Permanent magnets with embedded phase changing material for electric motor thermal management

The magnetic performance of NdFeB permanent magnets rapidly decreases as their operation temperature increases. This limits the power output of electric motors as their internal temperature quickly increases with the power demand. This is particularly problematic for applications where high peak power is required for a short period of time, for example during automobile highway acceleration or during an airplane lift-off. With the advances in additive manufacturing, one can envision to fabricate more complex motor geometries and magnetic structures, without additional costs, allowing for enhanced functionalities such as better thermal management. In this context, this paper investigates the feasibility of using phase changing materials (PCMs) to mitigate the temperature rise in permanent magnets (PMs) fabricated by additive manufacturing. The potential of PCM and its relevance was validated by modeling the thermal response of an electric motor during a representative electric vehicle driving scenario. It was found that segmented magnets with embedded phase changing materials would allow to efficiently control temperature rise. To validate the simulation results, PM test pieces with and without embedded PCMs were fabricated using cold spray additive manufacturing and tested using a custom laser thermal cycling setup.