EP0125752A2 - Aimants comportant des particules du système terre rare-fer et un liant - Google Patents
Aimants comportant des particules du système terre rare-fer et un liant Download PDFInfo
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- EP0125752A2 EP0125752A2 EP84301453A EP84301453A EP0125752A2 EP 0125752 A2 EP0125752 A2 EP 0125752A2 EP 84301453 A EP84301453 A EP 84301453A EP 84301453 A EP84301453 A EP 84301453A EP 0125752 A2 EP0125752 A2 EP 0125752A2
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- EP
- European Patent Office
- Prior art keywords
- magnet
- compact
- particles
- alloy
- magnets
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 title claims description 25
- 229910052742 iron Inorganic materials 0.000 title claims description 13
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 48
- 239000000956 alloy Substances 0.000 claims abstract description 48
- 239000002245 particle Substances 0.000 claims abstract description 46
- 239000011230 binding agent Substances 0.000 claims abstract description 10
- 230000005415 magnetization Effects 0.000 claims description 12
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 7
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 5
- 229910052796 boron Inorganic materials 0.000 claims description 5
- 229910052779 Neodymium Inorganic materials 0.000 claims description 4
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 claims description 4
- 229910052723 transition metal Inorganic materials 0.000 claims description 4
- 229910052777 Praseodymium Inorganic materials 0.000 claims description 3
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 claims description 3
- 239000013078 crystal Substances 0.000 claims description 2
- 229910000640 Fe alloy Inorganic materials 0.000 abstract description 11
- 239000000843 powder Substances 0.000 description 31
- 238000005056 compaction Methods 0.000 description 20
- 238000000034 method Methods 0.000 description 15
- 229910052751 metal Inorganic materials 0.000 description 13
- 239000002184 metal Substances 0.000 description 13
- 229910000938 samarium–cobalt magnet Inorganic materials 0.000 description 11
- 230000005347 demagnetization Effects 0.000 description 10
- KPLQYGBQNPPQGA-UHFFFAOYSA-N cobalt samarium Chemical compound [Co].[Sm] KPLQYGBQNPPQGA-UHFFFAOYSA-N 0.000 description 8
- 239000004593 Epoxy Substances 0.000 description 7
- 239000000203 mixture Substances 0.000 description 7
- 239000011347 resin Substances 0.000 description 7
- 229920005989 resin Polymers 0.000 description 7
- 238000002074 melt spinning Methods 0.000 description 6
- 229910001172 neodymium magnet Inorganic materials 0.000 description 6
- 239000000470 constituent Substances 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000003801 milling Methods 0.000 description 4
- 238000003825 pressing Methods 0.000 description 4
- 238000010791 quenching Methods 0.000 description 4
- 230000002411 adverse Effects 0.000 description 3
- 229910017052 cobalt Inorganic materials 0.000 description 3
- 239000010941 cobalt Substances 0.000 description 3
- 230000006698 induction Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- 229910001122 Mischmetal Inorganic materials 0.000 description 2
- 229910052772 Samarium Inorganic materials 0.000 description 2
- 238000013459 approach Methods 0.000 description 2
- 238000000498 ball milling Methods 0.000 description 2
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 2
- 239000011449 brick Substances 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 230000004907 flux Effects 0.000 description 2
- 238000000227 grinding Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- 230000005389 magnetism Effects 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 238000001000 micrograph Methods 0.000 description 2
- 238000012856 packing Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 239000010453 quartz Substances 0.000 description 2
- KZUNJOHGWZRPMI-UHFFFAOYSA-N samarium atom Chemical compound [Sm] KZUNJOHGWZRPMI-UHFFFAOYSA-N 0.000 description 2
- 238000001878 scanning electron micrograph Methods 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- YSUQLAYJZDEMOT-UHFFFAOYSA-N 2-(butoxymethyl)oxirane Chemical compound CCCCOCC1CO1 YSUQLAYJZDEMOT-UHFFFAOYSA-N 0.000 description 1
- ULKLGIFJWFIQFF-UHFFFAOYSA-N 5K8XI641G3 Chemical compound CCC1=NC=C(C)N1 ULKLGIFJWFIQFF-UHFFFAOYSA-N 0.000 description 1
- RZVAJINKPMORJF-UHFFFAOYSA-N Acetaminophen Chemical compound CC(=O)NC1=CC=C(O)C=C1 RZVAJINKPMORJF-UHFFFAOYSA-N 0.000 description 1
- 229910052582 BN Inorganic materials 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- PXAWCNYZAWMWIC-UHFFFAOYSA-N [Fe].[Nd] Chemical compound [Fe].[Nd] PXAWCNYZAWMWIC-UHFFFAOYSA-N 0.000 description 1
- 230000001154 acute effect Effects 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229910000828 alnico Inorganic materials 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 239000012300 argon atmosphere Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229940106691 bisphenol a Drugs 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000001739 density measurement Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- GYZLOYUZLJXAJU-UHFFFAOYSA-N diglycidyl ether Chemical compound C1OC1COCC1CO1 GYZLOYUZLJXAJU-UHFFFAOYSA-N 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000012634 fragment Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000000462 isostatic pressing Methods 0.000 description 1
- LQBJWKCYZGMFEV-UHFFFAOYSA-N lead tin Chemical compound [Sn].[Pb] LQBJWKCYZGMFEV-UHFFFAOYSA-N 0.000 description 1
- 239000004850 liquid epoxy resins (LERs) Substances 0.000 description 1
- 229910001004 magnetic alloy Inorganic materials 0.000 description 1
- 230000005381 magnetic domain Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 239000002952 polymeric resin Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 239000005297 pyrex Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000012261 resinous substance Substances 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 229910000679 solder Inorganic materials 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000003826 uniaxial pressing Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
Images
Classifications
-
- 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
- H01F1/0578—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 bonded together
Definitions
- This invention relates to bonded particle permanent magnets and to a method of making them.
