Tool arrangement for producing a permanent magnet from a magnetizable powder material, method for producing a permanent magnet, and method for producing a tool arrangement

Abstract

The invention relates to a tool arrangement (1) for producing a permanent magnet (3) from a magnetizable powder material, comprising: at least one tool part (5) which is designed to surround a hollow space (15) at least in regions, wherein, as an alignment tool part (7), the at least one tool part (5) has a first material with a first permeability or is formed from a first material with a first permeability, and at least one alignment element (9) which has a second material which is different from the first material and has a second permeability or is formed from a second material with a second permeability, wherein the first permeability is greater than the second permeability, wherein the at least one alignment element (9) surrounds the hollow space (15) at least in regions along with the at least one alignment tool part (7), wherein the at least one alignment element (9) and the at least one alignment tool part (7) are arranged behind one another in the direction towards the hollow space (15). The invention also relates to a method for producing a permanent magnet (3) from a magnetizable powder material in a powder method and to a method for producing a tool assembly (1) which is designed to produce a permanent magnet (3) from a magnetizable powder material.

Description

[0001] DESCRIPTION

[0002] Tool arrangement for producing a permanent magnet from a magnetizable powder material, method for producing a permanent magnet and method for producing a tool arrangement

[0003] The invention relates to a tool arrangement for producing a permanent magnet from a magnetizable powder material, a method for producing a permanent magnet from a magnetizable powder material and a method for producing such a tool arrangement.

[0004] Permanent magnets, especially those from the rare earth group, are used in a wide variety of technical applications, particularly in electric motors, sensors, loudspeakers, and other electronic components, and exhibit a comparatively high energy product. For example, neodymium-iron-boron magnets (NdFeB magnets), which belong to this group, have an energy product of up to 400 kJ / m. 3NdFeB magnets typically consist of anisotropic hard magnetic materials. In this context, anisotropic means that these materials have a preferred magnetic direction and can therefore achieve high remanence values. Hard magnetic, in this context, means that these materials are permanently magnetic. The preferred directions can be imprinted in one or more spatial directions during the manufacturing process, allowing, for example, the production of magnets with multiple pole pairs. Such magnets are usually manufactured from a powder material using a pressing process. During the pressing process, an external magnetic field is generated by an alignment magnet to align the magnetic moments of the powder particles.Such magnets can also be manufactured using a powder injection molding process, in which the powder material is introduced, particularly injected, into a cavity of a mold. During the injection molding process, an external magnetic field is generated to align the magnetic moments of the powder particles. The generated magnetic field penetrates the mold and the cavity, as well as the powder particles arranged within the cavity. It is also known that such magnets can be manufactured using an extrusion process, in which the powder material is extruded through an extrusion die. During the extrusion process, an external magnetic field with magnetic field lines is generated to align the magnetic moments of the powder particles.

[0005] During the generation of the magnetic field lines, the effect occurs that they are deflected at an interface – where, in this case, the tool borders on the first side of the interface and the cavity with the powder material arranged therein borders on the second side of the interface; it is thus the interface forming a cavity shape, where the cavity can in particular be a cavity of an injection molding or pressing tool, as well as extrusion channels of an extrusion die of an extrusion tool – within an area selected from the tool and the cavity that has a lower permeability than the other area, towards a straight line perpendicular to the interface, in particular towards a perpendicular to the interface.In particular, when a curved permanent magnet is produced from a magnetizable powder material with a lower permeability using a tool made from a first material with a higher permeability, the magnetic field lines within the magnetizable powder material, and thus within the permanent magnet being produced, are deflected towards the line perpendicular to the interface, especially towards the perpendicular of the interface. The generated magnetic field lines are deflected primarily due to the curved shape of the cavity—and thus due to the desired shape of the permanent magnet—and this deflection does not necessarily correspond to the desired final orientation of the magnetic moments of the powder particles.In this respect, there is an undesirable correlation between the desired shape of the permanent magnet and the resulting alignment of the magnetic moments of the powder particles.

[0006] Furthermore, the magnetic field lines cannot be aligned parallel, especially at the edges of the cavity. It can also happen that the powder material in the cavity reaches magnetic saturation in certain areas due to an excessively strong magnetic field, causing the magnetic field lines generated by the alignment magnet to bypass the saturated area and thus the cavity containing the powder material. The magnetic field lines then penetrate the tool surrounding the cavity, further disrupting the alignment of the magnetic moments of the powder particles within the cavity.

[0007] The invention is therefore based on the objective of providing a tool arrangement for producing a permanent magnet from a magnetizable powder material, a method for producing a permanent magnet from a magnetizable powder material and a method for producing such a tool arrangement, wherein the aforementioned disadvantages are at least reduced, preferably avoided.

[0008] The problem is solved by providing the present technical teaching, in particular the teaching of the independent claims as well as the embodiments disclosed in the dependent claims and the description.

[0009] The problem is solved in particular by providing a tool arrangement for producing a permanent magnet from a magnetizable powder material, especially in a powder injection molding process, particularly in a metal injection molding process (MIM), a powder compression process, or a powder extrusion process. The tool arrangement comprises at least one tool part, wherein the at least one tool part is configured to surround a cavity, at least partially.In particular, the powder material can be injected into the cavity – especially in a powder injection molding process – or – especially in a powder compression process – filled into the cavity for compression, or – especially in a powder extrusion process – extruded through the cavity, if a permanent magnet is to be produced with the tool arrangement, and / or a previously injection-molded or pressed permanent magnet blank can be inserted into the cavity, especially if the tool arrangement is designed as an injection mold or a compression mold. Furthermore, at least one tool part, acting as an alignment tool part, comprises a first material with a first permeability or is formed from a first material with a first permeability.Furthermore, the tool arrangement includes at least one alignment element that comprises a second material with a second permeability, different from the first material. The first permeability is greater than the second permeability. The at least one alignment element, together with the at least one alignment tool part, partially surrounds the cavity. The at least one alignment element and the at least one alignment tool part are arranged one behind the other in the direction of the cavity. In particular, the at least one alignment tool part is arranged behind the at least one alignment element, starting from the cavity.

[0010] The alignment element makes it advantageous to align the magnetic field lines generated by the alignment magnet, which penetrate the cavity and optionally the powder particles of the powder material arranged therein, in the desired manner.

[0011] The tool arrangement advantageously includes an alignment element located between the cavity and the alignment tool part. Thus, such an arrangement—and in particular the alignment element—has, in particular, an alignment-tool part-alignment element interface and an alignment element-permanent magnet interface. The alignment element-permanent magnet interface defines the cavity shape and determines the subsequent shape of the permanent magnet. The alignment element-permanent magnet interface is, in particular, the interface that delimits the at least one alignment element from the cavity—or conversely, the cavity from the alignment element. Specifically, the alignment element is arranged on a first side of the alignment element-permanent magnet interface, and the cavity is arranged on a second side of the alignment element-permanent magnet interface opposite the first side.In particular, the alignment element borders the first side of the alignment element-permanent magnet interface, while the cavity borders the second side of the alignment element-permanent magnet interface opposite the first side. Specifically, the alignment element-permanent magnet interface is a surface of the alignment element facing the cavity. It is possible that the surface of the alignment element is coated with a protective coating, such that the protective coating is located on the first side of the alignment element-permanent magnet interface and the cavity is located on the second side of the alignment element-permanent magnet interface, and in particular, borders it. The alignment tool part-alignment element interface is, in particular, the interface that is located between the at least one alignment element and the at least one alignment tool part.In particular, the alignment tool part is arranged on a first side of the alignment tool part-alignment element interface, and the alignment element is arranged on a second side of the alignment tool part-alignment element interface opposite the first side. Specifically, the alignment tool part borders the first side of the alignment tool part-alignment element interface, and the alignment element borders the second side of the alignment tool part-alignment element interface opposite the first side. If the alignment element has a protective coating, the alignment tool part is arranged on the first side of the alignment tool part-alignment element interface, and the protective coating of the alignment element is arranged on the second side of the alignment tool part-alignment element interface, and in particular, each borders the protective coating.Preferably, the alignment tool part and the alignment element are in direct contact with each other at the alignment-tool part-alignment element interface, provided there is no gap or air gap. In particular, the alignment-tool part-alignment element interface is a surface of the alignment element facing the alignment tool part. The alignment-tool part-alignment element interface can, in particular, be a contact surface of the alignment element. The alignment-tool part-alignment element interface is, in particular, the interface by means of which the generated magnetic field lines can be aligned—that is, which affects the deflection of the magnetic field lines; and which is specifically designed and arranged to deflect the magnetic field lines in a predetermined manner—whereby the alignment is advantageously decoupled from the cavity shape.

[0012] In particular, the alignment tool part alignment element interface and the alignment element permanent magnet interface of an alignment element of the at least one alignment element, especially of the same alignment element of the at least one alignment element, have different interface shapes. Specifically, the interface shape is selected from a group consisting of: a plane, a stepped shape, a simply curved shape, a multiply curved shape, a shape curved in one dimension, and a shape curved in two dimensions.

[0013] A simply curved shape is understood to be, in particular, a surface in which all curves lying within this surface have no inflection points, and in particular, the second derivative of these curves has only positive values ​​or only negative values. A multiply curved shape is understood to be, in particular, a surface in which at least one curve lying within this surface has at least one inflection point, and in particular, the second derivative of this at least one curve has positive values ​​in a first position and negative values ​​in a second position. A shape curved in one dimension is understood to be, in particular, a surface in which at least one straight line lies, for example, as in the case of a bisected circular cylindrical surface, and in particular, the at least one straight line is oriented parallel to the central axis of the cylinder.A shape curved in two dimensions is understood in particular to be a surface in which only curved curves lie, in which in particular no straight lines lie in the surface, for example as in a spherical cap, also called a spherical cap, in particular a hemispherical surface.

[0014] In one embodiment, the alignment tool part / alignment element interface is planar, and the alignment element / permanent magnet interface of the same alignment element is curved. In another embodiment, the alignment tool part / alignment element interface is curved, and the alignment element / permanent magnet interface of the same alignment element is planar. In yet another embodiment, the alignment tool part / alignment element interface and the alignment element / permanent magnet interface of the same alignment element have different curvatures, in particular having different radii of curvature and / or different centers of curvature.

[0015] Thus, the present tool arrangement allows for the targeted control—and, above all, independent of the cavity shape—of the alignment of the magnetic moments of the powder particles in a permanent magnet to be produced from magnetizable powder material, by means of a predetermined shaping of the interface between the alignment tool part and the alignment element. In this context, "independent" means, in particular, that two functions of the tool arrangement, especially the alignment element—namely, forming the cavity shape and aligning the magnetic field lines—are functionally separated. The cavity shape is determined by the interface shape of the alignment element and the permanent magnet, while the deflection of the magnetic field lines is determined by the interface shape of the alignment tool part and the alignment element.

[0016] In particular, the tool arrangement – ​​regardless of the cavity shape, especially regardless of curvature and / or the interface shape of the alignment element-permanent magnet interface – can be used to produce a homogeneous permanent magnet with uniformly aligned powder particles, especially uniformly aligned magnetic moments, from a magnetic powder material, by shaping the alignment-tool part-alignment element interface in such a way that the magnetic field lines are deflected in a predetermined manner to align the magnetic moments of the powder particles as desired.Furthermore, by suitable combination of materials with different magnetic permeabilities, the course of the magnetic field lines through the cavity and the alignment of magnetic moments of the powder material arranged therein can be specifically influenced, whereby in particular the degree of deflection of the magnetic field lines depends on a difference in permeability between the two materials adjacent to the alignment-tool part-alignment element interface, whereby the magnetic field lines are deflected more strongly at a higher difference than at a lower difference.

[0017] The at least one alignment tool component advantageously acts as a kind of conductive material, which initially roughly aligns the magnetic field lines, in particular deflects them, in particular focuses them, and in particular directs them towards the cavity. The at least one alignment element, in particular its alignment-tool component-alignment element interface, on the other hand, finely aligns the magnetic field lines – in particular on the way to the cavity – in particular deflects them, in particular manipulates them in such a way that a desired alignment of the magnetic moments of the powder particles is achieved.

[0018] In the context of this technical teaching, a magnet, permanent magnet, or permanent magnet blank is understood to mean, in particular, a magnet or magnetic blank that is produced or manufactured using the tool arrangement. Such a magnet or magnetic blank is produced, in particular, by introducing the powder material into the cavity, especially by injection, filling, or extruding it through the cavity, from which the magnet or magnetic blank is manufactured. For the sake of clarity, the magnetic alignment of the magnetic field lines of the magnet or magnetic blank is referred to in this context only as the "magnetic moment."

[0019] In contrast, in the context of this technical teaching, an alignment magnet is understood to be, in particular, a magnet used to align the magnetic moments of the powder particles of the powder material. Magnetic field lines emanate from the alignment magnet, whereby the term "magnetic field lines" is used only in connection with the alignment magnet.

[0020] In the context of this technical teaching, a powder material is understood to mean, in particular, powder particles mixed with a binder component, especially a polymer binder, to form a so-called feedstock. Specifically, the binder component ensures that the powder particles can be reliably and uniformly distributed into the cavity, that the powder particles retain their shape, and that the permanent magnet green body does not collapse in on itself after demolding.

[0021] In one embodiment, the second permeability depends—and is specifically chosen to depend—on a third permeability of the powder material. In particular, a first difference between the first and second permeability is greater than a second difference between the second and third permeability. Specifically, the second and third permeabilities are similar—compared to the differing first permeability—and in particular, equal or identical. Advantageously, this ensures that the magnetic field lines between the alignment element and the powder material introduced into the cavity—particularly at the alignment element-permanent magnet interface—are deflected as little as possible, and in particular not at all.Advantageously, the first larger difference ensures that the magnetic field lines are deflected, particularly predominantly, and especially completely, at the alignment-tool-part-alignment-element interface, particularly within the second material, especially towards or away from the line perpendicular to the alignment-tool-part-alignment-element interface, and especially towards or away from the perpendicular to the alignment-tool-part-alignment-element interface. In particular, the larger the first difference, the more strongly the magnetic field lines are deflected towards or away from the line perpendicular to the alignment-tool-part-alignment-element interface, and especially towards or away from the perpendicular to the alignment-tool-part-alignment-element interface.In particular, the larger the second difference, the more strongly the magnetic field lines are deflected towards or away from the straight line perpendicular to the alignment element-permanent magnet interface, especially towards or away from the perpendicular of the alignment element-permanent magnet interface, which is why this second difference should be as small as possible.

[0022] Whether the magnetic field lines are deflected towards or away from a line perpendicular to an interface, particularly towards or away from the normal of the interface, depends primarily on the permeability of the two materials adjacent to the interface. In the material with higher permeability, the magnetic field line is deflected away from the line perpendicular to the interface, particularly away from the normal of the interface. In the material with lower permeability, the magnetic field line is deflected towards the line perpendicular to the interface, particularly towards the normal of the interface.

