Filament Bond Magnet Layout for Ring Flux Direction Control
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Solution Overview
Problem
Conventional bond magnets have limited freedom in the direction of magnetic flux and surface magnetic flux density, particularly for ring/annulus-shaped magnets, due to restrictive magnetic field orientations during manufacturing, which hinders their performance in applications requiring high surface magnetic flux density.
Innovation Solution
A bond magnet composed of multiple filaments with aligned magnetic powder, arranged in a specific pattern to form a ring shape, where the magnetic flux direction is determined by the filament arrangement, allowing for higher freedom and alignment of magnetic flux, and manufactured using the Fused Deposition Modeling method to achieve a higher surface magnetic flux density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If resin molding using a mold is used to manufacture bond magnets, then the manufacturing process is simple and efficient, but the degree of freedom regarding the direction of magnetic flux inside the bond magnet is low
Solution Approach 1:
The bond magnet is divided into multiple magnet pieces arranged in a ring shape, where each magnet piece can be independently molded and then assembled. This segmentation allows each piece to be manufactured using simple resin molding while enabling flexible arrangement to achieve desired magnetic flux directions in the assembled ring-shaped bond magnet.
Solution Approach 2:
The invention transitions from manufacturing a single monolithic bond magnet to assembling multiple magnet pieces in a ring configuration. This dimensional change from a single-piece to a multi-piece assembled structure enables greater freedom in controlling magnetic flux direction while maintaining manufacturing simplicity.
2Ease of manufacture
If conventional resin molding is used for ring-shaped bond magnets, then the manufacturing process is straightforward, but the surface magnetic flux density on the working surface cannot be made high
Solution Approach 1:
The invention uses magnet pieces with specific local configurations and arrangements optimized for high surface magnetic flux density on the working surface. By carefully designing the local arrangement and orientation of magnetic powder in each magnet piece and their assembly configuration, high surface magnetic flux density is achieved while maintaining straightforward resin molding manufacturing.
3Productivity
If magnetic powder is magnetized in a mold during resin molding, then the manufacturing process is integrated and efficient, but the direction of magnetic field lines is restricted by the mold geometry
Solution Approach 1:
The bond magnet is segmented into multiple magnet pieces that are independently molded and then assembled into a ring shape. This segmentation allows each piece to be manufactured using integrated resin molding with magnetic powder magnetization, while the ring-shaped assembly provides the flexibility to configure magnetic field lines in various directions without being constrained by a single mold geometry.
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
The solution results in a bond magnet with increased surface magnetic flux density and flexibility in magnetic flux direction, outperforming conventional methods by enhancing the radial component of magnetic flux and maintaining the shape integrity through stronger resin bonding.
Implementation Method 1
magnetic powder is magnetized by resin molding in a state where a magnetic field is formed in the internal space of the mold
Implementation Method 2
manufactured using the Fused Deposition Modeling method
Data Source
AI summary
A bond magnet includes filaments bonded with each other to form a shape of the bond magnet. Each of the filaments is a filamentous member including a resin material and magnetic powder dispersed in the resin material, and has magnetic anisotropy for high degree of freedom of magnetic flux direction and high surface magnetic flux density on a working surface.