Permanent Magnet Bonding With Single-Cycle Curie Heating
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Solution Overview
Problem
The existing permanent magnet manufacturing method requires two thermal curing steps, which are time-consuming and hinder work efficiency.
Innovation Solution
A method that involves molding a magnetization target by applying pressure to magnet powder and a thermosetting resin, and then heating the magnet powder to its Curie point or higher while bringing permanent magnets close to the target, thereby magnetizing the powder and curing the resin to fix the target to a base member without using an adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two sessions of thermal curing step are used to manufacture permanent magnet, then the permanent magnet can be manufactured with adhesive bonding, but the work efficiency deteriorates due to time-consuming process
Solution Approach 1:
The patent merges the thermal curing step and the adhesive bonding step into a single integrated process. The thermosetting resin is cured at the same time the permanent magnet is bonded to the holder, eliminating the need for separate curing and bonding operations. This combines two previously separate thermal processes into one unified operation, directly resolving the contradiction between reliable bonding and work efficiency.
Solution Approach 2:
The thermosetting resin serves multiple functions simultaneously: it acts as both the bonding adhesive and the curing agent. By using a material that can perform both bonding and thermal curing functions in one step, the patent eliminates the need for separate adhesive application and curing processes, thereby improving productivity while maintaining bonding reliability.
2Reliability
If two sessions of thermal curing step are performed, then the permanent magnet can be properly bonded, but the thermal history increases leading to potential material degradation
Solution Approach 1:
The patent combines multiple thermal exposure events into a single thermal cycle. Instead of subjecting the permanent magnet to thermal curing twice (once for the magnet itself and once for the adhesive bonding), the process now performs both functions in one thermal exposure, thereby reducing the cumulative thermal history and potential material degradation while maintaining bonding reliability.
Solution Approach 2:
The thermal curing action is performed continuously in a single uninterrupted cycle that simultaneously cures the thermosetting resin and bonds the permanent magnet. This eliminates the interruption and repeated thermal exposure that would occur with separate curing steps, reducing overall thermal history while ensuring reliable bonding through continuous effective thermal action.
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 improves work efficiency by eliminating the need for multiple thermal curing steps and reduces thermal history, allowing the magnetization target to be fixedly adhered to the base member using only the cured thermosetting resin.
Implementation Method 1
heating the magnet powder to the Curie point or higher while permanent magnets of a field magnet part are brought close to the magnetization target placed at a base member to magnetize the magnet powder
Implementation Method 2
melting and curing the thermosetting resin to allow the magnetization target to fixedly adhere to the base member
Implementation Method 3
permanent magnets of a field magnet part are brought close to the magnetization target placed at a base member to magnetize the magnet powder
Data Source
AI summary
A permanent magnet manufacturing method includes at least a magnetization target forming step of molding a magnetization target by applying a predetermined pressure to a magnet powder and a thermosetting resin, and a heating step of heating the magnet powder to the Curie point or higher while permanent magnets of a field magnet part are brought close to the magnetization target placed on a base member to magnetize the magnet powder and melting and curing the thermosetting resin to allow the magnetization target to fixedly adhere to the base member.