheets, wherein the solder is at least one of solder paste, solder wire, and solder powder.

[0022] Optionally, the welding and fixing method is as follows:

[0023] The multiple magnetic material sheets stacked together in a preset order are sintered at high temperature, so that the matrix atoms of adjacent magnetic material sheets diffuse into each other and are fixed together by lattice recombination.

[0024] Optionally, the weld width between adjacent magnetic material sheets is less than 1 mm.

[0025] Optionally, the cutting process can be one of multi-wire cutting, internal circle cutting, laser cutting, or electrical discharge cutting.

[0026] Optionally, the plurality of magnetic material sheets have at least two different magnetization directions. When the plurality of magnetic material sheets are stacked and fixed together in a preset order, the angle between the magnetization directions of two adjacent magnetic material sheets is greater than 0 degrees and less than 180 degrees.

[0027] Optionally, the preset magnetization direction includes one of the thickness direction of the magnetic material sheet and the length direction of the magnetic material sheet;

[0028] During the stacking and fixing process, magnetic material sheets with magnetization direction in the thickness direction and magnetic material sheets with magnetization direction in the length direction are stacked in a preset order of alternating arrangement.

[0029] Optionally, the magnetization step includes:

[0030] The magnetic material sheet magnetized along the thickness direction in the small assembly that has undergone the surface processing is first magnetized.

[0031] The magnetic material sheet magnetized along the length direction in the small assembly that has undergone the surface processing is magnetized a second time.

[0032] Optionally, the magnetization step includes:

[0033] The small assembly that has undergone the surface treatment is then magnetized as a whole.

[0034] Among them, an electromagnet with a magnetic induction intensity greater than 2T is used so that the magnetization intensity of the small assembly in any easily magnetized direction reaches a saturation state during the magnetization process.

[0035] Optionally, the step of obtaining multiple magnetic material sheets having a preset magnetization direction includes:

[0036] A magnetic blank with a magnetization direction is cut according to a preset cutting direction to obtain a magnetic material sheet with a preset magnetization direction.

[0037] Optionally, the surface treatment method includes at least one of electroplating, electrophoresis, phosphating, spraying, and coating, and the surface treatment is applied to the small assembly to add an anti-corrosion coating to the surface of the small assembly.

[0038] The present invention also provides a motor, including a housing having a receiving cavity, and a vibration unit and a drive unit housed within the receiving cavity, wherein one of the vibration unit and the drive unit includes a magnet, the magnet being manufactured using the magnet manufacturing process described in any one of the above-mentioned methods.

[0039] The beneficial effects of this invention are as follows: During the preparation of the target magnet, by cutting a large assembly into smaller assemblies, a greater number of target magnets can be obtained after magnetization, thereby reducing the assembly cost. Furthermore, the size of each small assembly can be precisely controlled through the cutting process, ensuring that the size of the target magnet is not affected by assembly, thus improving the dimensional accuracy of the target magnet. Moreover, the preparation process is unaffected by the repulsive forces between magnets, reducing the likelihood of magnet ejection and simplifying assembly. [Attached Image Description]

[0040] Figure 1 A schematic flowchart illustrating the magnet manufacturing process provided by this invention;

[0041] Figure 2 This is a schematic diagram of the method for preparing magnets provided by the present invention;

[0042] Figure 3 A schematic diagram illustrating the step-by-step magnetization process for the magnetic steel manufacturing process provided by this invention;

[0043] Figure 4 A schematic diagram illustrating the integrated magnetization process in the magnetic steel manufacturing process provided by the present invention;

[0044] Figure 5This is a schematic diagram of the motor structure provided by the present invention.

Detailed Implementation Methods

[0045] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0046] Please see Figure 1 and Figure 2 An embodiment of the present invention provides a process for preparing a magnet, comprising the following steps:

[0047] Step S101: Obtain multiple magnetic material sheets with preset magnetization directions.

[0048] Specifically, each magnetic material sheet has its own preset magnetization direction, meaning that the magnetization directions of each magnetic material sheet may be the same or different. The magnetization direction of the magnetic material sheet can be along its length, its thickness, or even along its diagonal.

[0049] Step S102: Stack and fix multiple magnetic material sheets together in a preset order to obtain a large assembly.

[0050] Specifically, the preset order is determined based on the magnetization direction of the magnetic material sheet. Magnetic material sheets with the magnetization direction in the thickness direction and magnetic material sheets with the magnetization direction in the length direction can be stacked in an alternating preset order. For example, there are five magnetic material sheets, which are stacked sequentially, with the magnetic material sheets with the magnetization direction in the length direction and the magnetic material sheets with the magnetization direction in the thickness direction arranged alternately.

[0051] Step S103: Cut the large assembly to obtain multiple small assemblies with preset dimensions.

