EP2605253B1 - Herstellungsverfahren für ein Permanentmagnet, Formsystem und Permanentmagnet - Google Patents

Herstellungsverfahren für ein Permanentmagnet, Formsystem und Permanentmagnet Download PDF

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Publication number
EP2605253B1
EP2605253B1 EP11193247.1A EP11193247A EP2605253B1 EP 2605253 B1 EP2605253 B1 EP 2605253B1 EP 11193247 A EP11193247 A EP 11193247A EP 2605253 B1 EP2605253 B1 EP 2605253B1
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EP
European Patent Office
Prior art keywords
compartment
separator
mould
permanent magnet
shape
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EP11193247.1A
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English (en)
French (fr)
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EP2605253A1 (de
Inventor
Adriana Cristina Urda
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Siemens AG
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Siemens AG
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Filing date
Publication date
Application filed by Siemens AG filed Critical Siemens AG
Priority to EP11193247.1A priority Critical patent/EP2605253B1/de
Priority to DK11193247.1T priority patent/DK2605253T3/en
Priority to PCT/EP2012/075049 priority patent/WO2013087609A2/en
Priority to CN201210537415.3A priority patent/CN103157794B/zh
Publication of EP2605253A1 publication Critical patent/EP2605253A1/de
Application granted granted Critical
Publication of EP2605253B1 publication Critical patent/EP2605253B1/de
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Anticipated expiration legal-status Critical

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
    • H01F41/026—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets protecting methods against environmental influences, e.g. oxygen, by surface treatment
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
    • H01F41/0266—Moulding; Pressing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F7/00—Magnets
    • H01F7/02—Permanent magnets [PM]
    • H01F7/0205—Magnetic circuits with PM in general
    • H01F7/0221—Mounting means for PM, supporting, coating, encapsulating PM
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
    • H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
    • H01F1/047—Alloys characterised by their composition
    • H01F1/053—Alloys characterised by their composition containing rare earth metals
    • H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
    • H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
    • H01F1/0571—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes
    • H01F1/0575—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together
    • H01F1/0577—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together sintered

Definitions

  • the present invention relates to a method for manufacturing a permanent magnet, to a moulding system for manufacturing a permanent magnet and to a permanent magnet, wherein the permanent magnet may in particular be used in a rotor of an electric generator.
  • EP 2 017 859 A1 discloses a method for manufacturing of magnet poles, wherein a vitrifiable base material powder is filled into a mould, the mould is closed with a plate, the mould with the powder is placed in a magnetic field and the plate is pressed such onto the powder as to establish a compact and the compact is sintered.
  • WO 2010/066251 A1 discloses a permanent magnet rotor for a machine and a manufacturing method of a permanent magnet rotor, wherein a permanent magnet is formed in an inner opening of a sleeve between a first cap and a second cap.
  • EP 1 300 208 A2 discloses a manufacturing method and a composite powder metal rotor assembly for a circumferential type material permanent magnet machine, wherein a mould having a separator is filled with the powder metal, the powders are compacted and sintered.
  • a method for manufacturing a permanent magnet comprising separating, by a separator, a mould volume into a first compartment and a second compartment; filling a first material into the first compartment; filling a second material into the second compartment; compacting the first material and the second material, wherein the separator is shaped such that a shape of the first compartment corresponds to a target shape of the magnet.
  • the permanent magnet may in particular be or comprise a neodymium magnet (also known as NdFeB magnet), i.e. an alloy of neodymium, iron and boron to form the Nd 2 Fe 14 B tetragonal crystalline structure. Further, the magnet may comprise Dy (Dysprosium) between 0% and 10% wt.
  • the permanent magnet may have high coercivity (i.e. resistance to being demagnetized) and may have a high saturation magnetization of between 1 and 2 Tesla.
  • the permanent magnet may for example be used in an electromechanical machine, such as an electrical generator, in particular for an electrical generator of a wind turbine.
  • the generator may be an outer rotor generator in which the magnet (rotating with the rotor) is placed radially outwards from a stator.
