JPWO2010071111A1 - Iron-based magnet alloy powder containing rare earth element, method for producing the same, obtained resin composition for bonded magnet, bonded magnet, and compacted magnet - Google Patents

Abstract

Magnet alloy powder containing a rare earth element that is coated with a strong coating and does not generate rust even in corrosive environments and has excellent corrosion resistance and resin adhesion, a method for producing the same, and a resin for bonded magnets that uses the same to provide high mechanical strength Compositions, bonded magnets, and compacted magnets are provided. An iron-based magnet alloy containing a rare earth element in which a composite metal phosphate containing iron phosphate and a rare earth metal phosphate and an inorganic organic composite coating composed of an organic compound containing polyphenol are uniformly formed on the surface of the magnet powder Powder: Iron-based magnet alloy containing rare earth elements, or iron phosphate and rare earth metal phosphates on the surface of a molded product obtained by molding a resin composition containing a rare earth element-containing iron-based magnet alloy and a resin binder It is provided by a compacted magnet or a bonded magnet, in which an inorganic-organic composite film made of an organic compound containing polyphenol and an organic compound containing polyphenol is formed.

Description

  The present invention relates to a magnet alloy powder containing a rare earth element, a method for producing the same, a resin composition for a bonded magnet, a bonded magnet, and a compacted magnet. More specifically, the surface is coated with a strong coating film even in a corrosive environment. It relates to magnet alloy powder containing rare earth elements that do not generate rust and has excellent corrosion resistance and resin adhesion, a method for producing the same, and a resin composition for bonded magnets, bonded magnets, and compacted magnets that have excellent mechanical strength using the same. is there.

  In recent years, ferrite magnets, alnico magnets, rare earth magnets, and the like have been incorporated and used as motors and sensors in various products including general household electrical appliances, communication / acoustic equipment, medical equipment, and general industrial equipment. Although these magnets are mainly manufactured by a sintering method, they are fragile and difficult to be thinned, so it is difficult to mold them into complex shapes. Also, since they shrink by 15 to 20% during sintering, the dimensional accuracy cannot be increased. Post-processing such as polishing is necessary, and there are significant restrictions in terms of application.

  In contrast, bonded magnets (resin-bonded magnets) are thermoplastic resins such as polyamide resins and polyphenylene sulfide resins, or epoxy resins, bis-maleimide triazine resins, unsaturated polyester resins, vinyl esters when used in combination with curing agents. Since thermosetting resins such as resins can be used as binders and can be easily manufactured by filling them with magnet alloy powder, new applications are being developed.

  When a bonded magnet is manufactured by kneading iron-based magnet alloy powder containing a rare earth element with a resin binder, the magnet alloy powder needs to be pulverized to 150 μm or less. Although pulverization is performed in an inert gas or an organic solvent, the magnet alloy powder after pulverization is extremely active, and when exposed to the air, the magnet alloy powder rapidly oxidizes and deteriorates the magnetic properties. A method of gradually oxidizing by introducing a slight amount of oxygen into an inert atmosphere is employed.

  Among these bonded magnets, in particular, bonded magnets using iron-based magnet alloy powders containing rare earth elements are prone to rust in salt water. For example, a coating film such as a thermosetting resin is formed on the surface of the molded body. Thus, it has been proposed to suppress rusting by suppressing rusting or by applying a coating treatment with a phosphate-containing paint on the surface of the molded body (see, for example, Patent Document 1). However, even the magnetic alloy powder produced by the above method is not sufficiently satisfactory for the suppression of rust in a corrosive environment such as salt water.

  Further, chemical conversion treatment such as phosphate treatment or chromate treatment is performed on the powder surface (for example, see Patent Document 2), zinc or aluminum is vapor-deposited (for example, see Patent Document 3), and a polymer coating is applied. Techniques such as forming (see, for example, Patent Document 4) and metal plating (see, for example, Patent Document 5) have also been proposed.

  However, if any of the above methods is applied to, for example, an alloy powder for Nd—Fe—B or Sm—Fe—N bond magnets, the oxidation resistance is improved, but the properties of the powder surface are rough and magnetic. The characteristics will deteriorate. In addition, in order to obtain a sufficient oxidation resistance effect by forming a film, it is necessary to have a film thickness of about several tens of μm, so that the volume fraction of the material that exhibits magnetic characteristics decreases, and the magnetic characteristics decrease. Will be invited. Further, in any of the above methods, since the fine powders aggregate when forming the film, the direction of magnetic anisotropy becomes uneven, and the magnetic properties of the magnet compact cannot be avoided.

  Conventionally, when coating a magnetic alloy powder, a method of adding phosphoric acid in a grinding solvent to generate a rare earth or iron phosphate on the surface of the alloy powder has been studied (for example, see Patent Document 6). The magnetic alloy powder produced by this method has very little deterioration in magnetic properties even in a high temperature and high humidity environment. However, when a bonded magnet produced using this magnet alloy powder was immersed in salt water for 24 hours, the occurrence of red rust could be considerably reduced, but could not be completely eliminated. In addition, the magnet alloy powder produced by this method may cause stress concentration due to thermal strain at the time of injection molding at the interface with the binder resin, and the affinity with the binder resin is not sufficient. The molded body as a magnet has a relatively low mechanical strength, and may be broken when subjected to severe processing.

In recent years, motors for home appliances, automobile sensors and motors have to be transported by ship in order to assemble parts overseas, and the use environment and transport environment have become more severe, and the equipment has been downsized. A magnetic alloy powder having excellent magnetic properties as well as problems has been demanded.
Furthermore, bond magnets and compacted magnets are becoming thinner and smaller year by year, making it easier for magnetic powder to be exposed on the surface of the molded body, increasing the need to protect the entire surface of the molded body with an oxidation- and corrosion-resistant coating. Yes.

JP 2000-208321 A Japanese Patent Laid-Open No. 1-14902 JP-A-64-15301 JP-A-4-257202 Japanese Patent Laid-Open No. 7-142246 JP 2002-8911 A

  In view of the above-mentioned problems of the prior art, the object of the present invention is to provide a magnet alloy powder containing a rare earth element which is coated with a strong coating and does not generate rust even in a corrosive environment and has excellent corrosion resistance and resin adhesion. It is in providing the manufacturing method and the resin composition for bonded magnets, the bonded magnet, and the compacted magnet which are excellent in the mechanical strength using the same.

  As a result of intensive studies to solve the above problems, the present inventors have obtained a bonded magnet obtained by using a surface of an iron-based magnet alloy powder containing a rare earth element, or an iron-based magnet alloy powder containing a rare earth element, or When the inorganic magnet composite film containing not only the composite metal phosphate containing iron phosphate and rare earth metal phosphate but also polyphenol is formed on the surface of the compacted magnet and then sufficiently dried, this inorganic organic composite Since the coating is firmly fixed on the magnetic alloy powder, rust does not occur even in a corrosive environment, and it is found that a magnetic alloy powder containing a rare earth element having excellent corrosion resistance and resin adhesion can be obtained, and the present invention has been completed. It was.

  That is, according to the first invention of the present invention, the surface of a magnet powder made of an iron-based magnet alloy containing a rare earth element contains a composite metal phosphate containing iron phosphate and a rare earth metal phosphate, and a polyphenol. An iron-based magnet alloy powder containing a rare earth element, characterized in that an inorganic-organic composite coating composed of an organic compound is uniformly formed.

In addition, according to the second invention of the present invention, there is provided an iron-based magnet alloy powder containing a rare earth element, wherein the magnet alloy powder has an average particle size of 150 μm or less in the first invention.
According to the third invention of the present invention, in the first invention, the composite metal phosphate comprises at least one selected from Al, Zn, Zr, Mn, Ti, Cu, or Ca as the metal component. There is provided an iron-based magnet alloy powder containing a rare earth element characterized by further containing a metal phosphate.
According to the fourth invention of the present invention, in the first invention, the iron-based magnet alloy powder containing a rare earth element, wherein the polyphenol is at least one selected from tannin, catechin, or flavonoid Is provided.
According to a fifth aspect of the present invention, there is provided an iron-based magnet alloy powder containing a rare earth element characterized in that the organic compound contains a water-soluble resin in the first invention.
According to the sixth aspect of the present invention, in the first aspect, the water-soluble resin is selected from a phenol resin, an acrylic resin, a polyester resin, a vinyl resin, a polyamide resin, a polyimide resin, or a silicone resin. An iron-based magnet alloy powder containing a rare earth element, which is the above organic resin, is provided.
Furthermore, according to the seventh invention of the present invention, there is provided an iron-based magnet alloy powder containing a rare earth element characterized in that, in the first invention, the inorganic-organic composite coating film has a thickness of 1 to 500 nm. .

  On the other hand, according to the eighth aspect of the present invention, before or during pulverization of the iron-based magnet alloy coarse powder containing a rare earth element in an organic solvent, phosphoric acid, polyphosphoric acid, or organic phosphonic acid is used. Add a coating treatment solution containing at least one selected phosphoric acid compound (a) and polyphenol (b) and stir, or pulverize the magnet alloy coarse powder and then add the coating treatment solution By stirring, an inorganic-organic composite film is formed on the surface of the iron-based magnet alloy powder containing rare earth elements, and then heated in a vacuum or in an inert gas atmosphere at 60 ° C. or more for 0.5 hours or more and dried. A method for producing an iron-based magnet alloy powder containing a rare earth element is provided.

