Additive manufacturing of permanent magnets with post processing

Patent metadata

Field	Value
Publication number	US-2025174396-A1
Application number	US-202519027106-A
Country	US
Kind code	A1
Filing date	Jan 17, 2025
Priority date	Dec 10, 2021
Publication date	May 29, 2025
Grant date	—

Abstract

Permanent magnets and methods of making the same are disclosed herein. The permanent magnets include a 3D-printed, i.e., additively manufactured, framework and an infiltrate such that there is a discrete magnetic phase and a discrete non-magnetic phase or two discrete magnetic phases. The infiltrate may provide superior strength, elasticity or magnetic properties.

First claim

What is claimed is:

1 . A permanent magnet comprising:
a rare earth magnetic framework of stratified layers that defines a venous system having a predetermined shape; and an infiltrate disposed within the venous system.

2 . The permanent magnet of claim 1 , wherein the rare earth magnetic framework is provided by additive manufacturing techniques.

3 . The permanent magnet of claim 1 , wherein the rare earth magnetic framework is laser melted.

4 . The permanent magnet of claim 1 , wherein the rare earth magnetic framework includes Nd—Fe—B.

5 . The permanent magnet of claim 4 , wherein the infiltrate includes at least one of an epoxy, MnBi, Cu—P, Al—Si(Ge), and Al—Si(Ge)—Fe(Co,Cr).

6 . The permanent magnet of claim 5 , wherein the infiltrate includes the epoxy.

7 . The permanent magnet of claim 5 , wherein the infiltrate includes MnBi.

8 . The permanent magnet of claim 5 , wherein the infiltrate includes Cu—P.

9 . The permanent magnet of claim 5 , wherein the infiltrate includes Al—Si(Ge).

10 . The permanent magnet of claim 5 , wherein the infiltrate includes Al—Si(Ge)—Fe(Co, Cr).

11 . A permanent magnet comprising:
a first phase of stratified layers forming a predetermined shape defining a pathway system having a predetermined pattern; and a second phase disposed in the pathway system such that the permanent magnet includes a magnetic phase.

12 . The permanent magnet of claim 11 , wherein the first phase includes at least one of an epoxy, MnBi, Cu—P, Al—Si(Ge), and Al—Si(Ge)—Fe(Co,Cr).

13 . The permanent magnet of claim 11 , wherein the first phase includes Nd—Fe—B.

14 . The permanent magnet of claim 13 , wherein the infiltrate includes the epoxy.

15 . The permanent magnet of claim 13 , wherein the infiltrate includes MnBi.

16 . The permanent magnet of claim 13 , wherein the infiltrate includes Cu—P.

17 . The permanent magnet of claim 13 , wherein the infiltrate includes Al—Si(Ge).

18 . The permanent magnet of claim 13 , wherein the infiltrate includes Al—Si(Ge)—Fe(Co, Cr).

19 . The permanent magnet of claim 11 , wherein the pathway system is a venous pathway system.

Assignees

• Ford Global Tech Llc

Inventors

• Li Wanfeng
• Degner Michael W

Classifications

• B29C64/153

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B33Y80/00 Primary

  Products made by additive manufacturing · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title