Additively Oriented Permanent Magnets for Complex Field Shaping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing bulk permanent magnets are limited by their geometry and material costs, leading to inefficiencies in magnetic field distribution and susceptibility to demagnetization, especially in regions like corners and surfaces, which restricts the weight and volume efficiency of magnetic materials in applications such as electric motors.
Innovation Solution
The development of a permanent magnet structure with location-specific magnetic orientations and crystallographic textures achieved through additive manufacturing, allowing for independent alignment of magnetic domains and grains during solidification, enabling tailored magnetic field shapes and enhanced resistance to demagnetization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If die-press and sintering methods are used to produce permanent magnets, then magnetic and crystallographic alignment is achieved in one specific orientation, but the geometry is limited to prismatic shapes and material costs increase due to machining losses
Solution Approach 1:
The patent changes the manufacturing process parameters by using additive manufacturing (direct energy deposition) instead of conventional die-press and sintering. This allows the magnet to be built layer-by-layer with controlled solidification, achieving both complex geometries and precise magnetic/crystallographic alignment through process parameter control rather than post-manufacturing machining
Solution Approach 2:
The patent replaces the mechanical die-press consolidation process with a thermal-energy-based additive manufacturing process. Direct energy deposition uses laser or electron beam to melt and solidify material in place, eliminating the need for mechanical pressing and subsequent machining, thereby enabling complex geometries while maintaining alignment precision
2Manufacturing precision
If die-press and sintering methods are used to produce permanent magnets, then magnetic and crystallographic alignment is achieved, but material costs significantly increase due to machining losses
Solution Approach 1:
The additive manufacturing process is self-service in that it builds the magnet directly to its final complex geometry without requiring subsequent machining operations. The process inherently produces near-net-shape parts, eliminating material waste associated with removing excess material through machining while maintaining the required alignment precision
Solution Approach 2:
By changing from a subtractive manufacturing approach (die-press + machining) to an additive approach (direct energy deposition), the patent eliminates material loss. The process deposits material only where needed in the final geometry, achieving both alignment precision and material efficiency simultaneously
3Manufacturing precision
If conventional processing produces uniform texture throughout the magnet, then easy axis alignment is maximized, but regions like corners and surfaces become susceptible to demagnetization under non-uniform fields
Solution Approach 1:
The patent applies local quality by enabling different crystallographic textures and easy axis orientations in different regions of the magnet. Through controlled solidification during additive manufacturing, each region can be tailored with optimal grain orientation for its specific functional requirements, with corners and surfaces having orientations that maximize resistance to local demagnetization stresses
Solution Approach 2:
The patent segments the magnet into multiple regions with different textures and orientations. Rather than a uniform structure, the magnet is divided into zones that can independently optimize for their local magnetic field conditions, with transition regions between different texture zones to manage field continuity and prevent demagnetization
4Adaptability or versatility
If additive manufacturing is used to achieve location-specific magnetic orientations, then complex shapes and optimized field distribution are enabled, but manufacturing process complexity increases
Solution Approach 1:
The additive manufacturing process serves multiple functions simultaneously: it deposits material, controls solidification, orients grains, and creates complex geometries all in one integrated process. This multi-functionality reduces the need for separate manufacturing steps and post-processing operations, making the increased capability manageable despite process complexity
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
This approach improves the performance and efficiency of permanent magnets by optimizing magnetic field distribution, reducing material costs, and enabling the production of complex shapes that enhance motor efficiencies and reduce material waste.
Implementation Method 1
solidifying the first melt layer in the presence of an externally applied magnetic field, thereby generating a magnetic metal layer containing a plurality of individual voxels, wherein the externally applied magnetic field has a magnetic-field orientation, defined with respect to the scan direction, that is selected to control (i) a magnetic axis within the magnetic metal layer and/or (ii) a crystallographic texture within the magnetic metal layer
Implementation Method 2
exposing a first amount of the feedstock composition to an energy source for melting in a scan direction, thereby generating a first melt layer
Implementation Method 3
exposing a first amount of the feedstock composition to an energy source for melting in a scan direction, thereby generating a first melt layer
Implementation Method 4
solidifying the first melt layer in the presence of an externally applied magnetic field, thereby generating a magnetic metal layer
Data Source
AI summary
Some variations provide a permanent-magnet structure comprising: a region having a plurality of magnetic domains and a region-average magnetic axis, wherein each of the magnetic domains has a domain magnetic axis that is substantially aligned with the region-average magnetic axis, and wherein the plurality of magnetic domains is characterized by an average magnetic domain size. Within the region, there is a plurality of metal-containing grains characterized by an average grain size, and each of the magnetic domains has a domain easy axis that is dictated by a crystallographic texture of the metal-containing grains. The region has a region-average easy axis based on the average value of the domain easy axis within that region. The region-average magnetic axis and the region-average easy axis form a region-average alignment angle that has a standard deviation less than 30° within the plurality of magnetic domains. Many permanent-magnet structures are disclosed herein.