Vacuum Coating of Small Nd-Fe-B Magnets Using Rotating Roller
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Solution Overview
Problem
Existing methods for coating small Nd—Fe—B magnets are inefficient, prone to corrosion, and pose environmental and health hazards due to the use of acids and chemicals, and require complex furnace structures that are not suitable for vacuum coating.
Innovation Solution
A method and apparatus that utilize a furnace with a rotating roller and stirring pieces to mix small Nd—Fe—B magnets with conductors of specific sizes and weights, creating a simple structure for vacuum coating that minimizes damage to the magnets and uses environmentally friendly processes like arc ion plating or magnetron sputtering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If barrel plating or roll spray coating is used to coat small Nd-Fe—B magnets, then the coating process can be performed, but acid and base damage the magnets and chemicals harm the human body and environment
Solution Approach 1:
The patent employs vacuum coating technology to create an inert vacuum environment during the coating process, eliminating the need for acid, base, and chemical substances. This prevents damage to the Nd-Fe-B magnets while avoiding harm to human body and environment, directly resolving the technical contradiction between coating effectiveness and harmful factors.
Solution Approach 2:
The patent replaces the chemical-based barrel plating and roll spray coating methods with a physical vacuum coating method. This substitution eliminates harmful chemicals from the process while maintaining effective anti-corrosive coating, addressing both the reliability and harmful factors aspects of the contradiction.
2Ease of operation
If common fixture is used to fixate small Nd—Fe—B magnets, then the magnets can be held, but it is difficult to quickly fixate the small magnets
Solution Approach 1:
The patent uses a rotating drum structure where small Nd-Fe-B magnets are placed inside and automatically mixed and coated during rotation. The magnets themselves participate in the coating process through their own movement and interaction within the drum, eliminating the need for complex external fixating mechanisms and reducing preparation time.
Solution Approach 2:
The patent employs a dynamic rotating drum system that continuously moves and tumbles the magnets during coating. This dynamic approach allows magnets to be easily introduced and automatically processed without requiring precise fixation, significantly reducing the time and complexity of magnet handling compared to static fixture methods.
3Reliability
If roller spray coating is used, then coating can be applied, but the structure of the furnace is complex and has specific shape requirements for the coating samples
Solution Approach 1:
The patent employs a universal rotating drum coating chamber that can accommodate various shapes and sizes of magnets without requiring specific shape requirements. The drum structure serves multiple functions including magnet mixing, positioning, and coating application, simplifying the overall furnace structure while maintaining reliable coating capability across different magnet types.
Solution Approach 2:
Instead of using a complex stationary furnace structure with targeted spray nozzles, the patent inverts the approach by using a rotating drum that brings the magnets through a simplified coating field. This reversal of the coating application methodology dramatically reduces structural complexity while maintaining effective coating application.
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 and apparatus provide a high-efficiency, environmentally friendly coating process that minimizes damage to the Nd—Fe—B matrix, reduces shape specificity requirements, and ensures a uniform, protective film on small Nd—Fe—B magnets.
Implementation Method 1
A plurality of stirring pieces are disposed in the compartment of the roller and attached to the interior surface of the roller and extending radially inwardly from the interior surface of the roller for mixing the plurality of small Nd—Fe—B magnets
Implementation Method 2
uses environmentally friendly processes like arc ion plating or magnetron sputtering
Implementation Method 3
uses environmentally friendly processes like arc ion plating or magnetron sputtering
Data Source
AI summary
The present invention provides an apparatus and a method for coating small Nd—Fe—B magnets. The apparatus includes a furnace having a roller including at least one stirring piece disposed in the compartment. The stirring pieces have an isosceles triangle or trapezoidal shaped cross-section. The side wall of the furnace defines an inlet aperture and an outlet aperture disposed diametrically opposed to one another. A plurality of target source holders include two first target source holders and two second target source holders disposed on the side wall and spaced from one another and between the inlet aperture and the outlet aperture. The method includes a step of disposing a plurality of conductors with the small Nd—Fe—B magnets in the compartment of the roller. The small Nd—Fe—B magnets are mixed with the plurality of conductors in the roller with the roller being rotated of between 5 rpm and 20 rpm.