Orientation Anisotropic Injection Magnets, Injection Magnets Orientation Technology
Injection Bonded Anisotropic NdFeB Magnet
The common molding technics of anisotropic ndfeb magnet are injection molding and compression molding. Two major application samples of anisotropic ndfeb magnet are sensor magnet and expansion valve.
Injection bonded ndfeb sensor magnets made by HDDR ndfeb powder are widely used for auto speedometer, speed sensor, water temperature sensor etc. The surface magnetic field can reach 3000GS upwards, needle axis remained in the body of ndfeb magnet when injection molded, which is in favor of forming the excellent maving balance.
Electric expansion valve adopts HDDR injection magnetic ring that made by anisotropic ndfeb powder features good properties 30%~60% higher than other expansion valves made by common anisotropic ndfeb ring, thus, it can highly advance energy-efficiency-rate of air conditioner, and promotes the development of frequency conversion air conditioner towards energy-saving and environment-protection.
Application of Injection Bonded NdFeB Magnet:
Characteristics: good at consistency, recombination compaction, flexible in magnetized orientation and with high mechanical strength. Having high dimensional precision and impact-resistance. Capable of forming products with inlay; Versatile shapes and specification; Impact-resistant; advanced surface treatment technology, effectively protect; Integrated forming.
Anisotropic injection insert or over-molding of permanent magnetic materials in a thermoplastic matrix is well established technology, which enables manufacturing of complex shapes, highly automated processes and net shaped products magnetized to desired level and magnetic pattern in essentially one processing step. In this work, we would like to present utilization of anisotropic injection molding of a multipole rotor for IPM motor directly in the core stack. Main advantages of IPM rotors including a high degree of freedom in a pole configuration construction for flux concentration, which enables low ripple/torque ratio; and a one step process of aligned rotor manufacturing, which enables highly automated
manufacturing. This presentation will discuss the Anisotropic molding technology design, a comparison of magnetic properties to standard rotor, and magnetic properties of an 8-pole radially oriented IPM rotor.
What’s the difference between the isotropic magnet and anisotropic magnet?
Isotropic Magnet and Anisotropic Magnet
There are two kinds of magnet, isotropic and anisotropic.
■ Isotropic＝Magnet with same strength can be made by magnetizing from any direction of a cube.
■ Anisotropic＝By magnetizing from a specific direction, a directional magnet can be made.
E.g.:Ferrite Crystal and Easy Magnetization Direction
The shape of a ferrite crystal is similar to a short hexagonal prism. By magnetizing in the direction of the prism height, a strong magnet can be made.
Crystal Arrangement of an Isotropic Magnet
As the crystal direction and arrangement of isotropic crystals are various, so a magnet with the same strength can be made by magnetizing from any arrow direction.
Crystal Arrangement of an Anisotropic Magnet
As the crystal directionand arrangement of anisotropic crystals are unidirectional in the easy magnetization direction, so a strong magnet can be made only by magnetizing from the easy magnetization direction of the arrow.
Magnet Anisotropic Processing
There are two ways for anisotropic processing, “method by using a magnetic field” and “method by adding mechanical pressure”. It is called orientation to marshal material in the easy magnetization direction in a fixed direction using either of the methods.
1. Forming by the Magnetic Field Method (Ferrite, Plastic Magnet etc.)
Forming in a magnetic field is the method to orientate by using a magnetic flux generated from a magnetic field coil.
2. Machine (Rolling) Orientation Method (Rubber Magnet)
Marshall orientation method is the method to marshal particles of magnetic material using mechanical pressure.
What are the two ways of orientation technology for anisotropic injection magnet?
The orientation technology for anisotropic injection magnet includes permanent magnet orientation and electromagnetic orientation.
The sketches of electromagnetic orientation technology
According to magnet’s shape and final magnetization direction, the aligning direction of electromagnetic orientation technology includes axial-orientation and radial-orientation. Japanese injection magnet manufacturers have several years of experience in this area.
The sketches of permanent magnet orientation technology
The technical difficulty of the permanent magnet orientation is less than the electromagnetic orientation technology. The sintered NdFeB or SmCo magnets are embedded in the mold to generate magnetic field. The strength of magnetic field is affected by many factors. Engineers design it based on the experience and Finite element method.
PLASTIC-BONDED, INJECTION-MOULDED MAGNETS WITH VERY NARROW TOLERANCES
Plastic-bonded, injection-moulded magnets are typical composite materials that are created by embedding hard ferrite or rare earth magnetic powder in thermoplastic PLASTICS (matrix material PA6, PA12, PPS). The proportion of the magnetic powder dictates the magnetic and mechanical properties.
The filling degrees of plastic-bonded, injection-moulded magnets vary between a magnet powder content of between 84% and 94% (percent by weight). The magnetic values are therefore below those of plastic-bonded, injection-moulded magnets. Plastic-bonded, injection-moulded magnets can be produced in complex shapes and in combination with insert parts – all in a single process.
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