- such magnets are readily fabricated into desired shapes from melt-spun rare earth-iron alloy ribbons. These magnets have intrinsic coercivities and energy products of the same order as samarium-cobalt magnets but are much less costly.
- the bonded magnet compacts are magnetically isotropic. They may be readily magnetized in any preferred direction in a suitable magnetic field.
- sintered or bonded samarium-cobalt (Sm-Co) powder magnets have been used in applications where high magnetic remanence and coercivity are needed in a shaped permanent magnet.
- Sm-Co powder magnets are very expensive. The high price is a function of both the cost of the metals and the cost of their manufacture into magnets.
- Samarium is one of the least abundant rare earth elements, while cobalt is a critical metal with unreliable worldwide availability.
- each powder particle is a single crystal that is inherently magnetically anisotropic.
- the anisotropic powder particles must be oriented in a magnetic field before the position of each particle is fixed by sintering or bonding. After sintering or bonding, the magnet must be finally magnetically aligned in the same direction in which the particles were initially oriented to obtain optimum magnetic properties, That is, the magnets are anisotropic.
- Sintered Sm-Co magnets may approach densities nearing 100% of alloy density. For bonded Sm-Co magnets, however, it is difficult to obtain densities much greater than about 75%. Conventional powder metal compaction equipment is not capable of achieving higher packing densities because of the shape and hardness of the powder particles.
- This invention relates to high density, bonded, rare earth-transition metal magnets with properties nearly rivalling bonded samarium cobalt magnets.
- these novel magnets are based on the relatively common and inexpensive light rare earth elements, neodymium and praseodymium; the transition metal element, iron; and boron. These alloys and the method by which they are processed to achieve superior hard magnetic properties are described in detail in co-pending European application number 83304909.1.
- the magnetic alloys are made by melt-spinning.
- Melt-spinning is a process by which a molten stream of alloy is impinged on the perimeter of a rotating quench wheel to produce rapidly quenched alloy ribbons.
- These ribbons are relatively brittle and have a very finely crystalline microstructure. They-may be compacted and bonded as will be described hereafter to create - novel, isotropic, high density, high performance permanent magnets.
- isotropic, bonded particle magnets are produced with compact densities of at least about 75% of the constituent RE-Fe alloy density.
- the constituent alloy does not have to be ground into a fine powder in order to obtain a magnet with high magnetic remanence. Rather,melt-spun rare earth-iron ribbon is simply compacted in a powder metal die in a suitable press.
- a preferred alloy for use herein would be a melt-spun form of Nd 0.15 (Fe 0.95 B 0.05 ) 0.85 alloy having a suitable finely crystalline microstructure.
- the ribbon itself is magnetically isotropic. It need not be magnetized before or during compaction.
- the ribbon particles of the green compact are coated with a binder agent which may be later hardened to form a self-supporting, unmagnetized but magnetizable, magnetically isotropic, composite body.
- the binder agent may be a hardenable resinous substance such asian epoxy; a lower melting metal such as lead-tin solder; or any other suitable organic or inorganic binder.
- the ribbon segments may be compacted to high density in almost any conventional die press.
- the compacts are magnetically isotropic. That is, they may be magnetized in any desired direction to achieve optimum properties for a particular application.
- arcuate shaped field magnets for direct current motors could be formed by compacting melt-spun rare earth-iron ribbon in a punch and die set. These arcuate shaped bodies would first be magnetized after compaction in an applied magnetic field in which the field lines radially intersect the compact to induce radially oriented, remanent magnetization.
- a bonded magnet of any other shape could be magnetized in a magnetic field having field lines oriented in any desired direction.
- iron, rare earth elements and a small amount of boron are melted and rapidly quenched by the melt spinning process to create relatively brittle alloy ribbons.
- These alloys have high inherent intrinsic coercivities of the order of a kiloOersted or more, some higher than twenty kiloOersteds and remanent magnetization of the order of 8 kiloGauss.
- Such high coercivities and high remanent magnetism are believed to be due to the presence of a very finely crystalline phase (atomic ordering less than about 500 nanometers) composed of iron and low atomic weight rare earth elements (atomic No. less than or equal to 62) that do not have full or exactly half full f-orbitals.
- the phase is stabilized by the presence of a small amount of boron.
- European application No. 83304909.1 describes suitable compositions and methods of making such and is incorporated herein by reference.
- Preferred alloys contain from about 10 to 50 atomic percent neodymium, praseodymium; or mischmetal comprised principally of these rare earth elements; a small amount of boron (generally less than about 10 atomic percent); and the balance iron.