[0023] In one embodiment, the first permeability is greater than the second permeability, with the second permeability being greater than the third permeability. In particular, the first permeability is significantly greater than the second permeability, with the second permeability being—relatively speaking—only slightly greater than the third permeability. It is also possible that the second permeability is—relatively speaking—somewhat smaller than the third permeability.

[0024] In one embodiment, at least one tool part has a soft magnetic or a hard magnetic material or is formed from a soft magnetic or a hard magnetic material.

[0025] According to a further development of the invention, the tool arrangement comprises, as at least one tool part, a first tool part and a second tool part opposite the first tool part, wherein the first tool part and the second tool part are designed to surround the cavity at least partially in a joined, in particular closed, state.

[0026] Advantageously, a permanent magnet, in particular a green permanent magnet body, injection-molded by a powder injection molding process or pressed by a powder compression process, can be demolded particularly easily, in particular removed from the cavity, by separating the first tool part and the second tool part from each other, in particular by moving them apart. In one embodiment, at least one tool part, selected from the first tool part and the second tool part, in particular both tool parts, comprises a soft magnetic or a hard magnetic material or are formed from a soft magnetic or a hard magnetic material.

[0027] In one embodiment – ​​particularly when the tool arrangement is designed as an extrusion tool – the tool arrangement comprises exactly one alignment tool part or exactly two alignment tool parts. Specifically, the tool arrangement comprises exactly one alignment element or exactly two alignment elements. However, it is also possible for the tool arrangement to have more than two alignment elements.

[0028] In particular, if the tool arrangement has exactly two alignment tool parts and exactly one single alignment element, the alignment element is arranged between the two alignment tool parts.

[0029] In particular, if the tool arrangement comprises exactly one alignment tool part and exactly one alignment element, the alignment tool part has an alignment element recess for the alignment element. Specifically, the alignment element is arranged in the alignment element recess. In particular, the alignment element is thus surrounded, and in particular encompassed, by the alignment tool part. Specifically, the alignment tool part has an annular cross-section, and in particular, an annular cross-section. In particular, the annular cross-section, and in particular the annular cross-section, is conceptually extruded so that the alignment tool part is designed as an annular cylinder, and in particular as an annular cylinder, with the alignment element being arranged within the annular cylinder, and in particular the annular cylinder.

[0030] According to a further development of the invention, a first alignment element of the at least one alignment element is arranged between a first alignment tool part of the at least one alignment tool part and the cavity. A second alignment element of the at least one alignment element is arranged between a second alignment tool part of the at least one alignment tool part, which differs from the first alignment tool part, and the cavity. Advantageously, it is possible to align the magnetic field lines both on the side where the magnetic field lines enter the cavity—in particular, originating from the first alignment tool part or the second alignment tool part toward the cavity—and on the side where the magnetic field lines exit the cavity—in particular, originating from the cavity toward the second alignment tool part or the first alignment tool part.This makes it possible, in particular, to align the magnetic moments of the powder particles with exceptional precision.

[0031] In one embodiment, the tool arrangement comprises, as at least one alignment element, the first alignment element, the second alignment element, and at least one further alignment element. In particular, the tool arrangement comprises exactly three alignment elements.

[0032] According to a further development of the invention, an alignment element of the at least one alignment element is designed as an alignment coating of the alignment tool part. Alternatively or additionally, an alignment element of the at least one alignment element is designed as an element separate from the alignment tool part.

[0033] In one embodiment, an alignment element of the at least one alignment element is designed as an element separate from the alignment tool part, wherein the alignment element additionally has an alignment coating.

[0034] In one embodiment, the alignment coating has a thickness of 1 pm to 1000 pm, in particular up to 500 pm, in particular from 200 pm to 400 pm, in particular from 300 pm to 400 pm. In particular, the alignment coating is a coating from the group consisting of: a diamond-like carbon (DLC) coating, a titanium aluminum nitride coating, a chromium coating, a Teflon coating, an aluminum coating, a copper coating, and a combination of at least two of the aforementioned coatings.

[0035] In one embodiment, the alignment coating is produced by means of an energy beam cladding process, in particular a laser beam cladding process. In another embodiment—where an alignment element of the at least one alignment element is designed as an alignment coating of the alignment tool part—a cavity formed by means of the alignment coating is produced by means of a machining process or an electrical discharge machining (EDM) process, in particular within the alignment coating. In particular, the alignment coating then has a layer thickness of 200 pm to 1000 pm, in particular 500 pm to 1000 pm, such that sufficient layer material can be removed from the alignment layer to form the cavity.

[0036] In one embodiment, an alignment element of the at least one alignment element has a protective coating. In particular, the protective coating is a wear-resistant layer that advantageously reduces, and in particular prevents, wear on the alignment element. It is also possible that the protective coating is applied to the alignment element as an alternative to, or in addition to, the alignment layer. In particular, the protective coating has a nickel-based or cobalt-based material or is formed from a nickel-based or cobalt-based material. In particular, the protective coating has carbides. In particular, the protective coating has a Stellite or Inconel material or is formed from a Stellite or Inconel material. In particular, the protective coating has one or more hard materials from the group consisting of: tungsten carbide, chromium carbide, vanadium carbide, and niobium carbide.

[0037] According to a further development of the invention, an alignment element of the at least one alignment element forms a cavity shape of the cavity section by section.

[0038] In the context of the present technical teaching, the fact that an alignment element forms a cavity shape section by section means, in particular, that the alignment element forms the cavity required in an injection molding process, especially the present powder injection molding process, or in a pressing process, especially the present powder pressing process, or the extrusion channels of the extrusion die required in an extrusion process, especially the present powder extrusion process. In particular, the magnetizable powder material is introduced into the cavity, especially by injection or filling, or extruded through the cavity, whereby the magnetizable powder material comes into contact with the alignment element and, in particular, rests against it, thereby forming the finished shape of the permanent magnet, especially the permanent magnet green body.In particular, a shape, especially a finished shape, of the permanent magnet is formed by the cavity shape formed by the alignment element.

[0039] In one embodiment, the first alignment element and the second alignment element form a cavity shape of the cavity, section by section, and in particular completely. Specifically, the first alignment element forms a first partial shape of the cavity shape, and the second alignment element forms a second partial shape of the cavity shape. In particular, the first partial shape and the second partial shape thus form two halves which, when joined, and in particular closed, form the cavity shape.

[0040] In one embodiment, the first alignment element and the first alignment tool part are arranged one behind the other in the direction of the cavity. In particular, the first alignment tool part is arranged behind the first alignment element, starting from the cavity. In another embodiment, the second alignment element and the second alignment tool part are arranged one behind the other in the direction of the cavity. In particular, the second alignment tool part is arranged behind the second alignment element, starting from the cavity.

[0041] In one embodiment, the following arrangement results – particularly in this order; particularly for the magnetic field lines: First alignment tool part, first alignment element, cavity, optionally second alignment element and optionally second alignment tool part.

[0042] In one embodiment, an alignment element of the at least one alignment element is glued to an alignment receptacle of the alignment tool part. In another embodiment, the alignment element is flanged to an alignment receptacle of the alignment tool part, in particular screwed on or fastened by means of a plug-and-turn connection.

[0043] In one embodiment, an alignment element of the at least one alignment element is arranged on the alignment tool part, in particular attached to it, wherein the alignment element additionally has the alignment layer, in particular is coated with the alignment layer. In one embodiment – ​​when an alignment element of the at least one alignment element has the alignment layer – the magnetizable powder material, in particular during introduction, in particular injection or filling into the cavity, or in particular during extrusion through the cavity, comes into contact with the alignment layer of the alignment element and is in contact with it, in particular thereby forming the finished shape of the permanent magnet.

[0044] In one embodiment - if the first and the second alignment element each have an alignment layer - the following arrangement results - particularly in this order; particularly for the magnetic field lines: First alignment tool part, first alignment element, first alignment layer, cavity, optional second alignment layer, optional second alignment element and optional second alignment tool part.

[0045] According to a further development of the invention, the first permeability - specified as permeability number p - exhibits r The first relative permeability, also known as the first, has a value between 100 and 500,000, specifically between 1,000 and 500,000. The second permeability is given as the permeability number p. r ; also referred to as second relative permeability - has a value from 1 to 100, in particular from 1 to 10, especially from 1 to 7.

[0046] The permeability number p rPermeability, also known as relative permeability, is the quotient of the ratio p = B / H (also generally called permeability) of the magnetic flux density B and the magnetic field H, and the magnetic constant po, which is also known as the permeability of free space. The permeability number p r can be done in particular using the formula / J. r = be expressed.

[0047] According to a further development of the invention, the first material is selected from a group consisting of: pure iron, in particular with an iron content of 99% to 99.99%, a low-alloy carbon steel alloy with a mass fraction of at most 5% of another alloying element besides carbon, in particular SAE 1006, SAE 1010, SAE 1018, SAE 1020 and SAE 1117, a tool steel, a low-alloy steel alloy with a mass fraction of at most 5% of another alloying element besides carbon, a ferromagnetic stainless steel, in particular AISI 416, AISI 430 and AISI 455, an iron-silicon steel alloy, in particular Carpenter Silicon Core Iron “A”, M-15, M-19, M-22, M-27, M-36, M-43, M-45 and M-47, an iron-cobalt alloy, in particular FeCo35, FeCo50 and Fe-Co-V, an iron-nickel alloy and an iron-nickel-cobalt alloy, in particular FeNi50, a ferromagnetic nickel alloy,a ferromagnetic cobalt alloy and a mu-metal.

[0048] Alternatively or additionally, the second material is selected from a group consisting of: an aluminum alloy, an austenitic stainless steel, in particular AISI 316L, AISI 304, in particular Nitronic50, a non-magnetizable material, in particular a non-magnetizable hard alloy, in particular a Stellite alloy, in particular a Stellite 6 alloy, a magnesium alloy, a titanium material and a titanium alloy, in particular with high wear resistance, in particular with a hardness value of at least 26 HRC, in particular at least 45 HRC, in particular at least 54 HRC, in particular Ferro-Titanite.

[0049] For the materials, material alloys, material designations and material trademarks mentioned in this application, the compositions meant are those available on the date relevant for the priority date of the present intellectual property right.

[0050] According to a further development of the invention, an interface between the at least one alignment element and the at least one alignment tool part - in particular also referred to as the alignment tool part alignment element interface - is curved at least in some areas.

[0051] Advantageously, by varying the radius of curvature of the interface, the orientation of the magnetic field lines—in particular, the angle between a direction line of a magnetic field line, especially a vector, and a reference line, especially a horizontal—can be influenced. Specifically, if the interface has a first, larger radius of curvature, the magnetic field lines are deflected less, especially focused, than if the interface has a second radius of curvature that is smaller than the first. In particular, the interface acts like the surface of an optical lens, except that in this case, it is not light rays that are deflected, especially focused or fanned out, but rather magnetic field lines. In particular, the direction line is characteristic of a direction of the magnetic field line.In particular, the direction line can be a vector at any point on the magnetic field line that is tangential to the magnetic field line. However, it is also possible for the direction line to include two points on the magnetic field line, in particular a chosen starting point and a chosen endpoint. Specifically, the two points can be: a first intersection point between the magnetic field line and a first alignment element-permanent magnet interface, and a second intersection point between the magnetic field line and a second alignment element-permanent magnet interface.

[0052] In particular, the reference line is a straight line known in a coordinate system, whose direction, and especially its reference vector, is known. The reference line extends, in particular, from the first alignment tool part to the second alignment tool part, and especially from the first alignment element to the second alignment element. Advantageously, the reference line allows the differently oriented magnetic field lines resulting from different configurations of the alignment elements to be compared, in particular by relating them to the reference line, and especially to the reference vector.

[0053] In particular, the at least one alignment element has a concave or convex contact surface as its contact surface. In particular, the at least one alignment tool component has a corresponding, in particular similarly curved, concave or convex counter-contact surface.

[0054] In one embodiment, the at least one alignment element rests with its contact surface against the opposing contact surface of the at least one alignment tool part. In another embodiment, the interface is only an imaginary interface, particularly if a gap, especially an air gap, exists between the at least one alignment element, particularly its contact surface, and the at least one alignment tool part, particularly its opposing contact surface. In particular, the surfaces facing each other between the at least one alignment element and the at least one alignment tool part are curved in certain regions, particularly in the same direction, and in particular identically. According to a further development of the invention, a first interface between the first alignment element and the first alignment tool part—also referred to as the first alignment tool part-alignment element interface—is curved at least in certain regions.

[0055] In particular, the first alignment element has a concave or convex first contact surface. In particular, the first alignment tool part has a corresponding, in particular similarly curved, concave or convex first counter-contact surface.

[0056] In one embodiment, the first alignment element rests with its first contact surface against the first counter-contact surface of the first alignment tool part. In another embodiment, the first interface is merely an imaginary first interface, particularly if a gap, especially an air gap, exists between the first alignment element, particularly its first contact surface, and the first alignment tool part, particularly its first counter-contact surface. In particular, the surfaces facing each other between the first alignment element and the first alignment tool part are curved in certain areas, particularly in the same direction, and especially identically curved.

[0057] Alternatively or additionally, a second interface between the second alignment element and the second alignment tool part - also referred to as the second alignment tool part alignment element interface - is curved, at least in some areas.

[0058] In particular, the second alignment element has a concave or convex second contact surface. Specifically, the second alignment tool part has a corresponding, in particular similarly curved, concave or convex second counter-contact surface.

[0059] In one embodiment, the second alignment element rests with its second contact surface against the second counter-contact surface of the second alignment tool part. In another embodiment, the second interface is merely an imaginary second interface, particularly if a gap, especially an air gap, exists between the second alignment element, particularly its second contact surface, and the second alignment tool part, particularly its second counter-contact surface. In particular, the surfaces facing each other between the second alignment element and the second alignment tool part are curved in certain areas, particularly in the same direction, and especially identically curved.

[0060] In particular, the first interface and the second interface act like two surfaces of an optical lens, except that in this case no light rays are bundled or fanned out, but rather magnetic field lines.

[0061] According to a further development of the invention, the tool arrangement includes a magnetic device comprising two alignment magnets, each having a north pole and a south pole. The at least one tool part, the at least one alignment element, and the cavity are arranged between the opposing poles of the two alignment magnets such that predetermined magnetic field lines are generated, which pass through the at least one tool part, the at least one alignment element, and the cavity, so that the magnetic moments of the powder particles of the magnetizable powder material are aligned in a predetermined direction, particularly when the powder material is injected or filled into the cavity or extruded through the cavity.

[0062] In particular, at least one tool part is arranged as the alignment tool part between the opposing poles of the two alignment magnets facing each other.

