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HOME : PRODUCTS : PERM MAGNETS : BONDED : INJECTION MOLDED
INJECTION MOLDED MAGNETS
One of the more important developments in magnetic materials, polymer bonded magnets, have opened a new world of application opportunities. The processing temperatures employed to blend and mold the material mixture is low enough to allow many different magnet powders to be used alone or in combination in the polymer binder to achieve an unprecedented range of properties.
Another benefit of the injection molding process is that magnet material can be directly molded into, onto, or against other assembly components eliminating subsequent assembly steps. This is called insert injection molding.
Injection molded magnets can be of very simple shapes or very complex. All or only part of the device may be magnetized. It is sometimes cost advantageous to make an entire part out of the magnet material and just magnetize the portion requiring magnetic output.
MATERIALS
Magnetic powders include ferrite, neodymium-iron-boron (NdFeB), and samarium cobalt (SmCo). There are several alloy compositions available of ferrite and NdFeB providing many different magnetic properties. Magnets using combinations of the powders were introduced by Arnold in 1995 and are called "hybrid magnets."
Polymer binders utilized by the Plastiform Division include nylons 6 and 12 and PPS (polyphenylene sulfide). Binder evaluations are a continuous activity in the Development Laboratory, in an effort to improve physical strength, maximum recommended use temperature, improved corrosion resistance for the rare earth magnetic materials, improved dimensional stability in the presence of water and solvents, and greater ease of processing.
TEMPERATURE CHARACTERISTICS
Maximum use temperature is a function of both the magnetic alloy powder and of the binder. For example, ferrite powders in nylon 6 or PPS have tested satisfactorily at 180°C. On the other hand, nylon 12 melts above 170°C and is not recommended for use above 150°C. Magnetic material such as the highest energy NdFeB grade, with intrinsic coercivity of 9,500 Oersteds (760 kA/m), suffers significant irreversible magnetic loss above 120°C, regardless of which binder is used. Maximum use temperatures are listed on each product's specification sheet.
TOLERANCES
An important characteristic of injection molded magnets is that they conform dimensionally to the mold cavity which is precisely machined, the result being close tolerances in the finished product. What little dimensional variability there is results from shrinkage of the polymer during cooling. This depends upon part thickness and shape. Typical tolerances are +/-0.003 in/in. Closer tolerances on critical dimensions can be negotiated.
Please also visit the sections on Compression Bonded and Flexible Bonded magnets.
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