- Other rare earth elements such as samarium and transition metal elements such as cobalt may be incorporated in amounts that do not severely degrade the magnetic properties of the melt-spun alloys.
- Other metals may be incorporated in small amounts which tend to dilute but not destroy the magnetic properties of the preferred melt-spun RE-Fe alloys.
- a preferred method of making the high coercivity alloys is to melt suitable amounts of the elements together and then quench a stream of the alloy on the perimeter of a spinning quench wheel to create a friable alloy ribbon with a very finely crystalline microstructure. This process is referred to herein as melt-spinning.
- FIG 1 is a schematic representation of a method for making bonded permanent magnets in accordance with the invention.
- the alloy 2 is melted in a crucible 4 and ejected through a small orifice 6.
- the ejected stream of alloy impinges on a rotating quench wheel 8 to form a ribbon 10 of solidified alloy with a very.finely crystalline phase.
- Ribbon 10 is generally quite thin and very brittle. It can be broken into pieces small enough to fit into a die cavity by almost any crushing means.
- Melt-spun ribbons have been placed, for example, between two clean sheets of paper and an ordinary wooden writing pencil has been rolled over the sandwiched material. The resultant ribbon segments can be-poured directly into a die cavity.
- Figure l(b) shows a die for making a cylindrical compact 12.
- the compact is formed between a pair of opposing punches 14 and 16 in tool 18.
- This process is referred to herein as uniaxial compaction, the axis being parallel to the travel of the compaction punches.
- RE-Fe ribbon segments and to pack them together in a manner such that the ribbon sections lie parallel and directly adjacent to each other almost as the bricks in a brick wall are oriented with respect to one another.
- Each ribbon segment is much larger than a single magnetic domain. It is magnetically isotropic and is readily magnetized to a strong permanent magnet in an applied magnetic field.
- compact 12 is removed from the press and placed in side-arm tube 20.
- a hardenable liquid resin 22 is retained in a syringe 24.
- Syringe needle 26 is inserted through stopper 28 and a vacuum is drawn through the side arm of tube 20.
- tube 20 is evacuated, enough resin 22 is dripped onto compact 12 to saturate the pores between particles. The resin is then cured and any excess is machined away.
- This bonded body 30 need not be magnetized when it is formed. Permanent magnetism is induced in the bonded compact body 30 by exposing it to a magnetic field of suitable direction and field strength.
- the field may be created by suitable magnetizing means such as a magnetic induction coil 32.
- Coil 32 is activated to create a field represented by flux lines 34.
- the flux lines 34 run parallel to the axis of the cylindrical bonded body 30.
- magnets can be formed in almost any shape that is adaptable to formation by powder metal pressing techniques such as uniaxial compaction in a rigid die or isostatic compaction in a flexible sleeve.
- a key advantage of this method over the conventional methods of making particulate Sm-Co magnets is that the compaction need not take place concurrently with magnetization.
- the ribbons have to be ground to a size commensurate with single domain size.
- the rare earth-iron alloy ribbon of this invention is isotropic and need not be magnetized until after the bonded magnet is fully formed. This simplifies the magnet making process and eliminates all the problems associated with grinding fine powders and handling magnetized green compacts.
- Unexpectedly high remanent magnetizations of 7 kiloGauss (at least 6 kiloGauss being desired) and energy products of 9 megaGauss Oersted or more have been achieved.
- a very thin layer of lead or other low melting metal could be sputtered or sprayed on to melt-spun alloy ribbon before compacting. The compact could then be heated to melt the lead and bond the particles.
- Another practice would be to blend melt-spun RE-Fe ribbon fragments with a dry resin powder. After compaction, the resin would be cured or melted at a suitable elevated temperature to bond the alloy particles.
- Another clear advantage of the invention is that the direction of magnetization of the bonded rare earth-iron body can be tailored to a desired application.
- the body is first magnetized after it is shaped and the alloy particles are mechanically bonded together.
- the unmagnetized body is simply placed in a magnetic field of desired direction and adequate strength to establish its remanent magnetic direction and energy product.
- the magnet bodies can be made and stored in an unmagnetized state and be magnetized immediately before use.
- a preferred practice would be to install a bonded compact in the device in which it will be used and only then magnetize it in situ.
- the neodymium-iron alloys of the following examples were all made by melt spinning.
- the melt spinning tube was made of quartz and measured about 102 mm (4 inches) long and 12.7 nm (1/2 inth) in diameter.
- About 5 grams of premelted and solidified mixtures of pure neodymium, iron and boron-metals were melt-spun during each run.
- the mixtures were remelted in the quartz tube by means of an induction coil surrounding it.
- An ejection pressure of about 34.47 kPa( 5 psi) was generated in the tube with argon gas.
- the ejection orifice was round and about 500 microns in diameter.
- the orifice was located about 3.18 mm to 6.35 mm(1/8 to 1/4 inches) from the chill surface of the cooling,. disc.
- the disc was rotated at a constant revolution rate such that the-velocity of a point on the perimeter of the disc was about 15 meters per second.
- the chill disc was originally at room temperature and was not externally cooled.
- the resultant melt spun ribbons were about 30-50 microns thick and about 1.5 millimeters wide. They were brittle and, easily broken into small pieces. Melt spun ribbons processed in this manner exhibited optimum magnetic properties for a given RE-Fe-B composition.
