Permanent magnet, method for manufacturing same, and motor comprising same

Patent metadata

Field	Value
Publication number	US-11462959-B2
Application number	US-201816492985-A
Country	US
Kind code	B2
Filing date	Apr 11, 2018
Priority date	Apr 11, 2017
Publication date	Oct 4, 2022
Grant date	Oct 4, 2022

Abstract

A permanent magnet of an embodiment comprises: a base magnet represented by a-b-c (a includes a rare earth-based element, b includes a transition element, and c includes boron (B)); and a coating layer coated on a surface of the base magnet, wherein the coating layer comprises a compound containing a metal having magnetism, the compound including: a phosphor (P); and a metal belonging to the fourth period in the periodic table.

First claim

The invention claimed is:

1. A permanent magnet, comprising:
a base magnet denoted by “a-b-c” (where “a” comprises a rare-earth-based element, “b” comprises a transition element, and “c” comprises boron (B)), the base magnet having a plurality of surfaces, the plurality of surfaces including a first surface and a second surface;
a first coating layer directly contacting the first surface of the base magnet; and
a second coating layer directly contacting the second surface of the base magnet, other than the first surface of the base magnet, the second coating layer made of different material than the first coating layer,
wherein the first coating layer comprises a compound comprising a magnetic metal,
wherein the compound comprises:
phosphorus (P); and
one selected from the group consisting of iron (Fe), cobalt (Co), and nickel (Ni),
wherein the first coating layer has a reversible temperature coefficient for Hci of −0.35 to −0.05%/K, and
wherein the second coating layer has a thermal conductivity of 100 W/(m·K) or more.

2. The permanent magnet according to claim 1 , wherein the “a” is neodymium (Nd), and the “b” is iron (Fe).

3. The permanent magnet according to claim 1 , wherein the base magnet comprises voids formed in a surface thereof, and
wherein at least a portion of the first coating layer and at least a portion of the second coating layer are inserted into the voids formed in the base magnet.

4. The permanent magnet according to claim 1 , wherein the first coating layer has a thickness of 0.1 μm to 10 μm.

5. The permanent magnet according to claim 1 , wherein the second coating layer has a thickness of 1 μm to 30 μm.

6. The permanent magnet according to claim 1 , wherein, when an ambient temperature of the permanent magnet is 120° C., the permanent magnet has a residual magnetic flux density of greater than 11.71 kG.

7. The permanent magnet according to claim 1 , wherein, when an ambient temperature of the permanent magnet is 120° C., the permanent magnet has a coercive force of greater than 7.0 kOe.

8. The permanent magnet according to claim 3 , wherein a size of each of particles forming the first coating layer is smaller than a size of each of the voids.

9. The permanent magnet according to claim 3 , wherein a thickness of the first coating layer is greater than a depth of each of the voids.

10. The permanent magnet according to claim 1 , wherein the first coating layer comprises:
a first surface oriented toward the base magnet; and
a second surface formed opposite the first surface,
wherein a roughness of an outer surface of the base magnet is greater than a roughness of the second surface of the first coating layer.

11. The permanent magnet according to claim 1 , wherein, when an ambient temperature of the permanent magnet is 120° C., the permanent magnet has a maximum magnetic energy product of greater than 32 MGOe.

12. The permanent magnet according to claim 1 , wherein, when an ambient temperature of the permanent magnet is 120° C. or more, the permanent magnet has a squareness ratio of greater than 100%.

13. The permanent magnet according to claim 1 , wherein, when an ambient temperature of the permanent magnet is 120° C., a temperature coefficient has an absolute value of 0.6%/° C. or less, the absolute value of the temperature coefficient being expressed as follows:

β
=

[



Hc
⁡

(
Tr
)

-

Hc
⁡

(
Tp
)



Hc
⁡

(
Tr
)

·
100

]

·

1

Δ
⁢

⁢
T

where β represents the absolute value of the temperature coefficient, Hc(Tr) represents a coercive force at room temperature (Tr), Hc(Tp) represents a coercive force at the ambient temperature (Tp), and ΔT represents a difference between the ambient temperature (Tp) and the room temperature (Tr).

14. The permanent magnet according to claim 1 , wherein a content of the phosphorus (P) is 1% to 12% of the total content of the first coating layer.

15. A motor comprising:
a stator in which a cylindrical-shaped through-hole is formed;
a plurality of stator-winding slots disposed in an inner circumferential surface of the stator;
a rotor disposed in the through-hole in the stator; and
a plurality of permanent magnets coupled to the rotor,
wherein one of the permanent magnets comprises the permanent magnet of claim 1 .

Assignees

• Lg Innotek Co Ltd

Inventors

• Han Jong Soo
• Bae Seok
• Lee Young Jae
• Choi Dong Hyeok
• Lee Jung Eun

Classifications

• H02K9/223

  Heat bridges · CPC title

• H02K1/27 Primary

  Rotor cores with permanent magnets · CPC title

• H01F1/15383

  Applying coatings thereon (H01F1/15366 takes precedence) · CPC title

• H01F41/0253

  for manufacturing permanent magnets · CPC title

• H01F41/026

  protecting methods against environmental influences, e.g. oxygen, by surface treatment (magnetic particles with skin H01F1/061, H01F1/09, H01F1/24, H01F1/33 and G11B5/706) · CPC title