Hybrid Magnet Layered Structure for Magnetic Performance

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Solution Overview

Problem

Hybrid magnets comprising hard-magnetic and soft-magnetic materials integrated into a plastic matrix often suffer from limited magnetic properties, temperature stability, and mechanical strength, and are susceptible to media that can attack the plastic material.

Innovation Solution

A method involving the creation of layered hybrid magnets with alternating hard-magnetic and soft-magnetic layers separated by magnetically passive layers, where each layer sequence is formed using a specific coating technology and sintered at a temperature that maintains the integrity of the magnetic materials, preventing sintering of the hard and soft magnetic materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If hard-magnetic and soft-magnetic materials are integrated into a plastic matrix, then the hybrid magnet can be manufactured with complex shapes, but the magnetic properties are less pronounced and temperature stability is limited

Engineering Contradiction:

Improveability to produce complex shapesVSAvoidmagnetic properties and temperature stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses a composite structure combining hard-magnetic and soft-magnetic metal layers without plastic binder, creating a metal-based hybrid magnet that maintains both complex shape capability and superior magnetic properties with enhanced temperature stability

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The magnet is divided into alternating layers of hard-magnetic material (for coercivity) and soft-magnetic material (for saturation magnetization), with each layer contributing specific magnetic properties to achieve overall optimized performance

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If hard-magnetic and soft-magnetic materials are integrated into a plastic matrix, then the hybrid magnet can be manufactured with complex shapes, but mechanical strength is limited

Engineering Contradiction:

Improveability to produce complex shapesVSAvoidmechanical strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent replaces the plastic matrix with a metal-based composite structure consisting of alternating hard-magnetic and soft-magnetic layers, eliminating the weakness of plastic materials while maintaining the ability to produce complex shapes through powder metallurgy processes

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If hard-magnetic and soft-magnetic materials are integrated into a plastic matrix, then the hybrid magnet can be manufactured, but it cannot be exposed to media that could attack the plastic material

Engineering Contradiction:

Improvemanufacturability of hybrid magnetVSAvoidsusceptibility to media attack

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent creates a metal-based hybrid magnet composite without organic plastic components, making the material resistant to chemical attack from media such as water, moisture, and other environments that would degrade plastic materials

Inventive Principle:

Principle #40Composite materials

4Device complexity

If soft-magnetic layers are placed adjacent to hard-magnetic layers without separation, then the structure is simplified, but eddy currents increase and magnetic properties are compromised

Engineering Contradiction:

Improvelayer structure simplicityVSAvoidmagnetic properties

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent introduces non-magnetic separating layers at specific locations between hard-magnetic and soft-magnetic layers where eddy currents would form, locally preventing harmful electrical conductivity while maintaining the overall layered structure and magnetic functionality

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

This approach enhances the magnetic, mechanical, and thermal properties of the hybrid magnets by combining the high remanent magnetization of hard-magnetic materials with the high saturation magnetization of soft-magnetic materials, while minimizing eddy currents and maintaining magnetic properties.

Implementation Method 1

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Implementation Method 2

A method for producing a hybrid magnet comprises at least the following method steps: A) creating a hard-magnetic layer from a hard-magnetic material, B) creating a soft-magnetic layer from a soft-magnetic material, and C) creating a separating layer from a magnetically passive material, with a hybrid magnet being produced by repeatedly applying process steps A), B) and C).

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentEP3414768B1Hybrid magnet and method for the production thereof

Publication Date: 2020.04.15 VOLKSWAGEN AG

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Figure 5~6

AI summary

The invention relates to a method for producing a hybrid magnet (1), comprising at least the following method steps: A) producing a hard magnetic layer (13) of a hard magnetic material (5), B) producing a soft magnetic layer (14) of a soft magnetic material (6), and C) producing a separating layer (15) of a magnetically passive material (7), wherein a hybrid magnet (1) having a layer structure is formed by in each case multiple application of the method steps A), B) and C).