- a 15 gram sample of melt-spun Nd 0.2 (Fe 0.95 B 0.05 ) 0.8 ribbon was ground in an argon atmosphere in a vibrating mill (Shatterbox, Spex Industries). The resultant powder was sieved to a particle size less than about 45 microns.
- the powder was then placed in a rubber tube with an internal diameter of 8 mm. Rubber plugs sized to be slidable within the tube were inserted in either end. Steel rams were then inserted in either end of the tube.
- This assembly was placed in a pulsed magnetizing coil having a field strength of 40 kOe. The field was pulsed, drawing the rams together and causing the plugs to compress and lightly compact the powder between them. If the powder particles were magnetically anisotropic, this pulsed pressing step would physically orient them along their individual preferred magnetic axes.
- the rams were removed from the tube and the excess rubber sleeve was trimmed away.
- the plugged tube was then reinserted into a hydraulic press and compacted between rams to a pressure of 1,1 0 3,16 2 k P a (160,000 pounds per square inch).
- the resultant right circular cylindrical compact measured 8mm high and 8mm in diameter.
- the compact could be handled without breaking. It was taken out of the rubber compaction tube and placed in a side arm Pyrex test tube. The tube was evacuated with a mechanical vacuum pump. A hypodermic needle attached to a syringe carrying liquid epoxy resin was then inserted through the rubber stopper of the tube. The resin was dropped into the tube to saturate the compact.
- the epoxy was a conventional commercially available epoxy comprised of a diglycidyl ether of bisphenol-A diluted with butyl glycidyl ether and cured with 2-ethyl-4-methyl-imidazole. The compact was removed and allowed to cure overnight (approximately 16 hours) in air at 100°C.
- Figure 2 compares demagnetization curves for non-bonded powder of the same melt-spun ribbon batch as those used for the compact, corrected to 100% density (i.e., density of the alloy).
- the density of the alloy ribbon in the compact was 85% of the density of the alloy itself as determined by standard density measurement in water.
- the bonded magnet formed from' the 85% dense compact has a residual magnetic indication of 85% of that of the unbonded melt-spun ribbon corrected to 100% density.
- This experiment illustrates the magnetically isotropic behavior of the melt-spun, rapidly quenched alloy particles.
- the sieved powder included all particle fractions smaller than 45 micron metres, with many particles smaller than one micrometer, to align. If the smallest particles were near enough single domain size they would be expected to align along the field lines during the alignment step of Example 1.
- the resultant magnets should have measurably higher residual induction and a more square hysteresis loop than unoriented magnet counterparts if the method had achieved near domain size, magnetically anisotropic alloy particles.
- the very finely crystalline alloys may be made up of very tiny crystallites which would be expected to have preferred axes of magnetic alignment, apparently, they cannot be ground finely enough by ball milling to take advantage of magnetic alignments during the pressing step. It is not believed that using other state-of-the art milling techniques would provide different results so far as the creation of near domain size, anisotropic particles from the subject melt-spun alloys is concerned.
- Figures 5 and 6 are scanning electron micrographs of isostatically compacted, epoxy bonded magnets made in accordance with this example.
- the lighter regions are Nd-Fe-B melt-spun ribbon while the dark regions are epoxy resin or voids.
- the white line in the lower right-hand corner of each micrograph represents a length of 100 micrometers.
- Both are plan views of a section of isostatically pressed melt-spun ribbon that was not ground prior to compaction.
- the ribbon segments each contain many crystallites.
- Spherical powder particles of a like alloy do not compact well under like conditions.
- the green compacts are so weak that they cannot be handled prior to bonding.
- Figure 5 especially points out that there are several different regions of ribbon segments oriented parallel to one another in each compact.
- the particles in the region labeled 50 are oriented at an acute angle with respect to the particles in the region labelled 52.
- Figure 6 shows an enlarged section of a compact where the close packing arrangement of the ribbon segments to one another is clearly visible.
- melt-spun ribbons of rare earth-iron alloys are relatively easy to compact to densities over 80 percent employing ordinary uniaxial or isostatic pressing means.
- the compacts have very high green strengths.
- over-milling ribbon samples was found to adversely affect the magnetic properties of the material, i.e., reduce the remanent magnetization and energy product of magnets made from the over-milled materials.
- Figure 4 qualitatively compares the second quadrant hysteresis of the bonded Nd-Fe-B magnets of the preceding examples with bonded and magnetically prealigned Sm 2 Co 17 and (Sm, mischmetal) Co 5 magnets.
- Oriented Sm 2 Co 17 magnets made from near domain size powder particles, magnetically aligned during compaction, sintered, heat-treated and then finally magnetized exhibit the highest remanent magnetization, B r of approximately 11 kiloGauss.
- Sintered oriented Sm-Co 5 magnets (substantially 100% density) have a B r of approximately 8.5 kiloGauss.
- the unoriented Nd-Fe-B magnets of this invention fall about midway between the prealigned and bonded Sm 2 Co 17 type and the SmCo 5 type magnets. Our magnets are far superior to unaligned bonded Sm-Co magnets.