  • the separator may be a physical solid structure such as a bent sheet, bent metal piece or the like.
  • the separator may have at least partially a curved shape.
  • the separating the mould volume may be achieved by arranging the separator within the mould volume.
  • the separator may comprise one or more separation walls.
  • the separator may be adapted to confine the first material within the first compartment and to confine the second material within the second compartment. Thus, the separator may be tight for the first material as well as for the second material.
  • the first compartment may have a volume which is between 5 and 100 times larger than a volume of the second compartment.
  • the first compartment may be partly delimited by the separator and may be partly delimited by a portion of a mould wall. Alternatively, the first compartment may entirely be confined or delimited by the separator.
  • the second compartment may partly be delimited by the separator and may partly be delimited by a mould wall.
  • the target shape of the magnet is different from a cuboid shape and resembles a cuboid having two rounded edges.
  • the target shape of the magnet may have a mirror symmetry.
  • the target shape of the magnet may have a translational symmetry along a depth direction, wherein the depth direction (in particular parallel to a filling direction) may be perpendicular to a height direction and a width direction of the mould or the mould volume.
  • the first material may be filled into the first compartment along a filling direction which may be along the depth direction.
  • the second material may be filled into the second compartment along the filling direction.
  • the compacting the first material and the second material may be achieved by applying pressure to the first material and the material, in particular along the filling direction.
  • the first material may also be referred to as active (magnet) material, wherein the second material may be also referred to as a dummy material not contributing (or contributing less between 0% and 20%) to the magnetic properties of the finalized and manufactured permanent magnet.
  • the first material When the first material is filled into the first compartment the first material may be in the final desired target shape of the magnet (in particular when disregarding shrinking which may occur during compacting and/or sintering).
  • the first material and the second material no grinding, machining or other shaping process after the compacting need to be necessary, in order to obtain the permanent magnet having the desired target shape.
  • it may be omitted to remove some of the first material from the compacted product. Thereby, a waste of material may be reduced.
  • the manufacturing method may be simplified, since no grinding or machining or shaping steps may be required.
  • the manufacturing method further comprises placing the separator into the mould volume, in order to form the first compartment and the second compartment, wherein the mould volume has in particular a cuboid shape.
  • the separator may be placed into the mould volume by shifting or moving the separator along the filling direction into the mould volume.
  • the separator may have a at least partially curved shape.
  • a portion of the separator may comprise a flat shape.
  • the separator is shaped such that the first compartment has a shape resembling a cuboid having two rounded edges extending in a depth direction, wherein the separator has in particular a constant thickness.
  • the shape of the first compartment may at least partially be defined by the shape of the separator.
  • the first compartment may be partly or entirely enclosed or surrounded by the separator.
  • the first compartment and also the second compartment may comprise a mirror symmetry, wherein the mirror plane may be oriented parallel to a plane spanned by the height direction and the depth direction.
  • the mirror plane may be arranged at a half of an extent in the width direction of the mould volume or mould.
  • a permanent magnet having a suitable shape to be used as a rotating magnet in an electrical generator may be manufactured.
  • the separator is shaped such that an extent of the first compartment in a height direction decreases towards both ends in a width direction, the height direction and the width direction being in particular transverse, further in particular perpendicular to a filling direction along which the first material and/or the second material is filled into the respective compartment.
  • the separator may be shaped such an extent of the second compartment in the height direction increases towards both ends in the width direction.
  • a sum of the height of the first compartment and the height of the second compartment (the minimal height being in particular 1% to 10% of the height of the mould volume) may be constant across the width direction.
  • the height of the first compartment may be constant and in outer portions (along the width direction) the height may decrease in a symmetric (with respect to the mirror plane) way.
  • an appropriate shape of the permanent magnet may be achieved when such a separator is used in the manufacturing process.
  • the separator is made of separator material comprising any kind of material that can be shaped in an easy manner.
  • a think layer of plastic material can be used as separator material, since it is easy to shape.
