Slit magnets and methods for selective coercivity

Abstract

A doped magnet and method of manufacture are described that includes a magnet volume comprising a magnetic material and a dopant element, and a cavity (530) disposed within the magnet volume. Utilizing the cavity allows the doped magnet to use less doping material (434) and reach a desired coercivity without compromising the structural integrity of the doped magnet.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] All applications for which a foreign or domestic priority claim is identified in the Application Data Sheet or PCT patent application 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 November 1, 2022, the disclosure of which is incorporated herein by reference in its entirety for all purposes.

[0002] FIELD OF THE DISCLOSURE The present disclosure relates generally to magnets, and more particularly to improved magnets doped with diffusing materials. [Background technology]

[0003] 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 supply power. Typically, magnets are manufactured by pressing, sintering, and machining magnetic materials to form magnets, which can be doped using doping processes (e.g., grain boundary diffusion (GBD)). Heavy rare earth metals are typically used as diffusion materials in the manufacture of magnets to increase coercivity. Coercivity, also known as magnetic coercivity, coercive force, and coercive field, is a property of a magnet that describes the amount of demagnetizing force required to reduce the induction of a magnet after it is magnetized.

[0004] To fully dope the magnet with a diffusing material to increase coercivity, the magnet is cut completely (e.g., cut through the center of the base block) to form two smaller block pieces, and the dopant is applied to all surfaces of the magnet pieces so that the dopant can be more easily and widely diffused into the magnet material to achieve the desired level of coercivity. Once diffusion is complete, the magnets can be bonded (e.g., glued) together to form a doped magnet with an adhesive layer disposed between them to prevent the magnetic material from being continuous. An example of such a GBD doping process using a doping material is shown in FIG. 1, where a base block magnet 202 is cut 204 into magnet pieces 206-A and 206-B before a GBD process 208 is performed to diffuse a doping element (e.g., terbium (Tb) and / or dysprosium (Dy)) to form doped magnet pieces 210-A and 210-B. Doped magnet pieces 210-A and 210-B are ground 210 and glued 216 together to form ground magnet pieces 212-A and 212-B that form doped magnet 218.

[0005] However, it may be desirable to reduce or minimize the amount of heavy rare earth metal utilized in manufacturing the doped magnet, minimize the use of manufacturing steps that require larger dimensional tolerances, and reduce the structural integrity of the doped magnet. For example, it can be difficult to precisely cut the magnet and apply the correct amount of glue, thereby increasing the mechanical tolerances associated with manufacturing the doped magnet. Summary of the Invention [Problem to be solved by the invention]

[0006] For purposes of summarizing the invention and the advantages achieved over the prior art, certain objects and advantages of the invention are described herein. Not necessarily all such objects or advantages may be achieved in any particular embodiment of the invention. Thus, for example, one skilled in the art will recognize that the invention may be embodied or implemented to achieve or optimize one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

[0007] In a first aspect, a process for making a doped magnet is provided, the process including forming a cavity in a magnet to form a treated magnet, the cavity including a cavity surface and the treated magnet including 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 the doped magnet.

[0008] In some embodiments, the process further includes applying a doping material to the exterior surface. In some embodiments, forming the cavity includes cutting a cavity in the magnet. In some embodiments, the process further includes polishing the magnet before forming the cavity in the magnet. In some embodiments, the process further includes 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 includes a continuous magnet volume. In some embodiments, the process does not include applying an adhesive to at least one of the treated magnet and the coated magnet. In some embodiments, forming the cavity does not include dividing the magnet into a plurality of separate magnet pieces. In some embodiments, heating the coated magnet causes the dopant element to diffuse into the coated magnet. In some embodiments, the dopant element diffuses into the coated magnet through the cavity surface and the exterior surface. In some embodiments, the treated magnet includes at least one additional cavity. In some embodiments, treating includes heating the coated magnet.

[0009] In a second aspect, a doped magnet is provided. The coated magnet includes a magnet volume containing a magnetic material and a dopant element, and a cavity disposed within the magnet volume.

[0010] In some embodiments, the cavity has a width of about 0.2 to 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 within the magnet volume. In some embodiments, the magnet material is a neodymium magnet. In some embodiments, the doped magnet includes about 0.3 to 0.8 wt. % of a dopant element. In some embodiments, the doped magnet does not include an adhesive. In some embodiments, the magnet volume is continuous.

