Laminated magnets are becoming increasingly popular in high-performance applications where reducing eddy current losses is critical. But do you know how laminated magnets are made and what factors affect their cost? Follow me as I learn about the advantages of laminated magnets over standard magnets and our customization options for specific needs.
How are laminated magnets made?
Laminated magnets are made by bonding multiple pieces of magnets together with a specialized insulating glue. The manufacturing process is intricate and involves multiple stages of cutting rare earth magnet blanks, laminating with insulating glue, and finally cutting and grinding to shape. They are designed to minimize eddy current losses in high-frequency applications such as motors, generators, and transformers. There are several key steps involved in their manufacture:
- Material Selection:
It is critical to select the right material, usually Neodymium Iron Boron (NdFeB) or Samarium Cobalt (SmCo). NdFeB magnets are known for their high magnetic strength, making them ideal for applications that require strong magnetic fields. SmCo magnets, on the other hand, have excellent temperature stability and corrosion resistance, which is critical for environments with extreme conditions. Your choice depends on the requirements of the application and the environmental conditions. - Cutting:
Once the material is selected, the magnets are precisely cut into thin layers or slices. This stage requires high-precision cutting technology to ensure uniform thickness, as thickness variations can lead to inconsistent magnet performance. The goal is to create layers thin enough to minimize eddy currents while maintaining structural integrity. We use advanced cutting techniques to create thin layers, each ready to play its part in the final laminated structure. - Bonding:
The cut layers are bonded together using a high-strength adhesive to form a cohesive unit. This process ensures that the layers remain firmly connected during the operation of the magnet. We carefully select adhesives to provide a strong bond and maintain consistency in the gaps. In addition, the bonding process must be performed in a controlled environment to prevent contamination, which can weaken the bond and reduce the overall efficiency of the magnet. - Pressing:
After the layers are bonded, a pressing process is required. Pressing helps ensure that the layers fit tightly without air gaps or defects. The pressure applied at this stage must be carefully calibrated to ensure maximum contact between the layers of the magnet while avoiding excessive pressure that can damage the delicate layers. This step is critical to maintaining the laminate’s magnetic properties and structural integrity. - Final Cutting and Grinding:
The final step is to cut and grind the laminate block to precise dimensions. Grinding ensures a smooth surface free of imperfections that could affect the magnet’s performance or cause premature wear. The final cutting process can tailor the magnet size to the application to ensure it fits perfectly in the intended application.
Of course, there is a more economical manufacturing method for some relatively simple laminated magnets, which is the “mold bonding method”. First, use an adhesive to bond one side of a large block of magnet to the mold steel plate table. Then cut the large magnet block into the required small magnets of equal size and clean them. Then use adhesive to fill the cutting groove. After the adhesive is fully cured, heat the steel plate mold to X℃ (magnet cutting groove adhesive melting temperature>X>fixed on the mold table adhesive melting temperature), and separate the laminated magnet from the mold table. Finally, perform the final cutting to obtain the shape and size required for the actual application.
Producing laminated magnets involves meticulous steps that require careful material selection, precise cutting, strong bonding, and accurate finishing. Each stage is critical to ensure optimal performance and reduce eddy current losses. At Osencmag, we combine material science with precision engineering to create high-quality custom laminated magnets to meet your specific needs. We also offer a variety of coatings, such as epoxy or nickel, for enhanced durability and corrosion resistance.
What are the cost factors for laminated magnets?
Laminated magnets are magnetic components that effectively reduce eddy current losses in high-performance applications. The cost of manufacturing these magnets can vary greatly depending on several key factors. Understanding these factors is critical for companies looking to make informed purchasing decisions. Here, we break down the main cost drivers in laminated magnet production for easy reference when customers review quotes.
- Material Selection: The choice of magnetic material is one of the most important cost determinants. Laminated magnets are typically made of neodymium (NdFeB) or samarium cobalt (SmCo). Neodymium magnets are known for their high magnetic strength and are generally cheaper than samarium cobalt, which has better thermal stability and corrosion resistance. The specific grade of the material affects its magnetic properties and temperature tolerance, and also affects the cost. Common samarium cobalt magnet grades are SmCo5 and Sm2Co17. Neodymium magnets, as the most commonly used rare earth magnets, have a wide range of grade models: N35–N52, N35M–N52M, N35H–N52H, N35SH–N52SH, N28UH–N50UH, N28EH–N48EH, N28AH–N45AH.
- Lamination process and layering: The magnet lamination process involves creating thin layers bonded together to reduce eddy currents. The number of layers and the thickness of each layer directly affect the production cost. The more layers there are, the more processing time and materials are required, which increases the total cost. In addition, the accuracy of the layering is critical, as inconsistencies affect the performance of the magnet and may lead to higher production costs due to the need for stricter quality control.
- Size and shape customization: The complexity of the magnet size and shape is another factor that affects the cost. Standard sizes and shapes are generally more economical, while custom geometries may require specialized tools and longer production times, resulting in higher costs. The precision required to cut and form magnets also plays a role—tighter tolerances generally mean more complex manufacturing techniques and higher costs.
