Magnetic material assembly and method of manufacturing the same

Abstract

The application discloses a magnetic material assembly which comprises a neodymium-iron-boron permanent magnet and a samarium-cobalt permanent magnet combined into one whole through an adhesive, wherein the number of the samarium-cobalt permanent magnet is at least one piece, the neodymium-iron-boron permanent magnet is a far heat source end, and the samarium-cobalt permanent magnet is a near heat source end; and the application further discloses a preparation method based on the magnetic material assembly, which comprises the following steps: preparing an adhesive, heat treating after magnet adhesion, corrosion prevention treatment, magnetization to obtain a product. The samarium-cobalt permanent magnet with high temperature resistance and the neodymium-iron-boron permanent magnet with high magnetic performance are combined into one whole through an adhesive, so that the high-performance neodymium-iron-boron magnet and the high-temperature-resistant samarium-cobalt permanent magnet are developed into a combined magnet with excellent comprehensive magnetic performance under the condition of static magnetic interaction, and the demand for high performance and high use temperature can be met simultaneously without adding heavy rare earth elements.

Description

Technical Field

[0001] This invention relates to a magnetic material component and its preparation method, belonging to the field of magnetic material components and preparation methods. Background Technology

[0002] Rare earth permanent magnet materials are currently widely used in consumer electronics, home appliances, intelligent manufacturing, and aerospace. Among them, neodymium iron boron permanent magnet materials have the strongest magnetic properties, the largest application volume, and account for more than 94% of the total output of rare earth permanent magnet materials.

[0003] With continuous optimization of manufacturing processes and magnet composition, the maximum energy product of NdFeB magnets has approached the theoretical value. However, to achieve a high energy product, the content of rare-earth neodymium is slightly higher than the material's positive fraction, and heavy rare-earth elements such as dysprosium or terbium cannot be added. This typically results in lower coercivity in high-performance NdFeB magnets, leading to lower operating temperatures and significantly limiting their application scenarios. To achieve high coercivity and operating temperature, heavy rare-earth elements such as dysprosium or terbium are usually added, but this greatly reduces the magnet's magnetic properties and increases raw material costs.

[0004] Sintered samarium cobalt permanent magnets are currently the rare-earth permanent magnet materials with the highest Curie temperature. While the remanence and energy product of sintered samarium cobalt magnets are relatively lower than those of high-performance sintered neodymium iron boron magnets, they possess extremely high Curie temperatures and ultra-high coercivity. Some products can operate at temperatures reaching 500–550°C, far exceeding the operating temperature of high-performance neodymium iron boron magnets. Furthermore, the raw material cost is significantly lower than that of sintered neodymium iron boron magnets containing the heavy rare-earth elements dysprosium and terbium under the same operating temperature conditions. Meanwhile, eddy current losses are a crucial factor that must be avoided in magnet development and design during motor operation.

[0005] However, a low-cost permanent magnet material that can meet both ultra-high operating temperature requirements and high performance with low eddy current losses has not yet been developed, and related technologies still need further development. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a magnetic material component and its preparation method, overcoming the drawback of existing NdFeB materials requiring the addition of large amounts of heavy rare earth elements to improve the coercivity and thermal stability of NdFeB magnets, which results in high costs; at the same time, it solves the problem that samarium cobalt magnets have relatively low magnetic properties and cannot meet the requirements of high-performance motors.

[0007] The technical solution adopted in this invention is as follows:

[0008] A magnetic material assembly comprising a neodymium iron boron permanent magnet and a samarium cobalt permanent magnet assembled into a single unit by an adhesive, wherein the number of samarium cobalt permanent magnets is at least one piece, and the neodymium iron boron permanent magnet is at the far end of the heat source, while the samarium cobalt permanent magnet is at the near end of the heat source.

[0009] As a preferred embodiment of the present invention, the neodymium iron boron permanent magnet is composed of grains with a grain size of 200 nm to 10 μm.

[0010] As a preferred embodiment of the present invention, the adhesive is prepared by mixing a heat-insulating material and polyoxyethylene-8-octylphenyl ether at a mass ratio of 1:0.05-0.2.