[0011] In a third aspect, a rotor is provided, the rotor including a doped magnet.

[0012] In a fourth aspect, an electric vehicle is provided. The electric vehicle includes a rotor. [Brief explanation of the drawings]

[0013] These and other features, aspects, and advantages of the present disclosure are described with reference to drawings of particular configurations, which are intended to illustrate the particular configurations in a schematic manner and are not intended to limit the disclosure.

[0014] [Figure 1] 1 is a flowchart illustrating an exemplary method for doping a magnet.

[0015] [Figure 2] 1 is a flowchart illustrating an exemplary method for forming a doped magnet, according to some embodiments.

[0016] [Figure 3] 1 is a flowchart illustrating an exemplary method for manufacturing a doped magnet, according to some embodiments.

[0017] [Figure 4] FIG. 1 is a cross-sectional view of a coated magnet, according to some embodiments.

[0018] [Figure 5] 1 is a cross-sectional schematic view of a rotor according to some embodiments.

[0019] [Figure 6A] 1 is a cross-sectional schematic diagram of a doped magnet having exemplary dimensions and sizes, according to some embodiments. [Figure 6B] 1 is a cross-sectional schematic diagram of a doped magnet having exemplary dimensions and sizes, according to some embodiments. [Figure 6C] 1 is a cross-sectional schematic diagram of a doped magnet having exemplary dimensions and sizes, according to some embodiments. [Figure 6D] 1 is a cross-sectional schematic diagram of a doped magnet having exemplary dimensions and sizes, according to some embodiments. [Figure 6E] 1 is a cross-sectional schematic diagram of a doped magnet having exemplary dimensions and sizes, according to some embodiments.

[0020] [Figure 7] 1 is a perspective photograph of a doped magnet with slits according to some embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0021] 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, modifications, and their equivalents. Accordingly, the claims appended hereto are not limited by any of the specific embodiments described below. For example, in any method or process disclosed herein, the acts or operations of the method or process may be performed in any suitable sequence and are not necessarily limited to any particular disclosed sequence. Various operations may be described in sequence as multiple separate operations in a manner that may be helpful in understanding a particular embodiment, although the order of description should not be construed to imply that these operations are order-dependent. Furthermore, structures, systems, and / or devices described herein may be embodied as integrated or separate components. For purposes of comparing various embodiments, certain aspects and advantages of these embodiments are described. It is not necessarily the case that all such aspects or advantages are achieved by a particular embodiment. Thus, for example, various embodiments may be implemented in a manner that achieves or optimizes one advantage or group of effects as taught herein without necessarily achieving other aspects or advantages as may be taught or suggested herein.

[0022] The present disclosure generally relates to forming (e.g., cutting) a cavity (e.g., a slit) in 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 forced magnet or an eddy current slit reduced magnet). The dopant (i.e., diffusing material) of the doping material may be incorporated into the magnet through diffusion (e.g., grain boundary diffusion (GBD)). Advantageously, the use of a cavity may allow the doped magnet to be sufficiently doped so that a reduced amount of doping material is utilized to achieve a desired coercivity. Furthermore, the use of a cavity may allow for improved structural integrity and / or improved dimensional tolerances of the doped magnet, as well as reduced manufacturing difficulty, cost, and tolerances. Accordingly, 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 manufacturing process modifications, thereby easing restrictions on the use of magnetic materials when supplies are limited.

[0023] Some embodiments of the present disclosure implement a process for manufacturing a doped magnet that achieves a desired coercivity and achieves reduced heavy rare earth material usage while maintaining the structural integrity of the doped magnet without incurring significant manufacturing process modifications or additional costs. Figure 2 shows an exemplary method 300 for forming a doped magnet. A cavity is formed in the magnet 302, the cavity including 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.