  • a steel sheet is also an option since it is more firm (tight, solid) compared to the plastic sheet. The separation sheet will be removed before sintering, so it does not need to be a high temperature resistant material.
  • the separator needs to be kept in place, then this has to be a non-magnetic material, with the magnetic permeability close to 1.
  • the first material is a ferro magnetic powder material, in particular a high grade NdFeB powder material, which has a remanence and/or coercity and/or energy product that is between 2 and 10 times higher than that of the second material.
  • the ferromagnetic powder material may comprise tiny particles or grains having a size between 1 ⁇ m and 20 ⁇ m.
  • the tiny particles of the ferromagnetic powder material may comprise small crystalline grains.
  • the remanence or remanent magnetization is the magnetization left behind in a ferromagnetic material after an external magnetic field is removed.
  • the coercivity is the intensity of the applied magnetic field required to reduce the magnetization of the ferromagnetic powder material to zero after the magnetization of the ferromagnetic powder material has been driven to saturation.
  • the first material may be a high grade neodymium material suitable as serving for a rotating magnet of a generator.
  • the second material may be a low-grade material (and/or having more impurities), in particular much cheaper than the first material.
  • the second material may be selected not to affect (or affect to a smaller extent) the magnetic properties of the final product comprising the first material and the second material.
  • the first material comprises Fe in a mass ratio between 50 % and 75 %, Nd in a mass ratio between 15 % and 35 %, Dy in a mass ratio between 1 % and 15 %, and B in a mass ratio between 0% and 2 %.
  • the first material may primarily affect the magnetic property of the finished manufacturing product.
  • magnetic properties of the finished product may evolve to between 70 % and 100 % from the first material.
  • the second material comprises a plastic material, in particular a thermosetting or/and a thermoplastic material, in particular expoxy.
  • the second material comprises Fe in a mass ratio between 75 % and 100 %, Nd in a mass ratio between 0 % and 30 %, Dy in a mass ratio between 0 % and 10 %, and B in a mass ratio between 0 % and 1 %.
  • the second material may have between 0 % and 30% Nd and in particular 0% Dy.
  • the plastic material may comprise a polymer material.
  • the plastic material may comprise carbohydrates.
  • the thermosetting material may cure or crosslink or solidify upon application of heat.
  • the thermoplastic material may solidify by lowering the temperature.
  • the second material a low-cost material may be used.
  • a material may be used which affects the magnetic properties of the manufactured product only between 0 % and 20 %.
  • the finished permanent magnet may exhibit magnetic properties which are mainly governed by the first material shaped according to the shape of the separator (and/or a portion of the mould) into the target shape.
  • removing the second material from the finished product may not be required and also machining, polishing, grinding or shaping the first material after compacting may not be required, in order to achieve desired magnetic properties of the finished product.
  • the mould volume is delimited by a mould wall, wherein the mould wall provides an (closable) opening for filling in the first material and/or the second material into the mould volume.
  • the mould wall may for example comprise five flat surfaces, in particular made of a metal, such as iron or steel.
  • the planes of the mould wall portions may be oriented perpendicular to each other.
  • the opening may be a rectangular opening having a width being equal to the width of the mould and having a height being equal to the height of the mould.
  • the compacting comprises applying pressure, in particular via (or through) the opening, to the first material and the second material.
  • a stamp or a plate may be arranged in the opening, the plate just fitting into the opening and a pressure may be applied by excerpting a force onto the plate in the filling direction or depth direction. Different magnitudes of pressure may be applied. Further, a constant or varying pressure may be applied for a predetermined duration.
  • the compacting may comprise that the tiny particles forming the powder material partially adhere to each other such that they stick together. Thereby, the shape of the first material filled into the first compartment may be maintained even if the separator is removed.
  • applying pressure comprises: applying pressure of a first magnitude to the first material and the second material; then removing the separator; and then applying pressure of a second magnitude to the first material and the second material, wherein the second magnitude is between 2 times and 50 times greater than the first magnitude.
