Magnetic steel preparation process and motor

Abstract

The invention provides a preparation process of magnetic steel and a motor. The preparation process of the magnetic steel comprises the following steps: obtaining a plurality of magnetic material sheets with preset magnetization directions; magnetizing at least one of the plurality of magnetic material sheets for the first time; all the magnetic material sheets are stacked and fixed together according to a preset sequence to obtain a large assembly; cutting the large combination body to obtain a plurality of small combination bodies with preset sizes; carrying out surface process treatment on the small assembly; the small assembly is the target magnetic steel, or the small assembly is magnetized for the second time 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 magnetic steel can be obtained, and the assembling cost of the magnetic steel is reduced; and the size of each small assembly can be precisely controlled through a cutting process, so that the size of the magnetic steel is not influenced by assembly, and the size precision of the magnetic steel is improved.

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 manufacturing process for magnets 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] At least one of the plurality of magnetic material sheets is first magnetized;

[0009] Once the first magnetization is complete and all magnetic material sheets are magnetized, stack and fix all magnetic material sheets in a preset order to obtain a large assembly; or,

[0010] When the first magnetization is completed and there are magnetized magnetic material sheets and unmagnetized magnetic material sheets, the magnetized magnetic material sheets and unmagnetized magnetic material sheets are stacked and fixed in a preset order to obtain a large assembly.

[0011] The large assembly is cut to obtain multiple smaller assemblies with preset sizes;

[0012] The small assembly is subjected to surface processing.

[0013] When all the magnetic material sheets in the small assembly that has completed the surface processing are magnetized magnetic material sheets, then the small assembly that has completed the surface processing is the target magnet.

[0014] When there are unmagnetized magnetic material sheets in the small assembly after the surface processing is completed, the unmagnetized magnetic material sheets are magnetized a second time to obtain the target magnet; wherein the magnetization direction of the first magnetization and the magnetization direction of the second magnetization intersect.

[0015] Optionally, before first magnetizing at least one of the plurality of magnetic material sheets, a pretreatment step is further included, the pretreatment step comprising:

[0016] Each of the magnetic material sheets is electroplated.

[0017] Phosphating is performed on the electroplated magnetic material sheet.

[0018] The phosphated magnetic material sheet is then coated with resin to complete the pretreatment step.

[0019] Optionally, before first magnetizing at least one of the plurality of magnetic material sheets, a pretreatment step is further included, the pretreatment step comprising:

[0020] Each of the magnetic material sheets is subjected to acid washing to complete the pretreatment step.

[0021] Optionally, the stacking and fixing method is adhesive fixing or welding fixing.

[0022] Optionally, the plurality of magnetic material sheets are neodymium iron boron sheets.

[0023] Optionally, the welding and fixing method is as follows:

[0024] 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.

[0025] Optionally, the welding and fixing method is as follows:

[0026] 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.

[0027] Optionally, the weld width between adjacent magnetic material sheets is less than 1 mm.

[0028] Optionally, the cutting method is one of multi-wire cutting, inner circle cutting, laser cutting, or electrical discharge cutting.

[0029] Optionally, when there are magnetized magnetic material sheets and unmagnetized magnetic material sheets after the first magnetization is completed, the preset order is to alternate between each magnetized magnetic material sheet and each unmagnetized magnetic material sheet.

[0030] 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;

[0031] 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.

[0032] Optionally, the step of obtaining multiple magnetic material sheets with preset magnetization directions includes:

[0033] Obtain a magnetic blank with a magnetization direction;

[0034] The magnetic blank is cut according to a preset cutting direction to obtain a magnetic material sheet with a preset magnetization direction.

[0035] 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.

[0036] A motor includes a housing having a receiving cavity, and a vibrating unit and a driving unit housed within the receiving cavity, wherein one of the vibrating unit and the driving unit includes a magnet, the magnet being manufactured using the magnet manufacturing process described in any one of the above descriptions.

[0037] The beneficial effects of this invention are as follows: In the preparation process of the target magnet, by cutting the large assembly into smaller assemblies, a larger number of target magnets can be obtained, 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]

[0038] Figure 1 A schematic flowchart illustrating the manufacturing process of the magnet provided by this invention;

[0039] Figure 2 A schematic diagram illustrating the principle of the manufacturing process of the magnet provided by this invention;

[0040] Figure 3 A schematic diagram of the magnetization direction in the step-by-step magnetization process provided by the present invention for the preparation of the magnet.

[0041] Figure 4 This is a schematic diagram of the motor structure provided by the present invention.

Detailed Implementation Methods

[0042] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0043] Please see Figure 1 and Figure 2 An embodiment of the present invention provides a process for preparing a magnet, comprising the following steps:

[0044] Step S101: Obtain multiple magnetic material sheets with preset magnetization directions.

