Radially Anisotropic Multipolar Magnet Production Without Mold Core
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Solution Overview
Problem
The existing methods for producing radially anisotropic multipolar magnets are limited in manufacturing magnets with an inner diameter less than 3 mm, which is a challenge for high-precision micro-motors, as they require small-sized, lightweight, and energy-saving permanent magnetic components.
Innovation Solution
A novel method that removes the mold core and arranges oriented poles outside the mold, with the sum of their widths or arc lengths greater than 0.7πD, allowing for the production of radially anisotropic multipolar solid cylindrical magnets with any arbitrarily small inner diameter, using a series of magnetic fields and stress applications to align and demagnetize magnetic particles within a mold without rotating them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mold core is used in existing production methods, then radially anisotropic multipolar magnetic rings can be produced, but the inner diameter cannot be less than 15 mm
Solution Approach 1:
The patent removes the mold core from the production system entirely. Instead of using a central mold core that limits the minimum inner diameter to 15 mm, the invention extracts this limiting component and replaces it with oriented poles arranged outside the mold, enabling production of magnets with arbitrarily small inner diameters including those less than 3 mm
Solution Approach 2:
The invention changes the spatial arrangement from a central mold core configuration to an external oriented poles configuration. By moving the orientation function from the internal central axis to external poles arranged around the mold periphery, the system achieves freedom in inner diameter design while maintaining radial anisotropy and multipolar characteristics
2Reliability
If the sum of widths of oriented poles is less than 0.7πD, then the magnetic field distribution is insufficient, but if it is greater than 0.7πD, then the device complexity increases
Solution Approach 1:
The patent establishes a quantitative parameter threshold (sum of oriented pole widths ≥ 0.7πD) that optimizes the balance between magnetic field distribution quality and device complexity. This parameter change provides a clear design criterion that ensures reliable magnetic field generation while controlling the complexity of the oriented poles arrangement
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
Enables the mass production of high-precision radially anisotropic multipolar magnets with small diameters, suitable for micro-motors, offering improved magnetic performance, reduced energy consumption, and cost-effectiveness, breaking through the dimensional limitations of previous technologies.
Implementation Method 1
arranged outside a mold; and the sum L of widths or arc lengths of outer oriented poles is set to be greater than 0.7πD... applying a first magnetic field to fully magnetize the magnetic particles in the mold cavity
Implementation Method 2
magnetic particles are oriented by moving the magnetic particles but keeping the magnetic field unmoved, the magnetic particles are surface-scanned by converging the front end of the magnetic field
Implementation Method 3
applying an increased stress to the magnetic particles in the mold cavity by both the upper and lower rams and maintaining this stress for a certain period of time to obtain a blank
Data Source
AI summary
The present disclosure provides a molding method, a manufacturing method and a molding device for a radially anisotropic multipolar solid magnet, a micro-motor rotor using this magnet, and a component for a motor. A mold core is removed from a mold, and oriented poles, the number of which is the same as that of poles of a radially anisotropic multipolar solid cylindrical magnet, are arranged outside the mold. The sum L of widths or arc lengths of top ends of all the oriented poles is greater than or equal to 0.9πD, where D is the outer diameter of a mold sleeve. The magnet production method breaks through the dimensional restriction to the manufacturing of radially anisotropic multipolar magnets in the prior art, and can produce radially anisotropic multipolar magnets having an inner diameter or diameter less than 3 mm or even less for high-precision micro-motors.