3D-Printed Permanent Magnet Framework With Infiltration Strength
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Solution Overview
Problem
Conventional methods for manufacturing permanent magnets, such as rare earth magnets, face challenges in achieving optimal magnetic properties and mechanical strength due to limitations in material diffusion and structural design.
Innovation Solution
The development of a permanent magnet comprising a rare earth magnetic framework with a stratified layer structure, created via additive manufacturing, and an infiltrate disposed within the framework's venous system, which enhances magnetic and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used for permanent magnets, then material diffusion and structural design are limited, but achieving optimal magnetic properties and mechanical strength becomes difficult
Solution Approach 1:
The patent employs a porous framework structure created through additive manufacturing, which allows controlled infiltration of magnetic materials. The porous structure enables better material distribution and diffusion compared to conventional methods, while maintaining structural integrity and optimizing magnetic properties through the designed pore architecture.
Solution Approach 2:
The invention utilizes composite material architecture consisting of a framework and infiltrate material. This composite approach combines the structural benefits of the framework with the magnetic properties of the infiltrate, achieving optimal magnetic performance and mechanical strength that cannot be obtained with single materials alone.
2Strength
If additive manufacturing with infiltrate is used, then magnetic performance and mechanical strength are improved, but process complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct stages: framework fabrication through additive manufacturing, followed by separate infiltrate introduction. This segmentation allows each stage to be optimized independently, managing overall process complexity while achieving superior mechanical strength through the combined structure.
Solution Approach 2:
The framework is fabricated in advance with predetermined porous architecture before infiltrate introduction. This preliminary action enables precise control of the framework structure and simplifies the subsequent infiltration process, as the pathways are already established, reducing overall process complexity despite the multi-step nature of the method.
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 results in a magnet with improved magnetic performance and mechanical strength, as well as reduced defects such as brittleness and cracking, by allowing for controlled infiltration and optimized structural design.
Implementation Method 1
The infiltrate may be heated, melted, or sintered prior to, during, or after disposing it in the framework
Implementation Method 2
The infiltrate may be heated, melted, or sintered prior to, during, or after disposing it in the framework
Implementation Method 3
The infiltrate may be heated, melted, or sintered prior to, during, or after disposing it in the framework
Data Source
AI summary
Permanent magnets and methods of making the same are disclosed herein. The permanent magnets include a 3D-printed, i.e., additively manufactured, framework and an infiltrate such that there is a discrete magnetic phase and a discrete non-magnetic phase or two discrete magnetic phases. The infiltrate may provide superior strength, elasticity or magnetic properties.