Magnet structure having a plurality of individual magnets integrated into a mesh structure

A linear or rotating electromagnetic actuator having a three-dimensional magnet structure (6) comprising:

• a plurality of individual magnets (4), the magnet structure (6) having a length (4a) that extends along a thickness of the magnet structure (6), the thickness forming the smallest dimension of the magnet structure of 4 mm;
• at least one mesh structure (5a), with mesh cells each mesh cell including a housing (5) for a respective individual magnet (4), each housing (5) having inside dimensions that are sized to fit an individual magnet into its interior, the mesh cells being made from a fiber-reinforced insulating material, characterized in that a space is defined between the housing (5) and the individual magnet (4), wherein the space is filled by at least a fiber-reinforced resin;
• and
• a non-conducting composite layer coating the individual magnets (4) and the mesh structure (5a), the magnet structure or structures (6) forming a rectangular assembly or being part of a rotor (1, la) that rotates around its center, the magnet structure or structures (6) being arranged concentrically with respect to the rotor (1, la) whereby the linear or rotating electromagnetic actuator is an axial flux actuator, the magnet structure (6) forms a single magnet extending over the linear or rotating electromagnetic actuator;
• wherein the at least one support (2, 2a) advantageously is part of the rotor (1) and is in a partly hollow disc shape comprising branches (3) that extend essentially radially or are inclined in the radial direction of the rotor (1), the at least one disc-shaped support (2) being covered over at least one face by a covering disc (8) as axial holding means for the consolidation of the rotor (1).

A method for the fabrication of a magnet structure within a linear or rotating electromagnetic actuator (6), characterized in that it comprises the following steps:

• providing a linear or rotating electromagnetic actuator comprising:
• a plurality of individual magnets (4), the magnet structure (6) having a length (4a) that extends along a thickness of the magnet structure (6), the thickness forming the smallest dimension of the magnet structure of 4 mm;
• at least one mesh structure (5a), with mesh cells each mesh cell including a housing (5) for a respective individual magnet (4), each housing (5) having inside dimensions that are sized to fit an individual magnet into its interior, the mesh cells being made from a fiber-reinforced insulating material, characterized in that a space is defined between the housing (5) and the individual magnet (4), wherein the space is filled by at least a fiber-reinforced resin;
• and
• a non-conducting composite layer coating the individual magnets (4) and the mesh structure (5a), the magnet structure or structures (6) forming a rectangular assembly or being part of a rotor (1, la) that rotates around its center, the magnet structure or structures (6) being arranged concentrically with respect to the rotor (1, la) whereby the linear or rotating electromagnetic actuator is an axial flux actuator, the magnet structure (6) forms a single magnet extending over the linear or rotating electromagnetic actuator;
• wherein the magnet structure comprises a stack of two series of individual magnets (4), each with a respective mesh structure (5a);
• wherein within the magnet structure the two mesh structures (5a) are advantageously part of the same assembly, the mesh structures (5a) being arranged in relation to one another so that each individual magnet (4) of one series is aligned in the direction of its length with a respective individual magnet (4) of the other series with which it is placed end to end;
• and
• wherein within the magnet structure the two mesh structures (5a) are separated with a layer of composite interposed between the two mesh structures (5a);
• cutting, from a magnetized tile having a length, width and thickness forming three dimensions of the tile, of a plurality of individual magnets (4) along the three dimensions of the magnetized tile,
• positioning and holding of individual magnets (4) at a distance from one another by the introduction of each individual magnet (4) in a respective associated housing of a mesh structure (5a),
• adhesive bonding of each individual magnet by the introduction of a resin around the individual magnet (4) in each housing,
• injection of a layer of composite around the mesh structure (5a) and individual magnets (4) for their coating.

A linear or rotating electromagnetic actuator having a three-dimensional magnet structure (6) comprising:

• a plurality of individual magnets (4), the magnet structure (6) having a length (4a) that extends along a thickness of the magnet structure (6), the thickness forming the smallest dimension of the magnet structure of 4 mm;
• at least one mesh structure (5a), with mesh cells each mesh cell including a housing (5) for a respective individual magnet (4), each housing (5) having inside dimensions that are sized to fit an individual magnet into its interior, the mesh cells being made from a fiber-reinforced insulating material, characterized in that a space is defined between the housing (5) and the individual magnet (4), wherein the space is filled by at least a fiber-reinforced resin;
• and
• a non-conducting composite layer coating the individual magnets (4) and the mesh structure (5a), the magnet structure or structures (6) forming a rectangular assembly or being part of a rotor (1, la) that rotates around its center, the magnet structure or structures (6) being arranged concentrically with respect to the rotor (1, la) whereby the actuator is an axial flux actuator, there are a plurality of magnet structures (6) in the form of successive tiles forming alternating successive magnet poles, the magnet structures (6) being housed in at least one support (2, 2a) comprising branches (3, 3a), delimiting between them housings that each hold a respective magnet structure (6).

A method for the fabrication of a magnet structure (6) within a linear or rotating electromagnetic actuator, characterized in that it comprises the following steps:

• providing a linear or rotating electromagnetic actuator comprising:
• a plurality of individual magnets (4), the magnet structure (6) having a length (4a) that extends along a thickness of the magnet structure (6), the thickness forming the smallest dimension of the magnet structure of 4 mm;
• at least one mesh structure (5a), with mesh cells each mesh cell including a housing (5) for a respective individual magnet (4), each housing (5) having inside dimensions that are sized to fit an individual magnet into its interior, the mesh cells being made from a fiber-reinforced insulating material, characterized in that a space is defined between the housing (5) and the individual magnet (4), wherein the space is filled by at least a fiber-reinforced resin;
• and
• a non-conducting composite layer coating the individual magnets (4) and the mesh structure (5a), the magnet structure or structures (6) forming a rectangular assembly or being part of a rotor (1, 1a) that rotates around its center, the magnet structure or structures (6) being arranged concentrically with respect to the rotor (1, 1a) whereby the actuator is an axial flux actuator, there are a plurality of magnet structures (6) in the form of successive tiles forming alternating successive magnet poles, the magnet structures (6) being housed in at least one support (2, 2a) comprising branches (3, 3a), delimiting between them housings that each hold a respective magnet structure (6);
• cutting, from a magnetized tile having a length, width and thickness forming three dimensions of the tile, of a plurality of individual magnets (4) along the three dimensions of the magnetized tile,
• positioning and holding of individual magnets (4) at a distance from one another by the introduction of each individual magnet (4) in a respective associated housing of a mesh structure (5a),
• adhesive bonding of each individual magnet by the introduction of a resin around the individual magnet (4) in each housing,
• injection of a layer of composite around the mesh structure (5a) and individual magnets (4) for their coating.