[0063] In one embodiment – ​​where the tool arrangement comprises the first tool part and the second tool part as at least one tool part – the first tool part, the at least one alignment element, the cavity and the second tool part are arranged between the opposing poles of the two aligning magnets such that predetermined oriented magnetic field lines are generated which pass through the first tool part, the at least one alignment element, the cavity and optionally the second tool part, so that magnetic moments of the powder particles of the magnetizable powder material are aligned in a predetermined direction, particularly when the powder material is injected or filled into the cavity or extruded through the cavity.In particular, the first tool part as the first alignment tool part and the second tool part as the second alignment tool part are arranged between the opposing poles of the two aligning magnets.

[0064] In one embodiment – ​​particularly when the tool arrangement is designed as an extrusion tool – the first alignment tool part, the at least one alignment element, the cavity, and the second alignment tool part are arranged between the opposite poles of the two opposing alignment magnets. In particular, this results in the following arrangement – ​​especially in this sequence, and particularly with regard to the magnetic field lines: First alignment tool part, the at least one alignment element, optionally the at least one alignment layer, the cavity, optionally the at least one alignment layer again, optionally the at least one alignment element again, and optionally the second alignment tool part. The magnetic field lines here run directly between the opposite poles of the two opposing alignment magnets.In particular, the first alignment tool part and, optionally, the second alignment tool part are each encompassed by one of the two alignment magnets. Specifically, the first alignment magnet encompasses the first alignment tool part. Specifically, the second alignment magnet encompasses the second alignment tool part.

[0065] In another embodiment – ​​particularly when the tool arrangement is designed as an extrusion tool – the first alignment tool part, the at least one alignment element, the cavity, and the second alignment tool part are arranged between the opposing, like-named poles of the two aligning magnets. In particular, this results in the following arrangement – ​​especially in this sequence; particularly with regard to the magnetic field lines: first alignment tool part, the at least one alignment element, optionally the at least one alignment layer, the cavity, optionally again the at least one alignment layer, optionally again the at least one alignment element, optionally the second alignment tool part. Particularly due to this like-named arrangement, the magnetic field lines meet between the two poles and are deflected, in particular deflected transversely, and in particular by 90°.In particular, the first alignment tool part and, optionally, the second alignment tool part are each encompassed by one of the two alignment magnets. Specifically, the first alignment magnet encompasses the first alignment tool part. Specifically, the second alignment magnet encompasses the second alignment tool part.

[0066] In one embodiment – ​​particularly when the tool arrangement is designed as an injection mold or a press tool – the first tool part, in particular as the first alignment tool part, the at least one alignment element, the cavity, and the second tool part, in particular as the second alignment tool part, are arranged between the oppositely named poles of the two opposing alignment magnets. In particular, this results in the following arrangement – ​​especially in this order; particularly with regard to the magnetic field lines: first alignment tool part, first alignment element, optionally first alignment layer, cavity, optionally second alignment layer, optionally second alignment element, and second alignment tool part.A reverse arrangement is also conceivable: second alignment tool part, second alignment element, optionally a second alignment layer, cavity, optionally a first alignment layer, optionally a first alignment element, and first alignment tool part. The magnetic field lines run directly between the opposite poles of the two opposing alignment magnets. Specifically, the first alignment tool part and, optionally, the second alignment tool part are each surrounded by one of the two alignment magnets. Specifically, the first alignment magnet surrounds the first alignment tool part. Specifically, the second alignment magnet surrounds the second alignment tool part.

[0067] In another embodiment – ​​particularly when the tool arrangement is designed as an injection mold or a press tool – the first tool part, in particular as the first alignment tool part, the at least one alignment element, the cavity, and the second tool part, in particular as the second alignment tool part, are arranged between the opposing, like-named poles of the two opposing alignment magnets. In particular, this results – especially in this order; particularly with regard to the magnetic field lines – in the following arrangement: first alignment tool part, first alignment element, optionally first alignment layer, cavity. Particularly due to the like-named arrangement, the magnetic field lines meet between the two poles and are deflected, in particular laterally deflected, in particular by 90°.A reverse arrangement is also conceivable: second alignment tool part, second alignment element, optionally a second alignment layer, cavity. Thus, in this embodiment, the magnetic field lines do not run between the opposite poles of the two opposing alignment magnets, but rather between the opposite poles of the same alignment magnets. Specifically, the first alignment tool part and, optionally, the second alignment tool part are each encompassed by one of the two alignment magnets. Specifically, the first alignment magnet encompasses the first alignment tool part. Specifically, the second alignment magnet encompasses the second alignment tool part.

[0068] In particular, magnetic moments of the powder particles of the magnetizable powder material are aligned in the direction of the magnetic field lines, especially along the magnetic field lines, and especially coincidentally with the magnetic field lines.

[0069] In one embodiment, the tool arrangement comprises a first alignment magnet and a second alignment magnet as the two alignment magnets.

[0070] In one embodiment – ​​particularly when the tool arrangement is designed as an extrusion tool, which in particular has exactly one alignment element – ​​the first alignment magnet, the first alignment tool part, and the alignment element are arranged one behind the other in a first direction towards the cavity. In particular, starting from the cavity – and especially in this sequence – the alignment element, the first alignment tool part, and the first alignment magnet are arranged one behind the other opposite to the first direction. In particular, the second alignment magnet, the second alignment tool part, and the alignment element are arranged one behind the other in a second direction towards the cavity, different from the first direction. In particular, starting from the cavity – and especially in this sequence – the alignment element, the second alignment tool part, and the second alignment magnet are arranged one behind the other opposite to the second direction.In particular, this design is possible by arranging the alignment element as the sole alignment element between the first alignment tool part and the second alignment tool part, wherein the alignment element particularly forms the extrusion channels. Specifically, the extrusion channels are surrounded, and in particular encompassed, by the alignment element and are formed by means of the alignment element, wherein the alignment element is in turn partially surrounded, and in particular encompassed, by the first alignment tool part and the second alignment tool part, particularly on opposite sides.

[0071] In one embodiment – ​​particularly when the tool arrangement is designed as an injection mold or a compression mold, or when the tool arrangement is designed as an extrusion mold with two alignment elements – the first alignment magnet, the first alignment mold part, and the first alignment element are arranged one behind the other in the direction of the cavity. Specifically, starting from the cavity – and particularly in this order – the first alignment element, the first alignment mold part, and the first alignment magnet are arranged one behind the other. Specifically, the second alignment magnet, the second alignment mold part, and the second alignment element are arranged one behind the other in the direction of the cavity. Specifically, starting from the cavity – and particularly in this order – the second alignment element, the second alignment mold part, and the second alignment magnet are arranged one behind the other.In particular, the alignment layer is arranged between the cavity and an alignment element selected from the first alignment element and the second alignment element, in particular both alignment elements.

[0072] In one embodiment, the two alignment electromagnets are designed as permanent magnets.

[0073] In one embodiment, the tool arrangement comprises a controllable electromagnetic device having two alignment electromagnets, each with a north pole and a south pole, wherein the first tool part, the at least one alignment element, the cavity, and the second tool part are arranged between the opposing, differently named or identically named poles of the two opposing alignment electromagnets such that, when the electromagnetic device is switched on, predetermined oriented magnetic field lines are generated which pass through the first tool part, the at least one alignment element, the cavity, and optionally the second tool part, so that magnetic moments of the powder particles of the magnetizable powder material are aligned in a predetermined direction, in particular in the direction of the magnetic field lines, in particular along the magnetic field lines, and in particular coincidentally with the magnetic field lines.especially when the powder material is introduced into the cavity, particularly when injected or filled. In one embodiment – ​​particularly when the tool arrangement is designed as an extrusion tool – the tool arrangement includes the controllable electromagnetic device, which comprises the two alignment electromagnets.

[0074] According to a further development of the invention, the tool arrangement is designed as an injection mold, in particular for injection molding a permanent magnet from a magnetizable powder material. The injection mold has a powder material supply line, in particular a sprue line. In particular, the magnetizable powder material can be introduced into the cavity by means of the powder material supply line, in particular by injection. In particular, the powder material supply line opens into the cavity by means of a powder feed opening.

[0075] In one embodiment, the injection mold has a demolding parting plane, wherein the injection mold can be separated, in particular moved apart, for demolding the molded permanent magnet. In particular, the demolding parting plane is arranged between the first alignment tool part or the first alignment element and the second alignment tool part or the second alignment element. In particular, the first alignment tool part or the first alignment element and the second alignment tool part or the second alignment element are abutting each other in the demolding parting plane.

[0076] The injection molding tool makes it advantageous to injection mold complex, three-dimensional permanent magnets. Such permanent magnets can have surfaces curved on one or both sides. It is also possible to injection mold lens-shaped permanent magnets with convex and / or concave surfaces.

[0077] Particularly in a cavity designed for injection molding a lens element, the magnetic field lines are symmetrically aligned, especially point-symmetrically, axially symmetrically, or plane-symmetrically. Specifically, the magnetic field lines are oriented differently in different parts of the cavity.

[0078] In one embodiment, the powder material supply line runs through a tool part, selected from the first tool part, in particular the first alignment tool part, and the second tool part, in particular the second alignment tool part. In particular, the powder material supply line further runs through an alignment element of the at least one alignment element arranged on, and in particular connected to, the tool part, and further through at least one applied layer, selected from the alignment layer and the protective layer.

[0079] In another embodiment, the powder material feed line runs along the demolding parting line between the first alignment tool part or the first alignment element and the second alignment tool part or the second alignment element. This has the particular advantage that no additional feed line needs to be inserted, especially drilled, into the alignment tool part selected from the first and second alignment tool parts. Advantageously, this avoids introducing any obstructions to the magnetic field lines into the alignment tool part.

[0080] According to a further development of the invention, the powder material supply line opens into the cavity with a first conductor cross-section, wherein the powder material supply line has a larger, second conductor cross-section upstream of the first conductor cross-section, in particular adjacent to the powder supply opening.

[0081] This design can advantageously promote a laminar flow profile of the powder material flowing into the cavity, particularly a laminar powder material flow. The powder material can thus be injected into the cavity with minimal turbulence, thereby advantageously reducing, and in particular avoiding, unfavorable alignment of the magnetic moments of the powder particles.

[0082] In the context of this technical teaching, laminar flow is understood to mean, in particular, a flow, especially pipe flow, whose Reynolds number Re is less than a value of 2320.

[0083] In the context of this technical teaching, "downstream" refers in particular to a direction which, when the tool arrangement is used as intended, corresponds to a direction of powder movement, in particular a powder flow direction, powder injection direction, or powder extrusion direction. Conversely, in the context of this technical teaching, "upstream" refers in particular to a direction which, when the tool arrangement is used as intended, corresponds to a direction opposite to the direction of powder movement, in particular a powder flow direction, powder injection direction, or powder extrusion direction. In particular, an upstream direction and a downstream direction are opposite to each other.

[0084] In one embodiment, the second conductor cross-section tapers stepwise into the first conductor cross-section, in particular by means of a single step. In another embodiment, the second conductor cross-section tapers continuously, in particular steplessly, into the first conductor cross-section. In particular, the taper is conical or pyramidal.

[0085] Alternatively or additionally, the powder material feed line has a widening section in which at least one transverse dimension of the powder material feed line, oriented transversely to a powder material conveying direction, widens towards the cavity. In particular, one transverse dimension of the at least one transverse dimension of the line is at least 60%, and more specifically at least 90%, of a transverse dimension of the cavity, wherein the transverse dimension of the cavity is aligned parallel to the transverse dimension of the line and adjoins the powder feed opening within the cavity, and more specifically directly.

[0086] Advantageously, this allows for the realization of a flow profile that is as laminar as possible for the powder material flowing into the cavity, in particular the laminar powder material flow.

[0087] Alternatively or additionally, the powder material supply line opens into the cavity as a film gate.

[0088] Advantageously, this allows for a particularly uniform flow profile, especially a uniform powder material flow front, particularly with comparatively large-area permanent magnets, thereby reducing and, in particular, preventing internal stresses and distortion in the permanent magnet. According to a further development of the invention, the tool arrangement is designed as a pressing tool, specifically for pressing a permanent magnet, especially a permanent magnet blank, from a magnetizable powder material. The pressing tool has at least one pressing ram element, which is displaceable, in particular, along a pressing direction, and is specifically configured to compress the magnetizable powder material and, in particular, thereby produce the permanent magnet blank.

[0089] In one embodiment, the pressing tool comprises two pressing ram elements, namely a first pressing ram element and a second pressing ram element, as at least one pressing ram element. In particular, the two pressing ram elements are arranged on two, preferably opposite, sides of the cavity. Specifically, the two pressing ram elements are arranged and designed such that they can be displaced towards and away from the cavity along the pressing direction.

[0090] According to a further development of the invention, the at least one alignment tool part is designed as a press punch element of the at least one press punch element.

[0091] In one embodiment, the pressing tool is designed as an axial pressing tool. In the context of this technical teaching, an axial pressing tool is understood to be, in particular, a pressing tool designed such that the pressing direction of the pressing ram element and the magnetic field lines generated by the alignment magnets are aligned almost parallel, particularly parallel, in certain areas – especially within the cavity. "Axial" in this context is to be understood as "along the magnetic field lines" – as in an axis. Specifically, an imaginary, central connecting axis of the pressing ram elements, which passes through the two pressing ram elements, and an imaginary, central connecting axis of the alignment magnets, which passes through the two alignment magnets, run almost parallel, particularly parallel, to each other. This allows the powder material to be pressed parallel to the magnetic field lines.It is possible that a transverse orientation of the magnetic field lines exists in a partial region of the cavity, particularly because an alignment-tool-part-alignment-element interface of the axial press tool and / or an alignment-element-permanent magnet interface of the cavity of the axial press tool is shaped in such a way that a transverse orientation results in certain areas. In particular, if the press tool is designed as an axial press tool, the first press ram element of the at least one press ram element is formed by means of the first tool part, in particular the first alignment tool part. In particular, the second press ram element of the at least one press ram element is formed by means of the second tool part, in particular the second alignment tool part.

[0092] In particular, if the press tool is designed as an axial press tool, the at least one press punch element, in particular the at least one alignment tool part, comprises the at least one alignment element and in particular an applied layer selected from the alignment layer and the protective layer. In particular, the first press punch element, in particular the first alignment tool part, comprises the first alignment element and in particular at least one first applied layer selected from the first alignment layer and the protective layer. In particular, the second press punch element, in particular the second alignment tool part, comprises the second alignment element and in particular at least one second applied layer selected from the second alignment layer and the protective layer.

[0093] Alternatively, a press die element of the at least one press die element is designed as an element separate from the at least one alignment tool part.

