Magnetic circuit with multiple magnet types

Abstract

The present disclosure provides systems, methods and apparatus including a first magnet having a first remanent magnetization value and a first coercivity value, the first magnet having a first cross-sectional area substantially perpendicular to the magnetization direction of the first magnet, and a second magnet arranged in series with the first magnet, the second magnet having a second remanent magnetization value and a second coercivity value less than the first coercivity value, the second magnet having a second cross-sectional area substantially perpendicular to the magnetization direction of the second magnet, wherein the ratio of the first cross-sectional area to the second cross-sectional area is equal to or greater than the ratio of the second remanent magnetization value to the first remanent magnetization value.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Non-Provisional Patent Application No. 17 / 701,047, entitled "MAGNETIC CIRCUIT WITH MORE THAN ONE MAGNET TYPE," filed March 22, 2022, the entire contents of which are incorporated by reference herein.

[0002] Technical Field The present disclosure relates to the field of magnetic circuits, and more particularly to permanent magnets used in magnetic circuits.

[0003] 2. Description of Related Art Permanent magnets are widely used in electrical and electromechanical applications. For example, permanent magnets can be used to provide a magnetic field that can interact with a current carrying conductor. This interaction can generate a mechanical force in the conductor and magnet assembly that can be utilized in a variety of applications, such as in motors. Summary of the Invention [Means for solving the problem]

[0004] In some aspects, the technology described herein relates to an apparatus including a first magnet having a first remanent magnetization value and a first coercivity value, the first magnet having a first cross-sectional area substantially perpendicular to a magnetization direction of the first magnet, and a second magnet arranged in series with the first magnet, the second magnet having a second remanent magnetization value and a second coercivity value less than the first coercivity value and having a second cross-sectional area substantially perpendicular to the magnetization direction of the second magnet, wherein a ratio of the first cross-sectional area to the second cross-sectional area is equal to or greater than a ratio of the second remanent magnetization value to the first remanent magnetization value.

[0005] In some embodiments, the second magnet is positioned in the path of the magnetization direction of the first magnet. In some embodiments, the second remanent magnetization value is greater than the first remanent magnetization value. In some embodiments, an operating point of the second magnet, located in the second quadrant of a magnetization (BH) curve associated with the second magnet, is at a flux density value that is greater than a flux density value for a configuration in which the first cross-sectional area is equal to the second cross-sectional area.

[0006] In some embodiments, the first magnet has a shape with a non-constant cross-sectional area perpendicular to the magnetization direction of the first magnet, the first cross-sectional area being equal to the smallest cross-sectional area of ​​the non-constant cross-sectional areas. In some embodiments, the second magnet has a shape with a non-constant cross-sectional area perpendicular to the magnetization direction of the second magnet, the second cross-sectional area being equal to the largest cross-sectional area of ​​the non-constant cross-sectional areas.

[0007] In some embodiments, the first magnet has a first curved shape defined by a first curved surface and a second curved surface separated by a thickness of the first magnet, the magnetization direction of the first magnet is parallel to one radius of the first curved shape, and the first cross-sectional area includes an area of ​​a first plane perpendicular to the magnetization direction of the first magnet. In some embodiments, the first surface perpendicular to the magnetization direction of the first magnet has a smallest area among the set of planes perpendicular to the magnetization direction of the first magnet.

[0008] In some embodiments, the first magnet has a first curved shape defined by a first curved surface and a second curved surface separated by a thickness of the first magnet, the magnetization direction of the first magnet has a plurality of directions extending along a radius of the first curved shape, and the first cross-sectional area includes an area of ​​the curved surface perpendicular to the plurality of directions. In some embodiments, the curved surface perpendicular to the plurality of directions is a curved surface having a smallest area among the set of curved surfaces perpendicular to the plurality of directions.

[0009] In some embodiments, the second magnet has a second curved shape defined by a third curved surface and a fourth curved surface separated by a thickness of the second magnet, the magnetization direction of the second magnet is parallel to one radius of the second curved shape, and the second cross-sectional area includes the area of ​​a second plane perpendicular to the magnetization direction of the second magnet.

[0010] In some embodiments, the second plane perpendicular to the magnetization direction of the second magnet has the largest area among the set of planes perpendicular to the magnetization direction of the second magnet. In some embodiments, the second magnet has a second curved shape defined by a third curved surface and a fourth curved surface separated by a thickness of the second magnet, the magnetization direction of the second magnet has a plurality of directions extending along a radius of the second curved shape, and the second cross-sectional area includes the area of ​​the curved surface perpendicular to the plurality of directions. In some embodiments, the curved surface perpendicular to the plurality of directions is the curved surface having the largest area among the set of curved surfaces perpendicular to the plurality of directions.

[0011] In some aspects, the first magnet and the second magnet are separated by a spacer. In some aspects, the spacer comprises a ferromagnetic material. In some aspects, the spacer has a cross-sectional area at least equal to the larger of the first cross-sectional area and the second cross-sectional area. In some aspects, the spacer has a thickness of 3 mm or less. In some aspects, the apparatus further comprises an electric machine comprising a stator and a rotor separated from the stator by an air gap, the first magnet and the second magnet being disposed in series on only one of the stator or the rotor. In some aspects, the first magnet is disposed closer to the air gap than the second magnet. In some aspects, the electric machine comprises a plurality of poles, at least one pole of the plurality of poles comprising the first magnet and the second magnet.

[0012] In some embodiments, the first magnet is of the neodymium-iron-boron type. In some embodiments, the first magnet is of the samarium-cobalt type. In some embodiments, the second magnet comprises at least one of the iron nitride type. [Brief description of the drawings]

[0013] [Figure 1A-1B] 1A and 1B are diagrams illustrating an example of a magnetic device that includes two magnets connected in series.

[0014] [Figure 2A-2B] 2A and 2B depict exemplary graphs showing the magnetization characteristics (also known as BH curves) of two magnets connected in series.

[0015] [Figure 3A-3D] 3A-3D are diagrams showing various examples of magnet arrangements showing at least two magnets arranged in series. [Fig. 3E-3F] 3E-3F are diagrams showing various examples of magnet arrangements showing at least two magnets arranged in series.

