Slotted magnets for selective coercivity and methods thereof

Abstract

A doped magnet and method of manufacture is described, the doped magnet comprising: a magnet volume comprising a magnet material and a dopant element; a cavity is positioned within the magnet volume. The use of the cavity enables the doped magnet to achieve a desired coercivity with reduced use of doping material without including the structural integrity of the doped magnet.

Description

[0001] Incorporation by reference into any priority application

[0002] Any and all applications for which foreign or domestic priority claims are identified in the Application Data Sheet or PCT request filed with this application are incorporated herein by reference pursuant to 37 CFR 1.57 and Rules 4.18 and 20.6. This application claims priority to U.S. Provisional Patent Application No. 63 / 381,917, filed on November 1, 2022, the disclosure of which is hereby incorporated by reference in its entirety and for all purposes. Technical Field

[0003] The present invention relates generally to magnets and, in particular, to improved magnets doped with diffused materials. Background Art

[0004] Magnetic motors, generators or rotors can be used to power various devices or vehicles. Specifically, electric vehicles can utilize magnetic motors and generators to efficiently provide electricity. Typically, magnets are manufactured by pressing, sintering and mechanically treating magnetic materials to form magnets, and the magnets can be doped using doping methods such as grain boundary diffusion (GBD). Heavy rare earth metals are commonly used as diffusion materials in magnet production to increase coercivity. Coercivity, also known as magnetic coercivity, coercive force and coercive field, is a property of a magnet that represents the amount of demagnetizing force required to reduce the magnet's induction after the magnet is magnetized.

[0005] To fully dope a magnet with a diffused material to increase coercivity, the magnet is cut completely through (e.g., through a base block in the middle) to form two smaller pieces, and the dopant is applied to all surfaces of the magnet pieces so that the dopant can diffuse more easily and extensively into the magnet material to achieve the desired level of coercivity. Once the diffusion is complete, the magnets can be bonded (e.g., glued) together to form a doped magnet with an adhesive layer disposed therebetween so that the magnetic material is not abutting. Figure 1 An example of such a GBD doping method using a doping material is shown in , where a base block magnet 202 is cut 204 into magnet pieces 206-A and magnet pieces 206-B before a GBD method 208 is performed to diffuse doping elements (e.g., terbium (Tb) and / or dysprosium (Dy)) to form doped magnet pieces 210-A and 210-B. The doped magnet pieces 210-A and 210-B are ground 210 to form ground magnet pieces 212-A and 212-B, and the ground magnet pieces 212-A and 212-B are bonded 216 back together to form a doped magnet 218.

[0006] However, it may be desirable to reduce or minimize the amount of heavy rare earth metals used in manufacturing doped magnets, minimize the use of manufacturing steps that require larger dimensional tolerances, and reduce the structural integrity of the doped magnets. For example, it may be challenging to accurately cut through and apply the correct amount of glue to the magnets, thereby increasing the mechanical tolerances associated with manufacturing doped magnets. Summary of the invention

[0007] In order to summarize the present invention and achieve advantages over the prior art, certain objects and advantages of the present invention are described herein. Not all of these objects or advantages may be achieved in any particular embodiment of the present invention. Thus, for example, those skilled in the art will recognize that the present invention may be implemented or performed in a manner that achieves or optimizes one advantage or a group of advantages as taught herein without necessarily achieving other objects or advantages as taught or suggested herein.

[0008] In a first aspect, a method of making a doped magnet is provided. The method includes forming a cavity within a magnet to form a treated magnet, wherein the cavity includes a cavity surface and the treated magnet includes an outer surface; applying a doping material including a dopant element to the cavity surface to form a coated magnet; and treating the coated magnet to form a doped magnet.

[0009] In some embodiments, the method further comprises applying a doping material to the outer surface. In some embodiments, forming the cavity comprises cutting the cavity into the magnet. In some embodiments, the method further comprises grinding the magnet before forming the cavity in the magnet. In some embodiments, the method further comprises packaging the doped magnet. In some embodiments, the dopant element is selected from the group consisting of terbium, dysprosium and combinations thereof. In some embodiments, the treated magnet comprises a continuous magnet volume. In some embodiments, the method does not comprise applying an adhesive to at least one of the treated magnet and the coated magnet. In some embodiments, forming the cavity does not comprise dividing the magnet into a plurality of separate magnet pieces. In some embodiments, heating the coated magnet diffuses the dopant element into the coated magnet. In some embodiments, the dopant element is diffused into the coated magnet through the cavity surface and the outer surface. In some embodiments, the treated magnet comprises at least one additional cavity. In some embodiments, the processing comprises heating the coated magnet.