According to the ninth aspect of the present invention, in the eighth aspect, the organic solvent is one or more selected from N, N-dimethylformamide, formamide, 2-methoxyethanol, ethanol, methanol, or isopropyl alcohol. A method for producing an iron-based magnet alloy powder containing a rare earth element is provided.
According to the tenth aspect of the present invention, in the eighth aspect, the phosphoric acid compound (a) further comprises Al, Zn, Zr, Mn, Ti, Cu, Sm, Nd, Ce or Ca. Provided is a method for producing an iron-based magnet alloy powder containing a rare earth element, which comprises one or more of a phosphate or a hydrogen phosphate compound containing at least one selected metal.
According to the eleventh invention of the present invention, in the eighth to tenth inventions, the coating treatment liquid further contains an alcohol solvent (d), and the content thereof is 50 to 99 mass of the entire coating treatment liquid. %, A method for producing an iron-based magnet alloy powder containing a rare earth element is provided.
According to the twelfth aspect of the present invention, in the eighth to eleventh aspects, the coating treatment liquid further contains a water-soluble resin (c), and the content thereof is 0 to 50 mass of the entire coating treatment liquid. %, A method for producing an iron-based magnet alloy powder containing a rare earth element is provided.
In addition, in a thirteenth aspect of the present invention, in the eighth to twelfth aspects, the content of the polyphenol (b) and the water-soluble resin (c) is a mass ratio (b + c) / The manufacturing method of the iron-type magnet alloy powder containing rare earth elements characterized by being in the range of 0.1-100 as a is provided.
According to a fourteenth aspect of the present invention, there is provided the rare earth element according to the eighth to thirteenth aspects, wherein the amount of the coating treatment liquid added is 10 to 70 g per 1 kg of the magnetic alloy powder. A method for producing an iron-based magnet alloy powder is provided.
Furthermore, the fifteenth invention of the present invention is characterized in that, in the eighth to fourteenth inventions, the inorganic-organic composite coating formed on the magnet alloy powder is heated and dried at 60 to 250 ° C. for 1 to 30 hours. A method for producing an iron-based magnet alloy powder containing rare earth elements is provided.

  On the other hand, according to the sixteenth invention of the present invention, the iron-based magnet alloy powder containing a rare earth element contains a thermoplastic resin or a thermosetting resin as a resin binder according to any one of the first to seventh inventions. A bonded magnet resin composition is provided.

According to the seventeenth aspect of the present invention, a resin composition for a bonded magnet comprising an iron-based magnet alloy powder containing a rare earth element and a thermoplastic resin or a thermosetting resin as a resin binder is injection molded. , Compression molding method, injection compression molding method, extrusion molding method or bonded press molding method, a bonded magnet obtained by molding, and iron phosphate and rare earth metal on the surface of the molded body There is provided a bonded magnet characterized in that an inorganic-organic composite coating composed of a composite metal phosphate containing phosphate and an organic compound containing polyphenol is formed.
Furthermore, according to an eighteenth aspect of the present invention, in the seventeenth aspect, the iron-based magnet alloy is an iron-based magnet alloy powder containing the rare earth element according to any one of the first to seventh aspects. A bonded magnet is provided.

On the other hand, according to the nineteenth aspect of the present invention, there is provided a compacted magnet obtained by compacting iron-based magnet alloy powder containing a rare earth element, and having an apparent density of 85% or more of the true density, There is provided a compacted magnet characterized in that an inorganic-organic composite coating film comprising a composite metal phosphate containing iron phosphate and a rare earth metal phosphate and an organic compound containing polyphenol is formed on the surface.
Furthermore, according to a twentieth aspect of the present invention, in the nineteenth aspect, the iron-based magnet alloy powder containing a rare earth element is the iron-based magnet alloy powder containing the rare earth element of any one of the first to seventh inventions. A compacted magnet is provided.

The bond magnet or the compacted magnet obtained by using the iron-based magnet alloy powder containing the rare earth element of the present invention or the iron-based magnet alloy powder containing the rare earth element is an inorganic-organic composite coating containing a stable composite metal phosphate and polyphenol. Therefore, the surface of the magnet alloy powder is uniformly formed and protected, and is extremely excellent in corrosion resistance.
Therefore, the resin composition for bonded magnets using the magnet alloy powder coated with this inorganic organic composite coating has excellent mechanical strength of the molded body, and no rust is generated even in 5% salt water, and has excellent corrosion resistance and mechanical strength. Not only is it possible to produce a high bonded magnet, but this magnet alloy powder makes it possible to easily obtain a compacted magnet having good magnetic properties, and its industrial value is extremely high.

FIG. 1 is an electron micrograph showing a cross section of the Nd—Fe—B alloy powder of the present invention on which an inorganic / organic composite coating is formed.

  Hereinafter, iron-based magnet alloy powder (hereinafter also referred to as surface-coated magnet alloy powder) containing the rare earth element of the present invention, which has excellent corrosion resistance, oxidation resistance, and resin adhesion, and a method for producing the same, and a bond using the same The resin composition for magnets, bonded magnets, and compacted magnets will be described in detail.

The surface-coated magnet alloy powder of the present invention includes a composite metal phosphate containing iron phosphate and a rare earth metal phosphate on the surface of a magnet powder (A) made of an iron-based magnet alloy containing a rare earth element, and polyphenol. The inorganic organic composite film (B) made of an organic compound is formed uniformly.
The present invention also provides a surface of a compacted magnet obtained by molding a magnet powder (A) made of an iron-based magnet alloy containing a rare earth element, or a magnet powder (A) made of an iron-based magnet alloy containing a rare earth element. An inorganic organic composite coating (B) composed of a composite metal phosphate containing iron phosphate and a rare earth metal phosphate and an organic compound containing polyphenol on the surface of a bonded magnet obtained by molding a resin composition containing a resin binder ) Is formed.

1. Surface Covered Magnet Alloy Powder (A) Magnet Powder In the present invention, the magnet powder is not particularly limited as long as it is an iron-based magnet alloy powder containing a rare earth element. For example, various magnetic alloy powders such as rare earth-iron-boron, rare earth-iron-nitrogen, rare earth-cobalt-iron, etc. can be used, among which rare earth-iron-boron, rare earth-iron-nitrogen magnets. Alloy powder is preferred.

Examples of rare earth elements include Sm, Nd, Pr, Y, La, Ce, and Gd, and these can be used alone or as a mixture. Among these, those containing 5 to 40 atomic% of Sm or Nd and 50 to 90 atomic% of Fe are particularly preferable. The iron-based magnet alloy powder (coarse powder) containing rare earth elements is manufactured using a melting method or a reduction diffusion method.
The iron-based magnet alloy powder containing the rare earth element may be mixed with various magnetic alloy powders, such as ferrite and alnico, which are raw materials for bonded magnets and compacted magnets. Magnetic alloy powder is also a target, but magnet alloy powder having an anisotropic magnetic field (HA) of 4.0 MA / m or more is preferable.
Moreover, since the said magnet alloy powder is a raw material of a bond magnet or a compacted magnet, it is desirable that an average particle diameter is 150 micrometers or less, especially 100 micrometers or less. If the average particle size exceeds 150 μm, the moldability deteriorates, which is not preferable.

(B) Inorganic organic composite coating In the present invention, the inorganic / organic composite coating is an inorganic / organic composite coating in which a composite phosphate containing iron phosphate and a rare earth metal phosphate and a polyphenol are combined, whereby a magnet powder is obtained. The surface of is uniformly coated.
Here, uniformly coated means that 90% or more, preferably 95% or more, more preferably 99% or more of the surface of the magnet alloy powder is covered with the composite metal phosphate coating.

The composite phosphate is formed by reacting phosphoric acid with the rare earth element or iron constituting the iron-based magnet alloy powder containing the rare earth element. The composite phosphate may further contain any one or more of Al, Zn, Zr, Mn, Ti, Cu, and Ca as a metal component to form a metal phosphate. Examples of the metal phosphate include aluminum phosphate, zinc phosphate, zirconium phosphate, manganese phosphate, titanium phosphate, copper phosphate, calcium phosphate, or a metal salt in which two or more of these are combined. The metal component is not limited to Al, Zn, Zr, Mn, Ti, Cu, or Ca, and may be Cr, Ni, Mg, or the like.
The metal component content of the composite metal phosphate coating is not particularly limited, but in order to obtain sufficient salt water resistance, the metal components of the metal phosphate, that is, Al, Zn, Zr, Mn, A composite in which at least one selected from Ti, Cu or Ca is contained in an amount of 30% by weight or more, particularly 50% by weight or more, more preferably 80% by weight or more based on the total amount of metal components of the composite metal phosphate coating It is preferable to use a metal phosphate.

Composite phosphates containing iron phosphate and rare earth metal phosphates are combined with polyphenols to form inorganic-organic composite coatings that increase the bond strength with resin binders and greatly improve the corrosion resistance of magnet alloy powders. .
In the present invention, the polyphenol is at least one selected from tannin, catechin, or flavonoid. Specifically, epicatechin, epigallocatechin, epicatechin gallate, epigallocatechin gallate contained in green tea and tea, in addition to tannin and tannic acid contained in plants such as Genokosho, Clove, Oyster, Daio and Keihi Flavonoids such as flavones, flavonols, flavanols, anthocyanidins, isoflavonoids (compounds having a 1,3-diphenylpropanoid skeleton), which are naturally occurring organic compounds such as green leaves, white vegetables, and citrus fruits ) And the like.

