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