[0010] In a second aspect, a doped magnet is provided. The coated magnet comprises: a magnet volume including a magnet material and a dopant element; and a cavity positioned within the magnet volume.

[0011] In some embodiments, the width of the cavity is approximately 0.2-1.5 mm. In some embodiments, the cavity is a slit. In some embodiments, a first proximal end of the cavity extends from a first surface of the magnet volume, and a first distal end of the cavity terminates within the magnet volume. In some embodiments, a second proximal end of the cavity extends from a second surface of the magnet volume, and a second distal end of the cavity terminates at a third surface of the magnet volume. In some embodiments, the magnet material is a neodymium magnet. In some embodiments, the doped magnet includes approximately 0.3-0.8 wt. % of a dopant element. In some embodiments, the doped magnet does not include a binder. In some embodiments, the magnet volume is continuous.

[0012] In a third aspect, a rotor is provided. The rotor includes a doped magnet.

[0013] In a fourth aspect, an electric vehicle is provided. The electric vehicle includes a rotor. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] These and other features, aspects, and advantages of the present disclosure are described with reference to the accompanying drawings of certain configurations, which are intended to schematically illustrate certain configurations and not to limit the present disclosure.

[0015] Figure 1 is a flow chart illustrating an example method of doping a magnet.

[0016] Figure 2 is a flow chart depicting an example method for forming a doped magnet according to some embodiments.

[0017] Figure 3 is a flow chart illustrating an example method for making a doped magnet according to some embodiments.

[0018] Figure 4 is a cross-sectional illustration of a coated magnet according to some embodiments.

[0019] Figure 5 is a schematic cross-sectional view of a rotor according to some embodiments.

[0020] Figures 6A-6E is a schematic cross-sectional view of a doped magnet having example dimensions and sizes according to some embodiments.

[0021] Figure 7 is a perspective view photograph of a doped magnet including slots according to some embodiments. DETAILED DESCRIPTION

[0022] Although certain preferred embodiments and examples are disclosed below, the subject matter of the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and / or uses and modifications and equivalents thereof. Therefore, the scope of the appended claims is not limited to any specific embodiment described below. For example, in any method or process disclosed herein, the actions or operations of the method or process may be performed in any suitable order and are not necessarily limited to any specific disclosed order. Various operations may be described as multiple discrete operations in sequence in a manner that helps to understand certain embodiments; however, the order of description should not be interpreted as implying that these operations are sequentially related. In addition, the structures, systems and / or devices described herein may be implemented as integrated components or separate components. In order to compare various embodiments, certain aspects and advantages of these embodiments are described. It is not necessary to achieve all of these aspects or advantages by any particular embodiment. Therefore, for example, various embodiments may be implemented in a manner that achieves or optimizes an advantage or a group of advantages as taught herein without having to achieve other aspects or advantages as taught or suggested herein.

[0023] The present disclosure generally relates to forming a cavity (e.g., a slot) into (e.g., cutting) a magnet and applying a doping material to one or more surfaces of the magnet and / or within the cavity to form a doped magnet (e.g., a selectively coercive magnet, or a magnet with reduced eddy current slots). The dopant (i.e., diffusion material) of the doping material can be incorporated into the magnet by diffusion (e.g., grain boundary diffusion (GBD)). Advantageously, the use of the cavity can enable the doped magnet to be fully doped so that the doped magnet achieves a desired coercivity while using a reduced amount of doping material. In addition, the use of the cavity can also improve the structural integrity of the doped magnet and / or improve dimensional tolerances, as well as reduce manufacturing difficulty, cost, and tolerances. Therefore, one or more aspects of the present disclosure relate to systems and methods for reducing the use of heavy rare earth materials in magnets without incurring significant changes in manufacturing methods, thereby alleviating constraints on the use of magnetic materials when the supply of magnetic materials is limited.