[0094] In one embodiment, the pressing tool is designed as a transverse pressing tool. In the context of this technical teaching, a transverse pressing tool is understood to be, in particular, a pressing tool designed such that the pressing direction of the pressing ram element and the magnetic field lines generated by the alignment magnets are oriented transversely, particularly almost orthogonally, in certain areas – especially within the cavity. Specifically, the imaginary central axis connecting the pressing ram and the imaginary central axis connecting the alignment magnets run transversely, particularly almost orthogonally, to each other. This allows the powder material to be pressed transversely to the magnetic field lines.It is possible that a parallel alignment of the magnetic field lines exists in a partial region of the cavity, particularly because an alignment tool part / alignment element interface of the transverse pressing tool and / or an alignment element / permanent magnet interface of the cavity of the transverse pressing tool is shaped such that a parallel alignment results in certain areas. In one embodiment—particularly when the pressing tool is designed as a transverse pressing tool—the pressing tool comprises the first tool part, in particular the first alignment tool part, the second tool part, in particular the second alignment tool part, and at least one of these elements different from the pressing ram element, in particular two pressing ram elements, namely the first pressing ram element and the second pressing ram element. In particular, the two pressing ram elements are arranged on two, in particular opposite, pressing ram sides of the cavity.In particular, the first tool part, especially the first alignment tool part, and the second tool part, especially the second alignment tool part, are arranged on two opposite sides of the cavity. Specifically, the press die sides and the tool part sides are arranged offset around the cavity as the imaginary pivot point. Specifically, if the cavity is considered the center of an angle rose, the two press die elements are arranged at 0° and 180°, with the two tool parts, especially the two alignment tool parts, being arranged at 90° and 270°.

[0095] In one embodiment—particularly when the pressing tool is designed as a transverse pressing tool—the at least one press punch element has a punch material or is formed from a punch material that has a comparatively low permeability. In particular, the punch material has a permeability that lies between the first and third permeabilities. Specifically, the punch material is the same as the second material—of the at least one alignment element—with the second permeability. It is also possible that the punch material is a non-magnetizable material, in particular, that it is almost non-magnetically permeable, and in particular, not magnetically permeable at all.

[0096] The pressing tool, particularly the axial pressing tool and the transverse pressing tool, makes it advantageous to press simple three-dimensional permanent magnets. Such permanent magnets can have surfaces curved on one or both sides. It is also possible to press lens-shaped permanent magnets with convex and / or concave surfaces.

[0097] Particularly in a cavity designed for pressing a lens element, the magnetic field lines are symmetrically aligned, especially point-symmetrically, axially symmetrically, or plane-symmetrically. Specifically, the magnetic field lines are oriented differently in different parts of the cavity.

[0098] According to a further development of the invention, the tool arrangement is designed as the extrusion tool, wherein the extrusion tool has an extrusion die, wherein the extrusion die sectionally has the at least one alignment element and the at least one alignment tool part.

[0099] Advantageously, the extrusion tool allows for the extrusion of strand-shaped permanent magnets, particularly multiple connected permanent magnets, especially a permanent magnet strand. In particular, a strand-shaped permanent magnet has an approximately constant, preferably constant, cross-section oriented transversely to an extrusion direction. Advantageously, the strand-shaped permanent magnet exhibits the same, and in particular coincident, orientation of the magnetic moments of the powder particles in at least two cross-sections oriented transversely to the extrusion direction, and in particular in several cross-sections, especially continuously, i.e., in all conceivable cross-sections. Such a strand-shaped permanent magnet can have surfaces curved on one or both sides, and in particular also on multiple sides, which in particular partially encompass the extrusion direction.In particular, the strand-shaped permanent magnet is divided into individual permanent magnets after extrusion, especially separated.

[0100] According to a further development of the invention, the extrusion die has at least one extrusion channel as the cavity. The at least one alignment element and the at least one alignment tool part are arranged one behind the other in an alignment section of the extrusion die in one direction, in particular in a transverse direction oriented perpendicular to the at least one extrusion channel.

[0101] This method advantageously allows for the extrusion of complex permanent magnets. In particular, the magnetic field lines penetrating the extrusion channel are symmetrically aligned, especially axially or plane-symmetrically. Specifically, the magnetic field lines are oriented differently in different partial cross-sectional areas of the same cross-section of the extrusion channel. In particular, the magnetic field lines are identically aligned along the extrusion direction in identical, especially congruent, partial cross-sectional areas of cross-sections that differ along the extrusion direction.

[0102] Preferably, an alignment element of the at least one alignment element, in particular the only alignment element, is arranged between an alignment tool part of the at least one alignment tool part, in particular the only alignment tool part, and an extrusion channel of the at least one extrusion channel.

[0103] In one embodiment, the tool arrangement includes an extrusion conveying device, which is specifically designed and configured to convey the powder material, in particular to compact it and extrude it through the extrusion channels. In particular, the extrusion die is adjacent to the extrusion conveying device, wherein the extrusion die is specifically designed as an element distinct from the extrusion conveying device.

[0104] In one embodiment, the extrusion conveying device includes a heating device designed and configured to heat the powder material arranged in the extrusion conveying device, in particular to a temperature of T = 80 °C to 200 °C, and more specifically to T = 150 °C to 190 °C. In particular, the binder component transitions from a rigid state to a soft, rubbery, viscous state, allowing the magnetic moments of the powder particles to align when the powder material is extruded through the extrusion channels of the extrusion die.

[0105] In one embodiment, the extrusion die forms the at least one extrusion channel as the cavity. In particular, the alignment element of the extrusion die forms the at least one extrusion channel as the cavity.

[0106] According to a further development of the invention, the extrusion die has at least two extrusion channels as its at least one extrusion channel. A channel wall is arranged between the two extrusion channels. The channel wall material has either the first or the second permeability. Advantageously, the channel wall material is selected depending on the desired deflection of the magnetic field lines at an interface between the extrusion channel and the channel wall: If a greater deflection of the magnetic field lines is desired, a material with the first permeability is selected for the channel wall. If a lesser deflection of the magnetic field lines is desired—particularly as when the channel wall is made of a material with the first permeability—a material with the second permeability is selected for the channel wall.It is also possible that the channel wall is made of a non-magnetizable, and in particular non-magnetically permeable, material. Specifically, the material of the channel wall is chosen because of its permeability.

[0107] In particular, the extrusion die forms at least one extrusion channel and at least two extrusion channels.

[0108] According to a further development of the invention, the tool arrangement comprises at least one temperature control section. A first temperature control section of the at least one temperature control section is arranged section by section along the at least one extrusion channel. In particular, the first temperature control section forms the at least one extrusion channel section by section. Here, the first temperature control section is designed and configured to temperature-control, and in particular cool, the powder material arranged in the at least one extrusion channel. Alternatively or additionally, a second temperature control section of the at least one temperature control section is designed as a temperature-controlled conveyor belt and / or as temperature-controlled conveyor rollers. Here, the second temperature control section is designed and configured to temperature-control, and in particular cool, the extruded powder material exiting the at least one extrusion channel.

[0109] It is advantageous that at least one temperature control section allows the powder material to be tempered, and in particular cooled. This makes it possible to temper, and especially cool, the powder material while it is being extruded through the extrusion die.

[0110] In one embodiment, the tool arrangement comprises a first temperature control section and a second temperature control section. In particular, the second temperature control section is arranged downstream of the first temperature control section. In another embodiment, the tool arrangement, designed as an extrusion tool, comprises a fine forming tool, which is specifically designed and arranged to reshape the extruded strand-shaped permanent magnet, in particular to produce a comparatively precise outer shape of the extruded strand-shaped permanent magnet. In particular, the strand-shaped permanent magnet is guided through the fine forming tool or along the fine forming tool, whereby in both cases an outer shape of the strand-shaped permanent magnet is modified, in particular slightly. In particular, the fine forming tool is arranged downstream of the alignment section.In one embodiment, the fine forming tool is arranged downstream of the at least one temperature control section. In another embodiment, the fine forming tool is arranged upstream of the at least one temperature control section, in particular between the alignment section and the at least one temperature control section. In yet another embodiment, the fine forming tool is arranged alternatively to the at least one temperature control section.

[0111] According to a further development of the invention, a temperature control section, selected from the first temperature control section and the second temperature control section, is arranged downstream of the alignment section in the extrusion direction of the extrusion tool.

[0112] This makes it advantageous to first align the magnetic moments of the powder particles and only then temper, especially cool, the powder material.

[0113] In one embodiment, the first temperature control section and the second temperature control section are arranged downstream of the alignment section.

[0114] In one embodiment, the temperature control section, in particular the first temperature control section and / or the second temperature control section, is arranged completely downstream of the alignment section, particularly in the extrusion direction. Specifically, the temperature control section and the alignment section are non-overlapping, and the temperature control section is free of alignment elements. In particular, the temperature control section borders the alignment section in the extrusion direction, and a powder material extruded through the extrusion die first passes through the alignment section and only then—after exiting the alignment section—passes through the temperature control section.It is advantageously possible that the magnetic moments of the powder particles are initially only aligned in the alignment section, and only subsequently is the powder material tempered, or in particular cooled, in the temperature control section. Specifically, the powder material in the temperature control section is no longer penetrated by magnetic field lines, but is only tempered, or in particular cooled.

[0115] In another embodiment, the temperature control section, in particular the first temperature control section – especially in the extrusion direction – is arranged section by section downstream of the alignment section. In particular, a first subsection of the temperature control section overlaps with the alignment section. In particular, a second subsection of the temperature control section, different from the first subsection, is arranged downstream of the alignment section, such that the second subsection and the alignment section are free of overlap.In particular, a powder material extruded through the extrusion die first passes through the non-overlap alignment section, then through the first subsection of the tempering section, which overlaps with the alignment section, and then – after exiting the first subsection – through the second subsection of the tempering section, which is non-overlap, i.e., does not overlap the alignment section. Advantageously, the magnetic moments of the powder particles are initially only aligned in the alignment section, with the powder material being tempered, or in particular cooled, during the alignment process – as the powder material enters the first subsection. During tempering, or in particular cooling, the powder material continues to be penetrated by the magnetic field lines.Only afterwards, when the powder material leaves the first section and passes through the second section, is the powder material no longer penetrated by magnetic field lines, but only tempered, in particular cooled.

[0116] According to a further development of the invention, the at least one temperature control section, in particular the first temperature control section, is free of alignment elements.

[0117] This design offers the advantage of a particularly compact design for at least one of the temperature control sections. It also ensures, in a simple manner, that the magnetic moments of the powder particles in this section are not aligned due to the absence of an alignment element. Furthermore, it is advantageously possible to cleanly separate the temperature control section from the alignment section. In one embodiment, the first temperature control section is free of alignment elements, specifically, it has no alignment elements at all. In another embodiment, the second temperature control section is free of alignment elements, specifically, it has no alignment elements at all. In yet another embodiment, the second subsection of the first temperature control section is free of alignment elements, specifically, it has no alignment elements at all.

[0118] In one embodiment, the first subsection of the first temperature control section has an alignment element of at least one alignment element.

[0119] According to a further development of the invention, an insulating element, in particular a thermal insulating element, is arranged between the alignment section and a temperature control section, selected from the first temperature control section and the second temperature control section.

[0120] Advantageously, this ensures that the alignment section is thermally decoupled from the temperature control section and, in particular, is not unintentionally temperature-controlled, especially cooled, by the temperature control section. This specifically prevents the powder material arranged in the alignment section from being unintentionally temperature-controlled, especially cooled, and from the magnetic moments of the powder particles failing to align as intended due to excessively high viscosity of the powder material resulting from the temperature control, especially cooling. In particular, the insulating element—which prevents heat dissipation from the alignment section in certain segments—ensures that the powder material has a sufficiently low viscosity while the magnetic moments of the powder particles are being aligned within the alignment section.

[0121] According to a further development of the invention, the at least one temperature control section comprises a fourth material or is formed from a fourth material that has a higher thermal conductivity than the at least one alignment tool part, in particular than the first material, and / or than the at least one alignment element, in particular than the second material. Advantageously, this ensures that the magnetizable powder material can be temperature-controlled, and in particular cooled, more effectively, by means of the at least one temperature control section than with the at least one alignment tool part and the at least one alignment element. The fourth material is specifically chosen because of its comparatively high thermal conductivity.

[0122] According to a further development of the invention, the fourth material is a material selected from a group consisting of: an iron material, an iron alloy, a copper material, a copper alloy, an aluminum material, an aluminum alloy, a magnesium material, a magnesium alloy, a gold material, a gold alloy, a silver material and a silver alloy.

[0123] This offers the advantage of particularly high heat dissipation and thus particularly rapid temperature control, especially cooling, of the powder material.

[0124] In one embodiment, the fourth material is additionally selected based on its wear resistance. Preferably, a fourth material with a comparatively high wear resistance is chosen. In particular, this ensures that the fourth material is not damaged, especially worn down, or eroded by the extruded powder material.

[0125] Preferably, the fourth material is a material selected from the group consisting of: pure copper, a copper-beryllium alloy, a copper-silver alloy, a copper-tin alloy, a copper-chromium alloy, pure aluminum, an aluminum-silicon alloy, an aluminum-copper alloy, an aluminum-magnesium-silicon alloy, pure gold and pure silver.

[0126] This means that various materials are available, which offer the advantages mentioned above.

[0127] The problem is also solved by creating a method for producing a permanent magnet from a magnetizable powder material using a powder process. In this method, magnetic field lines penetrate a first material with a first permeability and a second material with a second permeability, both of which are present in addition to the powder material, thereby achieving a predetermined orientation. The first and second materials are selected such that the first permeability is greater than the second permeability. The predeterminedly oriented magnetic field lines penetrate a cavity into which the powder material is introduced. The predeterminedly oriented magnetic field lines thus traverse the powder material, aligning the magnetic moments of the powder particles of the magnetizable powder material in a predetermined direction.In connection with the method for manufacturing a permanent magnet, the advantages that have already been described in connection with the tool arrangement become particularly apparent.

[0128] In one embodiment, the first material, the second material, and the powder material are arranged one after the other – precisely in that order. In particular, the magnetic field lines penetrate the first material, the second material, and the powder material – precisely in that order.

[0129] In particular, when the magnetic field lines are generated by means of a permanent magnet, they are already present in the cavity when the permanent magnet is arranged as intended.

[0130] According to a further development of the invention, the magnetic field lines are generated while the powder material is introduced into the cavity. In particular, the pre-aligned magnetic field lines are generated in the cavity. This advantageously leads to a particularly precise alignment of the magnetic moments of the powder particles.

[0131] Alternatively or additionally, the magnetic field lines are generated after the powder material has been introduced into the cavity. Specifically, the magnetic field lines are generated before the powder material is pressed in, and optionally also during the pressed-in process.

[0132] In one embodiment, the powder material is introduced into a cavity, in particular by being inserted, injected, filled, or extruded through the cavity. Predetermined magnetic field lines are thereby generated in the cavity, such that the magnetic moments of the powder particles of the magnetizable powder material are aligned in a predetermined direction, in particular in the direction of the magnetic field lines, and in particular along the magnetic field lines, and especially coincidentally with the magnetic field lines. The magnetic field lines penetrate a first material with a first permeability and a second material with a second permeability and thereby acquire their predetermined alignment. The first and second materials are selected such that the first permeability is greater than the second permeability.

[0133] Advantageously, the magnetic moments of the powder particles are aligned while the powder material is being introduced into the cavity, in particular injected or filled, or extruded through the cavity.