  • the pressure of the first magnitude may just be high enough such that the particles of the ferromagnetic powder material (i.e. the particles of the first material) stick together and adhere to each other such as to maintain the shape of the first material filled into the first compartment even if the separator is removed.
  • Applying the pressure of the second magnitude may even further press the particles of the ferromagnetic powder material together such as to permanently (also when finally removed from the mould) maintain the shape defined by the first compartment.
  • the pressure of the second magnitude is in particular selected such that the resulting finished product may be used as a magnet of a wind turbine generator.
  • the removing the separator comprises drawing the separator out of the moulding volume, in particular in a direction opposite to the filling direction.
  • the drawing the separator out of the moulding volume may be performed at a constant velocity along an unchanging direction. Thereby, the removing process may be simplified.
  • the separator may be maintained between the first material and the second material, in particular in a case, wherein the separator comprises separator material not affecting (or only to a minor degree) the magnetic properties of the final product.
  • An actuator such as an electro motor may be used for removing the separator out of the moulding volume.
  • the method further comprises sintering the first material; and/or magnetizing the first material.
  • Sintering may be performed without applying additional pressure to the first material and the second material.
  • sintering is performed below the melting temperature of the first material, such as to maintain micro magnets comprised in the ferromagnetic powder material of the first material.
  • Sintering may be performed between 10 hours and 36 hours, for example. Thereby, the temperature may be adjusted to increase to be constant or to decrease, in particular in a cyclic manner.
  • the magnetizing may be in particular performed after the sintering. Thereby, the sintered product may be subjected to a strong magnetic field providing a homogenous magnetic field across the extent of the sintered product.
  • the final product may be used as an outer rotor magnet in particular for a direct drive wind turbine generator.
  • the target shape of the magnet may be selected such that undesired torque ripples waves are reduced.
  • the second material filled into the second compartment surrounds between 30% and 100% of an outer surface of the first material filled into the first compartment.
  • the second material may also serve as a protection layer or protection cover to protect (at least a portion of) the first material from corrosion and/or oxidation or other physical degradations or chemical degradations of the first material.
  • This protective effect may be in particular achieved, when the second material surrounds the first material.
  • the first material may be protected in an exposed area (when used a magnet in a generator), further the separator may be produced in a simple manner.
  • a mould system for manufacturing a permanent magnet comprising a mould having a mould volume; a separator, for separating the mould volume into a first compartment and a second compartment; an actuator for compacting the first material and the second material; wherein the separator is shaped such that a shape of the first compartment corresponds to an target shape of the magnet.
  • the mould may be high pressure resistant and also resistant to heat treatment during a sintering process.
  • the sintering may for example be applied at a temperature between 500°C and 1500°C, for example.
  • the pressure or maximal pressure applied to the first material and the second material filled into the mould volume may for example amount to between 50 MPa and 200 MPa.
  • the mould system may comprise a number of different separators which are differently shaped in order to manufacture differently shaped permanent magnets.
  • the shape of the second compartment taking together with the shape of the first compartment may have a cuboid shape.
  • the first material filled into the first compartment and the second material filled into the second compartment may be pressed within the cuboid mould and then sintered.
  • pressing the cuboid shaped or rectangular mould is much easier than pressing an irregular shaped mould having the shape of the desired target shape of the permanent magnet. Pressing or applying pressure to a cuboid shaped mould may obtain the best uniformity of the density of the first material. Thereby, the quality of the permanent magnet may be improved.
  • scraping or grinding or machining the sides of the finished product to form the geometrically desired shape may not be necessary anymore.
  • the target shape or desired shape is achieved within or inside the finished cuboid block of the produced magnet by layering the different powders in a rectangular or cuboid mould frame.
  • coating or protecting or applying a protection layer to the finished block of the first material and the second material may be avoided, since the second material located on top of at least a portion of the first material is not really active (in the magnetic sense) and is not used for the magnetic flux production.
  • grinding of the active first material due to oxidation on the outer layer of the magnet may not be necessary anymore, as a protective passive layer (formed by the second material) may surround at least partially the active material.
  • the separator between the first material and the second material is removed, diffusion in the boundary between the two different materials may occur during sintering.