[0024] Certain embodiments of the present disclosure enable a method of manufacturing a doped magnet that achieves a desired coercivity and reduces the use of heavy rare earth materials while maintaining the structural integrity of the doped magnet without incurring significant manufacturing process changes or additional costs. Figure 2 An example method 300 for forming a doped magnet is depicted. A cavity is formed within a magnet 302, wherein the cavity includes a cavity surface. A doping material is then applied to the cavity surface to form a coated magnet 304. The coated magnet is then processed to form a doped magnet 306.

[0025] The magnet used to form the doped magnet can be a ferrite magnet, a gallium magnet, a boron magnet, a nickel magnet, an aluminum nickel cobalt magnet, a rare earth magnet (e.g., a neodymium magnet, a samarium cobalt magnet), or a combination thereof. In some embodiments, the magnet includes a magnet material that includes at least one of Fe, Nd, Ga, B, Co, Al, Ni, and Sm. In some embodiments, the magnet has a variety of shapes, sizes, and / or dimensions. For example, the magnet can be a cube, a cuboid, a cylinder, other geometric shapes, other custom shapes, and / or other shapes. In some embodiments, the magnet includes a continuous magnet volume so that all the magnet material of the magnet is a single continuous piece of material without another material that divides the magnet into multiple pieces. For example, a bonding material (e.g., glue, etc.) does not divide the magnet into two different pieces or regions. In some embodiments, the magnet does not include a bonding agent.

[0026] A cavity is formed in the magnet by cutting a cavity into the magnet to form a processed magnet. In some embodiments, the cavity is formed by cutting (e.g., using a wire cutter), drilling, chiseling, grinding, or a combination thereof. In some embodiments, the processed magnet includes a single cavity or multiple cavities (e.g., a first cavity and at least one additional cavity). In some embodiments, the processed magnet includes 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 cavities. In some embodiments, before forming the cavity in the magnet, the magnet is ground. In some embodiments, the magnet can be ground to a suitable size (multiple) for forming the cavity. In some embodiments, forming a cavity in the processed magnet does not include dividing the magnet into a plurality of separate magnet pieces. In some embodiments, the processed magnet includes a continuous magnet volume (e.g., without compromising the structural integrity of the processed magnet), so that all the magnet material of the processed magnet is a single continuous piece of material without another material or cavity that separates the processed magnet into a plurality of pieces. For example, an adhesive material (e.g., glue, etc.) does not separate the processed magnet into two different pieces or regions. In some embodiments, the processed magnet does not include an adhesive.

[0027] The number, position and size of the cavity formed in the magnet of processing can vary. In certain embodiments, the cavity can be formed around the middle or center of the magnet of processing, or towards the top, bottom or side of the magnet of processing, or any combination thereof. In certain embodiments, some or all of the formed cavity are different or similar in size and dimension. In certain embodiments, at least two cavities are formed at symmetrical positions around the center of the magnet of processing.

[0028] The width of the cavity is the size of the cavity measured on the surface of the magnet. In some embodiments, the width of the cavity formed is, is approximately, is at least, is at least approximately 0.05mm, 0.07mm, 0.09mm, 0.1mm, 0.11mm, 0.13mm, 0.15mm, 0.17mm, 0.19mm, 0.2mm, 0.21mm, 0.25mm, 0.5mm, 0.75mm, 1mm, 1.25mm, 1.5mm, 2mm, 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm or 5mm or any value range therebetween. The depth of the cavity is the size of the cavity measured from the surface of the magnet to the volume of the magnet. In some embodiments, the depth of the cavity within the volume of the processed magnet is, is approximately, is at least, or is at least approximately 1 mm, 1.5 mm, 2 mm, 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, 5 mm, 5.5 mm, 6 mm, 6.5 mm, 7 mm, 7.5 mm, 8 mm, 8.5 mm, 9 mm, or 10 mm, or any range of values ​​therebetween. In some embodiments, the length of the processed magnet is, is approximately, is at least, or is at least approximately 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 21 mm, 22 mm, 23 mm, 24 mm, 25 mm, 26 mm, 27 mm, 28 mm, 29 mm, or 30 mm, or any range of values ​​therebetween. In some embodiments, the height of the treated magnet is, is approximately, is at least, or is at least approximately 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 21 mm, 22 mm, 23 mm, 24 mm, or 25 mm, or any range of values ​​therebetween.