[0134] In particular, the magnetic field lines are deflected, especially bundled, and especially guided to the cavity by means of the at least one alignment tool part, wherein the magnetic field lines are finally aligned by means of the at least one alignment element - for the desired alignment of the magnetic moments of the powder particles.

[0135] The fact that the powder material is placed, injected, filled, or extruded into the cavity is to be understood in particular as follows:

[0136] In the context of this technical teaching, the placement of the powder material into the cavity means, in particular, that a previously manufactured permanent magnet blank is placed into the cavity. Specifically, the powder particles of the manufactured permanent magnet blank can be aligned. First, the permanent magnet blank is placed into the tool arrangement, specifically into the cavity. Subsequently, predetermined magnetic field lines of a magnetic field penetrate the cavity containing the permanent magnet blank, aligning the magnetic moments of the powder particles within the permanent magnet blank. It is essential that the permanent magnet blank is heated above the melting temperature of the binder component so that the powder particles and their magnetic moments can align.In particular, the permanent magnet blank can be heated to its melting temperature before being inserted into the cavity. Alternatively, the permanent magnet blank can be heated to its melting temperature within the cavity itself. Subsequently, the permanent magnet blank is subjected to heat treatment, specifically firing, resulting in the finished permanent magnet. In the context of this technical teaching, the injection of the powder material into the cavity specifically means that a magnetizable powder material is injected into the cavity, thereby creating the permanent magnet blank. The magnetizable powder material is thus injection molded. The powder material can contain one or more additives, particularly binder components, especially polymer binders, to achieve a predetermined viscosity.In particular, the green permanent magnet body is subsequently subjected to heat treatment, especially firing, which creates the finished permanent magnet.

[0137] In the context of this technical teaching, the fact that the powder material is filled into the cavity means, in particular, that a magnetizable powder material is filled into the cavity for compression, whereby the permanent magnet green body is produced, especially by compression. The powder material may contain one or more additives, in particular binder components, especially polymer binders, particularly to achieve a predetermined viscosity. In particular, the permanent magnet green body is subsequently subjected to heat treatment, in particular firing, which produces the finished permanent magnet.

[0138] In the context of this technical teaching, the extrusion of the powder material through the cavity means, in particular, that the magnetizable powder material is introduced into the cavity through a first opening and is discharged from the cavity through a second opening. Specifically, the powder material entering the cavity conveys, or in particular, forces, the powder material located in the cavity out. Specifically, the magnetizable powder material is displaced, or in particular, conveyed, through the cavity. Specifically, the magnetizable powder material is extruded through the cavity by means of pressure. In particular, the pressure is generated by means of the extrusion conveying device, in particular an extrusion screw, which conveys, or in particular extrudes, the magnetizable powder material through the cavity.The cavity is formed, in particular, by means of the extrusion die of the tool arrangement, which has at least one extrusion channel, and in particular several extrusion channels, as the cavity. The powder material can contain one or more additives, in particular binder components, especially polymer binders, particularly to achieve a predetermined viscosity. In particular, at least one permanent magnet green part is extruded. However, it is also possible that several connected permanent magnet green parts are extruded, which are connected to each other, in particular, in a strand-like manner. In particular, the connected permanent magnet green parts are subsequently separated from each other, so that they are present as individual, and in particular no longer connected, permanent magnet green parts.In particular, the permanent magnet blanks are subsequently subjected to heat treatment, especially firing, which creates the finished permanent magnet.

[0139] In particular, the melting temperature is the temperature at which an amorphous solid, especially an amorphous polymer, and especially the binder component, transitions from a rigid state to a soft, rubbery, viscous state. The melting temperature is also referred to as the softening temperature. Within a permanent magnet green body, the melting temperature is therefore particularly dependent on the binder component used, especially the polymer binder.

[0140] In one embodiment, the magnetic field strength of the magnetic field lines is selected depending on the saturation polarization of the at least one alignment tool part and / or the at least one alignment element and / or the powder material. In particular, this prevents magnetic saturation of a section of the at least one alignment tool part and / or the at least one alignment element and / or the powder material. Advantageously, unwanted alignment of the magnetic field lines in the cavity is reduced, preferably avoided.

[0141] In one embodiment, the magnetic field lines are aligned, and in particular deflected, depending on the powder material, and in particular on its permeability, by means of at least one alignment element. It has been shown that magnetic field lines penetrating an air-filled cavity align differently than magnetic field lines penetrating a cavity filled with the powder material. Specifically, the orientation of first directional lines, and in particular their orientation, of predetermined magnetic field lines penetrating the air-filled cavity differs from the orientation of second directional lines, and in particular their orientation, of the same predetermined magnetic field lines penetrating the cavity filled with the magnetizable powder material.In the context of this technical teaching, "same location" is understood to mean, in particular, the same place, especially the same location within the cavity, and in particular that the first and second direction lines of magnetic field lines are considered to be at the same location within the cavity.

[0142] In particular, the following effects are taken into account in the process when aligning the magnetic moments of the powder particles:

[0143] The first effect is that the alignment of the powder particles exhibiting magnetic moments can only be achieved if there is a force-angle offset between the magnetic field lines and the magnetic moments, which generates an alignment force for the magnetic moments. The smaller the force-angle offset, the smaller the alignment force.

[0144] A second effect is friction between the powder particles, particularly due to the binder component. Therefore, a minimum aligning force is necessary to overcome this friction and initiate an alignment movement of the powder particles with their magnetic moments. This, in turn, implies that a minimum force-angle misalignment must exist between the magnetic moments and the magnetic field lines for the powder particles to begin aligning with their magnetic moments.

[0145] To reduce, and in particular compensate for, these effects, one embodiment provides that the powder material is first subjected to changing magnetic field lines to loosen, and in particular to agitate, the powder material. Specifically, the polarity of the two alignment electromagnets is changed, and in particular reversed. The polarity is repeatedly reversed, particularly at a specific frequency, and in particular for a predetermined loosening time. Subsequently, the predeterminedly aligned magnetic field lines are continuously generated for final alignment in the cavity, so that the magnetic moments of the powder particles of the magnetizable powder material are aligned in the predetermined direction, in particular in the direction of the magnetic field lines, and in particular along the magnetic field lines, and in particular coincidentally with the magnetic field lines.According to a further development of the invention, the powder method is a powder injection molding process, wherein the powder material is injected into the cavity transversely and / or parallel to the generated magnetic field lines.

[0146] In the context of this technical teaching, the fact that the powder material is injected transversely to the magnetic field lines means, in particular, that the powder material injection direction runs transversely to the imaginary alignment-magnet connection axis. Specifically, the powder material injection direction runs transversely to the magnetic field lines.

[0147] Advantageously, this allows for an orientation of the magnetic moments of the powder particles that is perpendicular to, and in particular almost orthogonal to, the direction of powder material injection.

[0148] In the context of this technical teaching, the fact that the powder material is injected parallel to the magnetic field lines means, in particular, that the powder material injection direction runs parallel to the imaginary alignment-magnet connection axis. Specifically, the powder material injection direction runs parallel to the magnetic field lines.

[0149] Advantageously, this allows for an alignment of the magnetic moments of the powder particles that is almost parallel, and in particular parallel, to the direction of powder material injection.

[0150] In one embodiment, a powder material injection pressure is maintained for a holding pressure period after the cavity has been completely filled. Advantageously, this reduces, and in particular avoids, any shrinkage that occurs with permanent magnets, especially of the green permanent magnet body.

[0151] According to a further development of the invention, the magnetic field lines are aligned transversely and / or parallel to the powder material injection direction, at least in the area of ​​a powder feed opening of a powder material feed line opening into the cavity.

[0152] In the context of the present technical teaching, the fact that the magnetic field lines in the area of ​​the powder feed opening are aligned transversely to the powder material injection direction means in particular that the two alignment magnets are arranged such that the imaginary alignment magnet connection axis and the generated magnetic field lines in the area of ​​the powder feed opening are aligned transversely to the powder material injection direction.

[0153] In the context of the present technical teaching, the fact that the magnetic field lines in the area of ​​the powder feed opening are aligned parallel to the powder material injection direction means in particular that the two alignment magnets are arranged such that the imaginary alignment magnet connection axis and the generated magnetic field lines in the area of ​​the powder feed opening are aligned parallel to the powder material injection direction.

[0154] According to a further development of the invention, a first orientation of the magnetic field lines relative to a first powder material flow direction in a first powder material flow path section of a powder material flow path differs from a second orientation of the magnetic field lines relative to a second powder material flow direction in a second powder material flow path section of the powder material flow path.

[0155] This method advantageously allows the production of permanent magnets with multiple pole pairs, each possessing a north pole and a south pole. It also makes it possible to produce permanent magnets where any two pole pairs within this plurality are oriented differently relative to each other. In particular, this method enables the production of a permanent magnet with a one-sided flux, also known as a Halbach array.

[0156] In one embodiment, a first orientation of the magnetic field lines in the first powder material flow path section differs – with reference to a laboratory system – from a second orientation of the magnetic field lines in the second powder material flow path section. In particular, with reference to a laboratory system, the first powder material flow direction and the second powder material flow direction are the same.

[0157] In another embodiment, the first orientation of the magnetic field lines in the first powder material flow path section is the same – with reference to a laboratory system – as the second orientation of the magnetic field lines in the second powder material flow path section. In particular, with reference to a laboratory system, the first and second powder material flow directions are different. In yet another embodiment, the first orientation of the magnetic field lines in the first powder material flow path section is different – ​​with reference to a laboratory system – than the second orientation of the magnetic field lines in the second powder material flow path section. In particular, with reference to a laboratory system, the first and second powder material flow directions are different.

[0158] In the context of this technical teaching, a laboratory system is understood in particular to be a physical reference system in which the observer, especially in his laboratory, is at rest.

[0159] In one embodiment, the powder material flow path comprises a first powder material flow path section and, in particular, a second powder material flow path section adjacent to it. It is also possible that the powder material flow path comprises further powder material flow path sections, in particular a third powder material flow path adjacent to the second powder material flow path.

[0160] In particular, the powder material in the first powder material flow path section is penetrated by magnetic field lines oriented transversely, especially horizontally transversely or vertically transversely, or parallel to the powder material flow direction. In particular, the powder material in the second powder material flow path section is penetrated by magnetic field lines oriented parallel or transversely, especially horizontally transversely or vertically transversely, to the powder material flow direction – in particular, in the opposite orientation to that in the first powder material flow path section.

[0161] In another embodiment, the powder material flow path comprises – in addition to the first and second powder material flow path sections – a third powder material flow path section, which is particularly adjacent to the second powder material flow path section. In particular, the powder material in the third powder material flow path section is – again – penetrated by magnetic field lines oriented transversely, particularly horizontally transversely or vertically transversely, or parallel to the powder material flow path.

[0162] Other orientations are also conceivable, in particular in a different sequence of the powder material flow path sections. According to a further development of the invention, the powder method is a powder pressing method, wherein the powder material is pressed transversely, in particular almost orthogonally, in particular orthogonally and / or parallel to the magnetic field lines.

[0163] In the context of this technical teaching, the fact that the powder material is pressed transversely to the magnetic field lines means, in particular, that the pressing direction of at least one press ram element runs transversely to the imaginary alignment-magnet connection axis. Specifically, the pressing direction runs transversely to the magnetic field lines.

[0164] Advantageously, this can result in an orientation of the magnetic moments of the powder particles that is perpendicular to the pressing direction, in particular almost orthogonal, in particular orthogonal.

[0165] In this case, it is possible – especially as with the transverse pressing tool – that in a partial area of ​​the cavity the pressing direction is aligned parallel to the magnetic field lines, particularly because an alignment-tool part-alignment element interface of the transverse pressing tool and / or an alignment element-permanent magnet interface of the cavity of the transverse pressing tool is shaped in such a way that a parallel alignment results in certain areas.

[0166] In the context of this technical teaching, the fact that the powder material is pressed parallel to the magnetic field lines means, in particular, that the pressing direction of at least one press ram element runs parallel to the imaginary alignment-magnet connection axis. Specifically, the pressing direction runs parallel to the magnetic field lines.

[0167] Advantageously, this allows for an orientation of the magnetic moments of the powder particles that is almost parallel, or in particular parallel, to the pressing direction.

[0168] In this process – particularly as with the axial press tool – it is possible that in a partial area of ​​the cavity the pressing direction is oriented transversely to the magnetic field lines, especially because an alignment-tool-part-alignment-element interface of the transverse press tool and / or an alignment-element-permanent magnet interface of the cavity of the axial press tool is shaped in such a way that a transverse orientation results in certain areas. According to a further development of the invention, the powder process is a powder extrusion process. In this process, the powder material is extruded transversely and / or parallel to the magnetic field lines.

[0169] In the context of the present technical teaching, the fact that the powder material is extruded perpendicular to the magnetic field lines means in particular that a powder material extrusion direction runs perpendicular to the magnetic field lines.

[0170] Advantageously, this allows for an orientation of the magnetic moments of the powder particles that is perpendicular to the powder extrusion direction, in particular almost orthogonal, in particular orthogonal.

[0171] In the context of the present technical teaching, the fact that the powder material is extruded parallel to the magnetic field lines means in particular that a powder material extrusion direction runs parallel to the magnetic field lines.

[0172] Advantageously, this allows for an alignment of the magnetic moments of the powder particles that is almost parallel, and in particular parallel, to the direction of powder material extrusion.

[0173] In one embodiment, the powder material has a temperature of T = 80°C to 200°C, in particular T = 150°C to 190°C, when the powder material is extruded, especially through the cavity. In particular, at this comparatively high temperature, it is ensured that the magnetic moments of the powder particles can align themselves towards the magnetic field lines, as the viscosity of the binder component contained in the powder material is reduced due to the comparatively high temperature.

[0174] According to a further development of the invention, the powder material is tempered, in particular cooled, while the magnetic moments of the powder particles are aligned in the predetermined direction and / or after the magnetic moments of the powder particles have been aligned in the predetermined direction.

[0175] Advantageously, the magnetic moments of the powder particles are first aligned at a comparatively high temperature, particularly from T = 80 °C to 200 °C, and especially from T = 150 °C to 190 °C. Particularly when the magnetic moments of the powder particles are sufficiently aligned, the temperature of the powder material is reduced to such an extent that the powder material exiting the extrusion die is dimensionally stable and does not collapse.

[0176] In one embodiment, the powder material is tempered, in particular cooled, in a tool arrangement, in particular spatially within a tool arrangement, in particular in an extrusion tool according to the invention or an extrusion tool according to one or more of the embodiments described above.

[0177] In one embodiment, the powder material is tempered, in particular cooled, by means of the first tempering section and / or by means of the second tempering section.

[0178] In one embodiment, the powder material is tempered to a temperature of T = 50 °C to 140 °C, in particular cooled, preferably when the magnetic moments of the powder particles are aligned.

[0179] In particular, the powder material is actively temperature-controlled, especially actively cooled, by conducting or convectively dissipating heat from the powder material. For this purpose, a fluid conveying device, especially a fan or liquid cooling, is used. In particular, the liquid cooling system features a thermodynamic cycle.