  • the final active shape (after sintering) of the first material may not accurately resemble the actual or initial target shape.
  • these discrepancies may be controlled by selection of process parameters, or for example by maintaining the separator or another separating material in between.
  • a permanent magnet in particular manufactured according to one of the embodiment described above, the magnet comprising: a first material shaped in a target shape different from a cuboid; a second material at least partially surrounding the first material, wherein an outer shape of the magnet is a cuboid.
  • Fig. 1 schematically illustrates a perspective view of a mould system 100 according to an embodiment of the present invention.
  • the mould system 100 comprises a mould 101 formed by five mould wall portions from which only the wall portions 103, 104, 105 and 106 (but not a back wall portion) are illustrated in Fig. 1 .
  • the mould wall portions of the mould 101 enclose a cuboid mould volume which is divided or separated by a separator 107 into a first compartment 109 and a second compartment 111. Together the first wall compartment 109, the second compartment 111 and the separator 107 are arranged within the mould volume.
  • the mould 101 extents in a width direction 113 by an extent w which may amount between 100 and 120 mm, for example. Further, the mould 101 extends in a height direction 115 to an amount h between 18 and 20 mm. Further, the mould 101 extends in a depth direction 117 to an amount d which is for example between 60 and 70 mm.
  • the mould 101 is adapted for manufacturing a permanent magnet (such as the one illustrated in Fig. 3 ) which may be utilized within in particular an outer rotor electrical generator for a wind turbine.
  • a permanent magnet such as the one illustrated in Fig. 3
  • the separator 107 is placed within the mould volume of the mould 101.
  • the first compartment 109 and the second compartment 111 are formed.
  • the first compartment 109 has a shape resembling or being equal to a target shape of the permanent magnet to be manufactured.
  • a first material 119 is filled into the first compartment 109, wherein the first material is a neodymium material supplied in a powder form.
  • a second material 121 is filled into the second compartment 111, wherein the second material 121 is different from the first material 119.
  • the second material 121 may be a plastic material or for example a powder of small iron particles.
  • the first material 119 and the second material 121 is filled into the mould volume of the mould 101 along the depth direction 117 which may also referred to as a filling direction.
  • the mould 101 For filling in the different material the mould 101 comprises an opening 123 which has the form of a rectangle having the width w and the height h.
  • the opening 123 allows filling in the different materials across the entire extent of the mould 101 in the lateral directions, i.e. the width direction 113 and height direction 115.
  • a plate is placed into the opening 123 (wherein the plate is not illustrated in Fig. 1 ) and a pressure (using actuator 114) is applied to the first material and the second material.
  • the constituents or particles of the first material 119 and the second material 121 stick to each other and adhere to each other such as to maintain the shape defined by the separator 107 and the mould wall portions of the mould 101.
  • the separator has a shape resembling a cuboid having two rounded edges 125. At the rounded edges 125 the separator 107 has a curved shape, while in the portion 127 the separator has a flat or planar shape.
  • the manufactured magnet comprises an upper surface 129 of the first material and an upper surface 131 of the second material covering the surface 129 of the first material.
  • the first material 119 is protected by the second material 121 covering the upper surface 129 of the first material.
  • the smallest thickness of the cover layer of the second material amounts to ⁇ being between 0.5 and 2 mm, in particular about 1 mm, in particular between 1/50 and 1/5, further in particular between 1/20 and 1/10, of the height h.
  • a sintering process is applied involving heat treatment below the melting temperature of the first material 119.
  • a magnetization is applied for example in the height direction 115 such that the magnetic field lines of an external magnetic field are co-linear with the height direction 115.
  • the separator 107 is withdrawn in a direction opposite to the filling direction 117 before applying a further pressure step. After the further pressure step a sintering step and a magnetization step may be applied. Finally, the manufactured end product may be removed from the mould 101 and may be connected to a rotor of an electric generator.
  • the separator 107 only partly surrounds the first compartment 109.
  • the mould wall portions 104 and 106 and 105 partly enclose or surround the first compartment 109.