[0029] In some embodiments, the cavity has various sizes and / or shapes (e.g., slits, cylinders, cubes, cuboids, etc.). Advantageously, the cavity can increase the surface area for the dopant element of the diffused doping material. In some embodiments, the proximal end of the cavity extends from the surface of the magnet volume, and the distal end of the cavity terminates within the magnet volume. In some embodiments, the proximal end of the cavity extends from the first surface of the magnet volume, and the distal end of the cavity terminates at the second surface of the magnet volume. In some embodiments, such as slits, the first proximal end and the first distal end of the cavity extend from the surface of the magnet volume into the magnet volume, and the second proximal end and the second distal end of the cavity extend from the second surface of the magnet volume to the third surface of the magnet volume. In some embodiments, the size of the cavity (e.g., width, length, or height) can be adjusted based on the size of the magnet to be partially cut. For example, the size of the cavity can increase as the size of the magnet being processed increases.

[0030] In some embodiments, the doping material includes a dopant element. In some embodiments, the doping element is selected from Tb (terbium), Dy (dysprosium), and combinations thereof. In some embodiments, the doping material includes a dopant compound. In some embodiments, the dopant compound is selected from (Nd x Dy) 2 Fe 14 B.Dy 2 O 3 ,DyF 3 , TbF 3 or a combination thereof. In some embodiments, the doping material is in the form of a slurry. In some embodiments, the doping material slurry includes a solvent and the dopant element and / or dopant compound.

[0031] A coated magnet is formed by applying a doping material to a processed magnet. In some embodiments, the doping material is applied to a cavity (e.g., a cavity surface) and / or an outer surface of the processed magnet. In some embodiments, the doping material can be applied by spin coating, coating, pasting, or sputtering. In some embodiments, the coated magnet includes a continuous magnet volume (e.g., without compromising the structural integrity of the magnet) such that all the magnet material of the coated magnet is a single continuous piece of material without another material or cavity that divides the coated magnet into multiple pieces. For example, an adhesive material (e.g., glue, etc.) does not divide the coated magnet into two different pieces or regions. In some embodiments, the coated magnet does not include an adhesive.

[0032] The coated magnet is treated to form a doped magnet. In some embodiments, the coated magnet is treated to include heating the coated magnet. In some embodiments, the heating is performed at a temperature of, about, or at least about 350°C, 400°C, 450°C, 500°C, 550°C, 600°C, 650°C, 700°C, 750°C, 800°C, 850°C, 900°C, 950°C, 1000°C, 1200°C, 1500°C, or 2000°C or any range of values ​​therebetween. In some embodiments, the heating is performed in a vacuum, an oxidizing gas environment (e.g., O2), or an inert gas environment. In some embodiments, the coated magnet is treated to be configured to diffuse the dopant element into the coated magnet to form a doped magnet. In some embodiments, the dopant element diffuses into the coated magnet through the cavity surface and / or the outer surface of the magnet.

[0033] In some embodiments, the doped magnet includes a magnet volume and a cavity positioned within the magnet volume. In some embodiments, the magnet volume includes a magnet material and a dopant element. In some embodiments, the doped magnet is a ferrite magnet, an alnico magnet, a gallium magnet, a boron magnet, a nickel magnet, a rare earth magnet (e.g., a neodymium magnet, a samarium cobalt magnet), or a combination thereof. In some embodiments, the magnet material includes at least one of Fe, Nd, Ga, B, Co, Al, Ni, and Sm. In some embodiments, the magnet volume is continuous so that all of the magnet material of the doped magnet is a single continuous piece of material without another material or cavity that divides the magnet into multiple pieces. In some embodiments, the dopant element is selected from the group consisting of Tb, Dy, and combinations thereof. In some embodiments, the doped magnet includes about, at least, or at least about 0.05 wt.%, 0.1 wt.%, 0.15 wt.%, 0.2 wt.%, 0.25 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1 wt.%, 1.1 wt.%, 1.2 wt.%, 1.3 wt.%, 1.4 wt.%, 1.5 wt.%, 1.6 wt.%, 1.7 wt.% or 2 wt.%, or any range of values ​​therebetween, of the dopant element. In some embodiments, the doped magnet does not include a binder. In some embodiments, forming the doped magnet does not include applying a binder (e.g., glue, etc.) to at least one of the magnet, the treated magnet, and the coated magnet. Advantageously, the cost and time associated with forming the doped magnet can be reduced. In some embodiments, the doped magnet is packaged and / or tested after formation. For example, doped magnets are packaged for shipping.

