NdFeB Magnet Sheet Stacking for Binderless Shaped Magnets
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Solution Overview
Problem
Existing methods for producing neodymium-iron-boron magnets face challenges such as complexity, safety hazards due to flammable powders, difficulty in shaping, low density and magnetic performance due to organic binders, and poor performance uniformity and efficiency.
Innovation Solution
A method involving the preparation of a Fe a G b metal sheet coated with a rare earth compound RE x M y B z , followed by stacking and 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 can be improved, but the process becomes complex and safety hazards increase 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 thin sheets, fundamentally altering the processing parameters and eliminating the need for complex sintering processes while maintaining magnetic performance
Solution Approach 2:
The invention extracts and eliminates the problematic micron-sized powder preparation step from the process, replacing it with a safer sheet-based approach that removes the safety hazard while simplifying the overall process
2Reliability
If sintering method is used to prepare special-shaped neodymium-iron-boron product, then magnetic performance is maintained, but difficulty in shaping increases and waste is created
Solution Approach 1:
The invention segments the manufacturing process into modular thin sheets that can be easily stacked and arranged in various configurations, enabling simple shaping of special-shaped products without complex machining
Solution Approach 2:
The invention transitions from three-dimensional powder compaction to two-dimensional sheet stacking, adding the dimension of layer arrangement that enables easy creation of complex shapes through simple stacking patterns
3Device complexity
If bonded neodymium-iron-boron magnet is prepared, then process simplicity and safety are improved, but density and magnetic performance decrease due to organic binders
Solution Approach 1:
The invention extracts and removes the organic binder component from the magnetic material system, achieving binderless magnets that eliminate the performance limitations while maintaining process simplicity
Solution Approach 2:
The invention creates a composite structure of multiple thin sheets with different compositions (Fe-Gb metal sheets and rare earth compound coatings) that achieves high performance without organic binders
4Adaptability or versatility
If bonded neodymium-iron-boron magnet is prepared, then various shapes and sizes can be manufactured, but residual magnetism and mechanical property decrease due to organic binders
Solution Approach 1:
The invention removes the organic binder that limits residual magnetism and mechanical properties, achieving binderless construction that maintains both shape versatility and high magnetic performance
Solution Approach 2:
The invention uses composite thin sheet structure with rare earth compound coatings that provides both shape adaptability and high residual magnetism without organic binders
5Device complexity
If bonded neodymium-iron-boron magnet is prepared, then production process is simple, but the magnet cannot operate at high temperature due to organic binders
Solution Approach 1:
The invention extracts and eliminates the organic binder that limits thermal stability, enabling the magnet to operate at high temperatures while keeping the manufacturing process simple
Solution Approach 2:
The invention creates a binderless composite structure of metal sheets and rare earth compounds that inherently withstands high temperatures without organic binder degradation
6Reliability
If hot pressing method is used to prepare neodymium-iron-boron magnet, then magnetic performance can be achieved, but productivity decreases and performance uniformity becomes poor
Solution Approach 1:
The invention segments the material into pre-fabricated thin sheets with controlled compositions, eliminating the need for slow hot pressing and enabling rapid assembly that improves productivity while maintaining performance uniformity
Solution Approach 2:
The invention performs preliminary preparation of thin sheets with precise compositions and coatings before assembly, eliminating the need for prolonged hot pressing and diffusion processes while ensuring uniform performance
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 method enhances safety by avoiding flammable powders, increases magnetic performance by eliminating organic binders, and enables efficient production of magnets with gradient magnetic properties and diverse shapes.
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
Data Source
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Figure 3~4
Figure 5
AI summary
Provided is a neodymium-iron-boron magnet and preparation method thereof. It relates to the technical field of magnet preparation. The preparation method includes the following steps: preparing a FeaGb metal sheet (1), covering the FeaGb metal sheet with a rare earth compound RExMyBz layer (2), performing multi-layer stacking on the metal sheet (1)covered with the rare earth compound RExMyBz layer (2), and then performing high-temperature diffusion under an extrusion force with certain strength, so as to prepare a neodymium-iron-boron magnet. By using the method to prepare the neodymium-iron-boron magnet, the production process is high in safety, the production process is simple, the product size and shape limitation is small, the production period is short, and the material utilization rate is high.