Wavelike Magnetic Separator Matrix for Sorting Accuracy
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Solution Overview
Problem
Conventional magnetic separators using matrices made of expanded metal or steel wool suffer from poor sorting accuracy and efficiency due to irregular magnetic force distribution and entanglement of non-magnetic particles, making it difficult to recognize and achieve a correct magnetic force distribution in the matrix space.
Innovation Solution
A matrix with wavelike plate-shaped magnetic walls having an orderly structure, providing a relatively uniform magnetic force distribution, is designed, where the wave-shaped bent sections are formed in an inverted V or U shape, and the ratio of inter-vertex pitch to wave height is optimized to minimize nonuniformity in the magnetic force, allowing for high accuracy and efficiency in sorting magnetic and non-magnetic particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If matrices made of expanded metal or steel wool are used to generate high magnetization gradient, then magnetic attraction force is improved, but sorting accuracy deteriorates due to entanglement of non-magnetic particles
Solution Approach 1:
The matrix is segmented into multiple plate-shaped magnetic walls arranged in parallel, each with wave-shaped bent sections. This segmentation creates discrete magnetic attraction zones that prevent entanglement of non-magnetic particles while maintaining strong magnetic forces on magnetic particles.
Solution Approach 2:
The wave-shaped bent sections create localized high magnetization gradient regions at the convex portions, while the concave portions provide flow channels. This local quality differentiation enables strong magnetic attraction where needed while maintaining open flow paths to prevent particle entanglement.
2Force
If ferromagnet thin lines are disposed in intricately entwined state to generate locally-high magnetization gradient, then magnetic force is improved, but flow path blockage increases
Solution Approach 1:
The intricately entwined ferromagnet thin lines are replaced by segmented plate-shaped magnetic walls with wave-shaped sections. This segmentation maintains magnetic force while creating defined flow channels that prevent blockage.
Solution Approach 2:
The matrix structure transitions from a two-dimensional tangled network to a three-dimensional arrangement of plates with wave-shaped profiles, creating depth and volume in the flow channels that prevents particle accumulation and blockage.
3Productivity
If sparsely disposed ferromagnet thin lines are used to reduce entanglement, then flow path blockage is reduced, but magnetic attraction area decreases
Solution Approach 1:
The wave-shaped bent sections with convex and concave portions create curved surfaces that increase the effective magnetic attraction area compared to flat plates, while maintaining adequate flow channels. The curvature concentrates magnetic flux at the convex portions, enhancing attraction without requiring increased spacing.
4Ease of manufacture
If conventional matrices with irregular structure are used, then manufacturing is simplified, but magnetic force distribution uniformity deteriorates
Solution Approach 1:
The matrix structure parameters are standardized with specific wave heights (1-10 mm) and pitch ratios (2.72-20.0), transforming the irregular conventional structure into a controlled periodic structure. This enables predictable magnetic force distribution while maintaining ease of manufacture through repetitive molding.
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 matrix enables high-accuracy and high-efficiency sorting of magnetic and non-magnetic particles while allowing for previous simulation-based recognition of the magnetic force distribution, significantly improving the separation efficiency and reducing entanglement issues.
Implementation Method 1
a magnetic force distribution in a matrix space inside the housing part when a magnetic field is applied
Implementation Method 2
magnetic walls each having an orderly structure... through which a sorting target fluid containing a magnetically attractable substance magnetically attractable to the magnetic walls
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
[Problem] To provide matrix for magnetic separator capable of sorting magnetic and non-magnetic particles highly accurately and efficiently and enabling previous simulative recognition of correct magnetic force distribution in matrix space, and magnetic separator. [Solution] Matrix for magnetic separator of present invention includes: entirely approximately wavelike plate-shaped magnetic walls each having orderly structure of wave-shaped bent sections continuously repeatedly formed in wave advancing direction and each having wave height h of ≤1 mm and approximately inverted V- or U-shape; and entirely approximately box-shaped housing part housing magnetic walls and having in opposite surfaces, introducing and discharging parts through which sorting target fluid containing magnetically-attractable substance magnetically-attractable to magnetic walls is passed thereinto/therefrom, magnetic walls arranged in juxtaposition such that convex shapes of wave-shaped bent sections in one magnetic wall face concave shapes thereof in another magnetic wall adjacent to one magnetic wall with constant interval therebetween.