NdFeB Magnet Diffusion Bonding with Sheet Stacking for Shape Flexibility
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Solution Overview
Problem
Existing methods for preparing neodymium-iron-boron magnets face challenges such as complexity, safety hazards due to flammable powders, low residual magnetism, limited shape flexibility, and poor performance at high temperatures, as well as inefficiencies and difficulties in producing special shapes.
Innovation Solution
A method involving the preparation of FeaGb metal sheets coated with a rare earth compound RexMyBz, stacked and subjected to high-temperature diffusion under vacuum to form neodymium-iron-boron magnets, allowing for various shapes and improved magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sintering method is used to prepare neodymium-iron-boron magnet, then magnetic performance is improved, but production complexity increases and safety hazards occur due to flammable micron-sized powder
Solution Approach 1:
The invention changes the physical state parameter of the raw material from micron-sized powder to metal sheets, fundamentally altering the processing parameters and eliminating the need for complex sintering procedures while maintaining magnetic performance
Solution Approach 2:
The invention converts the harmful flammability of micron-sized powder into a benefit by completely avoiding powder usage, thereby eliminating safety hazards while maintaining production efficiency
2Reliability
If sintering method is used to prepare special-shaped neodymium-iron-boron product, then magnetic performance is achieved, but shape flexibility decreases and material waste increases
Solution Approach 1:
The invention segments the magnet into thin sheet layers that can be stacked in various configurations, enabling flexible shape design while maintaining magnetic performance through controlled diffusion bonding between layers
Solution Approach 2:
The invention transitions from three-dimensional bulk material processing to two-dimensional sheet stacking, adding dimensional flexibility and enabling complex shapes to be constructed from simple planar elements
3Ease of manufacture
If bonded neodymium-iron-boron magnet is prepared using organic binders, then shape flexibility and ease of manufacture are improved, but density decreases and high-temperature performance deteriorates
Solution Approach 1:
The invention extracts and removes the organic binder component from the magnetic material system, achieving high-temperature performance by using only metal sheets and rare earth compounds that can withstand elevated temperatures
Solution Approach 2:
The invention creates a composite structure of metal sheets with rare earth compound coatings, combining the advantages of both materials to achieve ease of manufacture through stacking while maintaining high density and high-temperature stability
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 method enhances safety by avoiding flammable powders, increases residual magnetism by omitting organic binders, and enables efficient production of magnets with adjustable magnetic properties and temperature resistance.
Implementation Method 1
performing high-temperature diffusion on the metal sheets under a vacuum condition
Implementation Method 2
performing high-temperature diffusion on the metal sheets under a vacuum condition
Implementation Method 3
performing high-temperature diffusion on the metal sheets under a vacuum condition
Data Source
AI summary
Provided is a neodymium-iron-boron magnet and preparation method thereof. The preparation method includes the following steps: preparing a FeaGb metal sheet, covering the FeaGb metal sheet with a rare earth compound RexMyBz layer, performing multi-layer stacking on the metal sheet covered with the rare earth compound RexMyBz layer, and then performing high-temperature diffusion under an extrusion force with certain strength, so as to prepare a neodymium-iron-boron magnet.