[0180] According to a further development of the invention, the method is carried out with a tool arrangement according to the invention or a tool arrangement according to one or more of the embodiments described above. In connection with the method, the advantages that have already been explained in connection with the tool arrangement become particularly apparent.

[0181] The problem is also solved by providing a method for producing a tool arrangement according to the invention or a tool arrangement according to one or more of the previously described embodiments, which is configured for producing a permanent magnet from a magnetizable powder material. In this method, an alignment tool part comprising a first material with a first permeability and an alignment element comprising a second material different from the first material with a second permeability that is lower than the first permeability are provided, wherein a target alignment for magnetic field lines in a cavity of the tool arrangement is defined.In this process, the alignment tool component and the alignment element are each formed or selected at an interface, maintaining an alignment-tool component-alignment element interface, and brought into contact with one another such that magnetic field lines introduced into the tool assembly are deflected at the alignment-tool component-alignment element interface in such a way that they exhibit the desired orientation within the cavity. Here, the alignment element is formed on a cavity surface such that the cavity surface of the alignment element forms a predetermined cavity shape section by section. In connection with the method for manufacturing the tool assembly, the advantages that have already been described in connection with the tool assembly and the method for manufacturing a permanent magnet become particularly evident.

[0182] Furthermore, the method advantageously enables the production of a tool arrangement by means of which the alignment of the magnetic moments of the powder particles can be specifically controlled, adjusted, manipulated, and aligned in a method for producing a permanent magnet from a powder material. In particular, the alignment of the magnetic moments of the powder particles can be specifically controlled, adjusted, manipulated, and aligned by means of a predetermined shaping of the interface between the alignment tool part and the alignment element, and this preferably independently of the cavity shape, and in particular the cavity area.

[0183] According to a further development of the invention, the interface of the alignment element and the cavity surface are produced opposite each other on the alignment element, in particular on the same alignment element. Specifically, the alignment element thus has the alignment-tool part-alignment element interface on one side and the cavity surface on another side.

[0184] According to a further development of the invention, the interface of the alignment element and the cavity surface are manufactured with different shapes. Advantageously, two functions of the alignment element—forming the cavity shape and aligning the magnetic field lines—are functionally separated from one another, so that the cavity shape can be designed independently of the interface of the alignment element. The fact that the interface of the alignment element and the cavity surface are manufactured with different shapes means, in particular, that they are manufactured with different shapes.

[0185] According to a further development of the invention, the interface of the alignment element is produced as a flat surface and the cavity surface as a curved surface. Alternatively, the interface of the alignment element is produced as a curved surface and the cavity surface as a flat surface.

[0186] According to a further development of the invention, the interface of the alignment element and the cavity surface are produced with a different curvature, in particular differently curved.

[0187] Thus, various interface shapes are advantageously available for the interface of the alignment element and the cavity surface, in which the aforementioned advantages are realized to a particularly high degree.

[0188] The descriptions of the tool arrangement and the two methods are to be understood as complementary to each other. In particular, features of the tool arrangement that are explicitly or implicitly described in connection with the two methods are preferably, individually or in combination, features of the tool arrangement. Preferably, the tool arrangement is configured to carry out at least one of the process steps described in connection with the method for manufacturing a permanent magnet and / or has at least one of the features described in connection with the method for manufacturing the tool arrangement. Process steps—in manufacturing the permanent magnet or in manufacturing the tool arrangement—that are explicitly or implicitly described in connection with the tool arrangement are preferably, individually or in combination, steps of a preferred embodiment of the respective method.In particular, at least one step is preferably provided within the respective process, which results from at least one feature of the tool arrangement. The embodiments described and statements made in connection with the product according to the invention also apply mutatis mutandis to the processes according to the invention and vice versa.

[0189] The invention will be explained in more detail below with reference to the drawing. The drawing shows:

[0190] Figure 1 shows a schematic representation of a first embodiment of a tool arrangement for producing a permanent magnet from a magnetizable powder material.

[0191] Figure 2 shows a schematic representation of a second embodiment of a

[0192] Tool arrangement,

[0193] Figure 3 shows a schematic representation of a third embodiment of a

[0194] Tool arrangement compared with a fourth embodiment of a tool arrangement,

[0195] Figure 4 shows a schematic representation of a fifth embodiment of a tool arrangement,

[0196] Figure 5 shows a schematic representation of a sixth embodiment of a

[0197] Tool arrangement,

[0198] Figure 6 shows a schematic representation of a seventh embodiment of a

[0199] Tool arrangement,

[0200] Figure 7 shows a schematic representation of an eighth embodiment of a

[0201] Tool arrangement,

[0202] Figure 8 shows a schematic representation of the tool arrangement of Figure 2 with two embodiments of a powder material feed line,

[0203] Figure 9 shows a schematic representation of a ninth embodiment of a

[0204] Tool arrangement in a first view,

[0205] Figure 10 shows a schematic representation of a tenth embodiment of a

[0206] Tool arrangement,

[0207] Figure 11 is a schematic representation of the tool arrangement from Figure 9 in a second view; Figure 12 is a process flow diagram of a method for manufacturing a

[0208] Permanent magnets made from a magnetizable powder material in a

[0209] Powder process, and

[0210] Figure 13 shows a process flow diagram of an embodiment of a method for producing a tool arrangement set up for producing a permanent magnet from a magnetizable powder material.

[0211] Figure 1 shows a schematic representation of a first embodiment of a tool arrangement 1 for producing a permanent magnet 3 from a magnetizable powder material, in particular in a powder injection molding process or in a powder pressing process.

[0212] The tool arrangement 1 has a first tool part 5.1 as first alignment tool part 7.1, a second tool part 5.2 as second alignment tool part 7.2, a first alignment element 9.1 and a second alignment element 9.2.

[0213] The tool arrangement 1 further comprises a controllable electromagnet device, which has two alignment electromagnets 13, one of which is the first alignment electromagnet 13.1 and the other the second alignment electromagnet 13.2.

[0214] The two alignment electromagnets 13 are shown here only for clarity and are therefore only roughly sketched. In particular, the sketched representation may differ from the actual design and should therefore not be understood as a limitation. Although the two alignment electromagnets 13 are only shown in Figure 1, they can be conceptually transferred to the other figures as well, with a first electromagnet 13.1 on a left-hand side 11.1 and a second electromagnet 13.2 on a right-hand side 11.2 of each figure. Similarly, in sub-figures 3a and 3b, a first electromagnet 13.1 should be conceptually placed on the left-hand side 11.1 and a second electromagnet 13.2 on the right-hand side 11.2.

[0215] The two alignment electromagnets 13 each have a north pole (not shown) and a south pole, wherein the first tool part 5.1, the at least one alignment element 9, the cavity 15 and the second tool part 5.2 are arranged between the opposing, differently named poles of the two aligning electromagnets 13 such that, when the electromagnet device is switched on, predetermined aligned magnetic field lines 17 are generated, which are formed by the first alignment tool part 7.1, the first alignment element 9.1, the cavity 15, the second alignment element 9.2 and the second alignment tool part 7.2 such that magnetic moments of the powder particles of the magnetizable powder material are aligned in a predetermined direction, in particular in the direction of the magnetic field lines 17, in particular along the magnetic field lines 17, in particular coincident with the magnetic field lines 17, in particular when the powder material is injected into the cavity 15.

[0216] The first tool part 5.1 and the second tool part 5.2 are designed to surround the cavity 15, at least partially, in an assembled, and in particular closed, state. Specifically, powder material can be injected into the cavity 15 if a permanent magnet 3 is to be produced with the tool arrangement 1, and / or a previously injection-molded permanent magnet blank can be inserted into the cavity 15. An alignment tool part 7, selected from the first alignment tool part 7.1 and the second alignment tool part 7.2 (in this case, both alignment tool parts 7), comprises a first material with a first permeability or is formed from a first material with a first permeability. An alignment element 9, selected from the first alignment element 9.1 and the second alignment element 9.2. In this case, both alignment elements 9 have a second material with a different permeability than the first, or are made of a second material with a second permeability. The first permeability is greater than the second permeability. Both alignment elements 9, together with the two alignment tool parts 7, surround the cavity 15.

[0217] An alignment element 9, selected from the first alignment element 9.1 and the second alignment element 9.2, and an associated alignment tool part 7, selected from the first alignment tool part 7.1 and the second alignment tool part 7.2, are arranged one behind the other in the direction of the cavity. Specifically, the alignment tool part 7 is arranged behind the associated alignment element 9, starting from the cavity 15. The first alignment element 9.1 is arranged between the first alignment tool part 7.1 and the cavity 15. The second alignment element 9.2 is arranged between the second alignment tool part 7.2 and the cavity 15. The first alignment element 9.1 and the second alignment element 9.2 are each designed as a separate element from the associated alignment tool part 7, selected from the first alignment tool part 7.1 and the second alignment tool part 7.2. A tool part 5, selected from the first tool part 5.1 and the second tool part 5.2, in particular both tool parts 5, have a soft magnetic or a hard magnetic material or are made of a soft magnetic or a hard magnetic material.

[0218] The first permeability – given as the permeability number p r - has a value from 100 to 500,000, specifically from 1,000 to 500,000. The second permeability - given as the permeability number p r - has a value from 1 to 100, in particular from 1 to 10, in particular from 1 to 7.

[0219] Two interfaces 21, designated as alignment-tool part-alignment element interfaces, between the first alignment element 9.1 and the first alignment tool part 7.1, and between the second alignment element 9.2 and the second alignment tool part 7.2, are in this case each planar - as a plane - which is why the magnetic field lines 17 within the first alignment element 9.1 and the second alignment element 9.2 are each perpendicular to the two alignment-tool part-alignment element interfaces 21.

[0220] Two alignment element permanent magnet interfaces 23 between the first alignment element 9.1 and the cavity 15, as well as between the second alignment element 9.2 and the cavity 15, in particular the permanent magnet 3, are in the present case curved in the same direction, each having a simply curved shape and a shape curved in one dimension.

[0221] Preferably, the first alignment-tool-part-alignment-element interface 21.1 – as an interface 22, in particular a first interface 22.1 – and the first alignment-element-permanent magnet interface 23.1 – as a cavity surface 24, in particular a first cavity surface 24.1 – of the first alignment element 9.1 have different interface shapes. Furthermore, preferably, the second alignment-tool-part-alignment-element interface 21.2 – as an interface 22, in particular a second interface 22.2 – and the second alignment-element-permanent magnet interface 23.2 – as a cavity surface 24, in particular a second cavity surface 24.2 – of the second alignment element 9.1 have different interface shapes.

[0222] Also visible is a curved cavity shape 16 of the cavity 15, into which the powder material is introduced to produce the permanent magnet 3. The magnetic field lines 17 penetrate the cavity 15, and in particular the powder material arranged therein, almost parallel to each other. This is possible, in particular, because the powder material has a third component with a third permeability comparable to the second permeability of the alignment elements 9. As a result, the magnetic field lines 17 are deflected only slightly, or preferably not at all, at the alignment element-permanent magnet interface 23.

[0223] The present tool arrangement 1 can be configured as a pressing tool 4, in particular for pressing a permanent magnet 3 from a magnetizable powder material. The pressing tool 4 then has at least one pressing ram element 8, which is displaceable, in particular along a pressing direction 6 (indicated by an arrow), and which is specifically designed to compress the magnetizable powder material and, in particular, to produce the permanent magnet 3.

[0224] The press tool 4 comprises two press ram elements 8, namely a first press ram element 8.1 and a second press ram element 8.2, as at least one press ram element 8. In particular, the two press ram elements 8 are arranged on two opposite sides of the cavity 15. In particular, the two press ram elements 8 are arranged and designed such that they can be displaced towards and away from the cavity 15 along the pressing direction 6.

[0225] The present press tool 4 is designed as an axial press tool. An imaginary, dashed-line central press punch connection axis 10, which passes through the two press punch elements 8, and an imaginary, dashed-line central alignment magnet connection axis 12, which passes through two alignment magnets designed as electromagnets 13, run almost parallel to each other, in particular parallel. Specifically, the pressing direction 6 of the two press punch elements 8 and the magnetic field lines 17 generated by the alignment magnets are aligned almost parallel, in particular parallel. Figure 2 shows a schematic representation of a second embodiment of a tool arrangement 1 for producing a permanent magnet 3 from a magnetizable powder material, in particular in a powder injection molding process.

[0226] In this context, identical and functionally equivalent elements in all figures are provided with the same reference symbols, so that reference is always made to the preceding description.

[0227] In contrast to the tool arrangement 1 according to Figure 1, the second embodiment has a curved alignment tool part-alignment element interface 21 between the first alignment tool part 7.1 and the first alignment element 9.1, as well as between the second alignment element 7.2 and the second alignment tool part 9.1, each of which has a simply curved shape and a shape curved in one dimension.

[0228] In this case, a first alignment tool part alignment element interface 21.1 - with respect to the first alignment tool part 7.1 - is concavely curved and a second alignment tool part alignment element interface 21.2 - with respect to the second alignment tool part 7.2 - is convexly curved.

[0229] Also visible is the curved shape 16 of the cavity 15, on the first side 11.1 and the flat shape 11.2, into which the powder material is introduced to produce the permanent magnet 3. In contrast to the tool arrangement 1 in Figure 1, the magnetic field lines 17 penetrate the cavity 15, and in particular the powder material arranged therein, from the first side 11.1 to the second side 11.2, approaching each other, in particular converging. The magnetic field lines 17 in the cavity 15 are concavely curved in a transverse direction 31, extending from the center line 29 (shown with a dashed line) and extending from the center line 29, relative to an observer standing outside the tool arrangement 1. Here, too, the magnetic field lines 17 are deflected only slightly, preferably not at all, at the respective alignment element-permanent magnet interface 23.

[0230] Preferably, the first alignment tool part alignment element interface 21.1 – as interface 22, in particular the first interface 22.1 – and the first alignment element permanent magnet interface 23.1 – as cavity surface 24, in particular the first cavity surface 24.1 – of the first alignment element 9.1 have different curvatures, i.e., in particular different radii of curvature and different centers of curvature. Furthermore, preferably, the second alignment tool part alignment element interface 21.2 – as interface 22, in particular the second interface 22.2 – and the second alignment element permanent magnet interface 23.2 – as cavity surface 24, in particular the second cavity surface 24.2 – of the second alignment element 9.1 have different interface shapes.

[0231] The present tool arrangement 1 is designed as an injection mold 14, in particular for injection molding a permanent magnet 3 from a magnetizable powder material. The injection mold 14 has a powder material supply line 30 protruding from the plane of the image – the second cross-section 35.2 of which is shown as a dashed line; see Figure 8. In particular, the magnetizable powder material can be introduced, in particular injected, into the cavity 15 by means of the powder material supply line 30.