[0052] Specifically, there are multiple small assemblies, among which the size of the large assemblies is much larger than the size of the small assemblies, and a large assemblies can be cut into a large number of small assemblies.

[0053] It should be noted that since the small assembly is obtained by cutting the large assembly, the size of each small assembly can be the same or different, so that the size of the small assembly can be set according to actual needs and can meet the needs of different sized target magnets.

[0054] Step S104: Perform surface treatment on the small assembly.

[0055] Step S105: Magnetize the small assembly that has completed the surface treatment to obtain the target magnet.

[0056] In the fabrication process of the target magnets, by cutting large assemblies into smaller assemblies, a greater number of target magnets can be obtained after magnetization, thus reducing assembly costs. Furthermore, the cutting process allows for precise control of the dimensions of each small assembly, ensuring that the magnet dimensions are unaffected by assembly, thereby improving dimensional accuracy. Moreover, the fabrication process is unaffected by repulsive forces between magnets, reducing the likelihood of magnet ejection and simplifying assembly.

[0057] In some embodiments, the magnetic material sheet refers to any material sheet possessing magnetic or magnetic processing properties, and can be a magnetic material such as ferrite or neodymium iron boron. Before stacking and fixing multiple magnetic material sheets together in a preset order, a pretreatment step is also included, which includes:

[0058] Step S201: Electroplating is performed on each magnetic material sheet.

[0059] Specifically, when electroplating magnetic material sheets, nickel, zinc, aluminum, etc., can be plated on the surface of the magnetic material sheets.

[0060] Step S202: Phosphate the electroplated magnetic material sheet.

[0061] Specifically, a non-conductive, porous phosphate crystal film is generated on the coating surface to enhance the adhesion of subsequent coatings.

[0062] Step S203: Spray resin onto the phosphated magnetic material sheet to complete the pretreatment of the magnetic material sheet.

[0063] Specifically, the resin used for spraying can be epoxy resin, polyurethane, or silicone resin, etc.

[0064] It should be understood that pre-treated magnetic material sheets can prevent oxidation during subsequent processes.

[0065] The present invention also provides another preprocessing step, comprising:

[0066] Step S301: Perform acid washing on the magnetic material sheet to complete the pretreatment of the magnetic material sheet.

[0067] Specifically, the pickling solution dissolves the oxide layer and impurities on the surface of the magnetic material sheet, making it easier to stack and fix the magnetic material sheet.

[0068] Furthermore, the surface treatment methods include at least one of electroplating, electrophoresis, phosphating, spraying, and coating, and the above surface treatments are applied to the small assembly to add an anti-corrosion coating to the surface of the small assembly.

[0069] Furthermore, the step of obtaining multiple magnetic material sheets with preset magnetization directions includes: obtaining a magnetic blank with a magnetization direction, and cutting the magnetic blank according to a preset cutting direction to obtain magnetic material sheets with preset magnetization directions. Each magnetic material sheet can have the same size. Cutting the same magnetic blank with a magnetization direction in different directions will yield magnetic material sheets with different magnetization directions.

[0070] Furthermore, in an embodiment of the present invention, in the process of preparing the magnet, multiple magnetic material sheets are stacked and fixed together in a preset order, and the stacking and fixing method is adhesive fixing or welding fixing.

[0071] In some embodiments, the magnetic material sheets can be glued together, for example, a rear magnetic material sheet can be glued to a front magnetic material sheet.

[0072] In some embodiments, the multiple magnetic material sheets are neodymium iron boron (NdFeB) sheets, which have high magnetic permeability.

[0073] In some embodiments, the welding and fixing method is to add tin-containing solder between adjacent magnetic material sheets for soldering, wherein the solder is at least one of solder paste, tin wire, and tin powder.

[0074] In some embodiments, the weld width between adjacent magnetic material sheets is less than 1 mm, such as 0.5 mm, 0.6 mm, 0.8 mm, 0.9 mm, 1 mm, etc. This reduces the heat-affected zone and decreases magnetic property attenuation.

[0075] In some embodiments, the welding fixing method involves welding without adding solder, through the mutual diffusion of adjacent magnetic material sheets, and the process includes:

[0076] Multiple magnetic material sheets stacked in a preset order are sintered at high temperature, causing the matrix atoms of adjacent magnetic material sheets to diffuse into each other and fix each other to form a whole, i.e., a large composite, through lattice recombination.

[0077] It should be understood that fixing magnetic material sheets by welding results in higher strength and better reliability compared to fixing by bonding.

[0078] In some embodiments, in the process of preparing the magnet, the step of cutting the large assembly to obtain multiple small assemblies with preset sizes is carried out by one of the following cutting methods: multi-wire cutting, inner circle cutting, laser cutting, and electrical discharge cutting.