[0016] [Figure 3G-3H] 3G-3H are diagrams showing examples of magnet arrangements that are not considered to be in series.

[0017] [Figure 4A-4C] 4A-4C are diagrams illustrating the determination of the cross-sectional area of ​​magnets having various shapes and magnetization orientations. [Fig. 4D-4E] 4D-4E are diagrams illustrating the determination of the cross-sectional area of ​​magnets having various shapes and magnetization orientations.

[0018] [Diagram 5] FIG. 5 is a diagram showing a part (one pole) of a cross section of a permanent magnet motor. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Like reference numbers and designations in the various drawings indicate like elements.

[0020] Detailed Description The various concepts presented above and described in further detail below may be implemented in any of numerous ways, as the concepts described are not limited to any particular implementation methodology, and specific implementation and application examples are provided primarily for purposes of illustration.

[0021] As will be apparent to those of skill in the art upon reading this disclosure, each of the individual embodiments described and illustrated herein has separate components and features which may be readily separated from or combined with the features of any of the other embodiments without departing from the scope or spirit of the present disclosure.

[0022] Any recited method may be carried out in the order of events recited or in any other order which is logically possible. That is, unless expressly stated otherwise, it is not intended that the methods or aspects described herein be construed as requiring that its steps be performed in a particular order. Thus, unless a method claim specifically recites in the claim or description that the steps are limited to a particular order, no order is intended to be inferred in any respect. This applies to any implicit criteria of interpretation, such as logical matters regarding the arrangement or operational flow of steps, the plain meaning derived from grammatical construction and punctuation, the number and type of aspects described in the specification, etc.

[0023] All publications mentioned herein are incorporated by reference to disclose and describe the methods and / or materials in connection with which the publications are cited. The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein should be construed as an admission that the present invention is not entitled to antedate such publications by virtue of prior invention. Further, the publication dates provided herein may be different from the actual publication dates, which may require independent confirmation.

[0024] Although aspects of the present disclosure may be described and claimed in particular legal classes, such as the legal class of systems, this is for convenience and those skilled in the art will understand that aspects of the present disclosure may be described and claimed in any legal class.

[0025] It should also be understood that the terms used herein are for the purpose of describing specific embodiments only and are not intended to be limiting.Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the disclosed compositions and methods belong.Furthermore, it should be understood that terms as defined in commonly used dictionaries should be interpreted as having a meaning consistent with the meaning in the context of the present specification and related art, and should not be interpreted in an idealized or overly formal sense unless expressly defined herein.

[0026] It should be noted that ratios, concentrations, amounts, and other numerical data can be expressed herein in a range format. It will be further understood that the endpoints of each range are significant in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values ​​disclosed herein, and that each value is also disclosed herein as "about" that particular value, in addition to the value itself. For example, if the value "10" is disclosed, then "about 10" is also disclosed. Ranges can be expressed herein as from "about" one particular value and / or to "about" another particular value. Similarly, when values ​​are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms a further aspect. For example, if the value "about 10" is disclosed, then "10" is also disclosed.

[0027] When a range is expressed, a further aspect includes from one particular value and / or to the other particular value. For example, when a stated range includes one or both limits, ranges excluding either or both of those limits are also included in the disclosure, e.g., a phrase "from x to y" includes not only a range from "x" to "y", but also a range from greater than "x" to less than "y". Ranges may also be expressed as upper limits, e.g., "about x, y, z, or less", and should be interpreted to include the specific ranges of "about x", "about y", and "about z", as well as the ranges "less than x", "less than y", and "less than z". Similarly, the phrase "about x, y, z, or greater" should be interpreted to include the specific ranges of "about x", "about y", and "about z", as well as the ranges "greater than x", "greater than y", and "greater than z". Furthermore, the phrase "about 'x' to 'y'" includes "about 'x' to about 'y'", where "x" and "y" are numerical values.

[0028] It should be understood that such range formats are used for convenience and brevity and should be interpreted flexibly to include not only the numerical values ​​expressly recited as range limits, but also all individual numerical values ​​or subranges subsumed within the range as if each numerical value and subrange were expressly recited. By way of example, a numerical range of "about 0.1% to about 5%" should be interpreted to include not only the explicit numerical values ​​of about 0.1% to about 5%, but also the individual numerical values ​​(e.g., about 1%, about 2%, about 3%, about 4%) and subranges (e.g., about 0.5% to about 1.1%, about 5% to about 2.4%, about 0.5% to about 3.2%, about 0.5% to about 4.4%, and other possible subranges).

[0029] As used herein, the terms "about," "approximate," "at or about," and "substantially" mean that the amount or value in question may be an exact value or a value that provides an equivalent result or effect as claimed or taught herein. That is, it is understood that amounts, sizes, formulations, parameters, and other quantities and characteristics are not, and need not be, exact, but may be approximated and / or larger or smaller, as desired, to reflect tolerances, conversion factors, rounding, measurement errors, and the like, as well as other factors known to those skilled in the art that would provide an equivalent result or effect. In some circumstances, values ​​that would provide an equivalent result or effect cannot be reasonably determined. In such cases, as used herein, "about" and "at or about" are generally understood to mean a variation of ±10% of the nominal value indicated, unless otherwise indicated or inferred. In general, an amount, size, formulation, parameter, or other quantity or characteristic is "about," "approximate," or "at or about," whether or not expressly stated as such. When "about," "approximate," or "at or about" is used in front of a quantitative value, it is understood that the parameter also includes the particular quantitative value itself, unless specifically stated otherwise.

[0030] Prior to describing the various aspects of this disclosure, the following definitions are provided and should be used unless otherwise indicated. Additional terms may be defined elsewhere in this disclosure.