[0034] Advantageously, the dopant element can more easily diffuse through the additional surfaces associated with the one or more cavities formed in the coated magnet to form a doped magnet. Furthermore, the structural integrity of the doped magnet is not compromised because the magnet volume is continuous and not completely cut through. Additionally, unlike manufacturing methods where the magnet is cut through (e.g., Figure 1 ) the cost and time for manufacturing doped magnets may be reduced compared to conventional magnets because, for example, there is no need to glue magnet blocks back or grind through the surface to which they are applied.

[0035] Figure 3An example method 400 for manufacturing a doped magnet is shown. A base magnet block 402 is provided, and grinding 404 is performed on the base magnet block 402 to form a magnet 406 having appropriate dimensions. The magnet 406 is slotted 408 to form a cavity 430 within the magnet 406, thereby obtaining a processed magnet 408-A. The cavity 430 includes one or more cavity surfaces 432 and an outer surface 428 of the processed magnet 408-A. The cavity 430 has the shape of a slit and is formed around the center / middle of the magnet 406 to produce the processed magnet 408-A.

[0036] As shown in processed magnets 408-B, 408-C, 408-D, and 408-E, cavity 430 has the shape of a slit, wherein the width of the slit can vary. For example, processed magnet 408-B shows that cavity 430 has a width of 0.80 mm, processed magnet 408-C shows that cavity 430 has a width of 1.00 mm, processed magnet 408-D shows that cavity 430 has a width of 1.20 mm, and processed magnet 408-E shows that cavity 430 has a width of 1.50 mm.

[0037] During GBD 426, doping material 434 is applied to the cavity surface(s) 432 and the outer surface 428 of the processed magnet 408-A to form a coated magnet 440. The doping material 434 is diffused into the coated magnet 440 during GBD 426 (e.g., by heating) to form a doped magnet ( Figure 3 4). The doped magnets are tested 460 and / or packaged to form magnets for shipping 480.

[0038] Figure 4 A cross-sectional view of coated magnet 540 is shown. Coated magnet 540 is coated with doping material 534, wherein doping material 534 is coated on one or more cavity surfaces 532 and outer surface 528 of cavity 530. Cavity 530 has a depth 570. Coated magnet 540 has a length 550.

[0039] Figure 5 FIG. 6 is a schematic cross-sectional view of the rotor 600. Figure 5 As shown, rotor 600 has a plurality of holes including at least hole 602, wherein hole 602 can allow doped magnets (e.g., doped magnets 700A-700E) to be mated, assembled, and / or integrated with rotor 600. In some embodiments, the rotor can be assembled and / or integrated as part of an electric motor and / or vehicle. The doped magnets as described herein can be more precisely matched to fit within hole 602 because the doped magnets are not cut through (e.g., Figure 1As shown), thereby reducing the ratio of magnets that are too small or too large for the tolerance of the rotor. In this way, the doped magnets described herein can be advantageously more accurately matched and assembled into the rotor.

[0040] Example

[0041] Figures 6A-6E Schematic cross-sectional views of doped magnets 700A-700E having exemplary dimensions / sizes are shown. Fig. 6A As shown, the doped magnet 700A includes a slit-shaped cavity 730A, wherein the slit width is 0.42 mm and the slit depth is 5.16 mm. The bottom portion of the doped magnet near the slit has a width of 3.77 mm, and the top portion of the doped magnet away from the slit has a width of 3.69 mm. The total width of the doped magnet 700A is about 7.88 mm (i.e., 0.42 mm + 3.77 mm + 3.69 mm). Figure 6B As shown, the doped magnet 700B includes a slit-shaped cavity 730B, wherein the slit width is 0.85 mm and the slit depth is 5.01 mm. The bottom portion of the doped magnet near the slit has a width of 3.53 mm, the top portion of the doped magnet away from the slit has a width of 3.49 mm, and the total width of the doped magnet 700B is about 7.87 mm (i.e., 0.85 mm + 3.53 mm + 3.49 mm). Figure 6C As shown, the doped magnet 700C includes a slit-shaped cavity 730C, wherein the slit width is 1.06 mm and the slit depth is 5.00 mm. The bottom portion of the doped magnet near the slit has a width of 3.39 mm, the top portion of the doped magnet away from the slit has a width of 3.41 mm, and the total width of the doped magnet 700C is about 7.86 mm (i.e., 1.06 mm + 3.39 mm + 3.41 mm). Fig.6D As shown, the doped magnet 700D includes a slit-shaped cavity 730D, wherein the slit width is 1.25 mm and the slit depth is 5.02 mm. The bottom portion of the doped magnet near the slit has a width of 3.23 mm, the top portion of the doped magnet away from the slit has a width of 3.39 mm, and the total width of the doped magnet 700D is about 7.87 mm (i.e., 1.25 mm + 3.23 mm + 3.39 mm). Fig. 6E As shown, the doped magnet 700E includes a slit-shaped cavity 730E, wherein the slit width is 1.54 mm and the slit depth is 5.05 mm. The bottom portion of the doped magnet near the slit has a width of 3.17 mm, the top portion of the doped magnet away from the slit has a width of 3.16 mm, and the total width of the doped magnet 700E is about 7.87 mm (i.e., 1.54 mm+3.17 mm+3.16 mm).