  The inorganic / organic composite coating of the present invention can further contain a water-soluble resin. The water-soluble resin is not particularly limited, and examples thereof include a phenol resin, an acrylic resin, a polyester resin, a vinyl resin, a polyamide resin, a polyimide resin, a silicone resin, and modified resins thereof. Usually, phenolic resin, acrylic resin, polyester resin, vinyl resin, polyamide resin, polyimide resin, and silicone resin are high molecular weight and do not dissolve in water, but decrease the molecular weight and increase the abundance of hydrophilic groups Thus, a water-soluble resin can be obtained.

  As phenolic resin, trade name: Environment-friendly light-colored phenolic resin (manufactured by Sumitomo Bakelite Co., Ltd.), acrylic resin as acrylic polymer (manufactured by Toagosei Co., Ltd.), and polyester resin as saturated copolymerized polyester mainly composed of terephthalic acid Examples of the resin include a plus coat (manufactured by Reciprocal Chemical Co., Ltd.), and examples of the vinyl resin include general polyvinyl alcohol. Further, examples of the polyamide resin include AQ nylon (manufactured by Toray Industries, Inc.), trade names obtained by methoxymethylation of the amide group of 6-nylon: Toresin (manufactured by Nagase Chemitex Corporation), and the polyimide resin includes HPC-100. Water-soluble polyamideimide resin (manufactured by Hitachi Chemical Co., Ltd.) can be mentioned. In the present invention, other than these, natural polymers that can be water-solubilized by adding an alcohol can be used. These resins are preferably added with a solubilizer or a dispersant as necessary to enhance water solubility.

  In the inorganic-organic composite coating film of the present invention, the mass ratio (b + c) / a of the polyphenol (b) and the water-soluble resin (c) to the phosphoric acid compound (a) is in the range of 0.1-100. It is preferable. If the mass ratio is less than 0.1, the phosphoric acid compound becomes excessive, the metal etching becomes excessive, and the water resistance and corrosion resistance of the formed film become insufficient. On the other hand, if the mass ratio exceeds 100, etching is insufficient, the coating becomes thin, and the corrosion resistance is lowered. The mass ratio is most preferably in the range of 1-30. In the polyphenol (b), when the amount of the water-soluble resin (c) is increased, the fixability to the magnet powder is further improved.

  The film thickness of the inorganic / organic composite coating is preferably 1 to 500 nm on average. When the average film thickness is less than 1 nm, sufficient salt water resistance and mechanical strength cannot be obtained. On the other hand, when it exceeds 500 nm, the magnetic properties are deteriorated, and when a bonded magnet is produced, kneadability and moldability are reduced. End up.

As shown in FIG. 1, the film thickness of the inorganic organic composite coating can be measured from an electron micrograph of a cross section of an iron-based magnet alloy powder containing a rare earth element coated with the inorganic organic composite coating.
The inorganic-organic composite coating can take various forms depending on the production method, but the composite phosphate containing iron phosphate and rare earth metal phosphate is layered on the magnet powder, or the compacted magnet or bond magnet, It is preferable that polyphenols are deposited in a layered form thereon.

2. Method for producing iron-based magnet alloy powder containing rare earth element coated with inorganic-organic composite coating film Method for producing iron-based magnet alloy powder containing rare earth element coated with inorganic-organic composite coating film (surface-coated magnet alloy powder) Is at least one phosphoric acid compound selected from phosphoric acid, polyphosphoric acid, or organic phosphonic acid before or during pulverization of the iron-based magnet alloy coarse powder containing a rare earth element in an organic solvent. a) and a coating treatment solution containing polyphenol (b) and stirring, or after pulverizing the magnet alloy coarse powder, the coating treatment solution is added and stirred, thereby adding an iron-based material containing rare earth elements. An inorganic-organic composite coating film is formed on the surface of the magnet alloy powder, and then heated in a vacuum or an inert gas atmosphere at 60 ° C. or higher for 1 hour or longer and dried.

(1) Formation of inorganic-organic composite coating When the average particle size of the iron-based magnet alloy powder containing the rare earth element exceeds 150 μm, it is necessary to further pulverize in an organic solvent so that the average particle size is 150 μm or less.
Before and during the pulverization, a coating treatment liquid containing at least one phosphoric acid compound (a) selected from phosphoric acid, polyphosphoric acid, and organic phosphonic acid and polyphenol (b) is used. After the addition, the inorganic organic composite coating can be formed on the surface of the iron-based magnet alloy powder containing rare earth elements by stirring the solution. The coating treatment solution may contain the phosphoric acid compound (a) and the polyphenol (b), but it is preferable that a water-soluble resin (c) is further added.

  In order to form an inorganic-organic composite coating, first, an organic solvent is added to a coarse powder of an iron-based magnet alloy containing a rare earth element having an average particle size of more than 150 μm, and before or during the pulverization of the magnet alloy powder, Add processing solution and continue stirring. Stirring is usually continued for 1 to 180 minutes per kg of the coarse powder, although it varies depending on the stirring and pulverizing apparatus, and preferably 3 to 100 minutes. If the average particle diameter of the magnet alloy powder is already a fine powder of 150 μm or less, the coating treatment liquid may be added after pulverization.

(A) Organic solvent
There is no restriction | limiting in particular as an organic solvent used when grind | pulverizing the iron-type magnet alloy coarse powder containing rare earth elements, It selects from N, N- dimethylformamide, formamide, 2-methoxyethanol, ethanol, methanol, or isopropyl alcohol. One or more types can be used.
In order to adjust the dissolution of the magnet alloy powder appropriately by mixing a polar solvent such as N, N-dimethylformamide or formamide, the metal component of the magnet alloy powder is easily brought into contact with an organic solvent to generate metal ions. It is desirable to do. Moreover, in order to accelerate | stimulate melt | dissolution of magnet alloy powder, you may mix water and an acid with an organic solvent.

(I) Phosphoric acid compound (a)
The phosphoric acid compound (a) is at least one phosphoric acid compound selected from phosphoric acid, polyphosphoric acid, and organic phosphonic acid. A part of the phosphoric acid compound may be neutralized with an alkali such as ammonia or amine, but the pH is preferably 5 or less.
The polyphosphoric acid preferably has a low degree of polymerization including pyrophosphoric acid and tripolyphosphoric acid. Examples of the organic phosphonic acid include ethane-1,1-diphosphonic acid, ethane-1,1,2-triphosphonic acid, ethane-1-hydroxy-1,1-diphosphonic acid, and ethanehydroxy-1,1,2-. Triphosphonic acid, 1-hydroxyethylidene-1,1-diphosphonic acid, ethane-1,2-dicarboxy-1,2-diphosphonic acid, methanehydroxyphosphonic acid, 2-phosphonobutane-1,2-dicarboxylic acid, hydroxyethyldi Methylene phosphonic acid and the like are preferable.
The phosphoric acid compound (a) is preferably added in an optimum amount in accordance with the particle diameter, surface area and the like of the magnet alloy powder, and 0.01 to 1 mol / kg (per weight of powder) with respect to the magnet alloy powder. And If the addition amount is less than 0.01 mol / kg, the surface of the magnet alloy powder is not sufficiently coated, so that the salt water resistance is not improved. If the addition amount exceeds 1 mol / kg, the magnetization decreases significantly, and the performance as a magnet decreases. There are things to do.

(C) Polyphenol (b)
On the other hand, as described above, the polyphenol is at least one selected from tannin, catechin, or flavonoid.
Preferred types of tannin include tannin and tannic acid contained in plants such as Genokosho, Clove, Oyster, Daio, and Keihi, and catechins such as epicatechin, epigallocatechin, epicatechin gallate, and epigallocatechin gallate. Flavonoids such as flavones, flavonols, flavanols, anthocyanidins and isoflavonoids can be used.

(D) Water-soluble resin (c)
Moreover, it is preferable to add water-soluble resin (c) further to the process liquid of this invention. Although it does not specifically limit as a water-soluble resin, A phenol resin, an acrylic resin, a polyester resin, a vinyl resin, a urethane resin, a polyamide resin, a polyimide resin, a silicone resin, etc. are preferable. These resins are preferably modified and solubilized as necessary, or water-solubilized by adding a solubilizer or dispersant, but in the present invention, any resin that can be water-solubilized by adding an alcohol. Anything other than those described above can be used.
Since water-soluble resin (c) has high affinity with polyphenol, the fixability of polyphenol to the surface of magnet powder can be improved. In selecting the water-soluble resin (c), when the resin binder is thermoplastic, a polyamide resin is preferable, and when the resin binder is thermosetting, any of a phenol resin, an acrylic resin, and a urethane resin is preferable.

(E) Addition metal component compound In addition, the coating treatment liquid includes an oxide of one or more metals selected from Al, Zn, Zr, Mn, Ti, Cu, Sm, Nd, Ce, and Ca, and composite oxidation. Products, phosphates or hydrogen phosphate compounds can be added. These additional metal components are sources of ions such as Al, Zn, Zr, Mn, Ti, Cu, Sm, Nd, Ce, or Ca, and oxides that dissolve in organic solvents and generate metal ions. , Metal oxides such as complex oxides, phosphates or hydrogen phosphate compounds. These metal compounds are ionized in a solvent and react on the surface of the magnet alloy powder to form a composite metal phosphate coating as the rare earth metal and iron, which are components of the magnet alloy powder, dissolve into the solvent.