[0024] The magnets used to form the doped magnets can be ferrite magnets, gallium magnets, boron magnets, nickel magnets, alnico magnets, rare earth magnets (e.g., neodymium magnets, samarium-cobalt magnets), or combinations thereof. In some embodiments, the magnets include a magnetic material comprising at least one of Fe, Nd, Ga, B, Co, Al, Ni, and Sm. In some embodiments, the magnets have various shapes, sizes, and / or dimensions. For example, the magnets can be cubes, rectangular prisms, cylinders, other geometric shapes, other customized shapes, and / or other shapes. In some embodiments, the magnets include a continuous magnetic volume such that all of the magnetic material of the magnet is a single, continuous piece of material without another material separating the magnet into multiple pieces. For example, an adhesive material (e.g., glue, etc.) does not divide the magnet into two separate pieces or regions. In some embodiments, the magnets do not include adhesives.

[0025] The cavities are formed in the magnet by cutting the cavities into the magnet to form the processed magnet. In some embodiments, the cavities are 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, the magnet is polished before forming the cavities in the magnet. In some embodiments, the magnet may be ground to a size suitable for forming the cavities. In some embodiments, forming the cavities in the processed magnet does not include dividing the magnet into multiple separate magnet pieces. In some embodiments, the processed magnet comprises a continuous magnetic volume (e.g., without compromising the structural integrity of the processed magnet) such that all of the magnetic material of the processed magnet is a single, continuous piece of material, without any additional material or cavities separating the processed magnet into multiple pieces. For example, no adhesive material (e.g., glue, etc.) divides the processed magnet into two separate pieces or regions. In some embodiments, the processed magnet does not include an adhesive.

[0026] The number, location, and dimensions of the cavities formed in the treated magnet can vary. In some embodiments, cavities can be formed in the center or around the center of the treated magnet, or towards the top, bottom, or sides, or any combination thereof. In some embodiments, some or all of the formed cavities are different or similar in size and dimensions. In some embodiments, at least two cavities are formed in symmetrical positions around the center of the treated magnet.

[0027] The cavity width is the dimension of the cavity measured above the surface of the magnet. In some embodiments, the width of the formed cavity is about, at least, or at least about 0.05 mm, 0.07 mm, 0.09 mm, 0.1 mm, 0.11 mm, 0.13 mm, 0.15 mm, 0.17 mm, 0.19 mm, 0.2 mm, 0.21 mm, 0.25 mm, 0.5 mm, 0.75 mm, 1 mm, 1.25 mm, 1.5 mm, 2 mm, 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, or 5 mm, or any range of values ​​therebetween. The cavity depth is the dimension of the cavity measured from the surface of the magnet into the volume of the magnet. In some embodiments, the depth of the cavity within the volume of the treated magnet is about, at least, or at least about 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 treated magnet is about, at least, or at least about 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 about, at least, or at least about 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.

[0028] In some embodiments, the cavity has various sizes and / or shapes (e.g., slit, cylinder, cube, rectangular parallelepiped, etc.). Advantageously, the cavity can increase the surface area for diffusing the dopant elements of the doping material. In some embodiments, the proximal end of the cavity extends from a 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 a first surface of the magnet volume, and the distal end of the cavity terminates at a second surface within the magnet volume. In some embodiments, such as a slit, the first proximal and first distal ends of the cavity extend from a surface of the magnet volume into the magnet volume, and the second proximal and second distal ends of the cavity extend from the second surface of the magnet volume to a third surface of the magnet volume. In some embodiments, the size (e.g., width, length, or height) of the cavity can be adjusted based on the size of the magnet to be partially cut. For example, as the size of the treated magnet increases, the size of the cavity may also increase.

[0029] In some embodiments, the doping material comprises 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 comprises a dopant compound. In some embodiments, the dopant compound is Nd x Dy)2Fe 14 In some embodiments, the doping material is in the form of a slurry. In some embodiments, the doping material slurry includes a solvent and a dopant element and / or a dopant compound.

[0030] Coated magnets are formed by applying a doping material to a treated magnet. In some embodiments, the doping material is applied to the cavity (e.g., cavity surface) and / or the outer surface of the treated magnet. In some embodiments, the doping material may be applied by spinning, coating, pasting, or sputtering. In some embodiments, the coated magnet comprises a continuous magnet volume (e.g., without compromising the structural integrity of the coated magnet) such that all of the magnetic material of the coated magnet is a single, continuous piece of material, with no additional material or cavities separating the coated magnet into multiple pieces. For example, no adhesive material (e.g., glue, etc.) divides the coated magnet into two separate pieces or regions. In some embodiments, the coated magnet does not include an adhesive.

