Wireless Charging Magnet Unit Manufacturing Method
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Solution Overview
Problem
The existing manufacturing methods for magnet units in wireless charging are complex, time-consuming, and result in inconsistent magnet performance, making them inconvenient to install and disassemble.
Innovation Solution
A manufacturing method involving the magnetization of magnetic elements on a non-magnetic carrier followed by assembly onto a magnetically permeable carrier in an annular array, which simplifies the process, ensures consistency, and improves efficiency by using a magnetizing machine and manipulators for precise placement and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional magnet assembly methods are used, then magnet assembly can be manufactured, but the structure is complicated and installation/disassembly is time-consuming and laborious
Solution Approach 1:
The patent combines multiple magnet pieces with different polarities into a single integrated magnet assembly structure that can be installed and disassembled as one unit. The magnet assembly includes a first magnet piece with first polarity, a second magnet piece with second polarity, and a third magnet piece with third polarity, all integrated into a unified structure that simplifies handling while maintaining functional complexity.
Solution Approach 2:
The magnet assembly is segmented into multiple magnet pieces with different polarities (first, second, and third magnet pieces) that can be independently positioned and oriented. This segmentation allows for optimized magnetic field distribution while maintaining a simplified overall assembly process, as each segment can be pre-configured and then installed together as a complete unit.
2Reliability
If traditional magnet assembly methods are used, then magnet assembly can be manufactured, but the performance of magnets is inconsistent
Solution Approach 1:
The patent applies preliminary magnetization treatment to each magnet piece before assembly, ensuring that the first, second, and third magnet pieces have consistent and predetermined magnetic properties. This preliminary action includes controlling the polarity orientation and magnetic strength of each piece, which ensures performance consistency when they are assembled together, reducing the need for post-assembly adjustments and rework.
3Reliability
If complex magnet assembly structure is used, then magnetic performance can be optimized, but installation and disassembly become time-consuming and laborious
Solution Approach 1:
The patent merges multiple magnet pieces with different polarities into a single integrated assembly unit that maintains optimized magnetic field distribution. The first magnet piece with first polarity, second magnet piece with second polarity, and third magnet piece with third polarity are combined in a unified structure that can be installed and disassembled as one complete unit, eliminating the need for separate handling of each magnet piece during installation and disassembly operations.
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 method significantly simplifies the manufacturing process, ensures consistent magnet performance, and enhances the efficiency of magnet unit assembly and disassembly, improving the overall manufacturing efficiency and convenience.
Implementation Method 1
moving the first carrier along with the magnetic elements into a magnetizing machine, using the magnetizing machine to magnetize all the magnetic elements on the first carrier so that each magnetic element becomes a magnet piece, an N-pole and an S-pole are formed on different portions of the same surface of the magnet piece
Implementation Method 2
installing the magnet pieces onto a second carrier to form a magnet unit, the second carrier is made of magnetically permeable material; the magnet pieces carried by the second carrier are defined in an annular array around the central axis of the second carrier
Data Source
AI summary
The invention discloses a manufacturing method of magnet unit for wireless charging, including the steps: installing multiple magnetic elements onto a first carrier made of non-magnetic material; moving the first carrier into a magnetizing machine to magnetize all the magnetic elements so that each magnetic element becomes a magnet piece, an N-pole and an S-pole are formed on different portions of the same surface of the magnet piece; installing the magnet pieces onto a second carrier made of magnetically permeable material to form a magnet unit, the magnet pieces are defined in an annular array around the central axis of the second carrier installed on a wireless charging base, the magnet unit cooperates with a charging coil of the wireless charging base to charge a wireless headset. The invention simplifies the manufacturing process and ensures the consistency of magnet pieces in the same magnet unit, also improves the manufacturing efficiency.