- Oriented ferrite magnets have much lower remanent magnetization than the bonded magnets of the present invention and Alnico magnets have much lower coercivities. Given the tremendous cost and processing advantages of the magnets of the present invention, the fact that they approach the magnetic strength of the best oriented rare earth-cobalt magnets makes them highly commercially adaptable.
- the strength of the magnets of the present invention is obviously a function of the quality, i.e., the intrinsic magnetic properties of the constituent melt-spun rare earth-iron alloy. Melt-spun alloys with higher coercivities and remanent magnetization values would produce even stronger hard magnets than those disclosed herein.
- novel bonded magnets have been produced from fractured and compacted melt-spun rare earth-iron alloy ribbons.
- The.magnets are magnetically isotropic. They do not have to be magnetically prealigned yet they have properties rivalling those of much more expensive bonded samarium cobalt magnets.
- the method of the present invention may be used to make cylindrical magnets; arcuate-shaped magnets, irregularly shaped magnets, square magnets,and magnets of almost any shape which can be formed by powder metal compaction methods. None before has it been possible to efficiently and inexpensively produce such high quality permanent magnets of such varying shape from relatively inexpensive starting materials.
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- Chemical & Material Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Hard Magnetic Materials (AREA)
- Manufacturing Cores, Coils, And Magnets (AREA)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US49262983A | 1983-05-09 | 1983-05-09 | |
US492629 | 1983-05-09 |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0125752A2 true EP0125752A2 (fr) | 1984-11-21 |
EP0125752A3 EP0125752A3 (en) | 1987-01-28 |
EP0125752B1 EP0125752B1 (fr) | 1989-12-06 |
Family
ID=23956982
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP84301453A Expired EP0125752B1 (fr) | 1983-05-09 | 1984-03-06 | Aimants comportant des particules du système terre rare-fer et un liant |
Country Status (8)
Country | Link |
---|---|
EP (1) | EP0125752B1 (fr) |
JP (1) | JPS59211549A (fr) |
AU (1) | AU571497B2 (fr) |
BR (1) | BR8402029A (fr) |
CA (1) | CA1216623A (fr) |
DE (1) | DE3480673D1 (fr) |
ES (1) | ES8503163A1 (fr) |
MX (1) | MX167657B (fr) |
Cited By (27)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0155082A2 (fr) * | 1984-03-08 | 1985-09-18 | General Motors Corporation | Aimants à base de terres rares et de fer liés par des résines époxy |
DE3642228A1 (de) * | 1986-02-24 | 1987-08-27 | Matsushita Electric Ind Co Ltd | Harzgebundener magnet, umfassend einen spezifischen typ an ferromagnetischem pulver, dispergiert in einem spezifischen typ an harzbindemittel |
EP0242187A1 (fr) * | 1986-04-15 | 1987-10-21 | TDK Corporation | Aimant permanent et sa méthode de fabrication |
EP0248665A2 (fr) * | 1986-06-06 | 1987-12-09 | Seiko Instruments Inc. | Aimant à base de terre rare et fer et procédé de fabrication |
EP0255816A2 (fr) * | 1986-08-04 | 1988-02-10 | Treibacher Chemische Werke Aktiengesellschaft | Procédé de préparation de poudre magnétiquement dure, résistant à la corrosion, pour la fabrication d'aimants; aimants fabriqués à partir de poudre magnétiquement dure et leur procédé de fabrication |
EP0265006A1 (fr) * | 1986-10-13 | 1988-04-27 | Koninklijke Philips Electronics N.V. | Méthode de fabrication d'un aimant permanent |
EP0284033A1 (fr) * | 1987-03-23 | 1988-09-28 | Tokin Corporation | Méthode pour la fabrication d'un aimant anisotrope à liant, à base de terre rare-fer-bore, à partir de copeaux rubanés en alliage terre rare-fer-bore rapidement trempé |
US4829277A (en) * | 1986-11-20 | 1989-05-09 | General Motors Corporation | Isotropic rare earth-iron field magnets for magnetic resonance imaging |
US4832891A (en) * | 1987-11-25 | 1989-05-23 | Eastman Kodak Company | Method of making an epoxy bonded rare earth-iron magnet |
US4881988A (en) * | 1987-11-16 | 1989-11-21 | Rjf International Corporation | Novel flexible magnet for use in small dc motors |
US4921553A (en) * | 1986-03-20 | 1990-05-01 | Hitachi Metals, Ltd. | Magnetically anisotropic bond magnet, magnetic powder for the magnet and manufacturing method of the powder |
US4935075A (en) * | 1986-06-12 | 1990-06-19 | Kabushiki Kaisha Toshiba | Permanent magnet |