[0042] Figure 7 A perspective view of doped magnets including slits is shown, wherein each doped magnet is not cut completely through.

[0043] Table 1 shows example widths and weight percentages of doped neodymium magnets #1 to #5, which are formed from magnets having a length of approximately 20.5 mm, a height of approximately 7.9 mm, and a slot depth of 5 mm, wherein a wire cutter is used to form the various slot widths shown in Table 1. The width refers to the slot width of the cavity, and the weight percentage refers to the doping amount of the Tb dopant element in the composition of the doped magnet. A doping material including Tb is applied to the surface of the processed magnet and the cavity, and the coated magnet is processed to form the doped magnet. In Table 1, it is found that each of the doped magnets #1 to #5 have similar coercivity. As shown in Table 1, the cavity width can be adjusted to affect the amount of Tb required to achieve a desired doping level of approximately 5%, thereby affecting the desired coercivity.

[0044] Table 1

[0045] #1 #2 #3 #4 #5 Slit width (mm) 0.4 0.8 1 1.2 1.5 TB wt.% 0.58 0.61 0.62 0.62 0.64

[0046] It should be understood that not all objects or advantages may be achieved according to any particular embodiment described herein. Thus, for example, those skilled in the art will recognize that certain embodiments may be configured to operate in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as taught or suggested herein.

[0047] All processes described herein can be fully automated via software code modules (including one or more specific computer executable instructions executed by a computing system). The computing system may include one or more computers or processors. The code modules may be stored in any type of non-transitory computer readable medium or other computer storage device. Some or all of the methods may be implemented in dedicated computer hardware.

[0048] According to the present disclosure, many other changes except those described herein will be apparent.For example, depending on the embodiment, some actions, events or functions of any algorithm described herein can be performed in different orders, can be added, merged or completely omitted (for example, not all described actions or events are necessary for the practice of the algorithm). In addition, in certain embodiments, actions or events can be performed concurrently rather than sequentially, for example, by multithreading, interrupt processing, or multiple processors or processor cores or on other parallel architectures. In addition, different tasks or processes can be performed by different machines and / or computing systems that can work together.

[0049] The various illustrative logic blocks and modules described in conjunction with the embodiments disclosed herein may be implemented or executed by a machine designed to perform the functions described herein (e.g., a processing unit or processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof). The processor may be a microprocessor, but in an alternative, the processor may be a controller, a microcontroller, or a state machine, a combination thereof, or the like. The processor may include a circuit configured to process computer executable instructions. In another embodiment, the processor includes an FPGA or other programmable device that performs logic operations without processing computer executable instructions. The processor may also be implemented as a combination of client computing devices, such as a combination of a DSP and a microprocessor, a combination of multiple microprocessors, a combination of one or more microprocessors and a DSP core, or any other such configuration. Although primarily described herein with respect to digital technology, the processor may also primarily include analog components. The computing environment may include any type of computer system, including but not limited to a microprocessor-based computer system, a mainframe computer, a digital signal processor, a portable client computing device, a device controller, or a computing engine within an appliance, or the like.

[0050] Conditional language, such as "may," "can," "might," or "could," unless otherwise specifically stated, is understood in context as being generally used to convey that certain embodiments include and other embodiments do not include certain features, elements, and / or steps. Thus, such conditional language is generally not intended to imply that one or more embodiments require features, elements, and / or steps in any way, or that one or more embodiments must include logic for determining, with or without user input or prompting, whether such features, elements, and / or steps are included in any particular embodiment or are to be performed in any particular embodiment.