[0045] Specifically, each magnetic material sheet can have a different preset magnetization direction, meaning the magnetization directions of each magnetic material sheet can 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.

[0046] Step S102: Perform a first magnetization on at least one of the multiple magnetic material sheets.

[0047] Specifically, after the first magnetization is completed, all magnetic material sheets are magnetized, or all magnetic material sheets include both magnetized and unmagnetized magnetic material sheets.

[0048] In some embodiments, all magnetic material sheets may be magnetized for the first time according to their preset magnetization direction. For example, if there are five magnetic material sheets, all five magnetic material sheets may be magnetized for the first time.

[0049] In some embodiments, a portion of the magnetic material sheets may be magnetized for the first time according to their preset magnetization direction, while the other portion of the magnetic material sheets may not be magnetized. For example, if there are five magnetic material sheets, only two magnetic material sheets may be magnetized for the first time.

[0050] Step S103: When all magnetic material sheets have been magnetized after the first magnetization, stack and fix all magnetic material sheets in a preset order to obtain a large assembly; or, when there are magnetized and unmagnetized magnetic material sheets after the first magnetization, stack and fix the magnetized and unmagnetized magnetic material sheets in a preset order to obtain a large assembly.

[0051] Specifically, the preset order is determined according to the magnetization direction of the magnetic material sheet. For example, 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. If there are five magnetic material sheets, the five magnetic material sheets are stacked in sequence, and 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 are arranged alternately.

[0052] Step S104: Cut the large assembly to obtain multiple small assemblies with preset dimensions.

[0053] 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.

[0054] 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, thereby meeting the needs of different sized target magnets.

[0055] Step S105: Perform surface treatment on the small assembly.

[0056] Step S106: When all the magnetic material sheets in the small assembly that has undergone surface processing are magnetized, the small assembly that has undergone surface processing is the target magnet. When there are unmagnetized magnetic material sheets in the small assembly that has undergone surface processing, the unmagnetized magnetic material sheets are magnetized a second time to obtain the target magnet. That is, the target magnet is a small assembly in which all magnetic material sheets have been magnetized and have undergone surface processing.

[0057] Specifically, when all magnetic material sheets in the small assembly that has undergone surface treatment are magnetized, the magnet manufacturing process is a one-time magnetization. When there are unmagnetized magnetic material sheets in the small assembly that has undergone surface treatment, the unmagnetized magnetic material sheets are magnetized a second time, making the magnet manufacturing process a step-by-step magnetization, specifically two-step magnetization, and the magnetization direction of the first magnetization intersects with the magnetization direction of the second magnetization, for example, the magnetization direction of the first magnetization is perpendicular to the magnetization direction of the second magnetization.

[0058] In the fabrication process of the target magnets, by cutting large assemblies into smaller assemblies, a greater number of target magnets can be obtained, thereby 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 and improving dimensional accuracy. Moreover, the fabrication process is unaffected by repulsive forces between magnets, reducing the likelihood of magnet ejection and simplifying assembly.

[0059] In some embodiments, magnetic material sheets refer to all material sheets that are magnetic in themselves or have magnetic processing properties, and can be magnetic materials such as ferrite, neodymium iron boron, etc.

[0060] In some embodiments, a pretreatment step is further included before the first magnetization of at least one of the plurality of magnetic material sheets. The pretreatment step includes the following steps:

[0061] Step S201: Electroplating is performed on each magnetic material sheet.

[0062] Specifically, when electroplating magnetic material sheets, nickel, zinc, aluminum, etc., can be plated on the surface of the magnetic material sheets.

[0063] Step S202: Phosphate the electroplated magnetic material sheet.

[0064] Specifically, a non-conductive, porous phosphate crystal film is generated on the coating surface to enhance the adhesion of subsequent coatings.

[0065] Step S203: Spray resin onto the phosphated magnetic material sheet to complete the pretreatment step.

[0066] Specifically, the resin used for spraying can be epoxy resin, polyurethane, or silicone resin, etc.

[0067] It should be understood that pre-treated magnetic material sheets can prevent oxidation during subsequent processes.

[0068] In some embodiments, the present invention also provides another preprocessing step, including:

[0069] Step S301: Perform acid washing on the magnetic material sheet to complete the pretreatment of the magnetic material sheet.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] Furthermore, in some embodiments of the present invention, in the process steps of preparing the magnet, all the magnetized magnetic material sheets and all the unmagnetized magnetic material sheets are stacked and fixed together in a preset order, and the stacking and fixing method is adhesive fixing or welding fixing.

[0074] 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.

[0075] In some embodiments, the multiple magnetic material sheets are neodymium iron boron (NdFeB) sheets, which have high magnetic permeability.

[0076] In some embodiments, the welding and fixing method is to add tin-containing solder between two adjacent magnetic material sheets for soldering, wherein the solder is at least one of solder paste, tin wire, and tin powder.

[0077] In some embodiments, the weld width between two 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.