US4981532A (en) * | 1987-08-19 | 1991-01-01 | Mitsubishi Kinzoku Kabushiki Kaisha | Rare earth-iron-boron magnet powder and process of producing same |
US4983231A (en) * | 1988-05-25 | 1991-01-08 | Daihachi Chemical Industry Co., Ltd. | Coated magnetic powder and a bonded permanent magnet composition containing the same |
US4983232A (en) * | 1987-01-06 | 1991-01-08 | Hitachi Metals, Ltd. | Anisotropic magnetic powder and magnet thereof and method of producing same |
US5037492A (en) * | 1989-12-19 | 1991-08-06 | General Motors Corporation | Alloying low-level additives into hot-worked Nd-Fe-B magnets |
GB2241701A (en) * | 1990-03-07 | 1991-09-11 | Matsushita Electric Ind Co Ltd | A process for producing a resin bonded magnet structure |
US5062981A (en) * | 1989-06-27 | 1991-11-05 | Kanegafuchi Kagaku Kogyo Kabushiki Kaisha | Magnet and method for manufacturing the same |
US5076861A (en) * | 1987-04-30 | 1991-12-31 | Seiko Epson Corporation | Permanent magnet and method of production |
US5186761A (en) * | 1987-04-30 | 1993-02-16 | Seiko Epson Corporation | Magnetic alloy and method of production |
US5449417A (en) * | 1988-10-04 | 1995-09-12 | Hitachi Metals, Ltd. | R-Fe-B magnet alloy, isotropic bonded magnet and method of producing same |
US5460662A (en) * | 1987-04-30 | 1995-10-24 | Seiko Epson Corporation | Permanent magnet and method of production |
US5536334A (en) * | 1988-06-02 | 1996-07-16 | Seiko Epson Corporation | Permanent magnet and a manufacturing method thereof |
US5538565A (en) * | 1985-08-13 | 1996-07-23 | Seiko Epson Corporation | Rare earth cast alloy permanent magnets and methods of preparation |
DE19531861A1 (de) * | 1995-08-30 | 1997-03-06 | Danfoss As | Verfahren zum Herstellen von magnetischen Polen auf einem Grundkörper und Rotor einer elektrischen Maschine |
US6136099A (en) * | 1985-08-13 | 2000-10-24 | Seiko Epson Corporation | Rare earth-iron series permanent magnets and method of preparation |
USRE38042E1 (en) * | 1987-01-06 | 2003-03-25 | Hitachi Metals, Ltd. | Anisotropic magnetic powder and magnet thereof and method of producing same |
Families Citing this family (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS59219904A (ja) * | 1983-05-30 | 1984-12-11 | Sumitomo Special Metals Co Ltd | ボンド磁石の製造方法およびボンド磁石用材料の製造方法 |
JPS6017905A (ja) * | 1983-07-08 | 1985-01-29 | Sumitomo Special Metals Co Ltd | 永久磁石用合金粉末 |
JPS6032306A (ja) * | 1983-08-02 | 1985-02-19 | Sumitomo Special Metals Co Ltd | 永久磁石 |
CA1236381A (fr) * | 1983-08-04 | 1988-05-10 | Robert W. Lee | Aimants permanents a base de fer, terre rare et bore, ouvres a chaud |
JPS60153109A (ja) * | 1984-01-21 | 1985-08-12 | Sumitomo Special Metals Co Ltd | 永久磁石体 |
CA1244322A (fr) * | 1984-09-14 | 1988-11-08 | Robert W. Lee | Aimant permanent forme a chaud a regions a forte et a faible coercivites |
JPH0630295B2 (ja) * | 1984-12-31 | 1994-04-20 | ティーディーケイ株式会社 | 永久磁石 |
USRE34838E (en) * | 1984-12-31 | 1995-01-31 | Tdk Corporation | Permanent magnet and method for producing same |
JPH0687634B2 (ja) * | 1986-02-24 | 1994-11-02 | 松下電器産業株式会社 | 永久磁石型モ−タ |
JP2599378B2 (ja) * | 1987-02-06 | 1997-04-09 | 松下電器産業株式会社 | 樹脂磁石の製造方法 |
JP2619653B2 (ja) * | 1987-10-16 | 1997-06-11 | セイコーエプソン株式会社 | 希土類磁石 |
DE68916184T2 (de) * | 1988-11-14 | 1994-11-17 | Asahi Chemical Ind | Magnetische Stoffe, enthaltend Seltenerdelemente, Eisen, Stickstoff und Wasserstoff. |
JPH08181011A (ja) * | 1995-10-02 | 1996-07-12 | Seiko Epson Corp | 希土類磁石 |
JP5752094B2 (ja) * | 2012-08-08 | 2015-07-22 | ミネベア株式会社 | フルデンス希土類−鉄系ボンド磁石の製造方法 |
Citations (6)
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GB455806A (en) * | 1934-07-11 | 1936-10-28 | Max Baermann Junior | Process for making permanent magnets |
GB1190636A (en) * | 1966-09-01 | 1970-05-06 | Max Baermann | Method of Manufacturing Anisotropic pressed Permanent Magnets. |
US4197146A (en) * | 1978-10-24 | 1980-04-08 | General Electric Company | Molded amorphous metal electrical magnetic components |
JPS5754304A (en) * | 1980-09-19 | 1982-03-31 | Seiko Epson Corp | Manufacture of permanent magnet |
JPS57141901A (en) * | 1981-02-26 | 1982-09-02 | Mitsubishi Steel Mfg Co Ltd | Permanent magnet powder |
EP0066348A2 (fr) * | 1981-05-11 | 1982-12-08 | Crucible Materials Corporation | Procédé pour la fabrication d'aimants |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4851058A (en) * | 1982-09-03 | 1989-07-25 | General Motors Corporation | High energy product rare earth-iron magnet alloys |
