Additive manufacturing of ND—FE—B magnets with insulating layers

Patent metadata

Field	Value
Publication number	US-12243683-B2
Application number	US-202318506227-A
Country	US
Kind code	B2
Filing date	Nov 10, 2023
Priority date	Nov 30, 2021
Publication date	Mar 4, 2025
Grant date	Mar 4, 2025

Abstract

Permanent magnets and method of making the same are provided. The magnets include a magnetic layer having an insulation layer disposed thereon. The insulation layer is formed via additive manufacturing techniques such as laser melting such that it has discrete phases including a magnetic phase and an insulating phase.

First claim

What is claimed is:

1. A permanent magnet comprising:
a substrate;
a magnetic layer disposed on the substrate; and
a patterned insulation layer disposed on the magnetic layer opposite the substrate including magnetic segments and insulating portions disposed between the magnetic segments, wherein the substrate is a component of a motor.

2. The permanent magnet of claim 1 , wherein the magnetic layer includes Nd—Fe—B.

3. The permanent magnet of claim 1 , wherein the insulation layer includes stratified layers.

4. The permanent magnet of claim 1 , wherein the insulating portions include at least one selected from the group of Cu—P, Al—Si(Ge), Al—Si(Ge)—Fe(Co,Cr), ceramics, and glasses.

5. The permanent magnet of claim 4 , wherein the insulating portions include at least one selected from the group of Cu—P, Al—Si(Ge), Al—Si(Ge)—Fe(Co,Cr).

6. The permanent magnet of claim 1 , wherein the patterned insulation layer defines alternating or intermittent rectangular loops of the magnetic segments and insulating portions.

7. The permanent magnet of claim 1 , wherein the patterned insulation defines a weaved or mosaic pattern of the magnetic segments and insulating portions.

8. The permanent magnet of claim 1 , wherein a capping layer is disposed on the insulation layer opposite the magnetic layer.

9. The permanent magnet of claim 8 , wherein the capping layer includes a material having an electrical conductivity of at least 10 6 S/m.

10. The permanent magnet of claim 8 , wherein a thermal barrier layer is disposed between the magnetic layer and the capping layer.

11. The permanent magnet of claim 8 , wherein the capping layer includes magnetic sections and conductive sections.

12. The permanent magnet of claim 8 , wherein the capping layer has a second pattern that is different than the insulation layer.

13. The permanent magnet of claim 8 , further comprising a thermal barrier layer disposed between the insulation layer the capping layer.

14. A permanent magnet comprising:
a magnetic layer;
an insulation layer disposed on the magnetic layer and having a first pattern including a magnetic portion and an insulating portion, and
a capping layer disposed on the insulation layer opposite the magnetic layer and having a second pattern different than the first pattern, the second pattern including a discrete magnetic portion and a discrete non-magnetic portion.

15. The permanent magnet of claim 14 , wherein the discrete non-magnetic portion is a conductive material.

16. The permanent magnet of claim 15 , wherein the conductive material has an electrical conductivity of at least 10 6 S/m.

17. The permanent magnet of claim 14 , wherein the discrete non-magnetic portion is disposed between the discrete magnetic portion.

18. The permanent magnet of claim 1 , wherein the magnetics segments are a different magnetic composition than the magnetic layer.

19. The permanent magnet of claim 1 , wherein the magnetic segments are surrounded by the insulating portions.

20. The permanent magnet of claim 1 , wherein the motor is a traction motor.

Assignees

• Ford Global Tech Llc

Inventors

• Li Wanfeng
• Leonardi Franco
• Degner Michael W

Classifications

• B33Y80/00 Primary

  Products made by additive manufacturing · CPC title

• B22F10/60

  Treatment of workpieces or articles after build-up · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B33Y40/20

  Post-treatment, e.g. curing, coating or polishing · CPC title

• B22F2301/45

  Rare earth metals, i.e. Sc, Y, Lanthanides (57-71) · CPC title