- Magnetization Orientation: Magnetization orientation refers to the direction in which the magnetic domains within a magnet are aligned. Customizing magnetic orientation to meet specific application needs can increase costs. This is especially true for nonstandard orientations, which may require additional steps in the manufacturing process, such as specialized magnetizing equipment or multiple magnetizing stages.
- Coatings and Surface Treatments: Laminated magnets often require protective coatings to prevent corrosion and wear, especially in harsh environments. The type of coating, whether epoxy, nickel, or another material, can significantly affect cost. Some coatings offer greater durability or specific resistance properties, but are expensive. The type of material the coating is made of, and when it is applied in multiple layers or with precision, can also affect the overall cost.
- Production Volume: As with many manufacturing processes, production volume plays a critical role in determining unit cost. Higher production volumes often allow for economies of scale, which can reduce the cost per magnet. For laminated magnets, high-volume production can optimize the use of materials, labor, and equipment, resulting in more cost-effective pricing. Conversely, a single magnet for a small order may cost more due to less efficient production processes.
- Quality Assurance and Testing:Ensuring the quality and performance of laminated magnets requires comprehensive testing and quality assurance processes. These processes include checking for proper lamination, magnetic strength, and overall durability. The high standards of quality control for certain specialty applications can increase costs, especially if extensive testing is required to meet specific industry requirements or certifications. However, these costs are justified by the assurance of reliable performance and longevity of the product.
The cost of laminated magnets is affected by a variety of factors, from material selection and lamination processes to customization and production volume. Understanding these factors allows companies to make informed decisions that balance cost and performance needs. When purchasing laminated magnets, especially in bulk, working with a supplier that offers flexible customization options can provide significant cost advantages.At Osencmag, we leverage our extensive industry experience to provide high-quality laminated magnets tailored to your specific requirements. By working with us, you will benefit from competitive pricing, reliable delivery, and top-quality assurance, making us a trusted choice for your magnetic needs.
How can laminated magnets be customized?
Customization options for laminated magnets allow businesses, scientific research institutions, or volume purchasing users to tailor these components to meet specific performance requirements, ensuring optimal functionality and efficiency. Below, we explore the various aspects of laminated magnets that can be customized to suit your specific needs.
- Magnet Type: The foundation of any laminated magnet is the type of magnetic material used. The two primary options are Neodymium (NdFeB) and Samarium Cobalt (SmCo). Neodymium magnets are favored for their exceptional strength, making them ideal for applications where maximum magnetic force is required. In contrast, Samarium Cobalt magnets are chosen for their superior thermal stability and resistance to corrosion, making them suitable for environments with extreme temperatures or exposure to corrosive substances. Selecting the right material is the first step in customizing a laminated magnet to ensure it meets your application’s unique demands.
- Magnetic Strength: Customizing the magnetic strength of laminated magnets is crucial for matching the specific requirements of your application. The strength is determined by the grade of the material, with options ranging from lower-grade Neodymium (e.g., N35) to higher grades like N52, which offer the highest magnetic strength available. By choosing the proper magnetic grade, you can ensure that the magnets provide the necessary magnetic properties.
- Temperature Resistance: Temperature resistance is a key factor in determining the reliability and durability of laminated magnets in various environments. Customization options allow you to select the working temperature range that best suits your application. For example, Neodymium magnets are typically effective up to 80°C, but higher temperature grades (e.g., N35H or N52H) can withstand temperatures up to 230°C. Samarium Cobalt magnets, on the other hand, naturally offer higher thermal resistance, making them ideal for applications with extreme temperature fluctuations. By tailoring the temperature resistance, you can ensure that your magnets maintain their performance under the conditions they will encounter.
- Layer Count:The number of layers in a laminated magnet directly impacts its ability to reduce eddy currents. Customization allows you to specify the exact number of layers needed to optimize performance. More layers typically result in better reduction of eddy currents, making the magnet more efficient in high-frequency applications. However, the appropriate layer count will depend on the specific requirements of your application, including the frequency range and operational environment.
- Thickness of Layers: The thickness of each laminated layer is another critical customization option. By adjusting the thickness, you can fine-tune the balance between magnetic strength and eddy current reduction. Thicker layers generally provide stronger magnetic fields, but may be less effective at minimizing eddy currents. On the other hand, thinner layers improve eddy current suppression but might require higher overall magnet volume to achieve the desired magnetic strength.
- Magnetic Orientation:Magnetic orientation refers to the direction in which the magnetic domains are aligned within the magnet. Customizing the orientation is vital for ensuring that the magnet functions correctly within your device or system. Common orientations include axial and radial, but other configurations can be specified based on your application’s unique needs. Correct orientation ensures maximum efficiency and effectiveness in magnetic flux distribution, contributing to the overall performance of the system.