DE3379131D1 (en) * | 1982-09-03 | 1989-03-09 | Gen Motors Corp | Re-tm-b alloys, method for their production and permanent magnets containing such alloys |
CA1236381A (fr) * | 1983-08-04 | 1988-05-10 | Robert W. Lee | Aimants permanents a base de fer, terre rare et bore, ouvres a chaud |
-
1983
- 1983-12-15 CA CA000443441A patent/CA1216623A/fr not_active Expired
-
1984
- 1984-03-06 DE DE8484301453T patent/DE3480673D1/de not_active Expired - Lifetime
- 1984-03-06 EP EP84301453A patent/EP0125752B1/fr not_active Expired
- 1984-03-21 AU AU25958/84A patent/AU571497B2/en not_active Expired
- 1984-04-02 MX MX2660584A patent/MX167657B/es unknown
- 1984-04-30 BR BR8402029A patent/BR8402029A/pt not_active IP Right Cessation
- 1984-05-08 ES ES532283A patent/ES8503163A1/es not_active Expired
- 1984-05-09 JP JP59091153A patent/JPS59211549A/ja active Granted
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
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GB455806A (en) * | 1934-07-11 | 1936-10-28 | Max Baermann Junior | Process for making permanent magnets |
GB1190636A (en) * | 1966-09-01 | 1970-05-06 | Max Baermann | Method of Manufacturing Anisotropic pressed Permanent Magnets. |
US4197146A (en) * | 1978-10-24 | 1980-04-08 | General Electric Company | Molded amorphous metal electrical magnetic components |
JPS5754304A (en) * | 1980-09-19 | 1982-03-31 | Seiko Epson Corp | Manufacture of permanent magnet |
JPS57141901A (en) * | 1981-02-26 | 1982-09-02 | Mitsubishi Steel Mfg Co Ltd | Permanent magnet powder |
EP0066348A2 (fr) * | 1981-05-11 | 1982-12-08 | Crucible Materials Corporation | Procédé pour la fabrication d'aimants |
Non-Patent Citations (1)
Title |
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PATENTS ABSTRACTS OF JAPAN, vol. 6, no. 128 (E-118)[1006], 14th July 1982; & JP-A-57 054 304 (SUWA SEIKOSHA K.K.) 31-03-1982 * |
Cited By (42)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0155082A3 (fr) * | 1984-03-08 | 1988-01-07 | General Motors Corporation | Aimants à base de terres rares et de fer liés par des résines époxy |
EP0155082A2 (fr) * | 1984-03-08 | 1985-09-18 | General Motors Corporation | Aimants à base de terres rares et de fer liés par des résines époxy |
US5565043A (en) * | 1985-08-13 | 1996-10-15 | Seiko Epson Corporation | Rare earth cast alloy permanent magnets and methods of preparation |
US5538565A (en) * | 1985-08-13 | 1996-07-23 | Seiko Epson Corporation | Rare earth cast alloy permanent magnets and methods of preparation |
US5560784A (en) * | 1985-08-13 | 1996-10-01 | Seiko Epson Corporation | Rare earth cast alloy permanent magnets and methods of preparation |
US5597425A (en) * | 1985-08-13 | 1997-01-28 | Seiko Epson Corporation | Rare earth cast alloy permanent magnets and methods of preparation |
US6136099A (en) * | 1985-08-13 | 2000-10-24 | Seiko Epson Corporation | Rare earth-iron series permanent magnets and method of preparation |
DE3642228A1 (de) * | 1986-02-24 | 1987-08-27 | Matsushita Electric Ind Co Ltd | Harzgebundener magnet, umfassend einen spezifischen typ an ferromagnetischem pulver, dispergiert in einem spezifischen typ an harzbindemittel |
US5085715A (en) * | 1986-03-20 | 1992-02-04 | Hitachi Metals, Ltd. | Magnetically anisotropic bond magnet, magnetic powder for the magnet and manufacturing method of the powder |
US4952239A (en) * | 1986-03-20 | 1990-08-28 | Hitachi Metals, Ltd. | Magnetically anisotropic bond magnet, magnetic powder for the magnet and manufacturing method of the powder |
US4921553A (en) * | 1986-03-20 | 1990-05-01 | Hitachi Metals, Ltd. | Magnetically anisotropic bond magnet, magnetic powder for the magnet and manufacturing method of the powder |
US4836868A (en) * | 1986-04-15 | 1989-06-06 | Tdk Corporation | Permanent magnet and method of producing same |
EP0242187A1 (fr) * | 1986-04-15 | 1987-10-21 | TDK Corporation | Aimant permanent et sa méthode de fabrication |
EP0248665A2 (fr) * | 1986-06-06 | 1987-12-09 | Seiko Instruments Inc. | Aimant à base de terre rare et fer et procédé de fabrication |
EP0248665A3 (en) * | 1986-06-06 | 1988-12-07 | Seiko Instruments Inc. | Rare earth-iron magnet and method of making same |
US5026518A (en) * | 1986-06-06 | 1991-06-25 | Seiko Instruments Inc. | Rare earth-iron magnet |
US4935075A (en) * | 1986-06-12 | 1990-06-19 | Kabushiki Kaisha Toshiba | Permanent magnet |
