Magnet Fixturing with Thermal Isolation for Injection Molding
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Solution Overview
Problem
High flux density magnets, such as neodymium (NIB) magnets, suffer serious demagnetization at elevated temperatures, which is a concern during thermally active manufacturing processes like injection molding, where they are exposed to temperatures above their maximum operating temperature, leading to degradation of magnetic properties.
Innovation Solution
A fixturing device with a cooling mechanism and thermal isolation layer is used to maintain the magnetic properties of magnets during thermally active manufacturing processes. The device includes a sensor to monitor the magnetic element's temperature and properties, triggering the cooling mechanism to prevent overheating and a thermal isolation layer to reduce heat transfer from the external environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high flux density magnets are used to provide strong magnetic field in small space, then magnetic strength is improved, but sensitivity to elevated temperatures worsens
Solution Approach 1:
A thermal barrier layer is introduced as an intermediary between the magnetic element and the thermally active manufacturing environment. This layer mediates the thermal interaction by blocking heat transfer from the injection molding process to the magnet, allowing the magnet to maintain its high flux density properties without direct exposure to damaging temperatures.
Solution Approach 2:
The thermal barrier layer is applied in advance to the magnetic element before the thermally active manufacturing process. This preliminary protective action prevents the harmful thermal effects from occurring during subsequent manufacturing operations, eliminating the need for re-magnetization.
2Ease of manufacture
If thermally active manufacturing process is used to embed magnets in consumer products, then ease of manufacture is improved, but magnetic properties deteriorate due to demagnetization
Solution Approach 1:
The thermal barrier layer serves as a protective intermediary that enables the use of thermally active manufacturing processes while preserving magnetic properties. It allows the injection molding process to proceed at high temperatures without transferring those temperatures to the magnetic element, thus maintaining both manufacturing ease and magnetic property integrity.
3Productivity
If magnets are exposed to elevated temperatures during manufacturing, then manufacturing process efficiency is improved, but magnetic strength is lost
Solution Approach 1:
The thermal barrier layer acts as a protective intermediary that decouples the manufacturing process temperature from the magnet temperature. This allows the manufacturing process to operate efficiently at high temperatures while the magnet remains protected at lower temperatures, preserving its magnetic strength.
Solution Approach 2:
The thermal barrier layer provides beforehand cushioning by absorbing and blocking thermal energy before it can reach the magnetic element. This prior protection prevents the demagnetization that would otherwise occur during high-temperature manufacturing processes.
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 solution effectively maintains the magnetic properties of magnets within an acceptable range during thermally active processes, reducing the need for re-magnetization and enabling the use of magnets in consumer products without significant demagnetization.
Implementation Method 1
a cooling mechanism in communication with the sensor and having a transport conduit embedded at least partially within the walls of the fixturing device housing. The cooling mechanism is configured to move coolant medium through the transport conduit and into thermal contact with the magnetic element
Implementation Method 2
A magnetic element can include a thermal isolation layer. The thermal isolation layer can act to increase a thermal resistance between the magnetic element and an external environment
Data Source
AI summary
Methods, systems, and apparatuses for retaining magnetic properties of magnetic elements while undergoing manufacturing processes are presented. In one embodiment, a manufacturing fixture includes a temperature controlled region suitable for retaining a magnetic element. The manufacturing fixture also includes a cooling mechanism configured to maintain the magnetic element at an acceptable temperature range during a thermally active manufacturing process. The temperature controlled or stabilized region can include a structure configured to receive the magnetic element and a sensor, or sensors. In one embodiment, the sensor can be configured to measure an ambient temperature of the temperature stabilized region. In another embodiment, the sensor can be a magnetic sensor configured to determine a magnetic property of the magnetic element.