Bond Magnet Lamination for Multipolar Flux Density
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Solution Overview
Problem
Existing methods for manufacturing bond magnets often result in low productivity and inadequate magnetic properties due to limitations in magnetization techniques and material orientation during the molding process.
Innovation Solution
A method involving the preparation of a bond magnet composition with a magnetic material and resin, followed by extrusion molding to orient the magnetic material in one direction, axial magnetization, and laminating the magnetized layers in alternating directions to create a multipolar magnet with high magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional multipolar magnetization methods are used, then magnetization can be achieved, but productivity is low and magnetic properties are inadequate
Solution Approach 1:
The magnet is divided into multiple thin laminated layers, each independently magnetized in the extrusion direction. This segmentation allows each layer to achieve optimal magnetic properties through axial magnetization, while the overall assembly forms a multipolar structure, resolving the contradiction between productivity and magnetic quality
Solution Approach 2:
Magnetic material orientation is performed during the extrusion molding process itself, before the final magnetization step. This preliminary orientation ensures that the magnetic particles are aligned in the extrusion direction, so that subsequent axial magnetization can efficiently achieve the desired magnetic properties without requiring complex multipolar magnetization equipment
2Manufacturing precision
If magnetic material is oriented during extrusion molding, then material orientation is achieved, but complex magnetization processes are required
Solution Approach 1:
Instead of applying complex multipolar magnetization after molding to achieve directional magnetic properties, the invention inverts the approach by orienting magnetic particles during extrusion in the desired direction, then applying simple axial magnetization. This reverses the traditional sequence and simplifies the magnetization equipment required while maintaining precise material orientation
3Ease of manufacture
If simple axial magnetization is used, then manufacturing is simplified, but multipolar magnetic structure cannot be achieved
Solution Approach 1:
The magnet is segmented into multiple laminated layers, each with uniform axial magnetization. The alternating polarity of adjacent layers in the multipolar structure is achieved through the lamination arrangement itself, allowing simple axial magnetization of each layer to contribute to the overall multipolar magnetic configuration
Solution Approach 2:
The multipolar magnetic structure is achieved not through complex in-plane magnetization patterns, but by stacking multiple axially magnetized layers in the thickness dimension. This dimensional transition from 2D multipolar patterns to 3D laminated structure enables simple axial magnetization to produce complex multipolar effects
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 enables the production of multipolar magnets with high magnetic properties and a small magnetic pole pitch, enhancing productivity and magnetic flux density while avoiding defects associated with traditional multipolar magnetization methods.
Implementation Method 1
extruding the bond magnet composition in one direction to produce a molded body while orienting the magnetic material in the one direction
Implementation Method 2
magnetizing the molded body in the one direction using an axial magnetization to produce a magnetized molded body
Data Source
AI summary
A method for manufacturing a bond magnet includes providing a bond magnet composition including a magnetic material and a resin, extruding the bond magnet composition in one direction to produce a molded body while orienting the magnetic material in the one direction, magnetizing the molded body in the one direction using an axial magnetization to produce a magnetized molded body, and laminating the magnetized molded body to produce a laminated molded body including first magnetized molded layers and second magnetized molded layers. The first magnetized molded layers and the second magnetized molded layers are alternately laminated. A first magnetization direction of each of the first magnetized molded layers is opposite to a second magnetization direction of each of the second magnetized molded layers.