[0031] As used herein, "comprising" is to be construed as specifying the presence of the stated features, integers, steps, or components referred to, but does not exclude the presence or addition of one or more features, integers, steps, or components, or groups thereof. Additionally, the terms "by," "comprising," "comprises," "comprised of," "including," "includes," "included," "involving," "involves," "involved," and "such as" are used in their open, non-limiting sense and may be used interchangeably. Additionally, the term "comprising" is intended to include examples and aspects encompassed by the terms "consisting essentially of" and "consisting of." Similarly, the term "consisting essentially of" is intended to include examples encompassed by the term "consisting of."

[0032] As used herein, the term "and / or" includes any and all combinations of one or more of the associated list items. Phrases such as "at least one of," when preceding a list of elements, modify the entire list of elements and do not modify each individual element of the list.

[0033] As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a "proton beam degrader," a "degrader foil," or a "conduit" includes, but is not limited to, two or more such proton beam degraders, degrader foils, or conduits.

[0034] The various concepts presented above and described in further detail below may be implemented in any of numerous ways, as the concepts described are not limited to any particular manner of implementation. Specific examples and applications are provided primarily for purposes of illustration.

[0035] As used herein, the term "optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event or circumstance occurs and instances where it does not occur.

[0036] Permanent magnets are commonly used in a variety of devices, such as electric motors, electric generators, and electric actuators, where they provide a magnetic field that interacts with current-carrying or moving conductors. Permanent magnets have a remanent magnetization (B r ) and coercivity (H c ). The remanent magnetization of a permanent magnet generally refers to the magnetization of the magnet in the absence of an external magnetic field. Remanent magnetization is the magnetic flux density (B) when the external magnetic field (H) is zero. r ) can be measured as the coercive force of a permanent magnet (H c) generally refers to the magnitude of an external magnetic field that a permanent magnet can withstand without demagnetizing. Coercivity can be measured as the magnitude of the external magnetic field when the magnetic flux density becomes zero. It is desirable for a permanent magnet to have high remanence and high coercivity. For example, when permanent magnets are used in electric machines such as motors, they may encounter magnetic fields emanating from other magnets or current-carrying conductors. These magnetic fields may be large enough to permanently demagnetize the permanent magnet. Demagnetized permanent magnets must be replaced, increasing the operating costs of the electric machine.

[0037] One approach to reduce the risk of demagnetization is to use permanent magnets that have both high coercivity and high remanence. However, many permanent magnets with both high coercivity and high remanence are expensive, increasing the cost of the electric machine. However, there are also examples of relatively inexpensive magnets that have low coercivity but high remanence. The use of such magnets reduces costs, but increases the risk of demagnetization due to their low coercivity. Another approach is to reduce the magnitude of the demagnetizing field generated by the electric machine. In most cases, this is limited by limiting the current flowing through the current carrying conductors. However, limiting the current may also limit the torque generated by the electric machine. That is, on the one hand, limiting the magnitude of the demagnetizing field reduces the risk of demagnetizing the permanent magnets, but on the other hand, limiting the current flowing through the current carrying conductors limits the torque generated by the electric machine. Since it is desirable to extract as much torque as possible from the electric machine, limiting the generated torque may be undesirable.

[0038] As described in detail herein, one approach to reducing the risk of demagnetization and reducing the costs associated with high remanence and high coercivity permanent magnets without reducing torque production is to utilize multiple permanent magnets in series. Specifically, a first magnet having high coercivity is placed in series with a second magnet having a coercivity value less than the coercivity value of the first magnet. In addition to being placed in series, the dimensions of the first and second magnets are selected such that the flux density of the second magnet is higher when the first magnet is placed in series than when the first magnet is not placed in series. As described in more detail below, this increased flux density of the second magnet shifts the operating point of the second magnet, increasing the opposing magnetic field while reducing the risk of demagnetization of the second magnet. The increased opposing magnetic field translates into the ability to use a higher current in the current carrying conductor, producing more torque.

[0039] FIGURE 1A illustrates an exemplary first magnetic device 100 that includes two magnets arranged in series. Specifically, FIGURE 1A illustrates a first magnetic device 100 that includes a first magnet 102 arranged in series with a second magnet 104. The first magnet 102 has a first remanent magnetization value B r1 and the first coercivity value H c1 and the second magnet 104 has a second remanent magnetization value B r2 and the second coercivity value H c2 In the first magnetic device 100, the second coercivity value H c2 is the first coercivity value H c1 Additionally, the first magnet 102 has a first cross-sectional area S1, and the second magnet 104 has a second cross-sectional area S2.

[0040] FIG. 1B illustrates an exemplary second magnetic device 200 including two magnets in series separated by a spacer. Specifically, the second magnetic device 200 includes a first magnet 102 and a second magnet 104 separated by a spacer 202. In some examples, the spacer 202 is a ferromagnetic material. In some examples, the spacer 202 can include a ferromagnetic material, such as, for example, iron, steel, cobalt, nickel, neodymium, and the like. The spacer 202 can have a cross-sectional area at least as large as the effective cross-sectional area S1 of the first magnet 102 and the effective cross-sectional area S1 is larger than the cross-sectional area S2 of the second magnet 104, as shown in FIG. 1B for example. In some examples, the spacer 202 can be positioned such that the periphery of the spacer 202 coincides with or extends beyond the periphery of the first magnet 102. In the example shown in FIG. 1B, the periphery of the spacer 202 coincides with the periphery of the first magnet 102 (or the magnet with the larger surface area), but in other examples, the periphery may extend beyond the periphery of the first magnet 102 (or the magnet with the larger surface area). The presence of the spacer 202, and in particular the ferromagnetic spacer, helps redirect the magnetic flux as it leaves one of the magnets (e.g., the second magnet) before entering the other magnet (in the same example, the first magnet). This redirection of the magnetic flux allows for a fuller utilization of the total volume of the two magnets. Thus, optimal effect is achieved if the spacer 202 is wider than both magnets or at least as wide as the wider of the two magnets (example shown in FIG. 1B). The magnetic permeability of typical ferromagnetic materials (e.g., steel) is orders of magnitude greater than both the magnetic permeability of air and typical magnet materials, so the spacer 202 does not need to be thick. In fact, the primary constraint in determining the spacer thickness may not be for magnetic reasons, but rather for mechanical properties and manufacturing convenience.

