Sintered Raw Magnet Assembly for Complex Magnetization Shapes
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Solution Overview
Problem
Existing methods for producing permanent magnets, particularly neodymium-iron-boron magnets, are limited to simple shapes and magnetizations, and complex shapes and magnetizations are cumbersome, risky, and difficult to fix within assemblies due to magnet attraction and brittleness, leading to inefficiencies and safety hazards.
Innovation Solution
A method involving the production of raw magnet shapes in external magnetic fields, aligning magnetic particles to create complex shapes and magnetizations, followed by sintering to form a metallurgical bond, using various magnetic starting materials and binders to achieve tailored magnet properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple magnetized magnets are joined together to create complex shapes, then complex magnet shapes and magnetizations are achievable, but the process becomes very cumbersome and time-consuming due to mutual attraction
Solution Approach 1:
The patent applies preliminary action by producing raw shapes with pre-aligned magnetic particles in an external magnetic field before final assembly. This pre-alignment during raw shape production eliminates the need for time-consuming post-assembly magnetization and reduces handling operations, directly addressing the productivity issue while maintaining the capability to create complex shapes.
Solution Approach 2:
The patent merges multiple raw shapes into a single integrated magnet through sintering, combining what would otherwise require multiple separate assembly operations. This merging approach eliminates mutual attraction issues during assembly and reduces the overall number of handling steps, resolving both the complexity and time consumption problems.
2Adaptability or versatility
If multiple magnets are joined together to create complex shapes, then complex magnetizations are achievable, but magnets can be damaged and workers can be injured by uncontrollable collisions
Solution Approach 1:
The patent performs magnetic particle alignment during raw shape production in a controlled external magnetic field, rather than after assembly. This preliminary action eliminates unpredictable magnetic attraction forces during handling and assembly operations, preventing uncontrolled collisions and improving both safety and reliability.
Solution Approach 2:
The patent extracts the magnetization process from the final assembly stage and integrates it into the raw shape production stage. By taking out the dangerous post-assembly magnetization step and replacing it with controlled field application during manufacturing, the hazard of uncontrolled magnetic attraction is eliminated.
3Ease of manufacture
If simple press sintering is used to produce magnets, then production is simple, but threads and bores cannot be produced and mechanical fixing is not possible
Solution Approach 1:
The patent segments the magnet production process into raw shape formation and final sintering stages, allowing complex geometries including threads and bores to be formed in the raw shape before sintering. This segmentation enables features that would be difficult or impossible to create through traditional press sintering alone, while maintaining process simplicity.
Solution Approach 2:
The patent performs preliminary shaping of raw forms with complex geometries including threads and bores before sintering. This preliminary action creates magnet shapes that are directly suitable for mechanical assembly without requiring post-sintering machining, thereby expanding assembly options while keeping the manufacturing process simple.
4Adaptability or versatility
If magnets are glued or encapsulated with resin to fix them in assemblies, then mechanical fixing is possible, but assembly becomes very complex and corrosion can occur
Solution Approach 1:
The patent segments the magnet into multiple raw shapes that can be directly mechanically assembled through features like threads and bores formed during raw shape production. This eliminates the need for additional gluing or encapsulation layers, reducing assembly complexity while maintaining fixing capability.
Solution Approach 2:
The patent replaces chemical fixing methods (gluing, resin encapsulation) with direct mechanical connections through integrated threads and bores. This substitution eliminates corrosion risks associated with adhesives and resins while simplifying the assembly process.
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 production of permanent magnets with complex shapes and magnetizations, reducing post-processing needs and avoiding assembly complexities, while ensuring safe and efficient resource utilization.
Implementation Method 1
an external magnetic field is applied to at least one raw shape, selected from a group consisting of the first and second raw shapes, during its production. Alternatively or additionally, an external magnetic field is applied to the at least one raw shape after its production
Implementation Method 2
dipoles of the magnetic starting material are aligned in a parallel orientation by means of the externally applied magnetic field during and/or after the production of the at least one raw form
Implementation Method 3
The third raw shape is then sintered, yielding the raw magnet. Advantageously, the sintering of the third raw shape advantageously creates a metallurgical bond between the first and second raw shapes
Data Source
Figure 1~3
Figure 4a~5b
AI summary
The invention relates to a method for producing a raw magnet (4), wherein - a first raw shape (2.1) is produced from a first magnetic starting material (1.1), - a second raw shape (2.2) is produced from a second magnetic starting material (1.2), - an external magnetic field (21) is applied to at least one raw shape (2), selected from a group consisting of the first raw shape (2.1) and the second raw shape (2.2), during and/or after the raw shape (2) is produced, - a third raw shape (3) is produced from the first raw shape (2.1) and the second raw shape (2.2) by means of joining said raw shapes to one another, - the third raw shape (3) is sintered, and the raw magnet (4) is obtained.