The aluminum compound is not particularly limited as long as it is a source of aluminum ions and is soluble in an organic solvent. For example, aluminum acetate, aluminum sulfate, aluminum chloride, aluminum chloride ammonium, aluminum benzoate, aluminum carbonate, ethyl acetoacetate Aluminum, aluminum formate, aluminum hydroxide, aluminum nitrate, aluminum naphthenate, aluminum oleate, aluminum oxalate, aluminum oxide, aluminum phosphate, aluminum hydrogen phosphate, potassium chloride aluminum, aluminum stearate, aluminum sulfide, phthalocyanine aluminum Or aluminum tartrate. Particularly preferred is aluminum phosphate or aluminum hydrogen phosphate.
The zinc compound is not particularly limited as long as it is a source of zinc ions and is soluble in an organic solvent. For example, zinc acetate, zinc sulfate, zinc chloride, zinc ammonium chloride, zinc benzoate, zinc carbonate, ethyl acetoacetate Zinc, zinc formate, zinc hydroxide, zinc nitrate, zinc naphthenate, zinc oleate, zinc oxalate, zinc oxide, zinc phosphate, zinc phosphate tetrahydrate, zinc hydrogen phosphate, zinc calcium phosphate, Examples include potassium zinc chloride, zinc stearate, zinc sulfide, zinc phthalocyanine, or zinc tartrate. Particularly preferred is zinc oxide, zinc phosphate tetrahydrate, or zinc hydrogen phosphate.
The zirconium compound is not particularly limited as long as it is a source of zirconium ions and is soluble in an organic solvent. For example, zirconium nitrate, zirconium carbide, zirconium chloride, zirconium chloride hydrate, zirconium fluoride, boride Zirconium, zirconium oxalate, and zirconium silicate are exemplified. Particularly preferred are zirconium nitrate and zirconium fluoride.
The manganese compound is not particularly limited as long as it is a source of manganese ions and is soluble in an organic solvent. For example, manganese acetate, manganese sulfate, manganese chloride, manganese chloride, manganese benzoate, manganese carbonate, ethyl acetoacetate Manganese, manganese formate, manganese hydroxide, manganese nitrate, manganese naphthenate, manganese oleate, manganese oxalate, manganese oxide, manganese phosphate, manganese hydrogen phosphate, potassium chloride, manganese stearate, manganese sulfide, manganese phthalocyanine Or manganese tartrate. Particularly preferred is manganese oxide or manganese hydrogen phosphate.
The titanium compound is not particularly limited as long as it is a compound that is a source of titanium ions and is soluble in an organic solvent. For example, titanium fluoride, titanium carbide, titanium carbonitride, titanium chloride, titanium boride, titanium iodide, Examples include titanium oxide and zinc titanate. Particularly preferred is titanium fluoride.
The copper compound is not particularly limited as long as it is a compound that is a source of copper ions and is soluble in an organic solvent. For example, copper acetate, copper sulfate, copper chloride, ammonium copper chloride, copper benzoate, copper carbonate, Copper ethyl acetoacetate, copper formate, copper hydroxide, copper nitrate, copper naphthenate, copper oleate, copper oxalate, copper oxide, copper phosphate, copper hydrogen phosphate, potassium copper chloride, copper stearate, copper sulfide, For example, copper phthalocyanine or copper tartrate is used. Particularly preferred is copper (I) oxide or copper hydrogen phosphate.
The rare earth compound such as samarium, neodymium and cerium is not particularly limited as long as it is a compound that is a source of rare earth ions and is soluble in an organic solvent. For example, oxides, nitrates, hydroxides, sulfuric acids of these rare earth metals Salts and chlorides are exemplified. Particularly preferred are oxides and nitrates.
Furthermore, the calcium compound is not particularly limited as long as it is a source of calcium ions and is soluble in an organic solvent. For example, calcium acetate, calcium sulfate, calcium chloride, calcium chloride ammonium, calcium benzoate, calcium carbonate, Calcium ethylacetoacetate, calcium formate, calcium hydroxide, calcium nitrate, calcium naphthenate, calcium oleate, calcium oxalate, calcium oxide, calcium phosphate, calcium hydrogen phosphate, potassium chloride, calcium stearate, calcium sulfide, calcium phthalocyanine, Or calcium tartrate is illustrated. Particularly preferred is calcium oxide or calcium hydrogen phosphate.

  One or more metal oxides selected from Al, Zn, Zr, Mn, Ti, Cu, Sm, Nd, Ce or Ca, composite oxides, phosphates or hydrogen phosphates, which are metal components, It is preferable to add an optimum amount in accordance with the particle diameter, surface area, etc. of the magnet alloy powder. It is preferable to set it as 0.01-1 mol / kg (per powder weight) with respect to this magnet alloy powder similarly to the addition amount of a phosphoric acid type compound (a). If the addition amount is less than 0.01 mol / kg, the surface of the magnet alloy powder is not sufficiently coated, so that the salt water resistance is not improved. If the addition amount exceeds 1 mol / kg, the magnetization decreases significantly, and the performance as a magnet decreases. There are things to do.

Moreover, it is preferable that the solvent of this coating process liquid is an alcohol solvent (d) with a boiling point of 60-150 degreeC. For example, ethanol, isopropanol, butanol, methanol and the like are preferable. Those having a boiling point exceeding 150 ° C. are not preferable because they are difficult to remove from the coating film in the drying step. These can be used alone or as a mixture, but in the present invention, organic solvents other than alcohols compatible with water, such as acetone, dioxane, cellosolve, etc. can also be used.
The concentration of the alcohol-based solvent in the coating treatment liquid is preferably in the range of 50 to 99% by mass, and if it is less than 50% by mass, drying is slow and rust is likely to occur, and if it exceeds 99% by mass, the phosphate compound is ionized. This is not preferable because the reactivity is lowered.

  In the coating treatment liquid, the mass ratio of the polyphenol (b) and the water-soluble resin (c) to the phosphate compound (a): (b + c) / a is not particularly limited, but 0.1 to A range of 100 is desirable. The mass ratio: (b + c) / a is preferably 2-50, in particular 3-30. When the mass ratio: (b + c) / a is less than 0.1, the phosphoric acid compound becomes excessive, the metal etching becomes excessive, and the water resistance and corrosion resistance of the formed film become insufficient. On the other hand, if the mass ratio exceeds 100, etching is insufficient, the coating becomes thin, and the corrosion resistance is lowered.

The optimum amount of the coating treatment liquid is added according to the particle diameter, surface area, etc. of the magnet alloy powder. Usually, it is preferable to add 10 to 70 g of the coating treatment liquid to 1 kg of the magnet alloy powder to be pulverized. If the amount of the coating treatment liquid is less than 10 g, the surface of the magnetic alloy powder is not sufficiently coated, so that the salt water resistance is not improved. If it exceeds 70 g, the reaction with the magnet alloy powder may occur vigorously and the magnet alloy powder may be dissolved.
An iron-based magnet alloy coarse powder containing a powder having an average particle size exceeding 150 μm has an average particle size of 150 μm or less and a magnet powder having a pinning type coercive force mechanism, and has a nucleation type coercive force mechanism of 50 to 100 μm. If it is magnet powder, it is preferable to grind | pulverize to 1-5 micrometers. In order to complete the film formation, the magnetic alloy powder slurry is always stirred to sufficiently form the film.
When one or more metal components selected from Al, Zn, Zr, Mn, Ti, Cu, or Ca are added to the coating treatment liquid, the addition timing may be any time and is performed simultaneously with the addition of the coating treatment liquid. Alternatively, they may be added separately, or may be dissolved in a solvent before pulverization and added at a time during pulverization, or gradually added during pulverization. Alternatively, it may be immediately after pulverization.
As a result, the rare earth elements dissolved in the solution, such as iron, and the elements constituting the magnet form phosphates, react with the metal compound, and form an inorganic-organic composite film to form an iron-based magnet alloy containing the rare earth elements. Cover the powder.
In order to complete the reaction and form a film having a sufficient film thickness, it depends on the type of the stirring and pulverizing apparatus and the type of the metal compound, but 1 to 180 minutes, preferably 3 to 100 minutes, per 1 kg of the alloy powder. More preferably, stirring (pulverization) for 5 to 60 minutes and holding time are required.

FIG. 1 is an electron micrograph of a cross section of a magnet alloy fine powder obtained by pulverizing an iron-based magnet alloy coarse powder containing a rare earth element and covering the inorganic organic composite coating. The mechanism of this layer structure has not yet been fully elucidated, but the surface of the magnet is etched with phosphoric acid, and the elements that make up the magnet, such as rare earth elements and iron that are dissolved in the solution, are phosphates. Because it forms and reacts with metal compounds, quickly becomes inorganic phosphate and surrounds the magnet, polyphenol is large in molecule and is not as reactive with metal as phosphoric acid, so it gradually accumulates on the magnet Conceivable.
In the above description, the case where the coating treatment liquid is added before or during the pulverization of the magnetic alloy powder and the stirring is continued is described. However, the coating treatment liquid may be added after pulverization. In that case, add as much time as possible from the end of grinding. This is because the surface of the magnet powder is oxidized with time after grinding.

