Loading patent…
AssigneeFord Global Technologies, LLC
InventorsFeng Liang, C Bing Rong, Michael W. Degner
Estimating the term…
In at least one embodiment, a single sintered magnet is provided having a concentration profile of heavy rare-earth (HRE) elements within a continuously sintered rare-earth (RE) magnet bulk. The concentration profile may include at least one local maximum of HRE element concentration within the bulk such that a coercivity profile of the magnet has at least one local maximum within the bulk. The magnet may be formed by introducing alternating layers of an HRE containing material and a magnetic powder into a mold, pressing the layers into a green compact, and sintering the green compact to form a single, unitary magnet.
A method of forming a rare-earth magnet comprising:
The method of claim 11, wherein at least three layers of material including a HRE element or alloy are introduced into the mold.
The method of claim 11, wherein the layers of material including a HRE element or alloy have a thickness of 25 to 250 μm.
The method of claim 11, wherein the layers of material including a HRE element or alloy each have a same thickness.
The method of claim 11, wherein the material including a HRE element or alloy is a powder.
The method of claim 15, wherein the powder is selected from one of DyF3, TbF3, Dy2O3, Tb2O3, and DyFe.
The method of claim 11, wherein the material including a HRE element or alloy is a liquid.
The method of claim 11, wherein the material including a HRE element or alloy is mixed with an electrically resistive material prior to being introduced into the mold.
The method of claim 18, wherein the electrically resistive material includes a magnetic material.
Dependencies are inferred from the claim text.