[0041] In some examples, the spacer can have a shape and dimensions such that there is no intentional air gap between a surface of the spacer 202 and an adjacent magnet. For example, a surface of the spacer 202 adjacent to the first magnet 102 can have a shape that matches the shape of the surface of the first magnet 102 that faces the spacer. Similarly, a surface of the spacer 202 adjacent to the second magnet 104 can have a shape that matches the shape of the surface of the second magnet 104 that faces the spacer 202. In some examples, the thickness of the spacer can have a value between 1 mm and 5 mm, or can be 3 mm.

[0042] The series combination of the first magnet 102 and the second magnet 104, with the relative dimensions described below, allows the combination to have a lower risk of demagnetization. Specifically, such a series combination shifts the operating point of the magnet with the lower coercivity, reducing the risk of demagnetization of that magnet. Figures 2A and 2B show exemplary graphs depicting the BH characteristics of two magnets arranged in series. The same BH curves are shown in both Figures 2A and 2B, reflecting the use of the same magnet material for the first and second magnets. The difference between the two figures lies in the operating points of the two magnets. Specifically, Figure 2A shows a situation where the first magnet 102 and the second magnet 104 have similar effective cross-sectional areas, while Figure 2B shows another situation where the two magnets have different effective cross-sectional areas. Specifically, the ratio of the effective cross-sectional area of ​​the first magnet 102 to the effective cross-sectional area of ​​the second magnet 104 is equal to or greater than the ratio of the remanence value of the second magnet 104 to the remanence value of the first magnet 102. With reference to FIG. 2A, the x-axis represents the applied magnetic field (H) and the y-axis represents the magnetic flux density (B) of the magnets. Note that FIGS. 2A and 2B show portions of the BH curves of the two magnets (specifically the upper left quadrant). Generally, such BH curves are called hysteresis curves or magnetization curves. The upper left portion of the BH curves shows the magnetic flux density of the magnets in response to an opposing magnetic field (indicated by a negative value on the x-axis) H.

[0043] As mentioned above, a permanent magnet is magnetized in part by its remanent magnetization (B r ) and its coercive force (H c) can be characterized by the remanence (BH) of the second magnet 104. Referring to the BH curve of the second magnet in FIG. r ) can be determined by the value of the magnetic flux density B when the value of the magnetic field H is equal to zero. r The value of is indicated by the value of magnetic flux density B at which the BH curve intersects the y-axis. c ) can be determined by the value of the magnetic field H at which the magnetic flux density B is equal to zero. c The value of is indicated by the value of the magnetic field H at which the BH curve crosses the x-axis. In the example shown in FIGS. 2A and 2B, the coercive force H of the first magnet 102 is c1 is the coercive force H of the second magnet 104 c2 is larger than the residual magnetization B r1 is the residual magnetization B of the second magnet 104 r2 Less than.

[0044] Magnets can also be characterized by a demagnetization point (or commonly referred to as a "demagnetization knee"), which refers to the point on the BH curve where the magnetic flux density drops rapidly in response to a further increase in the magnitude of the opposing magnetic field. Operation of a permanent magnet beyond the demagnetization point may increase the risk of the permanent magnet demagnetizing. For example, referring to the BH curve of the second magnet in FIG. 2A, the BH curve decreases substantially linearly as a function of increasing magnitude of the opposing magnetic field from the point where the BH curve crosses the y-axis to the demagnetization point. As the magnitude of the opposing magnetic field is further increased, the BH curve drops nonlinearly and fairly quickly. Beyond the demagnetization point, the magnet may demagnetize irreversibly.

[0045] It is desirable to design the second magnet 104 so that its operating point does not fall below the demagnetization point on the BH curve. It should be noted that the operating point of a permanent magnet is the intersection of the BH curve with the load line (also known as the permeability line). The operating point indicates the magnetic flux density that corresponds to the magnitude of the opposing magnetic field. As long as the operating point remains above the demagnetization point on the BH curve, when the opposing magnetic field is removed, the operating point will drop to a residual magnetization value B rHowever, if the operating point of the permanent magnet falls below the demagnetization point, the operating point will return to the original residual magnetization value B even if the opposing magnetic field is removed. r Instead, the operating point will likely return to a value less than the original remanent magnetization value, indicating an irreversible demagnetization of the permanent magnet.

[0046] Considering the two magnets 104 and 102 individually (i.e., not in close proximity, but in a similar magnetic circuit), each magnet will have an operating point on its own BH curve. In many cases, when the two magnets have equal effective cross-sectional areas and are in a similar magnetic circuit, the operating point of the second magnet 104 will be at a higher magnetic flux density than the operating point of the first magnet 102 due to the stronger residual magnetization of the magnet 104. When placed in series and the effective cross-sectional areas of the two magnets are equal, however, flux conservation will cause the operating point of the second magnet 104 to be "biased down" or pulled further down on the BH curve of the second magnet. This can be seen in FIG. 2A, where the operating points of the first magnet 102 and the second magnet 104 have equal magnetic flux densities (B1=B2). The downward bias of the operating point of the second magnet 104 will bring it closer to the demagnetization point, which, as mentioned above, increases the risk of permanent demagnetization of the second magnet 104, which has a lower coercivity than the first magnet 102.

[0047] To mitigate the risk of demagnetization, the relative dimensions of the first magnet 102 and the second magnet 104 can be selected such that the operating point of the second magnet 104 (which has a relatively low coercivity) is biased upwards, away from the demagnetization point. In particular, the ratio of the effective surface area S1 of the first magnet 102 to the effective surface area S2 of the second magnet 104 is approximately 1 / 2 the remanence magnetization value B of the first magnet 102. r1 The residual magnetization value B of the second magnet 104 with respect to r2 is equal to or greater than the ratio of

number

[0048] Equation (1) suggests that the relative size of magnets in series is a function of the relative remanence of the magnets. In some instances, if the second magnet 104 has a remanence value greater than that of the first magnet 102, the effective cross-sectional area of ​​the second magnet 104 will be less than that of the first magnet 102. The extent to which the effective cross-sectional area of ​​the second magnet 104 is less than that of the first magnet 102 depends on the ratio of the remanences of the two magnets. FIG. 2B shows an example of the resulting relative location of the operating point of the second magnet 104. Specifically, by ensuring that the effective surface areas of the first magnet 102 and the second magnet 104 satisfy equation (1) above, flux conservation moves the operating point of the second magnet 104 further away from the demagnetization point on the BH curve. As a result, the risk of demagnetization of the second magnet 104 is reduced. Conversely, the operating point of the first magnet will be lower, but this is acceptable because the first magnet has a higher coercive force.