[0078] 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:

[0079] 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.

[0080] Specifically, multiple magnetic material sheets are acid-washed, stacked together in a preset order, and then sintered at high temperature.

[0081] It should be understood that fixing magnetic material sheets by welding results in higher strength and better reliability compared to fixing by bonding.

[0082] 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.

[0083] In some embodiments, after the first magnetization is completed and there are magnetized and unmagnetized magnetic material sheets, a preset order is used to alternate between each magnetized and each unmagnetized magnetic material sheet. This ensures that the magnetic material sheets do not interfere with each other when stacked, facilitating assembly.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] Please see Figure 3 In a specific example provided by this invention, five magnetic material sheets are provided. These five magnetic material sheets are fixed together by welding and stacked, specifically, the first, second, third, fourth, and fifth magnetic material sheets are stacked sequentially from bottom to top. The first magnetic material sheet is at the bottom, the third in the middle, and the fifth at the top. During the first magnetization process, the first, third, and fifth magnetic material sheets are not magnetized, while the second and fourth magnetic material sheets are magnetized along their thickness direction. During the second magnetization process, the first, third, and fifth magnetic material sheets are magnetized along their length direction.

[0088] Please see Figure 2In another specific example provided by this invention, five magnetic material sheets are provided. These five magnetic material sheets are fixed together by welding and stacked, specifically, the first, second, third, fourth, and fifth magnetic material sheets are stacked sequentially from bottom to top. The first magnetic material sheet is at the bottom, the third in the middle, and the fifth at the top. During the one-time magnetization process, an electromagnet with a magnetic induction intensity greater than 2T is selected to magnetize the first, second, third, fourth, and fifth magnetic material sheets together, so that the magnetization intensity of all five magnetic material sheets reaches saturation.

[0089] Please see Figure 4 This invention also provides a motor, including a housing 1 with a receiving cavity 11, and a vibration unit 2 and a drive unit 3 housed within the receiving cavity 11. One of the vibration unit 2 and the drive 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 vibration unit 2 respectively. The vibration unit 2 vibrates left and right within the housing 1 via the spring pieces 5. The magnet 4 is part of the vibration unit 2. The drive unit 3 includes a coil, and the coil and the magnet 4 interact to cause the vibration unit 2 to slide left and right within the housing 1.

[0090] Specifically, the magnets prepared using the manufacturing process of 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.

[0091] The above description is merely an embodiment 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; first magnetizing at least one of the plurality of magnetic material pieces; when all the magnetic material pieces have been magnetized after the first magnetization is completed, stacking and fixing all the magnetic material pieces in a preset order to obtain a large assembly; or, when there are magnetized magnetic material pieces and non-magnetized magnetic material pieces after the first magnetization is completed, stacking and fixing the magnetized magnetic material pieces and the non-magnetized magnetic material pieces in a preset order to obtain a large assembly; cutting the large assembly to obtain a plurality of small assemblies with a preset size; surface process treatment is performed on the small assembly; when all the magnetic material pieces in the small assembly that has completed the surface process treatment are magnetized magnetic material pieces, the small assembly that has completed the surface process treatment is a target magnetic steel; when there are non-magnetized magnetic material pieces in the small assembly that has completed the surface process treatment, second magnetizing is performed on the non-magnetized magnetic material pieces to obtain a target magnetic steel; wherein the magnetizing direction of the first magnetizing and the magnetizing direction of the second magnetizing intersect.

2. The process for preparing a magnetic steel according to claim 1, characterized in that, Before the first magnetizing of at least one of the plurality of magnetic material pieces, a pretreatment step is further included, and the pretreatment step comprises: electroplating treatment is performed on each of the magnetic material pieces; phosphating treatment is performed on the magnetic material pieces after the electroplating treatment; resin spraying is performed on the magnetic material pieces after the phosphating treatment to complete the pretreatment step.

3. The process for preparing a magnetic steel according to claim 1, wherein Before the first magnetizing of at least one of the plurality of magnetic material pieces, a pretreatment step is further included, and the pretreatment step comprises: pickling treatment is performed on each of the magnetic material pieces 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: tin solder is added between adjacent magnetic material pieces for tin soldering, 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 is performed on 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 width of the weld 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, When there are magnetized magnetic material pieces and non-magnetized magnetic material pieces after the first magnetization is completed, the preset order is that each magnetized magnetic material piece is arranged alternately with each non-magnetized magnetic material piece.

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; In the stacking and fixing, 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 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; The magnetic embryo is cut according to a preset cutting direction, so as to obtain a magnetic material sheet with a preset magnetization direction.

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

14. A motor characterized by, The application relates to a vibration unit and a driving unit, and a shell with a containing cavity, wherein one of the vibration unit and the driving unit comprises a magnetic steel prepared by the preparation process of the magnetic steel according to any one of claims 1 to 13.

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