Injection-Molded Magnet Module Assembly with Post-Magnetization
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Solution Overview
Problem
The existing methods for manufacturing magnet modules for linear motors are cumbersome and inefficient, particularly due to the strong magnetic forces that make it difficult to assemble and maintain the modules without adhesive issues and exposure of magnets.
Innovation Solution
A magnet module manufactured using an injection molding method, comprising a frame and a base with alternately arranged permanent magnets, where the magnets are initially non-magnetized and then magnetized post-assembly, and optionally includes a metal plate to prevent bending and enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If permanent magnets are directly assembled into the frame by inserting them into pre-formed openings, then the magnetic module can be assembled, but the strong magnetic force causes magnets to stick together making separation difficult and requiring cumbersome individual magnetization direction checking
Solution Approach 1:
The patent applies preliminary action by forming the openings in the frame before inserting the permanent magnets. This allows the magnetic modules to be pre-assembled with correct magnetization directions verified before final assembly, avoiding the need to separate stuck magnets during assembly. The openings are created through injection molding or other forming methods prior to magnet insertion, enabling efficient assembly without the magnets sticking together during the process.
2Strength
If adhesive is applied to the inside of the opening or rim of the permanent magnet to fix the magnet, then the magnet can be bonded, but the adhesive comes out making the assembled magnetic module appearance rough
Solution Approach 1:
The patent extracts the adhesive from the visible assembly areas by applying it only to specific internal surfaces where it will not be exposed. The adhesive is applied to the inner walls of the openings or to specific non-visible portions of the magnet rims, ensuring strong bonding while preventing adhesive extrusion that would ruin the aesthetic appearance of the assembled magnetic module.
Solution Approach 2:
The patent applies local quality by using adhesive only in specific localized areas where bonding is required, rather than coating entire surfaces. The adhesive is applied selectively to the inner walls of openings or specific portions of magnet contact surfaces, providing sufficient bonding strength while maintaining smooth external surfaces without adhesive exposure.
3Reliability
If multiple work processes are involved in assembling the magnet module including individual magnetization direction checking and adhesive application, then the magnets can be securely fixed, but the process becomes cumbersome and work efficiency decreases
Solution Approach 1:
The patent merges multiple separate work processes into a streamlined assembly operation. By pre-forming openings in the frame and pre-verifying magnetization directions before assembly, the patent combines magnet insertion, positioning, and fixation into a more efficient process. The openings are designed to guide magnet placement, reducing the need for separate alignment and adjustment steps while maintaining reliable fixation.
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 proposed method simplifies the manufacturing process, increases efficiency, prevents magnetic flux leakage, and ensures the magnets remain securely embedded within the module, reducing the risk of damage and separation.
Implementation Method 1
an injection molded frame to fix the plurality of permanent magnets; and an injection molded base in which a plurality of base holes are formed
Data Source
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AI summary
A method for manufacturing a magnet module. The method may comprise injecting a magnet module including a plurality of magnetless magnets arranged in a straight line; and magnetizing the plurality of magnetless magnets mounted on the injected magnet module. The injecting of a magnet module may comprise: mounting the plurality of magnetless magnets to a first part forming a frame of the magnet module in a mold frame comprising first and second mold frames molded inside to fit an external shape of the magnet module; injecting a resin in a liquid state into the mold frame; and separating the mold frame when the resin is hardened. The injecting of a magnet module may further comprise mounting a metal plate to a second part forming a base of the magnet module in the mod frame, before performing the step of injecting a resin in a liquid state into the mold frame. Fins for fixing the plurality of magnetless magnets may be protruded in at least one of the first and second mold frames.