PLASTIC BONDED NdFeB MAGNETS (MQ1)
Plastic Bonded NdFeB magnets are manufactured by binding rapidly-quenched nanocrystalline NdFeB powder with polymer binders. These plastic bonded magnets have an isotropic material structure. Different types of binders can be used depending on the requirements. Several techniques for producing plastic bonded NdFeB magnet types are available:
After mixing the nanocrystalline NdFeB powder with a polymer binder the material is filled into a mould and pressed. Different magnet shapes can be produced with this technology. Due to the high NdFeB content magnets with a Remanence (Br) between ~570-770 mT can be produced depending on the selected grade. The magnets will be coated to obtain a smooth and even protection layer. Several coating techniques are available depending on the application.
This manufacturing technique is particular effective for larger volume production and more severe applications. Though the Remanence (Br) of the products is slightly lower than those made with compression moulding, between ~410-720 mT, because of their lower content of NdFeB powder. As almost any shape can be obtained, this technique is especially suitable for complex shapes.
Advanced technologies like overmoulding and 2-shot moulding are possible with this technique. Below you can find an explanation of both technologies.
Using this injection moulding technique inserts can be overmoulded with magnetic material and/or technical plastic. In this way magnets can be combined with shaft, lamination stack, holder or other functional elements. By using high-end equipment and sophisticated mould designs it is possible to keep very strict specifications.
2-shot moulding technology makes it possible to connect magnet material together with several plastics and/or metal parts. This all is done in a single injection moulding process.
Advantages of this technique are:
High precision, all parts are fitted in one injection moulding process.
Combine different functionalities in one part.
Better adhesion between magnet and plastic, as these components are chemically connected.
Elimination of assembly steps.
Reduction of costly handling and reducing risks.
Plastic Bonded SmFeN Magnets
SmFeN magnet powders are produced in a similar way to NdFeB. However with SmFeN nitrogen is diffused by heat treatment (nitriding) into the rapidly quenched SmFe flakes. These flakes are then mixed with a polymer binder and can then be processed either by compression moulding or injection moulding to make isotropic plastic bonded SmFeN magnets.
The magnetic performance of SmFeN plastic bonded magnets is higher compared to plastic bonded NdFeB magnets. Besides this it has excellent corrosion- and heat-resistance behaviour which makes it suitable for demanding applications.
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