According to recent reports from international media, Toyota has made a groundbreaking advancement by developing the world's first heat-resistant motor. This innovation involves a new type of magnet that cuts the use of neodymium—a costly rare earth element—by nearly half. Neodymium magnets are crucial for high-performance motors in electric vehicles, but their high price and limited availability have long been a challenge.
The new magnet design eliminates the need for terbium (Tb) and dysprosium (Dy), two rare earth elements commonly used to enhance heat resistance. However, these materials come with significant geopolitical risks due to their concentrated sources and unstable supply chains. To address this, Toyota has substituted some of these elements with lanthanum (La) and cerium (Ce), which are more affordable and abundant, aiming to cut costs without compromising performance.
This substitution plays a critical role in maintaining both coercivity and heat resistance. Simply reducing the amount of neodymium could weaken these properties, so Toyota introduced a new technology to prevent degradation in high-temperature environments. The company also developed a new magnet structure that ensures consistent heat resistance compared to previous models.
Building on its existing design, Toyota reduced the magnetic grain size by 10% and implemented a double-layer surface coating to maintain coercivity at elevated temperatures. In traditional neodymium magnets, helium is evenly distributed throughout the material. However, Toyota optimized the distribution by increasing the concentration of helium on the surface while reducing it in the core, significantly lowering overall usage.
These advanced magnets are expected to be widely used in electric vehicle motors, generators, electric steering systems, robots, and household appliances. Toyota’s breakthrough could help reduce global reliance on rare earth elements, mitigating supply chain disruptions and price volatility. According to reports, the new motor technology is set for mass production between 2020 and 2025, with potential integration into electric vehicles over the next decade.
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