(2) Drying of coating The coating formed on the magnet powder is then firmly fixed on the surface of the magnet powder by drying. The drying temperature is preferably 60 to 300 ° C, particularly 100 to 250 ° C in vacuum or in an inert gas atmosphere. The higher the processing temperature, the denser and stronger the film can be obtained. However, if the temperature exceeds 300 ° C., the magnet alloy powder is thermally damaged and the magnetic properties (particularly the coercive force) of the magnet alloy powder are lowered. It is. When the temperature is less than 60 ° C., the magnet alloy powder does not sufficiently dry, and the formation of a stable surface film is hindered and cannot be sufficiently baked.

The drying time is not particularly limited, but is 0.5 hours or longer, preferably 1 to 5 hours. If it is less than 0.5 hours, depending on the components of the coating, the drying of the magnet alloy powder does not proceed sufficiently, and the formation of a stable surface coating is hindered and cannot be sufficiently baked. The longer the treatment time, the denser and stronger the film can be obtained. However, if it exceeds 30 hours, the magnet alloy powder is thermally damaged, and the magnetic properties (particularly the coercive force) of the magnet alloy powder may be lowered. Caution must be taken.
As described above, the average thickness of the inorganic / organic composite film obtained in the present invention is preferably 1 to 500 nm. When the average thickness is less than 1 nm, sufficient salt water resistance and mechanical strength cannot be obtained. On the other hand, when the average thickness exceeds 500 nm, the ratio of the magnet alloy powder decreases and the magnetic properties decrease, and when a bonded magnet is produced. However, kneadability and moldability are deteriorated.

3. Bonded Magnet Resin Composition The bonded magnet resin composition of the present invention contains a thermoplastic resin or a thermosetting resin as a resin binder in the above surface-coated magnet alloy powder, and optionally other additives. Is.
Resin binder is a component that acts as a binder for magnet powder, and is a thermoplastic resin such as polyamide resin, polyphenylene sulfide resin, or epoxy resin, bis-maleimide triazine resin, unsaturated polyester resin, vinyl ester resin, curing reaction type Although thermosetting resins such as silicone rubber can be used, thermoplastic resins are particularly preferable.

The kind in particular of a thermoplastic resin is not restrict | limited, A conventionally well-known thing can be used as a resin binder. Specific examples of the thermoplastic resin include nylon 6, nylon 66, nylon 11, nylon 12, nylon 612, aromatic nylon, polymerized fatty acid polyamide resin, and polyamide resin such as modified nylon obtained by partially modifying these molecules; Linear polyphenylene sulfide resin, crosslinked polyphenylene sulfide resin, semi-crosslinked polyphenylene sulfide resin; low density polyethylene, linear low density polyethylene resin, high density polyethylene resin, ultrahigh molecular weight polyethylene resin, polypropylene resin, ethylene-vinyl acetate Polymer resin, ethylene-ethyl acrylate copolymer resin, ionomer resin, polymethylpentene resin; polystyrene resin, acrylonitrile-butadiene-styrene copolymer resin, acrylonitrile-styrene copolymer resin; poly Vinyl chloride resin, polyvinylidene chloride resin, polyvinyl acetate resin, polyvinyl alcohol resin, polyvinyl butyral resin, polyvinyl formal resin; methacrylic resin; polyvinylidene fluoride resin, polytrifluoroethylene chloride resin, tetrafluoroethylene-hexafluoride Propylene copolymer resin, ethylene-tetrafluoroethylene copolymer resin, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer resin, polytetrafluoroethylene resin; polycarbonate resin, polyacetal resin, polyethylene terephthalate resin, polybutylene terephthalate resin, polyphenylene Oxide resin, polyallyl ether allyl sulfone resin, polyether sulfone resin, polyether ether ketone resin, polyarylate resin, aromatic polyester resin Cellulose acetate resin, each of the above-mentioned resin-based elastomers, etc. are listed. Random copolymers, block copolymers, graft copolymers with these homopolymers and other types of monomers, and end group-modified products with other substances Etc.
These thermoplastic resins are desirably those having a low melt viscosity and molecular weight within a range where desired mechanical strength can be obtained in the obtained bonded magnet. Further, the shape of the thermoplastic resin is not particularly limited, such as powder, bead, pellet, etc., but powder is preferable in that it is uniformly mixed with the magnet alloy powder in a short time.
The compounding quantity of a thermoplastic resin is 5-100 weight part normally with respect to 100 weight part of magnet alloy powder, Preferably it is 5-50 weight part. When the blending amount of the thermoplastic resin is less than 5 parts by weight, the kneading resistance (torque) of the composition becomes large, or the fluidity is lowered and it becomes difficult to mold the magnet. If it exceeds, desired magnetic properties cannot be obtained.

Thermosetting resins include epoxy resin, phenol resin, unsaturated polyester resin, xylene resin, urea resin, melamine resin, thermosetting silicone resin, alkyd resin, furan resin, thermosetting acrylic resin, thermosetting fluororesin And urea resin, diallyl phthalate resin, polyurethane resin, silicon resin and the like.
If it is a thermosetting resin, a two-pack type is advantageous from the viewpoint of its handleability and pot life, and after mixing the two liquids, a resin that can be cured at a temperature from room temperature to 200 ° C. is preferable. The reaction mechanism may be a general addition polymerization type or a condensation polymerization type. Further, a crosslinking reaction type monomer or oligomer such as peroxide may be added as necessary.
These are not limited by the degree of polymerization or molecular weight as long as they are in a reactable state, but in a final mixed state with a curing agent and other additives, the dynamic viscosity at 150 ° C. measured with an ASTM 100 rheometer is 500 Pa. · S or less, preferably 400 Pa · s or less, particularly preferably 100 to 300 Pa · s. If the dynamic viscosity exceeds 500 Pa · s, the kneading torque is significantly increased during molding and the fluidity is lowered, which is not preferable because molding becomes difficult. On the other hand, if the dynamic viscosity becomes too small, the magnet powder and the resin binder are easily separated at the time of molding, and thus it is preferably 0.5 Pa · s or more.
The said thermosetting resin is added in the ratio of 3-50 weight part with respect to 100 weight part of magnet alloy powder. The addition amount is preferably 7 to 30 parts by weight, and more preferably 10 to 20 parts by weight. If it is less than 3 parts by weight, the kneading torque will be significantly increased and the fluidity will be lowered, making it difficult to mold. On the other hand, if it exceeds 50 parts by weight, the desired magnetic properties cannot be obtained, which is not preferable.

A lubricant, an ultraviolet absorber, a flame retardant, various stabilizers, and the like can be added to the resin binder in the present invention.
Examples of the lubricant include waxes such as paraffin wax, liquid paraffin, polyethylene wax, polypropylene wax, ester wax, carnauba, and microwax; stearic acid, 1,2-oxystearic acid, lauric acid, palmitic acid, oleic acid, and the like Fatty acid salts such as calcium stearate, barium stearate, magnesium stearate, lithium stearate, zinc stearate, aluminum stearate, calcium laurate, zinc linoleate, calcium ricinoleate, zinc 2-ethylhexoate (metal soap) ); Stearic acid amide, oleic acid amide, erucic acid amide, behenic acid amide, palmitic acid amide, lauric acid amide, hydroxystearic acid amide, methylene bisste Fatty acid amides such as phosphoric acid amide, ethylene bis stearic acid amide, ethylene bis lauric acid amide, distearyl adipic acid amide, ethylene bis oleic acid amide, dioleyl adipic acid amide, N-stearyl stearic acid amide; butyl stearate, etc. Fatty acid esters; alcohols such as ethylene glycol and stearyl alcohol; polyethers composed of polyethylene glycol, polypropylene glycol, polytetramethylene glycol, and modified products thereof; polysiloxanes such as dimethylpolysiloxane and silicon grease; fluorine-based oils Fluorine compounds such as fluorine-based grease and fluorine-containing resin powders; inorganic compound powders such as silicon nitride, silicon carbide, magnesium oxide, alumina, silicon dioxide, molybdenum disulfide These lubricants may be used alone or in combination of two or more. The blending amount of the lubricant is usually 0.01 to 20 parts by weight, preferably 0.1 to 10 parts by weight with respect to 100 parts by weight of the magnet alloy powder.

Examples of the ultraviolet absorber include benzophenone series such as phenyl salicylate; benzotriazole series such as 2- (2′-hydroxy-5′-methylphenyl) benzotriazole; oxalic acid anilide derivatives and the like.
As stabilizers, bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate, bis (1,2,2,6,6-pentamethyl-4-piperidyl) sebacate, 1- [2 -{3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionyloxy} ethyl] -4- {3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionyloxy} -2,2,6,6-tetramethylpiperidine, 8-benzyl-7,7,9,9-tetramethyl-3-octyl-1,2,3-triazaspiro [4,5] undecane-2,4- Dione, 4-benzoyloxy-2,2,6,6-tetramethylpiperidine, dimethyl-1- (2-hydroxyethyl) -4-hydroxy-2,2,6,6-tetramethylpiperidine polycondensate Poly [[6- (1,1,3,3-tetramethylbutyl) imino-1,3,5-triazine-2,4-diyl] [(2,2,6,6-tetramethyl-4-piperidyl ) Imino] hexamethylene [[2,2,6,6-tetramethyl-4-piperidyl] imino]], 2- (3,5-di-tert-butyl-4-hydroxybenzyl) -2-n-butyl Examples include hindered amine stabilizers such as bis (1,2,2,6,6-pentamethyl-4-piperidyl) malonate, antioxidants such as phenols, phosphites, and thioethers. These stabilizers may be used alone or in combination of two or more. The amount of the stabilizer is usually 0.01 to 5 parts by weight, preferably 0.05 to 3 parts by weight with respect to 100 parts by weight of the magnet alloy powder.