[0049] As discussed above, currently known permanent magnets that have both high coercivity and high remanence values ​​(such as neodymium-iron-boron and samarium-cobalt based magnets) are expensive, limiting or even prohibiting their use in many applications. Other currently known magnets have high remanence values ​​but low coercivity and are relatively inexpensive, such as iron nitride based magnets. By utilizing a series combination of a first magnet 102 with high coercivity and a second magnet 104 with relatively low coercivity and relatively low cost, a desired level of performance in an application can be achieved while reducing the overall cost of using permanent magnets. That is, whereas previously the entire magnet was constructed from expensive high coercivity material, in the series combination only a portion of the entire magnetic system is constructed from expensive high coercivity material and the remainder of the magnetic system is constructed from relatively inexpensive low coercivity material.

[0050] Also described above was a technique for mitigating demagnetization by reducing the current in the current carrying conductors that generate an opposing and demagnetizing magnetic field. This technique affected the maximum torque that the electric machine could generate. However, by utilizing the series combination of magnets described herein, the current in the current carrying conductors is not affected or can at least be increased, potentially resulting in higher torque from a given electric machine. For example, referring to FIG. 2B, the "upward deflection" of the operating point of the second magnet 104 moves the operating point of the second magnet 104 away from the demagnetization point. This provides a larger margin in terms of magnetic field strength to operate the second magnet 104 before risk of demagnetization occurs. This larger margin translates to a larger current in the current carrying conductors in the electric machine, thereby allowing the electric machine to generate a relatively large torque before risk of irreversible demagnetization.

[0051] In the description of the first magnetic device 100 and the second magnetic device 200, it was mentioned that the first magnet 102 is disposed in series with the second magnet 104. As used herein, disposing a first magnet in series with a second magnet means that the second magnet is disposed with respect to the first magnet such that the entire magnetic flux of the second magnet crosses at least a portion of the first magnet in a magnetic circuit partially formed by the first magnet and the second magnet. "Entire magnetic flux" excludes leakage flux occurring within the second magnet or magnetic circuit.

[0052] FIG. 3A shows an example of a serial arrangement of two magnets. Specifically, FIG. 3A shows a first magnet 102 and a second magnet 104 in a serial arrangement. The first magnet 102 can have a cylindrical or rectangular shape with a constant cross-sectional area along its magnetization direction. Similarly, the second magnet 104 can have a cylindrical or rectangular shape with a constant cross-sectional area along its magnetization direction. For illustration purposes, the magnets in FIG. 3B-3H can have a similar shape to that shown in FIG. 3A, although the dimensions may differ. However, it should be noted that the cylindrical or rectangular shape is merely exemplary and does not limit the types of magnet shapes that can be employed. The first magnet 102 has a first magnetization direction 302 and the second magnet has a second magnetization direction 304. The first magnet 102 and the second magnet 104 may, in part, form a magnetic circuit 306, which may include one or more closed loop paths that include the magnetic flux generated by the first magnet 102 and the second magnet 104. The magnetic circuit 306 may include additional components, such as portions of a rotor or stator, air gaps, etc., in which the magnetic flux is contained. The entirety of the magnetic flux 308 of the second magnet 104 traverses at least a portion of the first magnet 102. In some instances, some leakage flux may be generated by the second magnet 104. In the present context, the entirety of the magnetic flux 308 does not include the leakage flux.

[0053] Figure 3B shows another example arrangement of two magnets. Specifically, the arrangement shown in Figure 3B is similar to the arrangement shown in Figure 3A, except that it includes a spacer similar to the spacer 202 shown in Figure 2B. In this arrangement, the entire magnetic flux 308 of the second magnet 104 also crosses at least a portion of the first magnet 102.

[0054] FIG. 3C shows another example arrangement of two magnets. In particular, the arrangement shown in FIG. 3C shows additional elements such as steel (310 and 312) and an air gap that typically form part of a magnetic circuit in an electric machine, such as a motor or generator. Specifically, a first steel element 310 is disposed adjacent to the first magnet 102 and between the first magnet 102 and the air gap, and a second steel element 312 is disposed adjacent to the second magnet 104. The steel elements 310 and 312 and the air gap form part of a magnetic circuit 306. Again, in this arrangement, the magnetic circuit 306 is formed in part by the first magnet 102 and the second magnet 104, with the entire magnetic flux 308 of the second magnet 104 crossing the first magnet 102. Although the arrangement shows steel elements, it is understood that other ferromagnetic materials may also form part of the magnetic circuit 306.

[0055] FIG. 3D shows an example of a three magnet arrangement. In this arrangement, two magnets are arranged in series with the first magnet 102. Specifically, a second magnet 104 and a third magnet 314 are each arranged in series with the first magnet 102. The third magnet 314 has a magnetization direction 316 that is parallel to the magnetization direction 304 of the second magnet 104. It should be noted that in this arrangement, the second magnet 104 is not in series with the third magnet 314 because the magnetic flux 308 of the second magnet 104 does not cross the third magnet 314. However, the second magnet 104 is in series with the first magnet 102 because the entire magnetic flux 308 of the second magnet 104 crosses the first magnet 102.

[0056] 3E shows yet another arrangement of two magnets, where the length of the second magnet 104 is disposed perpendicular to the length of the first magnet 102. The first magnet 102 and the second magnet 104 form, in part, a magnetic circuit 318. Within the magnetic circuit 318, the entire magnetic flux 308 of the second magnet traverses at least a portion of the first magnet 102. A portion 320 of the first magnet 102 is not traversed by the magnetic flux 308 of the second magnet 104. However, since the entire magnetic flux 308 traverses "at least a portion of the first magnet 102," the second magnet 104 can be considered to be in series with the first magnet 102.