  • Fig. 2 schematically illustrates another embodiment 200 of a moulding system in a perspective view. Elements or components similar in structure and/or function to elements or components illustrated in Fig. 1 are labelled with the same reference sign differing only in the first digit.
  • the mould system 200 illustrated in Fig. 2 comprises a mould 201 having mould wall portions 203, 204, 205, 206.
  • the mould 201 may have a similar size as the mould illustrated in Fig. 1 .
  • Differing from the moulding system 100 illustrated in Fig. 1 the moulding system 200 illustrated in Fig. 2 comprises a separator 207 having rounded edges 225.
  • the separator that entirely surrounds the first compartment 209 in the width direction 213 and the height direction 215.
  • the second compartment 211 surrounds the first compartment 209 entirely in the width direction 213 and the height direction 215.
  • the resulting permanent magnet from the manufacturing methods using either the mould system 100 illustrated in Fig. 1 or the mould system 200 illustrated in Fig. 2 may be magnetized in the height direction 115, 215, respectively.
  • the upper surface 229, 129 or the upper surface 131, 231 of the resulting permanent magnet may be opposite to a stator of an electric generator, when the permanent magnet is used as a permanent magnet of an electrical generator.
  • the thickness of the second material 221 above the upper surface 129, 229 of the first material 119, 219 may amount to ⁇ which may be in between 0,5 and 2 mm, in particular about 1 mm.
  • This thickness ⁇ may be small enough such that a gap between the upper surface 131, 231 of the permanent magnet and the stator may be maintained.
  • the second material at least partially covering the first material 119, 219 may not (or only slightly, e.g. 0% to 20%) interfere or affect the magnetically property of the resulting permanent magnet, in particular the magnetic properties may be governed by the material and the shape of the first material 119, 219.
  • Fig. 3 schematically illustrates a perspective view of a permanent magnet 300 manufactured using the mould system of Fig. 1 or Fig. 2 according to an embodiment of the present invention.
  • the permanent magnet 300 comprises a first material 119 shaped in a target shape (defined by surface 126 of the separator and surface 104 of the mould) different from a cuboid and a second material 121 at least partially surrounding the first material, wherein an outer shape of the magnet is a cuboid 124.
  • Dimensions of the magnet 300 can be taken from Figs. 1 or 2 .
  • the surface defining a border or interface between the first material 119 and the second material 121) is curved providing rounded edges of the magnet 300.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Environmental & Geological Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Hard Magnetic Materials (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)

Claims (15)

  1. Verfahren zum Herstellen eines Permanentmagneten, das Folgendes umfasst:
    Trennen eines Formwerkzeugvolumens durch ein Trennelement (107, 207) in eine erste Kammer (109, 209) und eine zweite Kammer (111, 211),
    Einfüllen eines ersten Materials (119, 219) in die erste Kammer (109, 209),
    Einfüllen eines zweiten Materials (121, 221) in die zweite Kammer (111, 211),
    Verdichten des ersten und des zweiten Materials,
    wobei das Trennelement so geformt ist, dass eine Form der ersten Kammer einer Sollform des Permanentmagneten entspricht,
    wobei das Formwerkzeugvolumen eine Quaderform (B*H*T) aufweist,
    wobei das Trennelement so geformt ist, dass die erste Kammer eine Form aufweist, die einem Quader mit zwei abgerundeten Kanten (125) ähnelt und in eine Tiefenrichtung des Formwerkzeugvolumens (117) verläuft.
  2. Verfahren nach Anspruch 1, bei dem das Trennelement eine konstante Dicke aufweist.
  3. Verfahren nach Anspruch 1 oder 2, das ferner Folgendes umfasst:
    Anordnen des Trennelements in dem Formwerkzeugvolumen, um die erste und die zweite Kammer zu bilden.
