公开(公告)号：US20220130607A1

公开(公告)日：2022-04-28

申请号：US17572193

申请日：2022-01-10

Applicant: Ford Global Technologies, LLC

Inventor： Wanfeng Li ,  Feng Liang ,  Michael W. Degner

IPC: H01F41/02 ,  B22F10/20 ,  H01F7/02 ,  H01F1/053 ,  B22F10/28

Abstract: A magnet structure includes columnar grains of rare earth permanent magnet phase aligned in a same direction and arranged to form bulk anisotropic rare earth alloy magnet having a boundary defined by opposite ends of the columnar grains and lacking triple junction regions, and rare earth alloy diffused onto opposite ends of the bulk anisotropic rare earth alloy magnet.

公开(公告)号：US20190131066A1

公开(公告)日：2019-05-02

申请号：US15795208

申请日：2017-10-26

Applicant: Ford Global Technologies, LLC

Inventor： C. Bing Rong ,  Feng Liang ,  Michael Degner ,  Wanfeng Li

IPC: H01F41/02 ,  H01F1/057 ,  B22F1/02

Abstract: A grain boundary diffusion method for a rare-earth (RE) magnet is provided. The method includes coating particles of the RE magnet with a coating material. Each RE magnet particle includes a plurality of grains. The coated particles are then simultaneously heat treated and compacted. The heat treated, compacted, and coated particles are then formed into a rare earth magnet. In a form of the method, the heat treated, compacted, and coated particles are hot deformed prior to being formed into a rare earth magnet. Another form of the method achieves the grain boundary diffusion without first sintering the rare earth magnet.

公开(公告)号：US12243683B2

公开(公告)日：2025-03-04

申请号：US18506227

申请日：2023-11-10

Applicant: FORD GLOBAL TECHNOLOGIES, LLC

Inventor： Wanfeng Li ,  Franco Leonardi ,  Michael W. Degner

IPC: H01F7/02 ,  B22F10/28 ,  B22F10/60 ,  B33Y10/00 ,  B33Y40/20 ,  B33Y80/00 ,  H01F1/057 ,  H01F41/02

Abstract: Permanent magnets and method of making the same are provided. The magnets include a magnetic layer having an insulation layer disposed thereon. The insulation layer is formed via additive manufacturing techniques such as laser melting such that it has discrete phases including a magnetic phase and an insulating phase.

公开(公告)号：US12046399B2

公开(公告)日：2024-07-23

申请号：US17585934

申请日：2022-01-27

Applicant: FORD GLOBAL TECHNOLOGIES, LLC

Inventor： Wanfeng Li ,  Chuanbing Rong ,  Michael W. Degner

IPC: H01F1/055 ,  B33Y70/00 ,  C22C38/00 ,  C22C38/06 ,  C22C38/10 ,  C22C38/12 ,  H01F1/057 ,  H01F41/02 ,  B22F10/28 ,  B33Y10/00

CPC classification number: H01F1/057 ,  B33Y70/00 ,  C22C38/005 ,  C22C38/06 ,  C22C38/105 ,  C22C38/12 ,  H01F41/0253 ,  B22F10/28 ,  B22F2301/355 ,  B33Y10/00 ,  C22C2202/02

Abstract: A permanent magnet formed by additively manufacturing magnetic phases and buffer phases is disclosed. The buffer phase(s) may improve performance, enhance mechanical properties and allow the magnet to better tolerate stresses such that defects such as cracking do not occur or are less likely to occur. The buffer phase may be a magnetic or non-magnetic material.

公开(公告)号：US20230412010A1

公开(公告)日：2023-12-21

申请号：US18336662

申请日：2023-06-16

Applicant: Ford Global Technologies, LLC

Inventor： Raphael Koch ,  Wanfeng Li

IPC: H02K1/02 ,  H02K15/02 ,  B33Y80/00

CPC classification number: H02K1/02 ,  H02K15/02 ,  B33Y80/00 ,  B33Y10/00

Abstract: The disclosure relates to a method for producing a rotor element for a rotor of an electric machine. The method includes screen printing at least one permanent magnetic material and a non-permanent magnetic material to form the rotor element, simultaneously sintering the permanent magnetic material and the non-permanent magnetic material, and magnetizing the permanent magnetic material.