- Shape and Size:The shape and size of laminated magnets can be fully customized to fit your specific application. Whether you require simple geometric shapes like blocks or discs, or more complex configurations with intricate designs, customization options are available to meet your needs. Precise shaping and sizing allow the magnet to integrate seamlessly into your assembly, reducing the need for additional adjustments or components.
Laminated magnets can be customized in multiple dimensions, including material, magnetic strength, number of layers, and thickness, to meet the specific needs of your application. By working with a supplier like Osencmag, you can leverage our extensive experience and customization capabilities to create laminated magnets that are exactly what you need. Whether you need small-scale production or large-scale manufacturing, we will help you achieve excellent results. Contact us today to discuss your project and learn how we can help you achieve the best results.
Which is better, laminated magnets or standard magnets?
When choosing between laminated magnets and standard magnets, it’s essential to understand the specific needs of your application. While both types serve vital roles in various industries, they offer distinct advantages depending on the conditions in which they are used. Below, we delve into the differences between laminated and standard magnets, helping you make an informed decision.
- Standard Magnets:Standard magnets, often made from materials like Neodymium (NdFeB), Samarium Cobalt (SmCo), or Alnico, are widely used across industries due to their strong magnetic properties. These magnets are typically solid blocks, discs, or rings without any internal layering. They are effective in applications where high magnetic strength is needed and where the magnet operates at a steady state with minimal exposure to fluctuating electromagnetic fields. The primary advantage of standard magnets lies in their simplicity and cost-effectiveness. They are easier to produce, which generally makes them more affordable.
- Laminated Magnets: Laminated magnets reduce eddy current losses in high-efficiency motors. These magnets undergo a structure that minimizes the flow of eddy currents by cutting and bonding multiple layers. Eddy currents are electric current loops that can cause heat buildup and energy loss in conventional magnets.
Although laminated magnets are generally more expensive to produce due to the complexity of their construction, they are particularly advantageous in motors, generators, and transformers, where efficiency and performance at high frequencies are critical.
Choosing Between Laminated and Standard Magnets.
The choice between laminated and standard magnets depends largely on the requirements of your application. If your needs are more general, focusing on cost-effectiveness and strong magnetic force without the complexity of high-frequency fields, then standard magnets may be more suitable. However, if your project involves high-frequency operation, efficiency and minimizing energy losses are critical, then laminated magnets may be a better choice. Unlike ordinary standard magnets, laminated magnets are bonded with insulating glue. This manufacturing method can split the eddy current path into multiple paths. The more divisions inside the magnet, the more eddy current paths there are.
| Laminated Magnets vs Standard Magnets | ||
|---|---|---|
| Feature | Laminated Magnets | Standard Magnets |
| Construction | Made by laminating two or more magnetic materials together with a thin insulating layer | A single body shape of a solid block, disk or ring without delamination |
| Eddy Current Losses | Significantly reduced due to lamination | Higher potential for eddy current formation |
| Performance in High Frequencies | Superior performance in high-frequency applications | Suitable for low-frequency or steady-state applications |
| Heat Generation | Lower heat generation due to reduced eddy currents | More heat generation in high-frequency fields |
| Cost | Higher due to complex construction | Generally lower, more cost-effective |
| Application Suitability | Ideal for motors, generators, and transformers | Ideal for general-purpose magnetic needs |
| Magnetic Strength | Comparable magnetic strength, tailored to application | High magnetic strength, widely available |
Both laminated and standard magnets have their own unique advantages and are suitable for different applications. Understanding these differences enables you to choose the right type of magnet for your specific needs. At Osencmag, we provide expert guidance and high-quality magnetic products to ensure that you get the best solution for your application, whether it is laminated magnets or standard magnets.
What are the benefits of using laminated magnets in high frequency applications?
Laminated magnets are specifically designed to reduce eddy current losses in high frequency applications such as motors and generators. This improves efficiency and performance, especially at higher operating speeds. Interlayer insulation minimizes energy losses, making them ideal for advanced applications.
How does the lamination process affect magnetic properties?
The lamination process may have a slight effect on magnetic properties due to the introduction of non-magnetic insulation layers between the magnet segments. However, this is usually negligible compared to the benefits of reduced eddy current losses. The overall magnetic performance remains strong and the insulation layers used are optimized to maintain high magnetic efficiency.
Which industries typically use laminated magnets?
Laminated magnets are widely used in industries such as automotive (especially electric vehicles), aerospace, and renewable energy, where high efficiency and performance are critical. These industries often involve high-speed motors and generators, and reducing eddy current losses can significantly improve performance.
What is the typical lead time for custom laminated magnets?
The lead time for custom laminated magnets depends on the complexity of the customization, the materials used, and the scale of production. For regular laminated magnets, Osencmag’s delivery time ranges from 4 to 6 weeks. In practice, it will fluctuate according to customer customization requirements. If you choose other suppliers, it is recommended to discuss the specific schedule with the supplier to ensure that it meets the project needs.