[0079] Furthermore, in the fabrication process of the magnet, multiple magnetic material sheets have at least two different magnetization directions. When these sheets are stacked and fixed together in a preset order, the angle between the magnetization directions of two adjacent sheets is greater than 0 degrees and less than 180 degrees. That is, at least two of the magnetic material sheets have different magnetization directions, or each sheet may have a different magnetization direction. Depending on the actual needs, different preset magnetization directions can be set. When stacked and fixed, magnetic material sheets with the same magnetization direction are not adjacent. This setting avoids direct alignment or complete reversal of the magnetic poles of adjacent sheets, thus preventing local saturation due to excessively strong magnetic fields, extending material lifespan, and improving overall performance. By presetting different magnetization directions, it is possible to flexibly adapt to complex structural requirements such as multi-pole magnets and toroidal magnets, meeting diverse application scenarios.

[0080] Specifically, in the manufacturing process of the magnet of the present invention, the preset magnetization direction includes one of the following: along the thickness direction of the magnetic material sheet and along the length direction of the magnetic material sheet; that is, among the multiple magnetic material sheets obtained, some magnetic material sheets are magnetized along their thickness direction, and the remaining magnetic material sheets are magnetized along their length direction. During stacking and fixing, magnetic material sheets with magnetization direction along the thickness direction and magnetic material sheets with magnetization direction along the length direction are stacked in a preset alternating order.

[0081] For a specific example in this embodiment, please refer to Figure 2 Five magnetic material sheets are provided. Magnetic material sheets with magnetization directions along their thickness and length are stacked in an alternating, predetermined order. Specifically, the first magnetic material sheet with its length direction as the magnetization direction is placed at the bottom, followed by the second, third, fourth, and fifth magnetic material sheets with their thickness and length directions as the magnetization directions, stacked sequentially on top. After stacking and fixing, a large assembly is obtained. The large assembly is then cut along its thickness and length directions to obtain multiple smaller assemblies with predetermined dimensions. In each smaller assembly, the stacking order of the five magnetic material sheets is the same as in the large assembly; that is, each smaller assembly also contains five magnetic material sheets with alternating magnetization directions.

[0082] Of course, other numbers of magnetic material sheets can be obtained according to actual needs, such as 3 sheets, 4 sheets, 6 sheets, 7 sheets, etc., as long as the magnetic material sheets with the magnetization direction in the thickness direction and the magnetic material sheets with the magnetization direction in the length direction are arranged alternately when stacking.

[0083] Please see Figure 3In this embodiment of the invention, the magnetization step includes: performing a first magnetization on the magnetic material sheet magnetized along the thickness direction in the small assembly after surface processing; and performing a second magnetization on the magnetic material sheet magnetized along the length direction in the small assembly after surface processing. In a specific embodiment, the second and fourth magnetic material sheets in the small assembly are first magnetized to saturate the magnetic material sheet in the thickness direction; then the first, third, and fifth magnetic material sheets in the small assembly are magnetized to saturate the magnetic material sheet in the length direction. This magnetization method simplifies the magnetization equipment and operation, improves magnetization efficiency, and helps ensure magnetization saturation in each magnetization direction.

[0084] This invention also provides another magnetization step: integrally magnetizing the small assembly after surface processing. This magnetization scheme requires the use of an electromagnet with a magnetic induction intensity greater than 2T to ensure that the magnetization intensity of the small assembly reaches saturation in any easily magnetized direction during the magnetization process. For example, a high-permeability iron-silicon alloy can be used as the core material of the electromagnet, resulting in a saturation magnetic induction intensity greater than 2T.

[0085] For details, please refer to Figure 4 Three magnetic material sheets with different preset magnetization directions can be obtained, stacked and fixed to obtain a large assembly. The large assembly is then cut to obtain a small assembly. The small assembly contains the same magnetic material sheets as the large assembly. Finally, an electromagnet with a magnetic induction intensity greater than 2T is used to magnetize the small assembly after surface processing, so that the magnetization intensity of the small assembly reaches saturation in any easy magnetization direction during the magnetization process.

[0086] This invention also provides a motor; please refer to [link / reference]. Figure 5 The device includes a housing 1 with a receiving cavity 11, a vibrating unit 2 housed within the receiving cavity 11, and a driving unit 3. One of the vibrating unit 2 and the driving unit 3 includes a magnet 4, which is manufactured using the magnet 4 manufacturing process described above. The motor also includes spring pieces 5 connected to the housing 1 and the vibrating unit 2 respectively. The vibrating unit 2 vibrates left and right within the housing 1 via the spring pieces 5. The magnet 4 is part of the vibrating unit 2. The driving unit 3 includes a coil, and the coil and the magnet 4 interact to cause the vibrating unit 2 to slide left and right within the housing 1.