EP0255816A2 (fr) * | 1986-08-04 | 1988-02-10 | Treibacher Chemische Werke Aktiengesellschaft | Procédé de préparation de poudre magnétiquement dure, résistant à la corrosion, pour la fabrication d'aimants; aimants fabriqués à partir de poudre magnétiquement dure et leur procédé de fabrication |
EP0255816A3 (fr) * | 1986-08-04 | 1988-12-21 | Treibacher Chemische Werke Aktiengesellschaft | Procédé de préparation de poudre magnétiquement dure, résistant à la corrosion, pour la fabrication d'aimants; aimants fabriqués à partir de poudre magnétiquement dure et leur procédé de fabrication |
EP0265006A1 (fr) * | 1986-10-13 | 1988-04-27 | Koninklijke Philips Electronics N.V. | Méthode de fabrication d'un aimant permanent |
US4829277A (en) * | 1986-11-20 | 1989-05-09 | General Motors Corporation | Isotropic rare earth-iron field magnets for magnetic resonance imaging |
US4983232A (en) * | 1987-01-06 | 1991-01-08 | Hitachi Metals, Ltd. | Anisotropic magnetic powder and magnet thereof and method of producing same |
USRE38042E1 (en) * | 1987-01-06 | 2003-03-25 | Hitachi Metals, Ltd. | Anisotropic magnetic powder and magnet thereof and method of producing same |
USRE38021E1 (en) | 1987-01-06 | 2003-03-11 | Hitachi Metals, Ltd. | Anisotropic magnetic powder and magnet thereof and method of producing same |
EP0284033A1 (fr) * | 1987-03-23 | 1988-09-28 | Tokin Corporation | Méthode pour la fabrication d'un aimant anisotrope à liant, à base de terre rare-fer-bore, à partir de copeaux rubanés en alliage terre rare-fer-bore rapidement trempé |
US5186761A (en) * | 1987-04-30 | 1993-02-16 | Seiko Epson Corporation | Magnetic alloy and method of production |
US5076861A (en) * | 1987-04-30 | 1991-12-31 | Seiko Epson Corporation | Permanent magnet and method of production |
US5460662A (en) * | 1987-04-30 | 1995-10-24 | Seiko Epson Corporation | Permanent magnet and method of production |
US5110374A (en) * | 1987-08-19 | 1992-05-05 | Mitsubishi Materials Corporation | Rare earth-iron-boron magnet powder and process of producing same |
US4981532A (en) * | 1987-08-19 | 1991-01-01 | Mitsubishi Kinzoku Kabushiki Kaisha | Rare earth-iron-boron magnet powder and process of producing same |
US4881988A (en) * | 1987-11-16 | 1989-11-21 | Rjf International Corporation | Novel flexible magnet for use in small dc motors |
US4832891A (en) * | 1987-11-25 | 1989-05-23 | Eastman Kodak Company | Method of making an epoxy bonded rare earth-iron magnet |
WO1989005032A1 (fr) * | 1987-11-25 | 1989-06-01 | Eastman Kodak Company | Aimants epoxy amalgames a base de bore de fer et de terre rare et procede de fabrication de tels aimants |
US4983231A (en) * | 1988-05-25 | 1991-01-08 | Daihachi Chemical Industry Co., Ltd. | Coated magnetic powder and a bonded permanent magnet composition containing the same |
US5536334A (en) * | 1988-06-02 | 1996-07-16 | Seiko Epson Corporation | Permanent magnet and a manufacturing method thereof |
US5449417A (en) * | 1988-10-04 | 1995-09-12 | Hitachi Metals, Ltd. | R-Fe-B magnet alloy, isotropic bonded magnet and method of producing same |
US5062981A (en) * | 1989-06-27 | 1991-11-05 | Kanegafuchi Kagaku Kogyo Kabushiki Kaisha | Magnet and method for manufacturing the same |
US5037492A (en) * | 1989-12-19 | 1991-08-06 | General Motors Corporation | Alloying low-level additives into hot-worked Nd-Fe-B magnets |
US5149477A (en) * | 1990-03-07 | 1992-09-22 | Matsushita Electric Industrial Co., Ltd. | Process for producing a resin bonded magnet structure |
GB2241701B (en) * | 1990-03-07 | 1993-03-24 | Matsushita Electric Ind Co Ltd | A process for producing a resin bonded magnet structure |
GB2241701A (en) * | 1990-03-07 | 1991-09-11 | Matsushita Electric Ind Co Ltd | A process for producing a resin bonded magnet structure |
DE19531861A1 (de) * | 1995-08-30 | 1997-03-06 | Danfoss As | Verfahren zum Herstellen von magnetischen Polen auf einem Grundkörper und Rotor einer elektrischen Maschine |
Also Published As
Publication number | Publication date |
---|---|
EP0125752A3 (en) | 1987-01-28 |
DE3480673D1 (de) | 1990-01-11 |
BR8402029A (pt) | 1984-12-18 |
AU571497B2 (en) | 1988-04-21 |
ES532283A0 (es) | 1985-02-01 |
AU2595884A (en) | 1984-11-15 |
JPH0420975B2 (fr) | 1992-04-07 |
ES8503163A1 (es) | 1985-02-01 |
MX167657B (es) | 1993-04-01 |
CA1216623A (fr) | 1987-01-13 |
JPS59211549A (ja) | 1984-11-30 |
EP0125752B1 (fr) | 1989-12-06 |
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