[0011] As a preferred embodiment of the present invention, the heat insulation material is prepared by adding at least one of the rare earth elements praseodymium and lanthanum in powder form and at least one of the metallic elements zirconium and yttrium in powder form, and then sintering and pulverizing the mixture.

[0012] The preparation method of the above-mentioned magnetic material component includes the following steps:

[0013] S1: Prepare a powder with a particle size of 5 μm by using ball milling or air jet milling processes, using at least one of the rare earth metals praseodymium and lanthanum, and at least one of the metallic elements zirconium and yttrium.

[0014] S2: Using cerium oxide with a fluorite structure as a base, add 10 wt.% of at least one of the rare earth elements praseodymium and lanthanum powder, and 10 wt.% of at least one of the metallic elements zirconium and yttrium powder. After mixing evenly, sinter in the range of 1000℃ to 1500℃ to prepare an oxide ceramic material. Then, use ball milling or air jet milling to prepare the oxide ceramic material into powder with a particle size of 3-30 μm.

[0015] S3: The oxide ceramic material powder and polyoxyethylene-8-octylphenyl ether are mixed evenly at a mass ratio of 1:0.05-0.2 to prepare an adhesive for later use;

[0016] S4: Cut the samarium cobalt permanent magnet to a suitable size along the easy magnetization axis, then evenly apply adhesive to the bonding surfaces of the neodymium iron boron permanent magnet and the samarium cobalt permanent magnet, cover the surface of the samarium cobalt permanent magnet with the neodymium iron boron permanent magnet, and use adhesive to bond the samarium cobalt permanent magnet and the neodymium iron boron permanent magnet together to form an assembly and compact it;

[0017] S5: The obtained components are heat-treated at the adhesive curing temperature to make the neodymium iron boron permanent magnet and the samarium cobalt permanent magnet tightly bonded together to form a whole;

[0018] S6: Perform surface anti-corrosion treatment on the obtained components;

[0019] S7: Magnetize the obtained components under pulsed magnetic field conditions until they reach magnetization saturation to obtain the final product.

[0020] The beneficial effects of this invention are as follows:

[0021] By using an adhesive to bond high-temperature-resistant samarium cobalt permanent magnets and high-magnetic-performance neodymium iron boron permanent magnets into a whole, a composite magnet with excellent comprehensive magnetic properties is developed under the condition of static magnetic interaction between high-performance neodymium iron boron magnets and high-temperature-resistant samarium cobalt magnets. This allows the requirements for high performance and high operating temperature to be met simultaneously without the addition of heavy rare earth elements. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the magnetic material component in Example 1. Detailed Implementation

[0023] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0024] A magnetic material assembly includes a neodymium iron boron permanent magnet and a samarium cobalt permanent magnet assembled into a single unit by an adhesive, wherein the number of samarium cobalt permanent magnets is at least one piece, and the neodymium iron boron permanent magnet is at the far end of the heat source, while the samarium cobalt permanent magnet is at the near end of the heat source.

[0025] Neodymium iron boron permanent magnets are composed of grains with a size ranging from 200 nm to 10 μm.

[0026] The adhesive is formulated from thermal insulation material and polyoxyethylene-8-octylphenyl ether at a mass ratio of 1:0.05-0.2.

[0027] The thermal insulation material is made by adding at least one of the rare earth elements praseodymium and lanthanum in powder form and at least one of the metallic elements zirconium and yttrium in powder form, sintering and then pulverizing.

[0028] The preparation method of the magnetic material component described above includes the following steps:

[0029] S1: Prepare a powder with a particle size of 5 μm by using ball milling or air jet milling processes, using at least one of the rare earth metals praseodymium and lanthanum, and at least one of the metallic elements zirconium and yttrium.