  4. Verfahren nach einem der vorhergehenden Ansprüche, bei dem das Trennelement (107, 207) so geformt ist, dass sich eine Ausdehnung (h1) der ersten Kammer (109, 209) in einer Höhenrichtung (115) zu beiden Enden hin in einer Breitenrichtung (113) verringert, wobei die Höhen- und die Breitenrichtung quer, insbesondere senkrecht zu einer Einfüllrichtung (117) verlaufen, in der das erste und/ oder das zweite Material in die jeweilige Kammer eingefüllt wird.
  5. Verfahren nach einem der vorhergehenden Ansprüche, bei dem es sich bei dem ersten Material um ein Magnetpulvermaterial, insbesondere ein hochwertiges NdFeB-Pulvermaterial, mit einer Remanenz und/ oder Koerzitivfeldstärke handelt, die 2- bis 10-mal höher ist als die des zweiten Materials.
  6. Verfahren nach einem der vorhergehenden Ansprüche, bei dem das erste Material Fe in einem Massenverhältnis zwischen 50% und 75%, Nd in einem Massenverhältnis zwischen 15% und 35%, Dy in einem Massenverhältnis zwischen 1% und 15% und B in einem Massenverhältnis zwischen 0% und 2% umfasst.
  7. Verfahren nach einem der vorhergehenden Ansprüche, bei dem das zweite Material ein Kunststoffmaterial umfasst, bei dem es sich um ein duroplastisches oder/ und ein thermoplastisches Material, insbesondere Epoxidharz, handelt, und/ oder
    bei dem das zweite Material Fe in einem Massenverhältnis zwischen 75% und 100%, Nd in einem Massenverhältnis zwischen 0% und 10%, Dy in einem Massenverhältnis zwischen 0% und 10% und B in einem Massenverhältnis zwischen 0% und 1% umfasst.
  8. Verfahren nach einem der vorhergehenden Ansprüche, bei dem das Formwerkzeugvolumen von einer Formwerkzeugwand (103, 104, 105, 106) begrenzt wird, die eine Öffnung (123) zum Einfüllen des ersten und/ oder des zweiten Materials in das Formwerkzeugvolumen bereitstellt.
  9. Verfahren nach einem der vorhergehenden Ansprüche, bei dem das Verdichten Folgendes umfasst:
    Aufbringen von Druck auf das erste und das zweite Material über die Öffnung (123).
  10. Verfahren nach dem vorhergehenden Anspruch, bei dem das Aufbringen von Druck Folgendes umfasst:
    Aufbringen von Druck einer ersten Höhe auf das erste und das zweite Material, dann
    Entfernen des Trennelements und dann
    Aufbringen von Druck einer zweiten Höhe auf das erste und das zweite Material,
    wobei die zweite Höhe zwischen 2- und 50-mal größer ist als die erste Höhe.
  11. Verfahren nach dem vorhergehenden Anspruch,
    bei dem das Entfernen des Trennelements das Herausziehen des Trennelements aus dem Formwerkzeugvolumen, insbesondere in einer zur Einfüllrichtung (117) entgegengesetzten Richtung, umfasst, wobei das Verfahren ferner Folgendes umfasst:
    Sintern des ersten Materials und/ oder
    Magnetisieren des ersten Materials.
  12. Verfahren nach einem der vorhergehenden Ansprüche, bei dem das in die zweite Kammer eingefüllte zweite Material zwischen 30% und 100% einer Außenfläche des in die erste Kammer eingefüllten ersten Materials umgibt.
  13. Formsystem (100, 200) zum Herstellen eines Permanentmagneten, das Folgendes umfasst:
    ein Formwerkzeug (101, 201), das ein Formwerkzeugvolumen mit einer Quaderform (B*H*T) aufweist,
    ein Trennelement (107, 207) zum Trennen des Formwerkzeugvolumens in eine erste Kammer (109, 209) und eine zweite Kammer (111, 211),
    ein Stellelement (114, 214) zum Verdichten von in die erste Kammer eingefülltem erstem Material und von in die zweite Kammer eingefülltem zweitem Material,
    wobei das Trennelement so geformt ist, dass eine Form der ersten Kammer einer Sollform des Permanentmagneten entspricht,
    wobei das Trennelement so geformt ist, dass die erste Kammer eine Form aufweist, die einem Quader mit zwei abgerundeten Kanten (125) ähnelt und in eine Tiefenrichtung des Formwerkzeugvolumens (117) verläuft.