[0232] The injection mold 14 has a demolding parting line 33, wherein the injection mold 14 can be separated, in particular moved apart, for demolding the molded permanent magnet 3. In particular, the demolding parting line 33 is arranged between the first alignment element 9.1 and the second alignment element 9.2. In particular, the first alignment element 9.1 and the second alignment element 9.2 are abutting each other in the demolding parting line 33.

[0233] In this case, the powder material supply line 30 runs along the demolding parting line 33 between the first alignment element 9.1 and the second alignment element 9.2. A section plane extending into the image plane along the transverse direction 31 is shown in Figure 8.

[0234] Figure 3 shows a schematic representation of a third embodiment of a tool arrangement 1 in comparison with a fourth embodiment of a tool arrangement 1, each for producing a permanent magnet 3 from a magnetizable powder material, in particular in a powder injection molding process. Figure 3 includes sub-figures 3a and 3b.

[0235] Part 3a shows a tool arrangement 1, the cavity 15 of which has a different cavity shape 16 than the cavity 15 in Figure 2, so that a differently shaped permanent magnet 3 can be produced with the tool arrangement 1 of Part 3a. Also shown is a first angle ai, which is intended to visualize the orientation of the magnetic field lines 17 within the first alignment element 9.1 and the second alignment element 9.2 of Part 3a. The two alignment-tool part-alignment element interfaces 21 here have a second, smaller radius of curvature 27.2.

[0236] It follows that the magnetic field lines 17 on the first page 11.1 and especially on the second page 11.2 are deflected relatively strongly, in particular fanned out.

[0237] Part 3b shows a tool arrangement 1 as in part 3a, however, the two alignment-tool part-alignment element interfaces 21 have a first, larger radius of curvature 27.1 than in part 3a. It follows that the magnetic field lines 17 on the first side 11.1 and especially on the second side 11.2 of part 3b are deflected, in particular fanned out, to a comparatively lesser extent than in part 3a, resulting in a smaller second angle 012, different from the first angle ou.

[0238] Thus, by varying the radii of curvature 27 of the alignment-tool-part-alignment-element interface 21, the alignment of the magnetic field lines 17 – in particular a first and second angle ai,a.2 between a direction line 18 of a magnetic field line 17 (shown with dashed lines), in particular a vector, and a reference line 20 (shown with dashed lines), in particular a horizontal line – can be influenced. In particular, the alignment-tool-part-alignment-element interface 21 acts like the surface of an optical lens, except that in this case, no light rays are deflected, in particular focused or fanned out, but rather magnetic field lines 17.

[0239] Preferably - for clarity, the reference numerals are shown only in the first subfigure 3a, with the following description also applying to subfigure 3b - the first alignment-tool part-alignment element interface 21.1 - as the interface 22, in particular the first interface 22.1 - and the first alignment element-permanent magnet interface 23.1 - as the cavity surface 24, in particular the first cavity surface 24.1 - of the first alignment element 9.1 have different interface shapes. Furthermore, the second alignment tool part alignment element interface 21.2 - as the interface 22, in particular the second interface 22.2 - and the second alignment element permanent magnet interface 23.2 - as the cavity surface 24, in particular the second cavity surface 24.2 - of the second alignment element 9.1 preferably have different interface shapes.In the present case, the alignment tool part alignment element interfaces 21 each have a simply curved shape and a shape curved in one dimension.

[0240] Figure 4 shows a schematic representation of a fifth embodiment of a tool arrangement 1 for producing a permanent magnet 3 from a magnetizable powder material, in particular in a powder injection molding process.

[0241] The first alignment tool part alignment element interface 21.1 between the first alignment tool part 7.1 and the first alignment element 9.1 and the second alignment tool part alignment element interface 21.2 between the second alignment tool part 7.2 and the second alignment element 9.2 are each concavely curved with respect to the respective alignment tool part 7.1, 7.2.

[0242] Also visible is the curved shape 16 of the cavity 15, shown on the first page 11.1 and flat on the second page 11.2, into which the powder material is introduced to produce the permanent magnet 3. The magnetic field lines 17 penetrate the cavity 15, and in particular the powder material arranged therein, in a curved manner. Within the cavity 15, the magnetic field lines 17 are concavely curved in the transverse direction 31, extending from the center line 29 (shown with dashed lines) as seen from an observer standing outside the tool arrangement 1. Here, too, the magnetic field lines 17 are deflected only slightly, preferably not at all, at the respective alignment element-permanent magnet interface 23.

[0243] Preferably, the first alignment tool part alignment element interface 21.1 – as interface 22, in particular the first interface 22.1 – and the first alignment element permanent magnet interface 23.1 – as cavity surface 24, in particular the first cavity surface 24.1 – of the first alignment element 9.1 have different curvatures, i.e., in particular different radii of curvature and different centers of curvature. Furthermore, the second alignment tool part alignment element interface 21.2 – as interface 22, in particular the second interface 22.2 – and the second alignment element permanent magnet interface 23.2 – as cavity surface 24, in particular the second cavity surface 24.2 – of the second alignment element 9.1 have different interface shapes. The two alignment tool part alignment element interfaces 21 each have a simply curved shape and a shape curved in one dimension.

[0244] It is also conceivable that the tool arrangement 1 is rotationally symmetrical about the central axis 29 – apart from a powder material feed line 30. The two alignment tool part-alignment element interfaces 21 then each have a simply curved shape and a two-dimensionally curved shape, i.e., are each shaped as a spherical cap, in particular a spherical cap. The same is also conceivable for the tool arrangements 1 of Figures 2, 3, 5, and 6. In the tool arrangement 1 of Figure 1, however, the rotation would lead to a two-dimensionally curved shape at the two alignment element-permanent magnet interfaces 23, in particular at the two cavity surfaces 24.

[0245] Figure 5 shows a schematic representation of a sixth embodiment of a tool arrangement 1 for producing a permanent magnet 3 from a magnetizable powder material, in particular in a powder injection molding process.

[0246] The first alignment tool part / alignment element interface 21.1 between the first alignment tool part 7.1 and the first alignment element 9.1 is concavely curved with respect to the first alignment tool part 7.1. The second alignment tool part / alignment element interface 21.2 between the second alignment tool part 7.2 and the second alignment element 9.2 is planar.

[0247] Also visible is the curved shape 16 of the cavity 15, shown on the first page 11.1 and flat on the second page 11.2, into which the powder material is introduced to produce the permanent magnet 3. The magnetic field lines 17 penetrate the cavity 15, in particular the powder material arranged therein, in a curved manner. The magnetic field lines 17 in the cavity 15 are concavely curved in the transverse direction 31, perpendicular to the center line 29 shown in dashed lines, starting from the center line 29 – relative to an observer standing outside the tool arrangement 1 – but not as strongly as in the tool arrangement 1 of Figure 4. In particular, on the second side 11.2 of Figure 5, the magnetic field lines 17 are less curved than the magnetic field lines 17 of Figure 4. Here too, the magnetic field lines 17 are only slightly deflected, preferably not at all, at the respective alignment part of the permanent magnet interface 23.Preferably, the first alignment-tool-part-alignment-element interface 21.1 – as interface 22, in particular the first interface 22.1 – and the first alignment-element-permanent magnet interface 23.1 – as cavity surface 24, in particular the first cavity surface 24.1 – of the first alignment element 9.1 are curved differently, i.e., they have different radii of curvature and different centers of curvature. The first alignment-tool-part-alignment-element interface 21.1 has a simply curved shape and a shape curved in one dimension.

[0248] Figure 6 shows a schematic representation of a seventh embodiment of a tool arrangement 1 for producing a permanent magnet 3 from a magnetizable powder material, in particular in a powder injection molding process.

[0249] The tool arrangement 1 of Figure 6 represents - with respect to a curvature direction of the alignment-tool part-alignment element interfaces 21 - virtually the opposite of the tool arrangement 1 of Figure 4.

[0250] The first alignment tool part alignment element interface 21.1 between the first alignment tool part 7.1 and the first alignment element 9.1 and the second alignment tool part alignment element interface 21.2 between the second alignment tool part 7.2 and the second alignment element 9.2 are each convexly curved with respect to the respective alignment tool part 7.1, 7.2.

[0251] Also visible is the curved shape 16 of the cavity 15, shown on the first page 11.1 and flat on the second page 11.2, into which the powder material is introduced to produce the permanent magnet 3. The magnetic field lines 17 penetrate the cavity 15, and in particular the powder material arranged therein, in a curved manner. Within the cavity 15, the magnetic field lines 17 are convexly curved in the transverse direction 31, extending from the center line 29 (shown with dashed lines) as seen from an observer standing outside the tool arrangement 1. Here, too, the magnetic field lines 17 are deflected only slightly, preferably not at all, at the respective alignment element of the permanent magnet interface 23. Preferably the first alignment tool part alignment element interface 21.1 - as the interface 22, in particular the first interface 22.1 - and the first alignment element permanent magnet interface 23.1 - as the cavity surface 24, in particular the first cavity surface 24.1 - of the first alignment element 9.1, are curved differently, thus exhibiting, in particular, different radii of curvature and different centers of curvature. Furthermore, preferably the second alignment-tool part-alignment element interface 21.2 - as the interface 22, in particular the second interface 22.2 - and the second alignment element-permanent magnet interface 23.2 - as the cavity surface 24, in particular the second cavity surface 24.2 - of the second alignment element 9.1, have different interface shapes. The two alignment-tool part-alignment element interfaces 21 each have a simply curved shape and a shape curved in one dimension.

[0252] Figure 7 shows a schematic representation of an eighth embodiment of a tool arrangement 1.

[0253] The present tool arrangement 1 is also designed as a pressing tool 4. In contrast to the pressing tool 4 of Figure 1, this is a transverse pressing tool.

[0254] In this case, a press punch element 8 of the at least one press punch element 8 is designed as an element separate from the at least one alignment tool part 7.

[0255] The present press tool 4 comprises the first alignment tool part 7.1, the second alignment tool part 7.2, and the press punch element 8, which is different from at least one of these elements, in particular two press punch elements 8, namely the first press punch element 8.1 and the second press punch element 8.2. In particular, the two press punch elements 8 are arranged on two opposite press punch sides of the cavity 15. In particular, the first alignment tool part 7.1 and the second alignment tool part 7.2 are arranged on two opposite tool part sides of the cavity 15.

[0256] The imaginary press die connecting axis 10, which runs through the two press die elements 8, and the imaginary alignment magnet connecting axis 12, which runs through the two alignment magnets designed as electromagnets 13, are arranged transversely, in particular almost orthogonally, in particular orthogonally to each other. In particular, the pressing direction 6 of the press die element 8 and the magnetic field lines 17 generated by the alignment magnets are aligned transversely, in particular almost orthogonally, in particular orthogonally. In particular, the pressing direction 6 – represented by an arrow – runs transversely to the magnetic field lines 17. The two press die elements 8 in this case have the second material with the second permeability.

[0257] Figure 8 shows a schematic representation of the tool arrangement 1 of Figure 2 designed as an injection mold 14 with two embodiments of a powder material supply line 30.

[0258] Figure 8 includes sub-figures 8a and 8b, each of which represents a sectional view of the section plane extending into the picture plane along the transverse direction 31 of Figure 2.

[0259] Both inset figures show a powder material feed line 30, which opens into the cavity 15 via a powder feed opening 32 with a first cross-sectional area 35.1. Upstream of the first cross-sectional area 35.1, the powder material feed line 30 has a larger, second cross-sectional area 35.2. The first cross-sectional area 35.1 is identical to the projected cavity shape 16; see Figure 2. The second cross-sectional area 35.2 is also shown in Figure 2, where it is depicted as a dashed line.

[0260] In subfigure 8a, the second conductor cross-section 35.2 narrows into the first conductor cross-section 35.1 by means of a single step 37.

[0261] In subfigure 8b, the second conductor cross-section 35.2 tapers continuously, in particular steplessly, into the first conductor cross-section 35.1. In particular, the taper is conical or pyramidal.

[0262] Figure 9 shows a schematic representation of a ninth embodiment of a tool arrangement 1 in a first view.

[0263] The tool arrangement 1 is designed as an extrusion tool 38, wherein the

[0264] Extrusion tool 38 has an extrusion die 41, wherein the extrusion die 41 has at least sectionally the alignment element 9, the first alignment tool part 7.1 and the second alignment tool part 7.2.

[0265] The extrusion die 41 has an extrusion channel 43 as the cavity 15. The alignment element 9 and one of the alignment tool parts 7.1, 7.2 are arranged one behind the other in an alignment section 45 of the extrusion die 41 in one direction, in particular in a dashed transverse direction 31 oriented perpendicular to the extrusion channel 43, towards the extrusion channel 43. The alignment element 9 forms the extrusion channel 43 as the cavity 15.

[0266] In this case, the alignment element 9 is formed as a single piece. The tool arrangement 1, designed as an extrusion tool 38, therefore has exactly one alignment element 9. It is also possible that the alignment element 9 is not formed as a single piece, but as two-part or multi-part, in which case the tool arrangement 1, designed as an extrusion tool 38, has two or more alignment elements 9.

[0267] Also shown is an extrusion conveying device 47, which is designed and configured to convey the powder material (not shown here), in particular to compact it and extrude it through the extrusion channel 43 along an extrusion direction 55, indicated by an arrow – which corresponds in particular to a direction designated as downstream, with an upstream direction being the opposite. The extrusion die 41 adjoins the extrusion conveying device 47, wherein in particular the extrusion die 41 is designed as an element distinct from the extrusion conveying device 47.

[0268] The tool arrangement 1 has at least one temperature control section 51. In this case, a second temperature control section 51.2 of the at least one temperature control section 51 is configured as a temperature-controlled conveyor belt 57 and as temperature-controlled conveyor rollers 59. The second temperature control section 51.2 is designed and configured to temperature-control, and in particular cool, the extruded powder material exiting the at least one extrusion channel 43. The second temperature control section 51.2 is arranged downstream of the alignment section 45 and is free of alignment elements 9, i.e., it does not have any alignment elements 9.

[0269] Figure 10 shows a schematic representation of a tenth embodiment of a tool arrangement 1 designed as an extrusion tool 38.

[0270] The embodiment shown in Figure 10 is based on the embodiment shown in Figure 9 with the following features, in particular the extrusion conveying device 47 and the second temperature control section 51.2 are not shown:

[0271] In Figure 10, the extrusion die 41 has several extrusion channels 43, namely four extrusion channels 43. A channel wall 49 is arranged between each pair of extrusion channels 43. The material of the channel wall 49 has either the first permeability or the second permeability.

[0272] The tool arrangement 1 further comprises a first temperature control section 51.1 of the at least one temperature control section 51. The first temperature control section 51.1 is arranged section by section along the extrusion channels 43. The first temperature control section 51.1 forms the extrusion channels 43 section by section. The first temperature control section 51.1 is designed and configured to temperature control, and in particular to cool, the powder material arranged in the extrusion channels 43.

