Magnet Extrusion With In-Flow Particle Orientation Control
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Solution Overview
Problem
Existing magnet manufacturing devices have limited flexibility in shaping and magnetization direction, restricting the design of magnetic circuits for applications like electric motors, due to separate orienting and magnetizing processes and limited freedom in forming arbitrary shapes and magnetization orientations.
Innovation Solution
A magnet manufacturing device that includes a heater for melting a mixture of magnetic particles and resin, a tubular nozzle with a discharge port for forming filaments, and a magnetic field applicator to orient and magnetize particles simultaneously, allowing for arbitrary shaping and magnetization direction control through movable nozzle and stage configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate orienting and magnetizing processes are used, then the manufacturing process is simple and reliable, but the flexibility in shaping and magnetization direction is limited
Solution Approach 1:
The patent combines the orienting and magnetizing functions into a single integrated magnetic field applicator. This allows magnetic particles to be oriented and magnetized simultaneously in one process step, enabling arbitrary shaping and magnetization direction control without requiring separate processing stages, thus resolving the contradiction between process simplicity and design flexibility.
Solution Approach 2:
The patent employs a movable nozzle and stage configuration that allows dynamic adjustment of the discharge port position and orientation. This dynamic capability enables the system to achieve arbitrary shapes and magnetization directions by moving the discharge port to different positions and angles during the extrusion process, thereby improving adaptability while maintaining a relatively simple integrated device structure.
2Adaptability or versatility
If a fixed nozzle and stage configuration is used, then the device structure is simple, but the ability to form arbitrary shapes and magnetization orientations is restricted
Solution Approach 1:
The patent implements a movable nozzle and stage configuration where the discharge port can be positioned at arbitrary locations and orientations. This dynamic positioning capability allows the system to form magnets with arbitrary shapes and magnetization directions by adjusting the discharge port position during extrusion, resolving the contradiction between structural simplicity and shaping flexibility.
Solution Approach 2:
The integrated magnetic field applicator serves multiple functions simultaneously: it orients magnetic particles, magnetizes them, and works in conjunction with the movable nozzle to enable arbitrary shaping. This multi-functionality allows a single device configuration to handle various magnet shapes and orientations without requiring complex separate systems for each function.
3Productivity
If magnetic particles are oriented and magnetized in separate steps, then each process can be optimized independently, but the overall manufacturing efficiency is reduced
Solution Approach 1:
The patent combines orientation and magnetization into a single simultaneous process using an integrated magnetic field applicator. This eliminates the need for separate processing steps, thereby improving manufacturing efficiency without sacrificing control precision, as both functions are performed together in one coordinated action during the extrusion process.
Solution Approach 2:
The patent enables continuous orientation and magnetization of magnetic particles as they are being extruded through the movable nozzle. This continuous simultaneous action eliminates idle time between separate orientation and magnetization steps, improving overall manufacturing efficiency while maintaining precise control through the integrated magnetic field system.
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 magnets with arbitrary shapes and magnetization directions, enhancing the design flexibility of magnetic circuits and improving the orientation and magnetization efficiency of magnetic particles, thus optimizing magnetic circuit performance.
Implementation Method 1
a heater that is configured to heat a mixture of magnetic particles and a resin material to melt the resin material
Implementation Method 2
a magnetic field applicator that is configured to apply a magnetic field, which is directed in the axial direction, to the internal flow passage, wherein the magnetic field has a magnitude that is sufficient to orient each of the magnetic particles in a direction along an axis of easy magnetization of the magnetic particle and to magnetize each of the magnetic particles
Data Source
AI summary
A magnet manufacturing device includes a heater, a nozzle, a magnetic field application magnet and a stage. The heater heats a mixture of magnetic particles and a resin material. The nozzle has an internal flow passage that conducts the mixture while the resin material is molten. The nozzle has a discharge port which discharges the mixture and thereby forms each of a plurality of filaments. The magnetic field application magnet applies a magnetic field to the internal flow passage. The stage has a stage surface on which the plurality of filaments are placed. The discharge port is relatively movable with respect to the stage surface such that the plurality of filaments are stacked to form an arbitrary shape.