[0087] Specifically, the magnets prepared using the manufacturing process provided by this invention can be used in vibration motors in electronic products such as mobile phones, as well as in voice coil motors in camera equipment.

[0088] The above are merely embodiments of the present invention. It should be noted that those skilled in the art can make improvements without departing from the inventive concept of the present invention, but these improvements all fall within the protection scope of the present invention.

Claims

1. A process for producing a magnetic steel, characterized by, The method comprises the following steps: obtaining a plurality of magnetic material pieces with a preset magnetization direction; stacking and fixing the plurality of magnetic material pieces together in a preset order to obtain a large assembly; cutting the large assembly to obtain a plurality of small assemblies with a preset size; performing surface process treatment on the small assemblies; magnetizing the small assemblies after the surface process treatment to obtain target magnetic steel.

2. The manufacturing process of magnetic steel according to claim 1, characterized in that, Before the plurality of magnetic material pieces are stacked and fixed together in a preset order, a pretreatment step is further included, and the pretreatment step comprises: electroplating each magnetic material piece; phosphating the electroplated magnetic material piece; spraying resin on the phosphated magnetic material piece to complete the pretreatment step.

3. The process for preparing a magnetic steel according to claim 1, wherein Before the plurality of magnetic material pieces are stacked and fixed together in a preset order, a pretreatment step is further included, and the pretreatment step comprises: pickling each magnetic material piece to complete the pretreatment step.

4. The process for manufacturing magnetic steels according to claim 1, characterized in that, The stacking and fixing method is adhesive fixing or welding fixing.

5. The process for preparing a magnetic steel according to claim 4, wherein The plurality of magnetic material pieces are neodymium iron boron pieces.

6. The process for preparing a magnetic steel according to claim 5, wherein The welding fixing method is: adding tin-containing solder between adjacent magnetic material pieces for tin welding, and the solder is at least one of tin paste, tin wire, and tin powder.

7. The process for manufacturing magnetic steels according to claim 4, characterized in that, The welding fixing method is: high-temperature sintering the plurality of magnetic material pieces stacked together in a preset order, so that the matrix atoms of adjacent magnetic material pieces diffuse into each other and are fixed to each other through lattice recombination.

8. The process for manufacturing a magnetic steel according to claim 6, wherein The welding seam width between adjacent magnetic material pieces is less than 1 mm.

9. The process for making a magnetic steel of claim 1 wherein, The cutting method is one of multi-wire cutting, inner circle cutting, laser cutting, and electric spark cutting.

10. The process for making a magnetic steel of claim 1 wherein, The plurality of magnetic material pieces have at least two different magnetization directions, and when the plurality of magnetic material pieces are stacked and fixed together in a preset order, the included angle between the magnetization directions of the two adjacent magnetic material pieces is greater than 0 degrees and less than 180 degrees.

11. The process for making a magnetic steel of claim 1 wherein, The preset magnetization direction includes one of the thickness direction of the magnetic material piece and the length direction of the magnetic material piece; When stacked and fixed, the magnetic material pieces with the thickness direction as the magnetization direction and the magnetic material pieces with the length direction as the magnetization direction are stacked in an alternating preset order.

12. The process for preparing a magnetic steel according to claim 11, wherein The magnetizing step comprises: first magnetizing the magnetic material pieces with the thickness direction as the magnetization direction in the small assembly after the surface process treatment; second magnetizing the magnetic material pieces with the length direction as the magnetization direction in the small assembly after the surface process treatment.

13. The process for producing a magnetic steel according to claim 10 or claim 11, wherein The magnetizing step comprises: integrally magnetizing the small assembly after the surface process treatment; wherein an electromagnet with a magnetic induction intensity greater than 2T is used, so that the magnetization intensity of the small assembly in any magnetizable direction reaches a saturation state during the magnetizing process.

14. The process for making a magnetic steel of claim 1 wherein, The step of obtaining a plurality of magnetic material pieces with a preset magnetization direction comprises: obtaining a magnetic embryo with a magnetization direction; cutting the magnetic embryo in a preset cutting direction to obtain a magnetic material piece with a preset magnetization direction.

15. The process for making a magnetic steel of claim 1 wherein, The method of the surface process treatment includes at least one of electroplating treatment, electrophoresis treatment, phosphating treatment, spraying treatment and coating treatment, and the small assembly is subjected to the surface process treatment to add a corrosion-resistant coating to the surface of the small assembly.

16. A motor characterized by The application relates to a vibration unit and a preparation method thereof, and a vibration device. The vibration unit comprises a shell with a containing cavity, and a vibration unit and a driving unit accommodated in the containing cavity. One of the vibration unit and the driving unit comprises a magnetic steel prepared by the preparation method of the magnetic steel according to any one of claims 1 to 15.

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