Extrusion compression molded critical rare earth free bonded permanent magnet

Abstract

A method of fabricating a high energy density bonded magnet is provided. The method includes combining a critical rare earth free magnetic material with a polymeric material to obtain a mixture. The method further includes extruding the mixture, and compression molding the extruded mixture to obtain a compression molded product. The critical rare earth free magnetic material may include Sm2Fe17N3 (Sm—Fe—N) in a content of at least 95 wt. %. The polymeric material may include one or more of a polyamide, a polycarbonate, a polyphenylene sulfide, a polyether ether ketone, a polyurethane, a polytetrafluoroethylene, a thermoplastic elastomer, a polyvinyl chloride, and polyethylene. A high energy density bonded magnet formed by the method is also provided. The high energy density bonded magnet may have a maximum energy product (BHmax) of at least 20 MGOe.

Dependencies are inferred from the claim text.