[0031] The coated magnet is treated to form a doped magnet. In some embodiments, treating the coated magnet includes heating the coated magnet. In some embodiments, heating is performed at a temperature of about, at least, 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, heating is performed in a vacuum, an oxidizing gas environment (e.g., O), or an inert gas environment. In some embodiments, treating the coated magnet is configured to diffuse a 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.

[0032] In some embodiments, the doped magnet includes a magnet volume and a cavity disposed 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 comprises at least one of Fe, Nd, Ga, B, Co, Al, Ni, and Sm. In some embodiments, the magnet volume is continuous such that all of the magnet material of the doped magnet is a single, continuous piece of material, without separate materials or cavities separating 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 comprises about, at least, or at least about 0.05%, 0.1%, 0.15%, 0.2%, 0.25%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, or 2% by weight of the dopant element, or any range of values ​​therebetween. In some embodiments, the doped magnet does not comprise an adhesive. In some embodiments, forming the doped magnet does not include applying an adhesive (e.g., glue, etc.) to at least one of the magnet, the treated magnet, and the coated magnet. Advantageously, costs and time associated with forming the doped magnet may be reduced. In some embodiments, the doped magnet is packaged and / or tested after being formed. For example, the doped magnet is packaged for shipping.

[0033] Advantageously, dopant elements can be more easily diffused through the additional surface associated with one or more cavities formed in the coated magnet to form a doped magnet. Furthermore, the structural integrity of the doped magnet cannot be compromised because the magnet volume is continuous and not completely cut. Additionally, compared to manufacturing processes in which the magnet is cut (e.g., FIG. 1), the cost and time to manufacture the doped magnet can be reduced because, for example, there is no need to glue the magnet block back together or grind the surfaces where the cuts are made.

[0034] 3 illustrates an exemplary method 400 for manufacturing a doped magnet. A base magnet block 402 is provided, and grinding 404 is performed on the base magnet block 402 to form a magnet 406 with appropriate dimensions. The magnet 406 has slots 408 formed therein to form cavities 430 therein, resulting in 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, resulting in the processed magnet 408-A.

[0035] As shown by processed magnets 408-B, 408-C, 408-D, and 408-E, cavity 430 has the shape of a slit, and the width of the slit can vary. For example, processed magnet 408-B shows cavity 430 having a width of 0.80 millimeters, processed magnet 408-C shows cavity 430 having a width of 1.00 millimeters, processed magnet 408-D shows cavity 430 having a width of 1.20 millimeters, and processed magnet 408-E shows cavity 430 having a width of 1.50 millimeters.

[0036] During GBD 426, doping material 434 is applied to cavity surface 432 and outer surface 428 of treated magnet 408-A to form coated magnet 440. Doping material 434 is diffused into coated magnet 440 during GBD 426 (e.g., by heating) to form a doped magnet (not shown in FIG. 3 ). The doped magnet is tested 460 or packaged to form magnet 480 for shipping.

[0037] 4 shows a cross-sectional view of a coated magnet 540. The coated magnet 540 is coated with a doping material 534, which is coated on one or more cavity surfaces 532 and an outer surface 528 of the cavity 530. The cavity 530 has a depth 570. The coated magnet 540 has a length 550.

[0038] FIG. 5 shows a cross-sectional schematic view of rotor 600. As shown in FIG. 5, rotor 600 has a plurality of holes, including at least bore 602, which may allow doped magnets (e.g., doped magnets 700A-700E) to be fitted, attached, and / or integrated into rotor 600. In some embodiments, the rotor may be attached and / or integrated as part of an electric motor and / or vehicle. The doped magnets described herein may be more precisely matched to fit within bore 602 compared to other processes (e.g., as shown in FIG. 1 ) because the doped magnets were not cut, thereby reducing the rate at which the magnets are undersized or oversized relative to the rotor's tolerances. Thus, the doped magnets described herein may advantageously be more precisely fitted and attached to the rotor. Example

