Monolithic Multi-Polarity Magnet Fabrication via Localized Heating
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Solution Overview
Problem
Existing methods for forming multi-pole magnets are time-consuming, expensive, and inefficient, particularly when using multiple magnets or electromagnets, which require high voltage and current, leading to material wastage and potential safety hazards.
Innovation Solution
A method involving a monolithic substrate where a first magnetic field is applied to impart polarity in one direction, and a second magnetic field is applied after altering the substrate's coercivity by heating, allowing for multiple polarity directions without the need for extensive cutting or high electrical currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If several individual magnets are aligned together to form a magnetic assembly, then multiple magnetic polarities are achieved, but the process becomes time consuming and expensive
Solution Approach 1:
The patent merges multiple magnetic polarities into a single monolithic magnet rather than using separate magnets. The method applies different magnetic fields to different zones of one substrate, creating multiple polarities in a unified structure, which eliminates the time-consuming alignment process while maintaining versatility.
Solution Approach 2:
The patent segments the magnetic substrate into multiple zones that can be independently magnetized in different directions. By applying localized magnetic fields to specific zones of the monolithic substrate, multiple polarities are achieved without physically separating the magnet into multiple pieces.
2Ease of manufacture
If magnets made from relatively hard materials are cut, then individual magnets are obtained, but a high end blade is required which erodes much of the substrate
Solution Approach 1:
The patent applies preliminary magnetic treatment to the monolithic substrate before any cutting operation. By pre-magnetizing the substrate in different zones, the need for extensive cutting is reduced, and when cutting is necessary, less substrate erosion occurs because the magnetic properties are already established.
Solution Approach 2:
The patent changes the magnetic parameters of the substrate by applying different magnetic field strengths and directions to different zones. This allows the creation of multiple polarities within a single substrate, reducing or eliminating the need for cutting hard magnetic materials and thereby minimizing substrate erosion.
3Adaptability or versatility
If an electromagnet is used to apply a magnetic field to a substrate, then magnetic polarity is achieved, but a relatively high amount of voltage and current is required
Solution Approach 1:
The patent applies local quality by using different magnetic field strengths for different zones of the substrate. Rather than applying a uniform high-strength field to the entire substrate, localized fields are applied only where needed, reducing the overall energy requirements while still achieving the desired magnetic polarity distribution.
Solution Approach 2:
The patent uses partial action by applying magnetic fields only to the specific zones that require magnetization, rather than treating the entire substrate uniformly. This selective approach reduces the total energy input required compared to using a high-power electromagnet that would need to saturate the entire material.
4Power
If high voltage and current are used in electromagnets, then magnetic field is achieved, but costs increase and safety hazards are created
Solution Approach 1:
The patent changes the magnetic field parameters by applying different field strengths to different zones rather than using uniformly high power. This allows achieving the necessary magnetic field strength for each zone's requirements while minimizing overall power consumption and associated safety hazards.
Solution Approach 2:
The patent replaces the high-power electromagnet system with a method that uses permanent magnets or lower-power magnetic field sources applied selectively to different zones. This substitution reduces the voltage and current requirements, thereby lowering costs and eliminating safety hazards associated with high-power electrical systems.
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 approach enables the efficient formation of multi-polarity magnets with reduced material loss and energy consumption, while maintaining desired magnetic properties and safety by altering coercivity through temperature changes.
Implementation Method 1
The method may include heating the substrate
Implementation Method 2
applying a first magnetic field to the substrate to impart a magnetic polarity in a first direction to the substrate
Data Source
AI summary
An article having a multiple magnetic polarities and a method for making the article are disclosed. The article can be a monolithic substrate form from a metallic material or materials. The article may include a first magnetic polarity and a second magnetic polarity opposite the first magnetic polarity. Methods for making the article include provide either providing a monolithic substrate having a first magnetic polarity, or applying a first magnetic field to the monolithic substrate to impart a first magnetic polarity. The method may also include raising the temperature of the monolithic substrate in order to reduce the coercivity of the monolithic substrate. The temperature of the monolithic substrate may also be selectively raised to lower the coercivity of the monolithic substrate in associated areas. By lowering the coercivity, the second magnetic polarity may be imparted on the monolithic substrate.