[0051] Unless specifically stated otherwise, disjunctive language, such as the phrase "at least one of X, Y, or Z," is understood along with the context to be generally used to indicate that an item, a term, etc. may be X, Y, or Z, or any combination thereof (e.g., X, Y, and / or Z). Thus, such disjunctive language is generally not intended to, and should not, imply that certain embodiments require that at least one of X, at least one of Y, or at least one of Z each be present.

[0052] Any process description, element or block in the flowcharts described herein and / or depicted in the accompanying drawings should be understood to potentially represent a module, segment or portion of code that includes one or more executable instructions for implementing a specific logical function or element in the process. Alternative implementations are included within the scope of the embodiments described herein, in which elements or functions may be deleted, performed, or performed from the order shown or discussed, including substantially simultaneously or in reverse order, depending on the functionality involved as will be understood by those skilled in the art.

[0053] Unless expressly stated otherwise, articles such as "a" or "an" should generally be interpreted as including one or more of the stated items. Thus, phrases such as "configured to" are intended to include one or more of the stated devices. Such one or more stated devices may also be configured together to perform the stated statements. For example, "a processor configured to perform statements A, B, and C" may include a first processor configured to perform statement A, the first processor working in conjunction with a second processor configured to perform statements B and C.

Claims

1. A method for producing a doped magnet, include: forming a cavity within the magnet to form a treated magnet, wherein the cavity includes a cavity surface and the treated magnet includes an outer surface; applying a doping material including a dopant element to the cavity surface to form a coated magnet; and The coated magnet is processed to form the doped magnet. 2 . The method of claim 1 , further comprising applying the doping material to the outer surface.

3. The method of claim 1 or 2, wherein forming the cavity comprises cutting the cavity into the magnet.

4. The method of any one of claims 1 to 3, further comprising grinding the magnet before forming the cavity therein.

5. The method according to any one of claims 1 to 4, further comprising packaging the doped magnet.

6. The method according to any one of claims 1 to 5, wherein the dopant element is selected from the group consisting of terbium, dysprosium and combinations thereof.

7. The method according to any one of claims 1 to 6, wherein the treated magnet comprises a continuous magnet volume.

8. The method of any one of claims 1 to 7, wherein the method does not include applying an adhesive to at least one of the treated magnet and the coated magnet.

9. The method of any one of claims 1 to 8, wherein forming the cavity does not include separating the magnet into a plurality of individual magnet pieces.

10. The method of any one of claims 1 to 9, wherein heating the coated magnet causes the dopant element to diffuse into the coated magnet.

11. The method of claim 10, wherein the dopant element is diffused into the coated magnet through the cavity surface and the outer surface.

12. The method according to any one of claims 1 to 11, wherein the treated magnet comprises at least one additional cavity.

13. A method according to any one of claims 1 to 12, wherein treating comprises heating the coated magnet.

14. A doped magnet, include: The volume of the magnet, including the magnet material and dopant elements; as well as A cavity is positioned within the magnet volume.

15. A doped magnet according to claim 14, wherein the width of the cavity is approximately 0.2-1.5 mm.

16. A doped magnet according to claim 14 or 15, wherein the cavity is a slit.

17. A doped magnet according to any one of claims 14 to 16, wherein a first proximal end of the cavity extends from a first surface of the magnet volume and a first distal end of the cavity terminates within the magnet volume.

18. A doped magnet according to any one of claims 14 to 17, wherein the second proximal end of the cavity extends from a second surface of the magnet volume and the second distal end of the cavity terminates at a third surface of the magnet volume.

19. A doped magnet according to any one of claims 14 to 18, wherein the magnet material is a neodymium magnet.

20. The doped magnet of any one of claims 14 to 19, wherein the doped magnet comprises approximately 0.3-0.8 wt. % of the dopant element.

21. The doped magnet of any one of claims 14 to 20, wherein the doped magnet does not include a binder.

22. A doped magnet according to any one of claims 14 to 21 wherein the magnet volume is continuous.

23. A rotor comprising a doped magnet according to any one of claims 14 to 22.

24. An electric vehicle comprising a rotor according to claim 23.

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