[0057] FIG. 3F shows yet another arrangement of two magnets. This arrangement is similar to the arrangement shown in FIG. 3E, but includes a complete magnetic circuit. This arrangement includes a first magnet 102, a first air gap 324, a first steel core 326 wound with a coil 328, a second air gap 330, and a second steel core 332. The coil 328 can carry a current to magnetize the first steel core 326. The first air gap 324 is between the first magnet and one end of the first steel core 326, and the second air gap 330 is between a second end of the first steel core 326 and the second steel core 332. The arrangement shown in Fig. 3F may represent a portion of an electric machine, where the first steel core 326 represents a portion of the stator, and the combination of the second steel core 332, the first magnet 102, and the second magnet 104 may represent a portion of the rotor, with the first air gap 324 and the second air gap 330 allowing the rotor to move relative to the stator. The first magnet 102 includes a portion 334 that is not traversed by the magnetic flux 308 of the second magnet 104. Similar to the arrangement shown in Fig. 3E, in the arrangement shown in Fig. 3F, the second magnet 104 is in series with the first magnet 102, since the entirety of the magnetic flux 308 of the second magnet 104 traverses at least a portion of the first magnet 102 within the magnetic circuit 322 formed in part by the first magnet 102 and the second magnet 104.

[0058] FIG. 3G illustrates another arrangement in which the two magnets are not in series. Specifically, the arrangement of FIG. 3G shows that the second magnet 104 is disposed adjacent to the first steel element 310, and the first magnet 102 is disposed adjacent to the second steel element 312. The third magnet 336 is disposed parallel to the first magnet 102 and has a magnetization direction 340 parallel to the first magnet 102. The third magnet 336 may have similar properties to the second magnet 102, but this is not necessary. For example, the third magnet 336 can have the same coercivity and remanence values ​​as the second magnet 104. In this arrangement, at least a portion of the second magnet 104 is not in series with the first magnet 102. This is because, although the magnetization direction of both magnets is the same, the entire magnetic flux 308 of the second magnet does not cross the first magnet 102. Therefore, the second magnet 104 is not considered to be in series with the first magnet 102 .

[0059] 3H shows another arrangement in which the two magnets are not in series. In this arrangement, at least a portion of the magnetic flux 308 of the second magnet 104 does not cross the first magnet 102. Thus, the second magnet 104 is not in series with the first magnet 102.

[0060] Referring to equation (1) above, the left side of equation (1) is the ratio of the effective surface area S1 of the first magnet 102 to the effective surface area S2 of the second magnet 104. This ratio, or the relative size of the magnets, may be a function of the relative remanence of the two magnets. In general, the effective surface area of ​​a magnet is the cross-sectional area of ​​the magnet perpendicular to the magnet's magnetization direction. If the magnet is shaped like a cylinder or a rectangular solid (such as the first magnet 102 and the second magnet 104 described above in connection with FIGS. 3A-3F) and the direction of magnetization is along the magnet's longitudinal axis, the effective cross-sectional area may be the cross-sectional area of ​​the actual magnet. However, if the direction of magnetization is not along the longitudinal axis or if the magnet's shape is not uniform in cross-sectional area along the direction of magnetization, the cross-sectional area perpendicular to the longitudinal axis is not representative of the effective cross-sectional area. In such cases, further consideration is required to determine the effective cross-sectional area.

[0061] FIG. 4A illustrates a permanent magnet 400 that has a non-constant cross-sectional area perpendicular to the magnetization direction. The magnet 400 includes a first surface 402, a parallel second surface 404 opposite the first surface 402, and a number of side surfaces 406 extending between the periphery of the first surface 402 and the second surface 404. The first surface 402 has a surface area that is greater than the surface area of ​​the second surface 404. As a result, the number of side surfaces 406 form a non-perpendicular angle with both the first surface 402 and the second surface 404. Additionally, the cross-sectional area of ​​the magnet 400 is not constant or equal along the length of the magnet 400. The magnet 400 has a magnetization direction indicated by an arrow 408 and is substantially perpendicular to the first surface 402 and the second surface 404. Given the shape of the magnet 400 that has a non-constant cross-sectional area along the magnetization direction, consideration must be given to which of the multiple cross-sectional areas should be selected to represent the effective cross-sectional area. One factor that may influence the selection may be whether the magnet 400 is being used as the first magnet 102 or the second magnet 104. In other words, the selection of the cross-sectional area may depend on whether the magnet 400 that is to be placed in series with the other magnet is a magnet with a higher coercivity or a magnet with a lower coercivity.

[0062] If magnet 400 is a magnet with a coercivity lower than the coercivity of the other magnets in the series, then the effective cross-sectional area will be equal to the largest of the non-constant cross-sectional areas. At least one reason for choosing the largest of the non-constant surface areas is that for low coercivity magnets, the magnetic flux density is lowest at the largest cross-sectional area, and therefore this is the area where the magnet is most susceptible to demagnetization. Thus, the effective surface area of ​​the low coercivity magnet is the cross-sectional area where the magnetic flux density is lowest. For magnet 400 shown in FIG. 4A, the largest cross-sectional area is the area of ​​first surface 402.

[0063] If magnet 400 is a magnet with a coercivity higher than the coercivity of the other magnets in the series, then the effective cross-sectional area will be equal to the smallest cross-sectional area among the non-constant cross-sectional areas. Thus, if magnet 400 is utilized as first magnet 102, then the effective cross-sectional area will be the area of ​​second surface 404 that has the smallest cross-sectional area among all the non-constant cross-sectional areas.

[0064] It should be noted that when determining the cross-sectional area, only the portion of the magnet 400 that is in the magnetic circuit formed in part by the magnets in series should be considered. For example, referring to FIG. 3F, the portion 334 of the first magnet 102 may not be considered when determining the effective cross-sectional area of ​​the magnet. This ensures that only the portions of the magnet that carry magnetic flux from the second magnet 104, and thus affect the magnetic flux density of the magnet, are included in determining the effective cross-sectional area in the manner described above.

