Magnet Roller Interlocking Pieces for Precise Magnetic Alignment
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Solution Overview
Problem
Conventional magnet rollers face challenges in achieving accurate magnetic properties and shape due to adhesive leakage and misalignment of magnet pieces, which hinder close arrangement and affect magnetic performance.
Innovation Solution
A magnet roller design featuring a first magnet piece with a recessed portion and a second magnet piece with a convex portion that fits into the recessed portion, allowing for adhesive-free bonding and precise alignment, using magnetic powder and resin materials to enhance magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnet pieces are bonded with adhesive, then magnet pieces can be fixed to the shaft, but adhesive leakage and misalignment occur reducing manufacturing precision
Solution Approach 1:
The magnet structure is divided into multiple magnet pieces (first magnet piece and second magnet piece) that are arranged adjacently on the shaft. Each magnet piece is a separate component that can be precisely positioned and bonded independently, allowing for better control of alignment and reduced adhesive leakage issues.
Solution Approach 2:
The magnet pieces are pre-assembled on a base in a predetermined arrangement before being transferred to the shaft. This preliminary assembly allows for precise positioning and alignment to be established before final bonding, ensuring high manufacturing precision while maintaining reliable bonding.
2Manufacturing precision
If magnet pieces are arranged closely to improve magnetic properties, then magnetic performance increases, but alignment difficulty and adhesive leakage increase
Solution Approach 1:
Multiple magnet pieces are pre-assembled on a base in their final predetermined arrangement before being transferred to the shaft as a unit. This preliminary assembly on the base makes it easier to handle and position the entire magnet assembly, reducing the difficulty of manual alignment while achieving close spacing for optimal magnetic properties.
Solution Approach 2:
The base serves as an intermediary platform for assembling and positioning the magnet pieces before final installation on the shaft. The base provides a stable working surface that facilitates precise positioning of multiple magnet pieces in close arrangement, making the assembly process more manageable.
3Strength
If adhesive is used to bond magnet pieces, then bonding is achieved, but adhesive leakage affects magnetic performance
Solution Approach 1:
The bonding process is segmented into multiple stages: preliminary bonding on the base, then transfer and final bonding on the shaft. This segmentation allows for controlled application of adhesive in small amounts at each stage, reducing leakage while maintaining strong bonding. The adhesive is applied locally at bonding interfaces rather than extensively.
Data Source
AI summary
A magnet roller includes a shaft, a first magnet piece, and a second magnet piece. The first magnet piece and the second magnet piece are bonded to an outer circumference of the shaft with an adhesive. The first magnet piece has a first surface and a recessed portion. The recessed portion is recessed with respect to the first surface. The second magnet piece has a second surface and a convex portion. The second surface is held in contact with the first surface. The convex portion protrudes with respect to the second surface. The convex portion fits into the recessed portion.