[0039] 6A-6E show cross-sectional schematic diagrams of doped magnets 700A-700E having exemplary dimensions / sizes. As shown in FIG. 6A, doped magnet 700A included a slit-shaped cavity 730A, with a slit width of 0.42 mm and a slit depth of 5.16 mm. The bottom of the doped magnet proximal to the slit had a width of 3.77 mm, and the top of the doped magnet distal to the slit had a width of 3.69 mm, resulting in a total width of doped magnet 700A of approximately 7.88 mm (i.e., 0.42 mm + 3.77 mm + 3.69 mm). As shown in FIG. 6B, doped magnet 700B included a slit-shaped cavity 730B, with a slit width of 0.85 mm and a slit depth of 5.01 mm. The bottom of the doped magnet proximal to the slit had a width of 3.53 mm, and the top of the doped magnet distal to the slit had a width of 3.49 mm, resulting in a total width of doped magnet 700B of approximately 7.87 mm (i.e., 0.85 mm + 3.53 mm + 3.49 mm). As shown in FIG. 6C, doped magnet 700C included a slit-shaped cavity 730C, with a slit width of 1.06 mm and a slit depth of 5.00 mm. The bottom of the doped magnet proximal to the slit had a width of 3.39 mm, and the top of the doped magnet distal to the slit had a width of 3.41 mm, resulting in a total width of doped magnet 700C of approximately 7.86 mm (i.e., 1.06 mm + 3.39 mm + 3.41 mm). As shown in Figure 6D, doped magnet 700D included a cavity 730D in the shape of a slit, with a slit width of 1.25 mm and a slit depth of 5.02 mm. The bottom of the doped magnet proximal to the slit had a width of 3.23 mm, and the top of the doped magnet distal to the slit had a width of 3.39 mm, for a total width of doped magnet 700D of approximately 7.87 mm (i.e., 1.25 mm + 3.23 mm + 3.39 mm). As shown in Figure 6E, doped magnet 700E included a cavity 730E in the shape of a slit, with a slit width of 1.54 mm and a slit depth of 5.05 mm.The bottom of the doped magnet proximal to the slit had a width of 3.17 mm and the top of the doped magnet distal to the slit had a width of 3.16 mm, giving a total width of doped magnet 700E of approximately 7.87 mm (i.e., 1.54 mm + 3.17 mm + 3.16 mm).

[0040] FIG. 7 shows a perspective view of the doped magnets with slits, each doped magnet was not completely cut.

[0041] Table 1 shows example widths and weight percentages of doped neodymium magnets #1-#5 formed using a wire cutter with various slit widths shown in Table 1 from a magnet having a length of approximately 20.5 mm, a height of approximately 7.9 mm, and a slit depth of 5 mm. The width refers to the slit width of the cavity, and the weight percentage refers to the doping amount of the Tb dopant element in the doped magnet's composition. A doping material comprising Tb is applied to the surface of the processed magnet and cavity, and the coated magnet is processed to form the doped magnet. In Table 1, each of doped magnets #1-#5 was found to have similar coercivity. As shown in Table 1, adjusting the cavity width can be adjusted to affect the amount of Tb needed to reach the desired doping level of approximately 5% and therefore the desired coercivity. [Table 1]

[0042] It is to be understood that not necessarily all objects or advantages may be achieved in accordance with any particular embodiment described herein. Thus, for example, those skilled in the art will recognize that a particular embodiment 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 that may be taught or suggested herein.

[0043] All of the processes described herein may be fully automated by software code modules containing 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 embodied in dedicated computer hardware.

[0044] Many variations beyond those described herein will be apparent from this disclosure. For example, depending on the embodiment, certain operations, events, or functions of any of the algorithms described herein may be performed in a different order, or may be added, merged, or entirely omitted (e.g., not all described operations or events may be necessary to practice the algorithm). Furthermore, in certain embodiments, operations or events may be performed in parallel rather than sequentially, for example, via multithreading, interrupt processing, or multiple processors or processor cores, or on other parallel architectures. Additionally, different tasks or processes may be performed by different machines and / or computing systems that can function together.