公开(公告)号：US20210335539A1

公开(公告)日：2021-10-28

申请号：US17371988

申请日：2021-07-09

Applicant: Ford Global Technologies, LLC

Inventor： Michael W. Degner ,  Wanfeng Li

IPC: H01F41/02 ,  H02K1/02 ,  B33Y10/00 ,  B22F10/16 ,  B22F10/28 ,  C22C38/00

Abstract: A method of forming a magnet is provided. The method includes disposing an anisotropic magnetic powder and a binder within a bed, the anisotropic magnetic powder having a defined magnetization direction. An energy beam selectively melts the binder such that the anisotropic magnetic powder forms a permanent magnet with the defined magnetization direction. The energy beam is a laser beam, a microwave beam and the like.

公开(公告)号：US11043319B2

公开(公告)日：2021-06-22

申请号：US16014055

申请日：2018-06-21

Applicant: Ford Global Technologies, LLC

Inventor： Wanfeng Li ,  Feng Liang

IPC: H01F1/047 ,  B22F1/00 ,  C22C22/00 ,  C22C12/00 ,  C22C1/02

Abstract: A method of increasing volume ratio of magnetic particles in a MnBi alloy includes depositing a MnBi alloy powder containing magnetic particles and non-magnetic particles on a sloped surface having a magnetic field acted thereupon. The method further includes collecting falling non-magnetic particles while separated magnetic particles are magnetically retained on the sloped surface.

公开(公告)号：US20210090779A1

公开(公告)日：2021-03-25

申请号：US16579117

申请日：2019-09-23

Applicant: FORD GLOBAL TECHNOLOGIES, LLC

Inventor： Wanfeng Li ,  Chuanbing Rong ,  Michael W. Degner

IPC: H01F27/245 ,  H01F27/255 ,  H01F41/02 ,  H01F3/10

Abstract: An inductor that is configured to store energy in a magnetic field includes a wire and a core. The wire is configured to deliver electrical current to the inductor to generate the magnetic field. The core is disposed radially about the wire. The core comprises magnetic particles that are suspended in a non-magnetic matrix. The magnetic particles are arranged such that a magnetic permeability of the core increases in a direction that extends radially outward from the wire along a cross-sectional area of the magnetic core from a first region that is adjacent to the wire to a second region that is adjacent to an outer periphery of the magnetic core.

公开(公告)号：US20210075280A1

公开(公告)日：2021-03-11

申请号：US16567720

申请日：2019-09-11

Applicant: FORD GLOBAL TECHNOLOGIES, LLC

Inventor： Franco Leonardi ,  Chuanbing Rong ,  Chun Tang ,  Wanfeng Li ,  Michael W. Degner

IPC: H02K1/28 ,  H02K1/27

Abstract: A rotor for an electric machine includes a core comprised of stacked laminations that define pockets between a hub portion and a pole portion. Each of the pockets are configured to receive magnetic material and define center cavities between regions of magnetic material to eliminate a flux leakage path between the magnetic materials. A cured mixture including an epoxy and a magnetic powder is disposed within the center cavities. The magnetic material may include sintered magnets and a cured mixture.

公开(公告)号：US10706997B2

公开(公告)日：2020-07-07

申请号：US15627517

申请日：2017-06-20

Applicant: FORD GLOBAL TECHNOLOGIES, LLC

Inventor： Wanfeng Li

IPC: B22F3/10 ,  B22F3/16 ,  C22C22/00 ,  H01F1/055 ,  C22C1/04 ,  H01F1/08 ,  B22F9/04 ,  B22F3/02

Abstract: A method comprising sintering a Mn and Bi powder compact at a first temperature for a first predetermined duration, based on the first temperature, and sintering the compact at a second temperature, less than the first temperature, for a second predetermined duration, greater than the first duration, is disclosed. The sintering at a first temperature for a first predetermined duration generates a predetermined MnBi LTP transition driving force to decrease a formation energy barrier for transition to MnBi LTP. Sintering the compact at the second temperature for the second predetermined duration forms a magnet containing the MnBi LTP.