[0065] FIG. 4B illustrates another exemplary permanent magnet 410 that does not have a constant cross-sectional area perpendicular to the magnetization direction. The permanent magnet 410 is similar in shape to the permanent magnet 400 illustrated in FIG. 4A, but unlike the permanent magnet 400, whose magnetization direction, indicated by arrow 408, is substantially perpendicular to the first and second surfaces 402, 404, the magnetization direction, indicated by arrow 412, of the magnet 410 is non-perpendicular to both the first and second surfaces 402, 404. As a result, the cross-sectional area is not constant along the magnetization direction. An example of a cross-sectional area, indicated by a dashed line, illustrates a cross-sectional area within a magnet that is at an angle to the first and second surfaces 402, 404, but perpendicular to the magnetization direction. Similar to the approach described in connection with FIG. 4A, the effective cross-sectional area of ​​the magnet depends on whether the magnet 410 is utilized as a high coercivity magnet or a low coercivity magnet in a series arrangement. If the magnet 410 is utilized as a magnet with a lower coercivity (e.g., the second magnet 104), the effective cross-sectional area will be the largest cross-sectional area within the magnet 410 perpendicular to the magnetization direction indicated by arrow 412. If the magnet 410 is utilized as a magnet with a higher coercivity (e.g., the first magnet 102), the effective cross-sectional area will be equal to the smallest cross-sectional area within the magnet 410 perpendicular to the magnetization direction.

[0066] FIG. 4C illustrates another exemplary permanent magnet 414 with magnetization along multiple directions. Specifically, arrows 416 indicate the magnetization directions of the magnet 414. In such an example, the cross-sectional area can be a curved surface within the magnet 414, the curved surface being shaped such that each direction of magnetization is normal to the curved surface. There can be multiple such curved surfaces along the length of the magnet 414. If the magnet 414 is a magnet with a lower coercivity when placed in series with other magnets (e.g., the second magnet 104), the effective cross-sectional area of ​​the magnet 414 is the area of ​​the largest curved surface of the multiple curved surfaces. On the other hand, if the magnet 414 has a higher coercivity, the effective cross-sectional area is the area of ​​the smallest curved surface of the multiple curved surfaces within the magnet 414.

[0067] FIG. 4D illustrates yet another example of a permanent magnet in which the magnet 418 has a curved shape. Specifically, the magnet 418 has a curved shape defined by a first curved surface 420 and a second curved surface 422 separated by the thickness T of the magnet. The magnetization direction, indicated by the arrow 424, is parallel to one of the radii 426 of the curved shape of the magnet 418. The magnet 418 may have multiple cross sections perpendicular to the magnetization direction. If the magnet 418 is a magnet with a lower coercivity when placed in series with other magnets (e.g., the second magnet 104), the effective cross-sectional area of ​​the magnet 418 is the area of ​​the first plane 428, which has the largest area. On the other hand, if the magnet 418 is a magnet with a higher coercivity when placed in series with other magnets (e.g., the first magnet 102), the effective cross-sectional area of ​​the magnet is the area of ​​the second plane 430, which has the smallest area. It should be noted that the second plane 430 may be located outside the shape of the magnet 418.

[0068] FIG. 4E illustrates yet another example of a permanent magnet in which the magnet 432 has a curved shape. In this example, the direction of magnetization may have multiple directions, as indicated by the arrow 424. For example, the curved shape of the magnet 432 may have multiple radii extending from an imaginary center, and the direction of magnetization may extend along these radii. The magnet 432 may include multiple curved surfaces, with each of the directions of magnetization for each curved surface being perpendicular to the curved surface. If the magnet 432 is a magnet with a lower coercivity when placed in series with other magnets (e.g., the second magnet 104), the effective cross-sectional area of ​​the magnet 432 will be the area of ​​the largest curved surface of the multiple curved surfaces, in this case the first curved surface 420. On the other hand, if the magnet 432 is a magnet with a higher coercivity when placed in series with other magnets (e.g., the first magnet 102), the effective cross-sectional area of ​​the magnet 432 will be the area of ​​the smallest curved surface of the multiple curved surfaces, in this case the second curved surface 422.

[0069] It should be noted that the above examples are not limiting and are merely provided as examples for determining the cross-sectional area of ​​magnets of different shapes. The cross-sectional area of ​​magnets of shapes other than those described above can be determined using techniques similar to those described above in connection with Figures 4A-4E.

[0070] The magnetic devices described herein may be utilized in a number of applications. By way of example, the magnetic devices may be utilized in electric machines, such as electric motors and generators. FIG. 5 is a cutaway view of a cross section of a permanent magnet motor 500. The portion of the motor 500 illustrated in FIG. 5 is, by way of example, one pole of the machine 500, specifically one of two poles in a pole pair, with this exemplary machine having three pole pairs. Specifically, the motor 500 includes a rotor 502 and a stator 504 separated by an air gap 506. The stator 504 includes one or more coil windings 510 that include current carrying conductors. The rotor 502 includes a magnetic device 508. The magnetic device 508 may include at least a first magnet 512, a second magnet 514, and a spacer 516 that separates the first magnet 512 and the second magnet 514. The first magnet 512 and the second magnet 514 may be similar to the first magnet 102 and the second magnet 104 described above. In some examples, the magnetic device 508 may not include a spacer 516. In some examples, the additional magnetic poles may or may not include a series configuration of the magnetic device 508, and instead may include only one type of magnet.

[0071] The magnetic device 508 is positioned such that the first magnet 512 is closer to the air gap 506 than the second magnet 514. This reduces the risk that the magnetic field generated by the current carrying conductors of the coil windings 510 will demagnetize the second magnet 514.