[0030] S2: Using cerium oxide with a fluorite structure as a base, add 10 wt.% of at least one of the rare earth elements praseodymium and lanthanum powder, and 10 wt.% of at least one of the metallic elements zirconium and yttrium powder. After mixing evenly, sinter in the range of 1000℃~1500℃ to prepare an oxide ceramic material. Then, use ball milling or air jet milling to prepare the oxide ceramic material into powder with a particle size of 3-30μm.

[0031] S3: The oxide ceramic material powder and polyoxyethylene-8-octylphenyl ether are mixed evenly at a mass ratio of 1:0.05-0.2 to prepare an adhesive for later use;

[0032] S4: Cut the samarium cobalt permanent magnet to a suitable size along the easy magnetization axis, then evenly apply adhesive to the bonding surfaces of the neodymium iron boron permanent magnet and the samarium cobalt permanent magnet, cover the surface of the samarium cobalt permanent magnet with the neodymium iron boron permanent magnet, and use adhesive to bond the samarium cobalt permanent magnet and the neodymium iron boron permanent magnet together to form an assembly and compact it;

[0033] S5: The obtained components are heat-treated at the adhesive curing temperature to make the neodymium iron boron permanent magnet and the samarium cobalt permanent magnet tightly bonded together to form a whole;

[0034] S6: Perform surface anti-corrosion treatment on the obtained components;

[0035] S7: Magnetize the obtained components under pulsed magnetic field conditions until they reach magnetization saturation to obtain the final product.

[0036] Example 1

[0037] See Figure 1 As shown, this embodiment is a magnetic material assembly, which includes a neodymium iron boron permanent magnet and a samarium cobalt permanent magnet assembled into a whole by an adhesive. There are two samarium cobalt permanent magnets, which are respectively adhered to the upper and lower surfaces of the neodymium iron boron permanent magnet. The neodymium iron boron permanent magnet is the far heat source end, and the samarium cobalt permanent magnet is the near heat source end.

[0038] Neodymium iron boron permanent magnets are composed of grains with a size ranging from 200 nm to 10 μm.

[0039] The adhesive is formulated from thermal insulation material and polyoxyethylene-8-octylphenyl ether at a mass ratio of 1:0.15.

[0040] The thermal insulation material is made by adding powdered rare earth elements praseodymium and lanthanum, as well as powdered metallic elements zirconium and yttrium, to cerium oxide with a fluorite structure as the base, followed by sintering and pulverization.

[0041] Example 2

[0042] This embodiment describes the preparation method of the magnetic material component in Example 1, including the following steps:

[0043] S1: Rare earth metals praseodymium and lanthanum, as well as metallic elements zirconium and yttrium, are prepared into powders with a particle size of 5 μm using ball milling or air jet milling processes;

[0044] S2: Using cerium oxide with a fluorite structure as a base, 10 wt.% of rare earth elements praseodymium and lanthanum powder, and 10 wt.% of metallic elements zirconium and yttrium powder are added respectively. After being mixed evenly, the mixture is sintered in the range of 1000℃~1500℃ to prepare oxide ceramic materials. Then, the oxide ceramic materials are prepared into powders with a particle size of 3-30μm by ball milling or air jet milling.

[0045] S3: Prepare an adhesive by uniformly mixing oxide ceramic material powder with polyoxyethylene-8-octylphenyl ether at a mass ratio of 1:0.15;

[0046] S4: Cut and polish the 30H samarium cobalt permanent magnet along the easy magnetization axis to a size of 10×5×3mm. 3 The sheet magnets were made by cutting neodymium iron boron permanent magnets of grade 50H into 10×5×1mm pieces. 3 The sheet magnets are then uniformly coated with adhesive on the bonding surfaces of the 50H neodymium iron boron permanent magnet and the 30H samarium cobalt permanent magnet. The neodymium iron boron permanent magnet is then placed on the surface of the samarium cobalt permanent magnet. The samarium cobalt permanent magnet and the neodymium iron boron permanent magnet are then bonded together with adhesive to form a component and compacted.

[0047] S5: The obtained components are heat-treated at the adhesive curing temperature to make the neodymium iron boron permanent magnet and the samarium cobalt permanent magnet tightly bonded together to form a whole;

[0048] S6: Perform surface anti-corrosion treatment on the obtained components;

[0049] S7: Magnetize the obtained components under pulsed magnetic field conditions until they reach magnetization saturation to obtain the final product PM.