  14. Permanentmagnet (300), der Folgendes umfasst:
    ein erstes Material (119, 219), das in einer Sollform (126) geformt ist, die sich von einem Quader unterscheidet, wobei die Sollform einem Quader mit zwei abgerundeten Kanten (125) ähnelt und in eine Tiefenrichtung (117) verläuft,
    ein zweites Material (121, 221), das das erste Material zumindest teilweise umgibt, wobei es sich bei einer Außenform des Magneten um einen Quader (124) handelt.
  15. Permanentmagnet nach Anspruch 14, der nach einem der Ansprüche 1 bis 12 hergestellt ist.
EP11193247.1A 2011-12-13 2011-12-13 Herstellungsverfahren für ein Permanentmagnet, Formsystem und Permanentmagnet Active EP2605253B1 (de)

Priority Applications (4)

Application Number Priority Date Filing Date Title
EP11193247.1A EP2605253B1 (de) 2011-12-13 2011-12-13 Herstellungsverfahren für ein Permanentmagnet, Formsystem und Permanentmagnet
DK11193247.1T DK2605253T3 (en) 2011-12-13 2011-12-13 Process for producing a permanent magnet, forming system and permanent magnet
PCT/EP2012/075049 WO2013087609A2 (en) 2011-12-13 2012-12-11 Manufacturing method for a permanent magnet, moulding system and permanent magnet
CN201210537415.3A CN103157794B (zh) 2011-12-13 2012-12-13 用于永磁体的制造方法、造型系统和永磁体

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
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EP3559964B1 (de) 2016-12-23 2024-04-10 ABB Schweiz AG Sintermagnet, elektrische maschine, verwendung des sintermagneten in einer elektrischen maschine und herstellungsverfahren eines sintermagneten

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US5722032A (en) * 1996-07-01 1998-02-24 General Motors Corporation AC generator rotor segment
US6856051B2 (en) * 2001-10-03 2005-02-15 Delphi Technologies, Inc. Manufacturing method and composite powder metal rotor assembly for circumferential type interior permanent magnet machine
US6655004B2 (en) * 2001-10-03 2003-12-02 Delphi Technologies, Inc. Method of making a powder metal rotor for a surface
JP3956760B2 (ja) * 2002-04-25 2007-08-08 松下電器産業株式会社 フレキシブル磁石の製造方法とその永久磁石型モ−タ
JP2005286235A (ja) * 2004-03-30 2005-10-13 Mg:Kk 極異方性ボンド磁石、およびその製造方法
CN1757148B (zh) * 2004-04-06 2010-05-26 日立金属株式会社 转子及其制造方法
JPWO2005123974A1 (ja) * 2004-06-22 2008-04-10 信越化学工業株式会社 Ｒ−Ｆｅ−Ｂ系希土類永久磁石材料
CN101401282B (zh) * 2006-03-16 2011-11-30 松下电器产业株式会社 径向各向异性磁铁的制造方法和使用径向各向异性磁铁的永磁电动机及有铁芯永磁电动机
EP2017859B1 (de) 2007-07-20 2012-08-29 Siemens Aktiengesellschaft Magnetpol und Verfahren zum dessen Herstellung
WO2010066251A1 (en) 2008-12-12 2010-06-17 Sintex A/S A permanent magnet rotor for a machine, a method for manufacturing a permanent magnet rotor and a manufacturing system
EP2378634A1 (de) * 2010-04-13 2011-10-19 Siemens Aktiengesellschaft Elektrische Maschine und Permanentmagnet

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DK2605253T3 (en) 2016-05-09
CN103157794A (zh) 2013-06-19
CN103157794B (zh) 2016-12-21
WO2013087609A2 (en) 2013-06-20
EP2605253A1 (de) 2013-06-19

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