  The mixing method is not particularly limited. A kneader such as a twin screw extruder can be used.

4). Bonded magnet The bonded magnet of the present invention comprises a resin composition for a bonded magnet using the magnet powder (A) on which the inorganic-organic composite coating (B) is uniformly formed, on an injection molding method, a compression molding method, an injection compression method. It is obtained by molding by any molding method selected from a molding method, an extrusion molding method or an injection press molding method (hereinafter also referred to as a first bonded magnet).
In the bonded magnet of the present invention, the bonded magnet resin composition using the magnet powder (A) is selected from an injection molding method, a compression molding method, an injection compression molding method, an extrusion molding method, or an injection press molding method. An inorganic-organic composite film (B) is uniformly formed on a molded body obtained by molding by a molding method (hereinafter also referred to as a second bonded magnet). The first bonded magnet and the second bonded magnet are collectively referred to simply as a bonded magnet.

  In the second bonded magnet, the thickness of the inorganic-organic composite coating (B) is preferably 10 nm or more on average. If the inorganic organic composite coating (B) is not formed or if the average film thickness is less than 10 nm, sufficient salt water resistance and mechanical strength cannot be obtained. However, if it exceeds 1 μm, the magnetic properties may be deteriorated. Moreover, the magnet powder (A) containing the iron-based magnet alloy containing the rare earth element has, on its surface, a composite metal phosphate containing iron phosphate and a rare earth metal phosphate, and an organic compound containing the above polyphenol. What formed the inorganic organic composite film (B) which becomes is preferable.

When the resin binder which is a component of the resin composition for bonded magnets is a thermoplastic resin, the bonded magnet is heated and melted at the melting temperature and then formed into a magnet having a desired shape. In the first bonded magnet, a magnet powder (A) having an inorganic-organic composite coating (B) uniformly formed on the surface is used as the bonded magnet resin composition.
Examples of molding methods include various molding methods such as injection molding methods, extrusion molding methods, injection compression molding methods, injection press molding methods, and transfer molding methods that have been conventionally used for plastic molding and the like. In particular, an injection molding method, an extrusion molding method, an injection compression molding method, and an injection press molding method are preferable.
On the other hand, when the resin binder is a thermosetting resin, it is preferable to use a mixer having a low shearing force and a cooling function so that curing does not proceed due to shearing heat generation during mixing. Since the composition is agglomerated by mixing, it is molded by an injection molding method, compression molding method, extrusion molding method, rolling molding method, transfer molding method, or the like.
In the bonded magnet of the present invention, even when immersed in 5% salt water near the salinity of seawater for 24 hours, red rust hardly occurs in the bonded magnet. This is because, in the bonded magnet obtained as described above, the inorganic-organic composite coating formed on the magnet alloy powder is firmly fixed on the surface. In particular, the polyphenols that make up the inorganic / organic composite coating cause deterioration in high-temperature environments, which are practically important, due to the synergistic barrier effect accompanying the toughening and strengthening of defects in the phosphate film formed on the surface of the magnet alloy This is considered to suppress penetration of water, oxygen, and corrosive ions. Conventionally, the rare earth-iron alloy magnet has a problem that the coercive force is lowered, but the present invention completely overcomes such a problem. This bonded magnet has excellent mechanical strength and can withstand severe deformation loads without cracking.

5. Compacted magnet The compacted magnet of the present invention is obtained by compacting the magnet powder (A) on which the inorganic-organic composite film (B) is formed, and the apparent density is 85% or more of the true density (hereinafter referred to as the following). This is also called the first compacted magnet).
In the compacted magnet of the present invention, the inorganic-organic composite coating (B) is uniformly formed on a molded body obtained by compacting the magnet powder (A) and having an apparent density of 85% or more of the true density. (Hereinafter, this is also referred to as a second compacted magnet).

In the second compacted magnet, the inorganic-organic composite coating (B) preferably has a thickness of 10 nm or more on average. If the inorganic organic composite coating (B) is not formed or if the average film thickness is less than 10 nm, sufficient salt water resistance and mechanical strength cannot be obtained. However, if it exceeds 1 μm, the magnetic properties may be deteriorated. Moreover, the magnet powder (A) containing the iron-based magnet alloy containing the rare earth element has, on its surface, a composite metal phosphate containing iron phosphate and a rare earth metal phosphate, and an organic compound containing the above polyphenol. What formed the inorganic organic composite film (B) which becomes is preferable.
The method for producing the compacted magnet is not particularly limited as long as a high compressive force is applied to the surface-coated magnet alloy powder and the apparent density can be 85% or more of the true density. If the apparent density is less than 85%, the magnetic characteristics are low, and open pores that are paths of oxygen and moisture, which are the causes of deterioration of the magnet alloy powder, are not preferable. The magnet alloy powder of the present invention exhibits high corrosion resistance as it is, but higher corrosion resistance can be realized by eliminating open pores as a compacted magnet. A magnet obtained by consolidating the magnet alloy powder exhibits high salt water resistance like a bonded magnet.
By producing a compacted magnet from the surface-coated magnet alloy powder of the present invention, magnetic properties, particularly the coercive force of the magnet, are improved in addition to the above-mentioned corrosion resistance. When consolidation is performed, decomposition and denitrification of the rare earth-iron-nitrogen compound are prevented, and a decrease in coercive force can be prevented because a non-magnetic inorganic-organic composite coating is uniformly present between the particles.

6). The manufacturing method of the 2nd bonded magnet in which the inorganic organic composite film is formed, and the 2nd compacted magnet As above-mentioned, the 2nd bonded magnet of this invention is a magnet powder containing the iron-type magnet alloy containing rare earth elements ( An inorganic-organic composite coating (B) composed of a composite metal phosphate containing iron phosphate and a rare earth metal phosphate and an organic compound containing polyphenol as described above on the surface of a molded product made of the resin composition using A). ) Is formed.
The method for producing the second bonded magnet is the same as the method for producing the first bonded magnet with respect to the molding means and molding conditions of the resin composition for the bonded magnet as the raw material. The feature point is the formation conditions of the inorganic-organic composite film (B) on the obtained molded body.

  On the other hand, in the second compacted magnet of the present invention, the inorganic / organic composite coating (B) is uniformly formed on a molded product obtained by compacting the magnet powder (A) and having an apparent density of 85% or more of the true density. It is formed. The method for producing the second compacted magnet is the same as the method for producing the first compacted magnet with respect to the molding means and molding conditions of the raw magnet powder. The feature point is the formation conditions of the inorganic-organic composite film (B) on the obtained molded body.

  In the second bonded magnet of the present invention, since the inorganic / organic composite coating (B) is formed on the surface of the molded body formed from the resin composition of the resin component and the magnet powder (A), Mild conditions are adopted compared to magnets. In the second compacted magnet of the present invention, although it does not contain a resin component, milder conditions than those in the case of the first compacted magnet are adopted so that the surface of the molded body is not collapsed by the coating treatment liquid. .

That is, each of the second bonded magnet and the second compacted magnet comprises at least one phosphoric acid compound (a) selected from phosphoric acid, polyphosphoric acid, or organic phosphonic acid, and polyphenol (b). A coating treatment liquid comprising an organic solvent is used. Then, the molded body is immersed in the coating treatment solution for a predetermined time to form an inorganic-organic composite coating on the surface of the molded body, and then heated for a specific time in a specific temperature range and baked and dried. The
The surface of the molded body is preferably a clean surface that has been degreased in advance with methyl ethyl ketone, acetone or the like to remove adhering fine powder.
Moreover, it is preferable that the solvent of this coating process liquid is an alcohol solvent (d) with a boiling point of 60-150 degreeC. For example, ethanol, isopropanol, butanol, methanol and the like are preferable. Those having a boiling point exceeding 150 ° C. are not preferable because they are difficult to remove from the coating film in the drying step. These can be used alone or as a mixture, but in the present invention, organic solvents other than alcohols compatible with water, such as acetone, dioxane, cellosolve, etc. can also be used.
The concentration of the alcohol-based solvent in the coating treatment liquid is preferably in the range of 50 to 99% by mass, and if it is less than 50% by mass, drying is slow and rust is likely to occur, and if it exceeds 99% by mass, the phosphate compound is ionized. This is not preferable because the reactivity is lowered.
In the coating treatment liquid, the mass ratio of the polyphenol (b) and the water-soluble resin (c) to the phosphoric acid compound (a): (b + c) / a is not particularly limited, but is 1 to 100. A range is desirable. The mass ratio: (b + c) / a is preferably 2-50, in particular 3-30. When the mass ratio: (b + c) / a is less than 1, the phosphoric acid compound becomes excessive, the metal etching becomes excessive, and the water resistance and corrosion resistance of the formed film become insufficient, which is not preferable. On the other hand, if the mass ratio exceeds 100, etching is insufficient, the coating becomes thin, and the corrosion resistance is lowered.

