Additive Manufacturing of Magnet Arrays with Customized Orientations

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Solution Overview

Problem

Manufacturing magnet arrays with complex shapes and customized magnetization directions is challenging due to the difficulty in designing and machining magnets with intricate designs, which limits design flexibility and performance in applications requiring strong and spatially periodic magnetic fields.

Innovation Solution

A method involving anisotropic magnetic powder and a binder, where an external magnetic field aligns the magnetization direction, and an energy beam selectively melts the binder to form permanent magnets with defined orientations, allowing for the creation of magnet arrays with unique magnetization directions and complex geometries, such as Halbach arrays.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional machining methods are used to manufacture magnet arrays with complex shapes, then manufacturing precision can be achieved, but device complexity and difficulty of manufacture increase significantly

Engineering Contradiction:

Improvemagnet array shape precisionVSAvoidmanufacturing difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces conventional mechanical machining processes with an energy beam-based additive manufacturing process. The energy beam (laser or electron beam) selectively melts and fuses magnetic powder particles layer by layer to form complex magnet array geometries, eliminating the need for complex mechanical tooling and machining operations required by traditional methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state and processing parameters of magnetic materials from solid block machining to powder-based additive deposition. By controlling parameters such as energy beam power, scanning speed, and powder feed rate, the process achieves precise control over magnet array geometry and magnetization direction without the constraints of conventional machining.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If magnet arrays with customized magnetization directions are manufactured using traditional methods, then magnetic field control can be improved, but assembly complexity and time increase

Engineering Contradiction:

Improvemagnetization direction controlVSAvoidassembly time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent merges the manufacturing and magnetization processes into a single integrated additive manufacturing operation. The energy beam process simultaneously forms the magnetic material structure and establishes the desired magnetization directions through controlled deposition and field application during building, eliminating the need for separate assembly and magnetization steps required by traditional methods.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent performs preliminary magnetization alignment during the additive manufacturing process itself. By applying magnetic fields during powder deposition and layer formation, the magnetic particles are oriented in the desired directions before the structure is complete, preventing the need for time-consuming post-assembly magnetization operations.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If complex shaped magnets are manufactured using conventional methods, then design flexibility can be achieved, but material waste increases

Engineering Contradiction:

Improvedesign flexibilityVSAvoidmaterial waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The patent applies local quality by selectively depositing magnetic powder only where needed to form the final magnet array geometry. The additive process allows different regions of the structure to have different material densities, compositions, and magnetization properties tailored to specific functional requirements, while minimizing material waste through precise localized deposition rather than subtractive machining.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables the production of magnet arrays with customized magnetization directions and shapes, improving magnetic field control and flexibility, while reducing material waste and assembly complexities, thus enhancing the performance and design capabilities of magnetic devices.

Implementation Method 1

an external magnetic field aligns the magnetization direction

Methodology Applied

Scientific EffectMagnetic field alignment: Magnetic Field

Implementation Method 2

an energy beam, e.g., an electron beam, laser beam, or a microwave beam, to selectively melt the binder

Methodology Applied

Scientific EffectSelective melting: Melting

Implementation Method 3

selectively melt the binder such that the anisotropic magnetic powder forms a permanent magnet with the defined magnetization direction

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS20210335539A1Additive manufacturing of magnet arrays

Publication Date: 2021.10.28 FORD GLOBAL TECH LLC

AI summary

A method of forming a magnet is provided. The method includes disposing an anisotropic magnetic powder and a binder within a bed, the anisotropic magnetic powder having a defined magnetization direction. An energy beam selectively melts the binder such that the anisotropic magnetic powder forms a permanent magnet with the defined magnetization direction. The energy beam is a laser beam, a microwave beam and the like.