Method of increasing the coercivity of a sintered Nd—Fe—B permanent magnet

1. A method of increasing coercivity of a sintered Nd-Fe-B permanent magnet, the method including the steps of:

a) providing a sintered Nd-Fe-B magnet block having a pair of block surfaces, opposite and spaced from one another, extending perpendicular to a magnetization direction;

b) depositing an organic adhesive layer, selected from one of a pressure-sensitive adhesive or a double-sided tape on one of the block surfaces of the sintered Nd-Fe-B magnet block;

c) depositing a powder containing at least one heavy rare earth element on the organic adhesive layer under an inert gas environment;

d) pressing the sintered Nd-Fe-B magnet block containing the powder to adhere the powder to the organic adhesive layer;

e) removing excess powder from the sintered Nd-Fe-B magnet block to form a film on the sintered Nd-Fe-B magnet block;

f) diffusing the powder into the sintered Nd-Fe-B magnet block under a vacuum environment or an inert gas environment to produce a diffused magnet block;

g) aging the diffused magnet block under the vacuum environment or the inert gas environment.

2. The method as set forth in claim 1 wherein the organic adhesive layer has a predetermined thickness of between 3 μm and 30 μm.

3. The method as set forth in claim 1 wherein the organic adhesive layer is a pressure-sensitive adhesive or a double-sided tape.

4. The method as set forth in claim 3 wherein said step of depositing an organic adhesive layer is further defined as screen printing the pressure-sensitive adhesive on the one of the block surfaces.

5. The method as set forth in claim 3 wherein said step of depositing is further defined as pasting the double-sided tape on the one of the block surfaces.

6. The method as set forth in claim 3 wherein the pressure-sensitive adhesive is one selected from the group consisting of an acrylic based pressure-sensitive adhesive, a silicon based pressure-sensitive adhesive, a urethane based pressure-sensitive adhesive, and a rubber based pressure sensitive adhesive.

7. The method as set forth in claim 3 wherein the double-sided tape is one selected from the group consisting of a substrate-free double-sided tape, a Polyethylene terephthalate double-sided tape, and a Polyvinyl Chloride double-sided tape.

8. The method as set forth in claim 1 wherein the at least one heavy rare earth element is one selected from the group consisting of Tb, Dy, a chemical compound containing Tb or Dy, and an alloy containing Tb or Dy.

9. The method as set forth in claim 1 wherein the powder has a particle size of between 100 mesh and 500 mesh.

10. The method as set forth in claim 1 wherein said step of diffusion is further defined as heating the sintered Nd-Fe-B magnet block containing the powder at a diffusion temperature of between 850° C. and 950° C. for a diffusion duration of between 6 hours to 72 hours.

11. The method as set forth in claim 1 wherein said step of aging is further defined heating as the diffused magnet block under an aging temperature of between 450° C. and 650° C. for an aging duration of between 3 hours and 15 hour.

12. The method as set forth in claim 1 further including the steps of:

rotating the sintered Nd-Fe-B magnet block including the film 180° along an axis orthogonal to the magnetization direction exposing another one of the block surfaces of the Nd-Fe-B magnet block prior to said step of diffusing; and

repeating steps b) e) on the another one of the block surfaces of the sintered Nd-Fe-B magnet block.

13. A method of increasing coercivity of a sintered Nd-Fe-B permanent magnet, the method including the steps of:

a) providing a sintered Nd-Fe-B magnet block having a pair of block surfaces, opposite and spaced from one another, extending perpendicular to a magnetization direction;

b) depositing an organic adhesive layer, has a predetermined thickness of between 3 μm and 30 μm, on one of the block surfaces of the sintered Nd-Fe-B magnet block with the organic adhesive layer being a pressure-sensitive adhesive or a double-sided tape;

c) depositing a powder containing at least one heavy rare earth element on the organic adhesive layer under an inert gas environment, the least one heavy rare earth element being one selected from the group consisting of Tb, Dy, a chemical compound containing Tb or Dy, and an alloy containing Tb or Dy, and the powder having a particle size of between 100 mesh and 500 mesh;

d) pressing the sintered Nd-Fe-B magnet block containing the powder to adhere the powder to the organic adhesive layer;

e) removing excess powder from the sintered Nd-Fe-B magnet block to form a film on the Nd-Fe-B magnet block;

f) rotating the sintered Nd-Fe-B magnet block including the film 180° along an axis orthogonal to the magnetization direction exposing another one of the block surfaces of the sintered Nd-Fe-B magnet block;

g) repeating steps b) e) on the another one of the block surfaces of the sintered Nd-Fe-B magnet block h) diffusing the powder into the sintered Nd-Fe-B magnet block under a vacuum environment or an inert gas environment to produce a diffused magnet block;

i) cooling the diffused magnet block;

j) aging the diffused magnet block under the vacuum environment or the inert gas environment.

14. The method as set forth in claim 13 wherein said step of depositing is further defined as screen printing the pressure-sensitive adhesive on the one of the block surfaces.

15. The method as set forth in claim 13 wherein said step of depositing is further defined as pasting the double-sided tape on the one of the block surfaces.

16. The method as set forth in claim 13 wherein the pressure-sensitive adhesive is one selected from the group consisting of an acrylic based pressure-sensitive adhesive, a silicone based pressure-sensitive adhesive, a urethane based pressure-sensitive adhesive, and a rubber based pressure sensitive adhesive.

17. The method as set forth in claim 13 wherein the double-sided tape is one selected from the group consisting of a substrate-free double-sided tape, a Polyethylene terephthalate double-sided tape, and a Polyvinyl Chloride double-sided tape.

18. The method as set forth in claim 13 wherein said step of diffusion is further defined as heating the sintered Nd-Fe-B magnet block containing the powder at a diffusion temperature of between 850° C. and 950° C. for a diffusion duration of between 6 hours to 72 hours.

19. The method as set forth in claim 13 wherein said step of aging is further defined heating as the diffused magnet block under an aging temperature of between 450° C. and 650° C. for an aging duration of between 3 hours and 15 hour.