The inorganic-organic composite coating is composed of a phosphate coating on the inner layer close to the surface of the molded body, a mixed coating of polyphenol and phosphate coating on the intermediate layer, and a coating mainly composed of polyphenol on the outer layer. The mechanism of this layer structure has not yet been fully elucidated, but the surface of the molded body is etched with phosphoric acid, and the rare earth elements dissolved in the solution, such as iron, the elements that make up the magnet are phosphates. It reacts with the metal compound and quickly becomes an inorganic phosphate to surround the magnet, and the polyphenol has a large molecule and is not as reactive with the metal as phosphoric acid, so it gradually accumulates on the bonded magnet This is probably because of this.
Thereafter, the coating formed on the surface of the molded body is firmly fixed by baking and drying. The baking drying temperature is preferably 30 to 200 ° C., particularly preferably 30 to 150 ° C. or less. The higher the processing temperature, the denser and stronger the film can be obtained. However, when the temperature exceeds 200 ° C., the magnet is thermally damaged, and care must be taken because the magnetic properties (particularly the coercive force) are lowered. When the temperature is lower than 30 ° C., the magnet alloy powder is not sufficiently dried and the formation of a stable surface film is hindered and cannot be sufficiently baked.
The drying time is not particularly limited, but is 10 minutes or more, preferably 15 to 60 minutes. If it is less than 10 minutes, depending on the components of the coating, the drying of the magnet does not proceed sufficiently and the formation of a stable surface coating is hindered, and it cannot be sufficiently baked. The longer the treatment time, the denser and stronger the film can be obtained. However, if the treatment time is longer than 60 minutes, the magnet is thermally damaged, and the magnetic properties (particularly the coercive force) may be lowered.
As described above, the film thickness of the inorganic / organic composite film obtained in the present invention is 10 nm or more on average, and preferably 20 to 500 nm. If the average thickness is less than 10 nm, sufficient salt water resistance and mechanical strength cannot be obtained.

For both the bond magnet and the compacted magnet, a protective film is formed by applying a paint last. By forming the protective film, not only gloss and aesthetics are increased, but also it is possible to suppress moisture and corrosive gas from entering the molded body.
Although the kind of coating material to be used is not particularly limited, one or more of thermosetting resins represented by epoxy resin, phenol resin, acrylic resin, melamine resin, polyester resin, and alkyd resin can be mentioned. Also, the means for painting is not particularly limited, but spray painting is preferable if it has a simple shape. In the case of spray coating, it may be performed once or twice or more. The coating film is then fired, for example, in the air at 80 to 150 ° C. for 10 to 60 minutes. The film thickness after coating is not particularly limited, but is preferably 5 to 30 μm.

  EXAMPLES Hereinafter, although an Example and a comparative example are given and this invention is demonstrated concretely, this invention is not limited at all by these Examples.

(1) Component <Magnet alloy powder>
A: Isotropic Nd—Fe—B based magnet alloy powder [MQP-B manufactured by Magnequench International, average particle size: 90 μm]
B: Anisotropic Nd—Fe—B magnet alloy powder [manufactured by Sumitomo Special Metal Co., Ltd., average particle size: 77 μm]
C: anisotropic Nd-Fe-B magnet alloy powder [Aichi Steel Co., Ltd., average particle size: 120 [mu] m] D: Sm-Fe-N magnet alloy powder [Sumitomo Metal Mining Co., Ltd.] Average particle size: 30 μm]
E: Sr ferrite [Dowa Mining Co., Ltd. SF-500, average particle size: 1.5 μm]
<Organic solvent>
・ Isopropyl alcohol (IPA) [Kanto Chemical Co., Ltd.]

<Coating treatment liquid containing phosphoric acid compound, polyphenol, alcohol solvent, water>
(component)
Phosphoric acid compound (a): 85% phosphoric acid, pyrophosphoric acid, polyphosphoric acid, or organic phosphonic acid (ethane-1-hydroxy-1,1-diphosphonic acid) was used.
Polyphenol (b): selected from black tea catechins, tannic acid, persimmon tannins, green tea catechins, and flavones.
Water-soluble resin (c): selected from water-soluble phenol resin, water-soluble acrylic resin, water-soluble modified polyamide resin, and urethane resin.
Alcohol solvent (d): Methanol, ethanol, isopropanol, butanol and acetone were used alone or in combination. The remaining solvent other than the alcohol solvent was water. <Zinc oxide> [Kanto Chemical Co., Ltd.]
<Resin binder (nylon resin)>
・ Nylon 12 (manufactured by Ube Industries)

(2) Evaluation method Iron-based magnet alloy powder containing rare earth elements coated with an inorganic / organic composite coating and a molded body were evaluated using the following methods.
(2-1) Film thickness of inorganic-organic composite coating The film thickness of the coating was measured from an electron micrograph of a cross section of an iron-based magnet alloy powder containing a rare earth element coated with the inorganic-organic composite coating.
(2-2) Salt water resistance (corrosion resistance)
An iron-based magnet alloy powder sample containing a rare earth element coated with an inorganic organic composite coating and nylon 12 are kneaded in a lab plast mill at 200 ° C. for 30 minutes, and after air cooling, each composition is pulverized with a plastic pulverizer. Each was made into a pellet for molding. The obtained pellets were put into an injection molding machine to produce a cylindrical magnet of φ10 mm × 7 mm. At this time, injection molding was performed while applying an orientation magnetic field of 560 kA / m in the column height direction of the molded body.
The obtained molded body was immersed in a 5% NaCl aqueous solution so as to be half of the molded body and then left at room temperature for 24 hours, and the presence or absence of rust was visually observed.
(2-3) Fluidity (melt index MI method)
Using a melt indexer manufactured by Toyo Seiki Co., Ltd., measuring temperature: 250 ° C., load: 21.6 kg, die swell: 2.1 mm in diameter x 8 mm in thickness From the time required for the compound to pass through a predetermined weight, The fluidity (cm ³ / sec) was evaluated. The larger this value, the higher the fluidity and the better the injection moldability.

(2-4) Magnetic properties A bonded magnet is formed by molding a resin composition into a cylindrical magnet having a diameter of 20 mm and a thickness of 15 mm by an injection molding method, and 5.6 MA with a pulse magnetizer in the column height direction of the molded body. An external magnetic field of / m (70 kOe) was applied and magnetized. Thereafter, the residual magnetization Br (T (kG)) of the magnet was measured using a thiophye self-recording magnetometer manufactured by Toei Kogyo Co., Ltd.
In the case of a compacted magnet, the measurement was performed in the same manner by placing the magnet powder in a mold having a diameter of 15 mm and a height of 10 mm and performing discharge sintering at 800 ° C. for 3 hours.
(2-5) Mechanical strength Width W: 8 mm x Length L: 40 mm x Thickness H: 2 mm is supported by a distance between supporting points (Lv) of 30 mm, a load is applied to the center, and when it breaks The bending strength (σb) calculated from the weight (Pb) by the following equation was used as the mechanical strength. The greater this value, the higher the mechanical strength.
The bending strength is calculated according to the following formula:
σb = 3Pb · Lv / (2WH ² )

[Examples 1 to 11]
Magnet powder A is pulverized as it is, and magnet powder B is pulverized with an organic solvent as a pulverizing solvent in a medium agitation mill until the average particle size becomes 50 μm. The magnet alloy powder used for processing was pulverized.
Next, the coating treatment liquid containing the phosphoric acid compound, polyphenol, alcohol solvent, and water described in Table 1 is added to the above alloy powder at a rate of 15 g per 1 kg of the magnetic alloy powder, and 5 to 60 with a mixer. The slurry was stirred for a minute. As the alcohol solvent, methanol, ethanol, isopropanol, butanol, and acetone were used alone or in combination. The remaining solvent other than the alcohol solvent was water.
Here, in Examples 2, 3, 6, 7, 9, and 10, a water-soluble resin was also added, and in Example 11, a slurry containing 2% by mass of zinc oxide in phosphoric acid instead of the water-soluble resin. Turned into. Thereafter, the mixture was kept at 60 to 250 ° C. in vacuum with continued stirring and dried for 2 hours.
The film thickness of the obtained inorganic organic composite coating was measured from an electron micrograph of the cross section of the Nd—Fe—B alloy powder, and confirmed to be in the range of 50 to 500 nm. FIG. 1 shows a transmission electron micrograph in which the surface treatment state of the magnetic powder treated in Example 1 was observed.
Next, using the obtained magnet alloy powder, nylon 12 was added so that the magnetic powder volume fraction was 60%, kneaded with a lab plast mill, and then injection molded at 200 ° C. to produce a bonded magnet. . The magnetization and mechanical strength of the obtained magnet sample were measured by the above methods, and the results shown in Table 3 were obtained.
Magnet powders A to C are Nd—Fe—B based magnet alloy powders having an average particle size of 50 to 90 μm, and there was no significant difference in effect.

[Examples 12 to 22]
Magnet powder D was mixed with an organic solvent, placed in a medium stirring mill in which the inside of the container was replaced with nitrogen, and pulverized to an average particle size of 3 μm to produce a magnet alloy powder.
Next, the coating treatment liquid containing the phosphoric acid compound, polyphenol alcohol solvent, and water described in Table 2 is added to the alloy powder at a rate of 50 g per 1 kg of the magnet alloy powder, and stirred for 5 to 60 minutes. To make a slurry. As the alcohol solvent, methanol, ethanol, isopropanol, butanol, and acetone were used alone or in combination. The remaining solvent other than the alcohol solvent was water.
Here, in Examples 13, 14, 17, 18, 20, and 21, a water-soluble resin was also added. In Example 22, a slurry containing 2% by mass of zinc oxide in phosphoric acid instead of the water-soluble resin. Turned into. Thereafter, the slurry was filtered, and the filtrate was put into a Henschel mixer. While stirring, the mixture was kept at 130 ° C. in vacuum and dried for 2 hours.
The film thickness of the obtained inorganic / organic composite coating was measured from an electron micrograph of the cross section of the Sm—Fe—N alloy powder, and confirmed to be in the range of 1 to 100 nm.
Next, using the obtained magnet alloy powder, nylon 12 was added so that the magnetic powder volume fraction was 60%, kneaded with a lab plast mill, and then injection molded at 200 ° C. to produce a bonded magnet. . The magnetization and mechanical strength of the obtained magnet sample were measured by the above methods, and the results shown in Table 4 were obtained.

