Low Rare Earth Permanent Magnet Material Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current permanent magnet materials have high costs due to high rare earth content and do not meet the requirements for higher maximum energy product and better high-temperature properties.
Innovation Solution
A permanent magnet material with a rare earth element content of less than 13% atomic percentage, achieving a maximum energy product of at least 18 MGOe, prepared through a hot press deformation process with controlled temperature gradients and stress relief treatment, using a mixture of rare earth and transition metal powders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rare earth permanent magnet materials are used to achieve high performance, then maximum energy product and magnetic properties are improved, but cost increases due to high rare earth content
Solution Approach 1:
The patent changes the compositional parameters by reducing rare earth content from traditional high levels to ≤13% atomic percentage, while adjusting transition metal ratios (Fe:Co between 1:4 to 4:1) to achieve optimal magnetic properties at lower cost
Solution Approach 2:
The patent creates a composite permanent magnet material combining multiple transition metals (Fe, Co, Ni, Cu, Zr) with reduced rare earth content, forming a composite structure that achieves high maximum energy product (≥18 MGOe) without relying on high rare earth concentrations
2Ease of manufacture
If rare earth content is reduced to lower cost, then production cost decreases, but maximum energy product and magnetic properties deteriorate
Solution Approach 1:
The patent optimizes compositional parameters within specific ranges: rare earth content ≤13% atomic percentage, Fe:Co ratio between 1:4 to 4:1, and controlled addition of Ni (0-15%), Cu (0-10%), Zr (0-5%) to maintain magnetic performance while reducing rare earth dependency
Solution Approach 2:
The patent applies local quality by creating specific phase distributions and microstructures where transition metal-rich regions provide magnetic properties while rare earth regions provide structural stability, achieving performance without uniform high rare earth content throughout the material
3Reliability
If traditional permanent magnet materials are used, then magnetic properties are achieved, but high temperature performance is poor
Solution Approach 1:
The patent develops a composite structure with transition metal phases (Fe-Co-Ni-Cu-Zr system) that provide thermal stability and high temperature resistance, complementing the rare earth phases to maintain magnetic properties at elevated temperatures
Solution Approach 2:
The patent adjusts compositional parameters including Fe:Co ratio (1:4 to 4:1) and adds elements like Zr (0-5%) and Cu (0-10%) specifically to enhance Curie temperature and high temperature magnetic stability while maintaining room temperature performance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting magnet exhibits improved magnetic properties such as higher maximum energy product, saturation magnetization, and remanent magnetization with reduced rare earth content, while maintaining lower production costs.
Implementation Method 1
The permanent magnet material is prepared by hot press deformation
Implementation Method 2
during the hot press deformation, the hot press unit is subjected to cooling treatment at both ends along the hot press pressure direction
Data Source
AI summary
A permanent magnet material and a method thereof. The permanent magnet material comprises one or more rare earth elements and one or more transition metal elements, wherein the atomic percentage of the one or more rare earth elements is less than or equal to 13%, and the permanent magnet material has a maximum magnetic energy product of greater than or equal to 18 MGOe.