[0072] As mentioned above, the series arrangement of the first and second magnets reduces the risk of demagnetization of the second magnet. As a result, the magnets can maintain a higher magnetic field strength. These magnetic fields are generated by current carrying conductors in one or more coil windings 510. These current carrying conductors can therefore carry a relatively larger current than if the poles incorporated only the second magnet. The maximum torque generated by the motor 500 is a function of the magnitude of the current in the one or more coil windings 510, so the higher the current, the greater the maximum torque provided by the motor 500.

[0073] Although FIG. 5 shows the magnetic device 508 disposed on the rotor 502, it should be understood that the magnetic device 508 could also be disposed on the stator 504 and one or more coil windings 510 could be disposed on the rotor 502.

[0074] As described herein, the first magnet can be high coercivity and can include magnet types such as neodymium-iron-boron, samarium-cobalt, etc. As described herein, the second magnet can be low coercivity relative to the coercivity value of the first magnet and can include magnet types such as iron nitride, etc. In some examples, iron nitride type magnets can include those described in WO / 2020 / 237192 and WO / 2021 / 168438, each of which is incorporated herein by reference in its entirety.

[0075] Various modifications to the embodiments described in this disclosure will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other implementations without departing from the spirit or scope of the present disclosure. Thus, the claims are not intended to be limited to the implementations shown herein, but should be accorded the widest scope consistent with the present disclosure, the principles and novel features disclosed herein.

Claims

1. An apparatus comprising: a first magnet having a first remanent magnetization value and a first coercivity value, the first magnet having a first cross-sectional area substantially perpendicular to a direction of magnetization of the first magnet; a second magnet disposed in series with the first magnet, the second magnet having a second remanent magnetization value and a second coercivity value less than the first coercivity value, the second magnet having a second cross-sectional area substantially perpendicular to a direction of magnetization of the second magnet; A ratio of the first cross-sectional area to the second cross-sectional area is equal to or greater than a ratio of the second remanent magnetization value to the first remanent magnetization value.

2. The apparatus of claim 1 , wherein the second magnet is disposed in a path of a magnetization direction of the first magnet.

3. The apparatus of claim 1 , wherein the second remanent magnetization value is greater than the first remanent magnetization value.

4. 2. The apparatus of claim 1, wherein an operating point of the second magnet located in a second quadrant of a BH curve corresponding to the second magnet is at a flux density value that is greater than a flux density value for a configuration in which the first cross-sectional area is equal to the second cross-sectional area.

5. 2. The apparatus of claim 1, wherein the first magnet has a shape with a non-constant cross-sectional area perpendicular to a magnetization direction of the first magnet, the first cross-sectional area being equal to a smallest cross-sectional area of ​​the non-constant cross-sectional areas.

6. 2. The apparatus of claim 1, wherein the second magnet has a shape with a non-constant cross-sectional area perpendicular to a magnetization direction of the second magnet, the second cross-sectional area being equal to a maximum cross-sectional area of ​​the non-constant cross-sectional areas.

7. 2. The apparatus of claim 1, wherein the first magnet has a first curved shape defined by a first curved surface and a second curved surface separated by a thickness of the first magnet, a magnetization direction of the first magnet is parallel to one of the radii of the first curved shape, and the first cross-sectional area comprises an area of ​​a first plane perpendicular to the magnetization direction of the first magnet.

8. The apparatus of claim 7 , wherein the first plane perpendicular to the magnetization direction of the first magnet has a smallest area among a set of planes perpendicular to the magnetization direction of the first magnet.

9. 2. The apparatus of claim 1, wherein the first magnet has a first curved shape defined by a first curved surface and a second curved surface separated by a thickness of the first magnet, the magnetization direction of the first magnet has a plurality of directions extending along a radius of the first curved shape, and the first cross-sectional area comprises an area of ​​the curved surface perpendicular to the plurality of directions.

10. The apparatus of claim 9 , wherein the curved surface perpendicular to the plurality of directions is a curved surface having a smallest area among a set of curved surfaces perpendicular to the plurality of directions.

11. 2. The apparatus of claim 1, wherein the second magnet has a second curved shape defined by a third curved surface and a fourth curved surface separated by a thickness of the second magnet, a magnetization direction of the second magnet is parallel to one of the radii of the second curved shape, and the second cross-sectional area comprises an area of ​​a second plane perpendicular to the magnetization direction of the second magnet.

12. The apparatus of claim 11 , wherein the second plane perpendicular to the magnetization direction of the second magnet has a maximum area among a set of planes perpendicular to the magnetization direction of the second magnet.

13. 2. The apparatus of claim 1, wherein the second magnet has a second curved shape defined by a third curved surface and a fourth curved surface separated by a thickness of the second magnet, the magnetization direction of the second magnet has a plurality of directions extending along a radius of the second curved shape, and the second cross-sectional area includes an area of ​​the curved surface perpendicular to the plurality of directions.

14. The apparatus of claim 13 , wherein the curved surface perpendicular to the plurality of directions is a curved surface having a maximum area among a set of curved surfaces perpendicular to the plurality of directions.

15. The apparatus of claim 1 , wherein the first magnet and the second magnet are separated by a spacer.

16. The apparatus of claim 15 , wherein the spacer comprises a ferromagnetic material.

17. 16. The apparatus of claim 15, wherein the cross-sectional area of ​​the spacer is at least equal to the larger of the first cross-sectional area and the second cross-sectional area.

18. 16. The apparatus of claim 15, wherein the spacer has a thickness of 3 mm or less.

19. [0023] The electric machine further includes a stator and a rotor separated from the stator by an air gap; The apparatus of claim 1 , wherein the first magnet and the second magnet are disposed in series on only one of the stator or the rotor.

20. 20. The apparatus of claim 19, wherein the first magnet is positioned closer to the air gap than the second magnet.

21. The apparatus of claim 19 , wherein the electric machine comprises a plurality of poles, and at least one pole of the plurality of poles includes the first magnet and the second magnet.

22. 2. The apparatus of claim 1, wherein the first magnet is of the neodymium-iron-boron type.

23. 2. The apparatus of claim 1, wherein the first magnet is of the samarium-cobalt type.

24. The apparatus of claim 1 , wherein the second magnet comprises at least one of the iron nitride type.

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