Magnetic Materials Additive Manufacturing System High Resolution
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Solution Overview
Problem
Conventional methods for forming small magnetic devices are limited by low resolution, complexity, and high costs, particularly when dealing with non-conductive ceramic permanent magnets or ferrite materials, and require complex multi-layer growth processes.
Innovation Solution
A magnetic materials additive manufacturing system (MMAMS) that uses a controller and dispensers to form compact magnetic structures with high resolution patterns, integrating with other systems to create complex electronic devices quickly and inexpensively, by dispensing magnetic material matrices in three-dimensional shapes using additive manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional lithography and embossing processes are used, then magnetic devices can be formed with relatively simple processes, but the minimum resolution is limited to approximately 40-60 um and complex multi-layer growth processes are required
Solution Approach 1:
The patent replaces conventional mechanical lithography and embossing processes with a magnetic field-based additive manufacturing system. The system uses a moving magnet assembly that generates time-varying magnetic fields to selectively cure photopolymer resin in a liquid state, allowing direct writing of three-dimensional magnetic structures with resolutions of 10-20 micrometers without requiring complex multi-layer growth processes
Solution Approach 2:
The patent changes the state of the magnetic material from solid (conventional lithography) to liquid photopolymer resin that can be selectively cured. By maintaining the resin in a liquid state during patterning and using magnetic field-induced curing, the system achieves higher resolution (10-20 um vs. 40-60 um) and eliminates the need for complex multi-layer processing
2Manufacturing precision
If electroforming is used, then high resolution of 10's of nanometers can be achieved, but the technique cannot be used with non-conductive ceramic permanent magnets or ferrite materials
Solution Approach 1:
The patent changes the material state from solid ceramic/ferrite (incompatible with electroforming) to liquid photopolymer resin containing magnetic particles. This liquid state allows the material to be deposited and patterned using magnetic field-induced curing, enabling compatibility with ceramic permanent magnets and ferrite materials while achieving 10-20 micrometer resolution
Solution Approach 2:
The patent introduces photopolymer resin as an intermediary medium that contains magnetic particles. This resin acts as a carrier that enables the formation of non-conductive magnetic materials (ceramics and ferrites) through light-induced curing, bypassing the conductivity requirement of electroforming while maintaining high resolution capability
3Productivity
If conventional methods are used to form compact magnetic devices, then devices can be manufactured, but the process takes relatively more time and costs more
Solution Approach 1:
The patent replaces time-consuming conventional manufacturing steps with a direct-write magnetic field-based system. The moving magnet assembly can be rapidly repositioned to deposit magnetic material layer by layer, achieving 10-20 micrometer resolution while reducing overall manufacturing time compared to sequential lithography, electroforming, and assembly 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
Enables the creation of compact magnetic devices with reliable dimension resolutions of approximately 10 to 20 um, maintaining significant magnetic properties, allowing for complex and compact three-dimensional magnetic fields, which can be integrated into electronic devices for improved performance.
Implementation Method 1
the at least one ferromagnetic matrix is configured to provide a poling field to the ferrite matrix to modify an electromagnetic propagation characteristic of the signal while it propagates between the signal source and the signal sink
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
Techniques are disclosed for systems and methods to provide a magnetic materials additive manufacturing system (MMAMS) configured to form compact magnetic structures and/or devices. A MMAMS includes a controller and one or more dispensers configured to dispense magnetic material matrix in a high resolution pattern in order to form the compact magnetic structures and/or devices. The MMAMS receives a magnetic device design including a magnetic structure to be formed from a magnetic material matrix, where the magnetic material matrix is configured to be used in the MMAMS. The MMAMS receives magnetic material matrix and dispenses the magnetic material matrix to form the magnetic structure.