[0273] The first temperature control section 51.1 is located downstream of the alignment section 45 and is free of alignment elements 9, i.e., in particular, it does not have any alignment elements 9.

[0274] An insulating element 53, in particular a thermal insulating element, is arranged between the alignment section 45 and the first temperature control section 51.1.

[0275] The first temperature control section 51.1 comprises a fourth material or is formed from a fourth material which has a higher thermal conductivity than the alignment tool part 7, in particular than the first material, and / or than the alignment element 9, in particular than the second material. The fourth material is a material selected from the group consisting of: an iron material, an iron alloy, a copper material, a copper alloy, an aluminum material, an aluminum alloy, a magnesium material, a magnesium alloy, a gold material, a gold alloy, a silver material, and a silver alloy.

[0276] Figure 11 shows a schematic representation of the tool arrangement 1 of Figure 9 in a second view.

[0277] The second view corresponds to a sectional view of a section running along the dashed transverse direction 31 in Figure 9, i.e., along a plane that is orthogonal to the image plane. In Figure 11, the extrusion direction 55 is therefore oriented orthogonally to the image plane and emerges from it.

[0278] The first alignment tool part 7.1, the second alignment tool part 7.2, the alignment element 9, the cavity 15 designed as an extrusion channel 43, and the magnetic field lines 17 are shown. The magnetic field lines 17 run from the first alignment electromagnet 13.1 to the second alignment electromagnet 13.2.

[0279] In this embodiment, the tool arrangement 1 has only a single alignment element 9. The first alignment-tool-part-alignment-element interface 21.1 – as interface 22, in particular the first interface 22.1 – is thus the interface located between the first alignment tool part 7.1 and the alignment element 9. The second alignment-tool-part-alignment-element interface 21.2 – as interface 22, in particular the second interface 22.2 – is thus the interface located between the second alignment tool part 7.2 and the alignment element 9. The first alignment element-permanent magnet interface 23.1 – as the cavity surface 24, in particular the first cavity surface 24.1 – is therefore, in particular, the interface that is arranged between the cavity 15 and the first alignment tool part-alignment element interface 21.1. The second alignment element-permanent magnet interface 23.2 - as the cavity surface 24, in particular the second cavity surface 24.2 - is therefore in particular that interface which is arranged between the cavity 15 and the second alignment tool part alignment element interface 21.2.

[0280] Preferably, the first alignment-tool-part-alignment-element interface 21.1 – as interface 22, in particular the first interface 22.1 – and the first alignment-element-permanent magnet interface 23.1 – as cavity surface 24, in particular the first cavity surface 24.1 – of the first alignment element 9.1 have different interface shapes. Furthermore, preferably the second alignment-tool-part-alignment-element interface 21.2 – as interface 22, in particular the second interface 22.2 – and the second alignment-element-permanent magnet interface 23.2 – as cavity surface 24, in particular the second cavity surface 24.2 – of the second alignment element 9.1 have different curvatures, i.e., they have, in particular, different radii of curvature and different centers of curvature. The two alignment tool part alignment element interfaces 21 each have a simply curved shape and a shape curved in one dimension.

[0281] Figure 12 shows a process flow diagram of an embodiment of a method for producing a permanent magnet 3 from a magnetizable powder material in a powder process.

[0282] In a first step S1 of the process, magnetic field lines 17 penetrate a first material with a first permeability and a second material with a second permeability, both of which are present in addition to the powder material, thereby acquiring a predetermined orientation. The first and second materials are selected such that the first permeability is greater than the second permeability. The predeterminedly oriented magnetic field lines 17 penetrate a cavity 15, into which the powder material is introduced during the first step S1 or in a preceding zeroth step SO. The predeterminedly oriented magnetic field lines 17 penetrate the powder material, aligning the magnetic moments of the powder particles of the magnetizable powder material in a predetermined direction.

[0283] The method is carried out in particular with a tool arrangement 1 according to one of the figures 1 to 11.

[0284] It is possible that the powder process is a powder injection molding process, wherein the powder material is injected into the cavity 15 transversely and / or parallel to the generated magnetic field lines 17. Such a powder injection molding process is carried out, for example, using a tool arrangement 1 designed as an injection mold 14, as shown in Figure 2. In this configuration, the powder material is injected transversely to the generated magnetic field lines 17. Furthermore, the magnetic field lines 17 are aligned transversely to the powder material injection direction, at least in the region of a powder feed opening 32 of a powder material feed line 30 opening into the cavity 15. Carrying out the powder injection molding process using the tool arrangement 1 from Figures 3 to 6 is also possible if the tool arrangement 1 shown there is designed as an injection mold 14.

[0285] Alternatively, the powder pressing process can also be a powder pressing process, in which the powder material is pressed transversely, in particular almost orthogonally, and in particular orthogonally and / or parallel to the magnetic field lines 17. Such a powder pressing process is carried out, for example, using a tool arrangement 1 designed as a pressing tool 4, as shown in Figures 1 and 7. If the pressing process is carried out using a pressing tool 4 from Figure 1, the powder material is pressed parallel to the magnetic field lines 17. If, on the other hand, the pressing process is carried out using a pressing tool 4 from Figure 7, the powder material is pressed transversely to the magnetic field lines 17. Carrying out the powder pressing process using the tool arrangement 1 from Figures 3 to 6 is also possible if the tool arrangement 1 shown there is designed as a pressing tool 4.

[0286] Alternatively, the powder process can also be a powder extrusion process. In this case, the powder material is extruded transversely and / or parallel to the magnetic field lines 17. Such a powder extrusion process is carried out, for example, using a tool arrangement 1 designed as an extrusion tool 38, as shown in Figures 9 to 11. If the powder process is carried out using an extrusion tool 38 as shown in Figures 9 to 11, the powder material is extruded transversely to the magnetic field lines 17. The powder material is tempered, in particular cooled, after the magnetic moments of the powder particles have been aligned in the predetermined direction. Carrying out the powder extrusion process using the tool arrangement 1 from Figures 1 to 7 is also possible if the tool arrangement 1 shown there is designed as an extrusion tool 38.In particular, the cavity 15 is then designed as at least one extrusion channel 43 – i.e., it does not have a closed cavity 15 as in the injection mold 14 or the compression mold 4 – so that the powder material can be extruded through the cavity 15. Figure 13 shows a process flow diagram of an embodiment of a method for manufacturing a tool arrangement 1, in particular that of Figures 1 to 11, which is set up for manufacturing a permanent magnet 3 from a magnetizable powder material.

[0287] In a first step S1, an alignment tool part 7, which has a first material with a first permeability, and an alignment element 9, which has a second material different from the first material with a second permeability that is smaller than the first permeability, are provided, whereby a target alignment for magnetic field lines 17 in a cavity 15 of the tool arrangement 1 is determined.

[0288] In a second step S2, the alignment tool part 7 and the alignment element 9 are each formed or selected at an interface 22, maintaining an alignment-tool part-alignment element interface 21, and brought into contact with one another such that magnetic field lines 17 introduced into the tool arrangement 1 are deflected at the alignment-tool part-alignment element interface 21 in such a way that they exhibit the desired orientation in the cavity 15. Here, the alignment element 9 is formed at a cavity surface 24 such that the alignment element 9, by means of the cavity surface 24, section by section forms a predetermined cavity shape 16 of the cavity 15.

[0289] In the second step S2, the interface 22 of the alignment element 9 and the cavity surface 24 are preferably produced opposite each other on the alignment element 9, particularly on the same alignment element 9. Furthermore, in the second step S2, the interface 22 of the alignment element 9 and the cavity surface 24 are preferably produced with different shapes. Additionally, in the second step S2, the interface 22 of the alignment element 9 is preferably produced as a plane surface and the cavity surface 24 as a curved surface. Alternatively, the interface 22 of the alignment element 9 is preferably produced as a curved surface and the cavity surface 24 as a plane surface. As a further alternative, the interface 22 of the alignment element 9 and the cavity surface 24 are preferably produced with different curvatures, preferably with different radii of curvature and / or different centers of curvature.

Claims

REQUIREMENTS 1. Tool arrangement (1) for producing a permanent magnet (3) from a magnetizable powder material, comprising: - at least one tool part (5) designed to surround a cavity (15) at least partially, wherein - that at least one tool part (5) as an alignment tool part (7) has a first material with a first permeability or is formed from a first material with a first permeability, and - at least one alignment element (9) comprising a second material different from the first material with a second permeability or formed from a second material with a second permeability, wherein the first permeability is greater than the second permeability, wherein - that at least one alignment element (9) together with at least one alignment tool part (7) partially surrounds the cavity (15), wherein - that at least one alignment element (9) and at least one alignment tool part (7) are arranged one behind the other in the direction towards the cavity (15).

2. Tool arrangement (1) according to claim 1, comprising as the at least one tool part (5) a first tool part (5.1) and a second tool part (5.2) opposite the first tool part (5.1), wherein - the first tool part (5.1) and the second tool part (5.2) are designed to surround the cavity (15) at least partially in an assembled state.

3. Tool arrangement (1) according to one of the preceding claims, wherein - an alignment tool part (7) of the at least one alignment tool part (7) and an alignment element (9) of the at least one alignment element (9) adjoin each other at an alignment tool part-alignment element interface (21), wherein - the alignment element (9) abuts the cavity (15) at an alignment element permanent magnet interface (23), in particular limiting the cavity (15), wherein - the alignment tool part alignment element interface (21) and the alignment element permanent magnet interface (23) of the alignment element (9), in particular of the same, have different interface shapes.

4. Tool arrangement (1) according to claim 3, wherein - the boundary shape is selected from a group consisting of: a plane, a stepped shape, a simply curved shape, a multiply curved shape, a shape curved in one dimension, and a shape curved in two dimensions.

5. Tool arrangement (1) according to claim 3 or 4, wherein - the alignment tool part alignment element interface (21) is planar and the alignment element permanent magnet interface (23) is curved, or wherein - the alignment tool part alignment element interface (21) is curved and the alignment element permanent magnet interface (23) is planar, or wherein - the alignment tool part alignment element interface (21) and the alignment element permanent magnet interface (23) are curved differently, in particular having different radii of curvature and / or different centers of curvature.

6. Tool arrangement (1) according to one of the preceding claims, wherein - the tool arrangement (1) is designed as an injection mold (14), wherein the injection mold (14) has a powder material supply line (30), or wherein - the tool arrangement (1) is designed as a press tool (4), wherein the press tool (4) has at least one press ram element (8), or wherein - the tool arrangement (1) is designed as an extrusion tool (38), wherein the extrusion tool (38) has an extrusion die (41), wherein the extrusion die (41) sectionally has the at least one alignment element (9) and the at least one alignment tool part (5).

7. Tool arrangement (1) according to claim 6, wherein - the extrusion die (41) has at least one extrusion channel (43) as the cavity (15), in particular forming, wherein - the at least one alignment element (9) and the at least one alignment tool part (7) in an alignment section (45) of the extrusion die (41) in a direction, in particular in a transverse direction (31) oriented transversely to the at least one extrusion channel (43), on which at least one extrusion channel (43) is arranged one behind the other, wherein - the tool arrangement (1) has at least one temperature control section (51), wherein - a first tempering section (51.1) of the at least one tempering section (51) is arranged section by section along the at least one extrusion channel (43), in particular forming section by section the at least one extrusion channel (43), wherein the first tempering section (51.1) is designed and configured to temper, in particular to cool, the powder material arranged in the at least one extrusion channel (43), and / or wherein - a second temperature control section (51.2) of the at least one temperature control section (51) is designed as a temperature-controlled conveyor belt (57) and / or as temperature-controlled conveyor rollers (59), wherein the second temperature control section (51.2) is designed and configured to temperature control, in particular to cool, the extruded powder material exiting the at least one extrusion channel (43).

8. Tool arrangement (1) according to claim 7, wherein - a tempering section (51), selected from the first tempering section (51.1) and the second tempering section (51.2), is arranged in an extrusion direction (55) of the extrusion tool (38) downstream of the alignment section (45), wherein - which at least one temperature control section (51), in particular the first temperature control section (51.1), is free of alignment elements (9).

9. Method for producing a permanent magnet (3) from a magnetizable powder material in a powder process, wherein - Magnetic field lines (17) penetrate a first material with a first permeability and a second material with a second permeability, in addition to the powder material, and in particular thereby obtain a predetermined orientation, wherein - first and second materials are selected such that a first permeability is greater than a second permeability, wherein - the predeterminedly aligned magnetic field lines (17) penetrate a cavity (15), wherein - the powder material is introduced into the cavity (15), whereby the predeterminedly aligned magnetic field lines (17) penetrate the powder material, so that magnetic moments of the powder particles of the magnetizable powder material are aligned in a predetermined direction.

10. Method according to claim 9, wherein - the magnetic field lines (17) are generated while the powder material is introduced into the cavity (15), and / or wherein - the magnetic field lines (17) are generated after the powder material has been introduced into the cavity (15).

11. Method according to claim 9 or 10, wherein - the powder process is a powder injection molding process, wherein the powder material is injected into the cavity (15) transversely and / or parallel to the generated magnetic field lines (17), or wherein - the powder process is a powder pressing process wherein the powder material is pressed transversely and / or parallel to the magnetic field lines (17), or wherein - the powder process is a powder extrusion process in which the powder material is extruded transversely and / or parallel to the magnetic field lines (17).

12. Method for producing a tool arrangement (1) according to any one of claims 1 to 8, which is configured for producing a permanent magnet (3) from a magnetizable powder material, wherein - an alignment tool part (7) having a first material with a first permeability, and an alignment element (9) having a second material different from the first material with a second permeability that is smaller than the first permeability, are provided, wherein - a target orientation for magnetic field lines (17) in a cavity (15) of the tool arrangement (1) is defined, wherein - the alignment tool part (7) and the alignment element (9) are each formed or selected at an interface (22) while maintaining an alignment-tool part-alignment element interface (21) and brought into contact with each other such that magnetic field lines (17) introduced into the tool arrangement (1) are deflected at the alignment-tool part-alignment element interface (21) such that they have the desired alignment in the cavity (5), wherein - the alignment element (9) is shaped on a cavity surface (24) such that the cavity surface (24) of the alignment element (9) forms a predetermined cavity shape (16) of the cavity (5) section by section.

13. Method according to claim 12, wherein the interface (22) of the alignment element (9) and the cavity surface (24) are produced opposite each other on the alignment element (9), in particular on the same alignment element (9).

14. Method according to claim 12 or 13, wherein the interface (22) of the alignment element (9) and the cavity surface (24) are produced in different shapes.

15. Method according to any one of claims 12 to 14, wherein the interface (22) of the alignment element (9) is produced as a plan and the cavity surface (24) is produced as a curved surface, or wherein the interface (22) of the alignment element (9) is produced as a curved surface and the cavity surface (24) is produced as a plan.

16. Method according to one of claims 12 to 14, wherein the interface (22) of the alignment element (9) and the cavity surface (24) are produced with a different curvature, in particular with a different radius of curvature and / or a different center of curvature.

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