[0050] The resulting final product PM was tested in a fluxmeter to measure the magnetic flux of the magnet at room temperature.

[0051] The final product PM was aged in a high-temperature oven at 120°C for 30 minutes and then cooled to room temperature. The magnetic flux of the magnet was then tested in a fluxmeter, and the irreversible loss rate of magnetic flux was calculated.

[0052] Samarium cobalt permanent magnets of grade 30H and neodymium iron boron permanent magnets of grade 50H were cut into magnets PM1 and PM2, respectively, which are equivalent to the size of the final product. The magnetic flux of the magnets was measured at room temperature. The magnets were then aged in a high-temperature oven at 120°C for 30 minutes and cooled to room temperature. The magnetic flux was then measured in a fluxmeter and the irreversible loss rate of the magnetic flux was calculated.

[0053] The results are shown in the table below.

[0054]

[0055]

[0056] The measured data show that the magnetic flux of the magnetic material component is higher than that of the samarium cobalt permanent magnet corresponding to comparative example PM1, mainly due to the ultra-high performance of the neodymium iron boron magnet in the combined magnet. The magnetic flux of the combined magnet is lower than that of the neodymium iron boron permanent magnet corresponding to comparative example PM2, but after aging at 120℃, the magnetic flux of the combined magnet is significantly better than that of the neodymium iron boron permanent magnet. The results indicate that, on the one hand, the adhesive with heat insulation material provided by this invention plays a role in heat insulation protection for the high-performance neodymium iron boron permanent magnet; on the other hand, the high-temperature resistant samarium cobalt permanent magnet promotes the maintenance of the high performance of the neodymium iron boron permanent magnet.

[0057] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A magnetic material component, characterized in that, The magnetic material assembly includes a neodymium iron boron permanent magnet and a samarium cobalt permanent magnet assembled into a single unit by an adhesive, wherein the number of samarium cobalt permanent magnets is at least one piece, and the neodymium iron boron permanent magnet is at the far end of the heat source, while the samarium cobalt permanent magnet is at the near end of the heat source; the preparation method includes the following steps: S1: Prepare a powder with a particle size of 5 μm by using ball milling or air jet milling processes, using at least one of the rare earth metals praseodymium and lanthanum, and at least one of the metallic elements zirconium and yttrium. S2: Using cerium oxide with a fluorite structure as a base, add 10 wt.% of at least one of the rare earth elements praseodymium and lanthanum powder, and 10 wt.% of at least one of the metallic elements zirconium and yttrium powder. After mixing evenly, sinter in the range of 1000℃~1500℃ to prepare an oxide ceramic material. Then, use ball milling or air jet milling to prepare the oxide ceramic material into powder with a particle size of 3-30μm. S3: The oxide ceramic material powder and polyoxyethylene-8-octylphenyl ether are mixed evenly at a mass ratio of 1:0.05-0.2 to prepare an adhesive for later use; S4: Cut the samarium cobalt permanent magnet to a suitable size along the easy magnetization axis, then evenly apply adhesive to the bonding surfaces of the neodymium iron boron permanent magnet and the samarium cobalt permanent magnet, cover the surface of the samarium cobalt permanent magnet with the neodymium iron boron permanent magnet, and use adhesive to bond the samarium cobalt permanent magnet and the neodymium iron boron permanent magnet together to form an assembly and compact it; S5: The obtained components are heat-treated at the adhesive curing temperature to make the neodymium iron boron permanent magnet and the samarium cobalt permanent magnet tightly bonded together to form a whole; S6: Perform surface anti-corrosion treatment on the obtained components; S7: Magnetize the obtained components under pulsed magnetic field conditions until they reach magnetization saturation to obtain the final product.

2. A magnetic material assembly according to claim 1, characterized in that, The neodymium iron boron permanent magnet is composed of grains with a grain size of 200 nm to 10 μm.

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