Systems and methods for producing magnetic structures

• US 10,204,727 B2
• Filed: 03/28/2016
• Issued: 02/12/2019
• Est. Priority Date: 06/02/2009
• Status: Active Grant

• Current Assignee: Correlated Magnetics Research, LLC
• Original Assignee: Correlated Magnetics Research, LLC
• Inventors: Fullerton, Larry W., Roberts, Mark D., Morgan, Jason N.
• Primary Examiner(s): Bauer, Scott
• Application Number:
  US15/082,605
• Publication Number:
  US 20160211066A1
• Time in Patent Office: 1,051 Days
• CPC Class Codes: H01F 13/003 Methods and devices for magnetising permanent magnets permanent magnets H01F7/02
• CPC Class Codes: H01F 41/02 for manufacturing cores, coils, or magnets H01F41/14 takes precedence; for dynamo-electric machines H02K15/00
• CPC Class Codes: H01F 7/021 Construction of PM H01F7/0278 takes precedence; PM compositions H01F1/032

Abstract

A system for magnetizing magnetic sources into a rare earth permanent magnet material includes a first inductor coil, a second inductor coil, and at least one magnetizing circuit for supplying a first current having a first direction for a first duration to said first inductor coil to produce a first magnetic field and a second current having a second direction for a second duration to said second inductor coil to produce a second magnetic field. The first inductor coil comprises a first plurality of layers of a flat conductor about a first aperture positioned on a first side of the rare earth permanent magnet material at a first location where a magnetic source is to be magnetized into the rare earth permanent magnet material from the first side of the rare earth permanent magnet material. The second inductor coil comprising a second plurality of layers of a flat conductor coiled about a second aperture positioned on a second side of the rare earth permanent magnet material at a second location where a magnetic source is to be magnetized into the rare earth permanent magnet material from the second side of said rare earth permanent magnet material, where the second side is opposite the first side.

Claims

1. A system for magnetizing magnetic sources into a rare earth permanent magnet material;

comprising;

a first inductor coil comprising a first plurality of layers of a flat conductor about a first aperture positioned on a first side of said rare earth permanent magnet material at a first location where a magnetic source is to be magnetized into said rare earth permanent magnet material from said first side of said rare earth permanent magnet material;

a second inductor coil comprising a second plurality of layers of a flat conductor coiled about a second aperture positioned on a second side of said rare earth permanent magnet material at a second location where a magnetic source is to be magnetized into said rare earth permanent magnet material from said second side of said rare earth permanent magnet material, said second side being opposite said first side; and

at least one magnetizing circuit for supplying a first current having a first direction for a first duration to said first inductor coil to produce a first magnetic field and a second current having a second direction for a second duration to said second inductor coil to produce a second magnetic field, wherein the first and second inductor coils concentrates a flux in a desired direction and disperse a return flux that does not magnetize the rare earth permanent magnet material in an area with an opposite magnetic polarity.

2. The system of claim 1, wherein the first inductor coil and the second inductor coil are configured to produce magnetic fields having substantially the same field strengths when substantially the same amount of current is supplied to each of the two print heads.

3. The system of claim 1, wherein said first inductor coil and said second inductor coil are connected in series to a magnetizing circuit via a supply line.

4. The system of claim 1, wherein the first aperture and the second aperture are substantially aligned with each other.

5. The system of claim 1, wherein said first inductor coil and said second inductor coil are driven by independent magnetizing circuits via separate supply lines.

6. The system of claim 5, wherein said first inductor coil and said second inductor coil are configured to have substantially matched impedance.

7. The system of claim 5, wherein the first inductor coil and the second inductor coil are supplied substantially the same amounts of current having the same directions for the same durations.

8. The system of claim 5, wherein the first inductor coil and the second inductor coil are supplied at least one of a different amount of current, currents for different durations, or currents having different directions.

9. The system of claim 1, wherein the coil diameter of the first inductor coil is substantially the same as the coil diameter of the second inductor coil.

10. The system of claim 1, wherein the diameter of the first aperture is substantially the same as the diameter of the second aperture.

11. The system of claim 1, wherein the first inductor coil and the second inductor coil have substantially the same aperture diameter-to-coil diameter ratio.

12. The system of claim 1, wherein the conductor layers of the first inductor coil have substantially the same thickness as the conductor layers of the second inductor coil.

13. The system of claim 1, wherein the first inductor coil and the second inductor coil have substantially the same number of coil layers.

14. The system of claim 1, wherein the first inductor coil and second inductor coil have vertical apertures.

15. The system of claim 1, wherein at least one of the first inductor coil or the second inductor coil has one of an angled aperture or a conical aperture.

16. The system of claim 1, wherein the first magnetic field and the second magnetic field at least partially cancel.

17. The system of claim 1, wherein the first magnetic field and the second magnetic field produce a magnetic source that extends from said first side of said rare earth permanent magnet material to said second side of said rare earth permanent magnet material.

18. The system of claim 17, wherein said magnetic source has a substantially cylindrical volume in said rare earth permanent magnet material.

19. A method for magnetizing magnetic sources into a rare earth permanent magnet material;

comprising;

providing a first inductor coil comprising a first plurality of layers of a flat conductor about a first aperture;

positioning said first aperture on a first side of said rare earth permanent magnet material at a first location where a magnetic source is to be magnetized into said rare earth permanent magnet material from said first side of said rare earth permanent magnet material;

providing a second inductor coil comprising a second plurality of layers of a flat conductor coiled about a second aperture;

positioning said second aperture on a second side of said rare earth permanent magnet material at a second location where a magnetic source is to be magnetized into said rare earth permanent magnet material from said second side of said rare earth permanent magnet material, said second side being opposite said first side; and

supplying using at least one magnetizing circuit a first current having a first direction for a first duration to said first inductor coil to produce a first magnetic field and a second current having a second direction for a second duration to said second inductor coil to produce a second magnetic field, wherein the first and second inductor coils concentrates a flux in a desired direction and disperse a return flux that does not magnetize the rare earth permanent magnet material in an area with an opposite magnetic polarity.

20. The method of claim 19, wherein the first magnetic field and the second magnetic field produce a magnetic source that extends from said first side of said rare earth permanent magnet material to said second side of said rare earth permanent magnet material.