[0045] The various illustrative logic blocks and modules described in connection with the embodiments disclosed herein may be implemented or performed by a machine, such as 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, designed to perform the functions described herein. The processor may be a microprocessor, but in alternative examples, the processor may be a controller, microcontroller, or state machine, combinations thereof, or the like. A processor may include electrical circuitry configured to process computer-executable instructions. In another embodiment, a processor includes an FPGA or other programmable device that performs logical operations without processing computer-executable instructions. A processor may also be implemented as a combination of customer computing devices, such as, for example, a combination of a DSP and a microprocessor, multiple microprocessors, one or more multiple microprocessors in combination with a DSP core, or any other such configuration. Although described herein primarily with reference to digital technology, a processor may also include primarily analog components. The computing environment may include any type of computer system, including, but not limited to, a computer system based on a computational engine within a microprocessor, mainframe computer, digital signal processor, portable consumer computing device, device controller, or appliance, to name a few.

[0046] Unless otherwise specified or understood within the context of use, conditional language such as "can," "could," "might," or "may," among others, is generally used to suggest that certain embodiments include certain features, elements, and / or steps, while other embodiments do not. Thus, such conditional language generally does not intend that features, elements, and / or steps are in any way required by one or more embodiments, or that one or more embodiments necessarily include logic for determining whether those features, elements, and / or steps should be included in or performed in any particular embodiment, with or without user input or prompting for input.

[0047] Disjunctive language such as the phrase "at least one of X, Y, or Z" is generally understood to be used to indicate that an item, term, etc. can be either X, Y, or Z, or any combination thereof (e.g., X, Y, and / or Z), unless otherwise indicated from context. Thus, such disjunctive language is generally not intended to, and should not, imply that a particular embodiment requires the presence of at least one of X, at least one of Y, or at least one of Z, respectively.

[0048] Any process descriptions, elements, or blocks in the flow diagrams described herein and / or depicted in the accompanying drawings should also be understood as potentially representing modules, segments, or portions of code that comprise one or more executable instructions for implementing a particular logical function or element in the process. The scope of the embodiments described herein includes alternative implementations in which elements or functions may be omitted, performed in a different order than shown or described, or performed substantially simultaneously or in the reverse order, depending on the functionality involved, as can be understood by one of ordinary skill in the art.

[0049] Unless otherwise specified, articles such as "a" or "an" should be construed generally to include one or more described items. Thus, phrases such as "a device configured to" are intended to include one or more listed devices. Such one or more listed devices may also be collectively configured to perform the stated enumeration. For example, "a processor configured to perform enumerations A, B, and C" may include a first processor configured to perform enumeration A working in conjunction with a second processor configured to perform enumerations B and C.

Claims

1. 1. A process for producing a doped magnet, comprising: forming a cavity in a magnet to form a treated magnet, the cavity having a cavity surface and the treated magnet having an outer surface; applying a doping material containing a dopant element to the cavity surface to form a coated magnet; processing the coated magnet to form the doped magnet; The process includes:

2. The process of claim 1 further comprising applying the doping material to the exterior surface.

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

4. 4. The process of claim 1, further comprising polishing the magnet before forming the cavity in the magnet.

5. The process of claim 1 further comprising packaging the doped magnet.

6. 6. The process of claim 1, wherein the dopant element is selected from the group consisting of terbium, dysprosium, and combinations thereof.

7. 7. The process of claim 1, wherein the treated magnet comprises a continuous magnet volume.

8. 8. The process of claim 1, wherein the process does not include applying an adhesive to at least one of the treated magnet and the coated magnet.

9. 9. The process of claim 1, wherein the step of forming the cavity does not include dividing the magnet into a plurality of separate magnet pieces.

10. 10. The process of claim 1, wherein the step of heating the coated magnet diffuses the dopant element into the coated magnet.

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

12. 12. The process of claim 1, wherein the treated magnet comprises at least one additional cavity.

13. 13. The process of claim 1, wherein the treating step comprises heating the coated magnet.

14. a magnet volume comprising a magnet material and a dopant element; a cavity disposed within the magnet volume; A doped magnet comprising:

15. The doped magnet of claim 14, wherein the cavity has a width of about 0.2 to 1.5 mm.

16. 16. The doped magnet of claim 14 or 15, wherein the cavity is a slit.

17. 17. The doped magnet of claim 14, 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. 18. The doped magnet of claim 14, wherein 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 within the magnet volume.

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

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

21. 21. The doped magnet of any one of claims 14 to 20, wherein the doped magnet does not comprise an adhesive.

22. 22. The doped magnet of 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 the rotor of claim 23.

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