Sintered Permanent Magnets with Insulating Elements for Eddy Current Reduction

The patent creates a composite magnet structure by incorporating insulating material particles into the metallic magnetic material matrix. This composite approach maintains the desirable magnetic properties of the metallic phase while the insulating particles disrupt eddy current paths, reducing energy losses. The composite structure allows simultaneous achievement of low eddy current losses and high magnetic performance.

Instead of globally segmenting the magnet into multiple pieces, the patent applies local quality modification by distributing insulating material particles throughout the continuous magnetic material. This creates localized barriers to eddy currents at the particle level, achieving the effect of segmentation without the mechanical complexity of assembling multiple magnet pieces. The magnet remains a single integrated component while having locally modified electrical properties.

The patent changes the physical state and distribution parameters of the insulating material from continuous laminated layers to discrete particles dispersed within the magnetic material. This parameter change simplifies production by allowing the insulating material to be incorporated during the standard sintering process rather than requiring complex layering operations. The particle size and distribution density are optimized to achieve effective eddy current blocking while maintaining manufacturing simplicity.

The patent uses small, simple insulating material particles instead of attempting to create precise continuous layers. These small particles are inexpensive and easy to handle, and their individual irregularities are negligible when distributed throughout the magnet. The collective effect of many small particles provides sufficient eddy current blocking without requiring precise shape control or uniform thickness, thereby achieving high resistivity with simple manufacturing.