[Comparative Examples 1 to 12]
As shown in Tables 1 and 2, the slurry was stirred for 5 to 60 minutes in the same manner as in Example 1 except that a coating treatment liquid not containing a phosphoric acid compound or polyphenol was added to the alloy powder.
Here, in Comparative Example 2, a coating treatment solution containing a phosphoric acid compound or polyphenol was used, but the mass ratio of polyphenol to the phosphoric acid compound was reduced. In Comparative Examples 3 and 9, a water-soluble resin was also added. The slurry was filtered, and the filtrate was put into a Henschel mixer. While stirring, the mixture was heated and maintained within 200 ° C. in a vacuum for 2 hours.
In Comparative Examples 5 and 11, when the coating formed in Examples 1 and 12 was dried in vacuum at 90 ° C. for 2 hours, Comparative Examples 6 and 12 were the coatings formed in Examples 1 and 12. This is a case of drying at 130 ° C. in vacuum for 0.1 hour.
The film thickness of the obtained treated film was measured from an electron micrograph of a cross section of the magnet powder coated with the inorganic organic composite film. Although it was in the range of 1 to 100 nm, it was confirmed that Comparative Examples 5 and 11, 6 and 11 had some defects.
Next, using the obtained magnet alloy powder, nylon 12 was added so that the magnetic powder volume fraction was 60%, kneaded with a lab plast mill, and then injection molded at 200 ° C. to produce a bonded magnet. . The magnetization and mechanical strength of the obtained magnet sample were measured by the above methods, and the results shown in Tables 3 and 4 were obtained.

[Examples 23 to 27]
Using the magnetic powders A to E shown in Table 5 alone or in combination, an injection-molded bonded magnet is prepared by the method described in the salt water resistance evaluation, and the molded body is coated, and the salt water resistance is increased. evaluated. In addition, about the magnetic powder D, what was grind | pulverized by the same method as the comparative example 7 and used as the magnet alloy powder was used.

[Examples 28 to 31]
As shown in Table 6, the magnet powders described in Examples 1 to 3 and 12 were used for injection molding in the same manner as in Examples 23 to 27, and the surface of the obtained molded body was coated.

[Examples 32 and 33]
Magnet powders A and B were put into a mold having a diameter of 15 mm and a height of 10 mm and subjected to discharge sintering at 800 ° C. for 3 hours to obtain a compacted magnet. These were immersed in the coating treatment liquid of Example 1 and then dried at 50 ° C. for 1 h. The compacted magnet after the coating treatment was immersed in a 5% NaCl aqueous solution so as to be half of the magnet, and then left at room temperature for 24 hours, and the presence or absence of rust was visually observed. As a result, the occurrence of rust was minimal.

[Examples 34 to 42]
The bond magnet prepared in Examples 23 to 31 was spray-coated with a dry coat 2910 paint manufactured by Sumiko Lubrication Co., Ltd. The coating was a two-layer coating and baked at 130 ° C. for 30 minutes in the air. The film thickness after coating was 18 μm ± 3 μm.
After dipping in a 5% NaCl aqueous solution so as to immerse up to half of the bonded magnet after coating, it was left at 60 ° C. for 24 hours, and the presence or absence of rust was visually observed.

"Evaluation"
From the results shown in Tables 3 and 4, in the bonded magnets of Examples 1 to 11 and Examples 12 to 22, the surface of the magnet alloy powder is uniformly protected by a stable composite metal phosphate coating, and the molded machine It can be seen that it is excellent in strength and has little or no rust even in 5% salt water.
On the other hand, in the bonded magnets of Comparative Examples 1 and 7, the composite metal phosphate coating is not formed on the magnet alloy powder, and the bonded magnets of Comparative Examples 3, 4, 9, and 10 are made of the magnet alloy powder. Although the composite metal phosphate coating is formed, the magnetic properties are slightly lower and the corrosion resistance is inferior because there is no polyphenol. Moreover, since the mechanical strength of a molded object is also low and this does not have polyphenol, it is thought that the affinity of magnet alloy powder and resin fell. In the bonded magnets of Comparative Examples 2 and 8, a composite metal phosphate coating was formed on the magnet alloy powder and had polyphenol, but the coating was not uniform, so the magnetic properties were insufficient. In Comparative Examples 5 and 11, the drying temperature of the film was less than 60 ° C., and in Comparative Examples 6 and 12, the drying time of the film was less than 30 minutes, so that the fixability was insufficient and the magnetic properties were insufficient. It was.
From the results shown in Table 5, it can be seen that even with a magnet using magnet powder that has not been coated, the corrosion resistance is improved by coating the magnet molding itself. In addition, it can be seen that by forming a protective film on the surface by coating, rust is not generated or is slight even in high-temperature salt water (Table 7).
Moreover, it can be seen from the results shown in Table 6 that the corrosion resistance is further improved by further coating the magnet produced from the magnet powder that has been coated.

The iron-based magnet alloy powder containing the rare earth element of the present invention has an extremely excellent corrosion resistance because the surface of the magnet alloy powder is uniformly formed and protected by an inorganic-organic composite coating containing a stable composite metal phosphate and polyphenol. Yes. In addition, the bonded magnet or the compacted magnet of the present invention uses a magnet alloy powder on which the specific inorganic-organic composite coating is formed, or an inorganic-organic composite coating containing a composite metal phosphate and a polyphenol whose surface of the molded body is stable Is uniformly protected by.
For this reason, it can be used as a component such as a motor or sensor in various products including general home appliances, communication / acoustic devices, medical devices, and general industrial devices.

Claims (20)

  An inorganic organic composite coating made of an organic compound containing iron phosphate and rare earth metal phosphate and an organic compound containing polyphenol is uniformly formed on the surface of the magnet powder made of an iron-based magnet alloy containing rare earth elements. An iron-based magnet alloy powder containing rare earth elements.   2. The iron-based magnet alloy powder containing a rare earth element according to claim 1, wherein the magnet alloy powder has an average particle size of 150 μm or less.   The composite metal phosphate further contains a metal phosphate containing one or more selected from Al, Zn, Zr, Mn, Ti, Cu, or Ca as a metal component. Iron-based magnet alloy powder containing rare earth elements.   2. The iron-based magnet alloy powder containing a rare earth element according to claim 1, wherein the polyphenol is at least one selected from tannin, catechin, or flavonoid.   The iron-based magnet alloy powder containing rare earth elements according to claim 1, wherein the organic compound contains a water-soluble resin.   6. The rare earth element according to claim 5, wherein the water-soluble resin is at least one organic resin selected from a phenol resin, an acrylic resin, a polyester resin, a vinyl resin, a polyamide resin, a polyimide resin, or a silicone resin. Containing iron-based magnet alloy powder.   The iron-based magnet alloy powder containing a rare earth element according to claim 1, wherein the inorganic-organic composite coating has a thickness of 1 to 500 nm.   At least one phosphoric acid compound (a) selected from phosphoric acid, polyphosphoric acid, or organic phosphonic acid before or during pulverization of the iron-based magnet alloy coarse powder containing rare earth elements in an organic solvent And an iron-based magnet alloy containing a rare earth element by adding and stirring the coating treatment liquid containing polyphenol (b) or by pulverizing the magnet alloy coarse powder and then adding and stirring the coating treatment liquid. An iron-based magnet alloy containing a rare earth element, characterized in that an inorganic-organic composite coating is formed on the surface of the powder, and then heated in a vacuum or an inert gas atmosphere at 60 ° C. or higher for 0.5 hours or longer and then dried. Powder manufacturing method.   9. The iron-based iron containing rare earth element according to claim 8, wherein the organic solvent is at least one selected from N, N-dimethylformamide, formamide, 2-methoxyethanol, ethanol, methanol, or isopropyl alcohol. Method for producing magnet alloy powder.   1 of the phosphate or hydrogen phosphate compound in which the phosphoric acid compound (a) further contains one or more metals selected from Al, Zn, Zr, Mn, Ti, Cu, Sm, Nd, Ce or Ca The method for producing an iron-based magnet alloy powder containing a rare earth element according to claim 8, comprising at least a seed.   The rare earth element according to any one of claims 8 to 10, wherein the coating treatment liquid further contains an alcohol solvent (d), and the content thereof is 50 to 99 mass% of the whole coating treatment liquid. The manufacturing method of the iron-type magnet alloy powder containing this.   The rare earth element according to any one of claims 8 to 11, wherein the coating treatment liquid further contains a water-soluble resin (c), and the content thereof is 0 to 50 mass% of the entire coating treatment liquid. The manufacturing method of the iron-type magnet alloy powder containing this.   The content of the polyphenol (b) and the water-soluble resin (c) is in the range of 0.1 to 100 as a mass ratio (b + c) / a to the phosphoric acid compound (a). The manufacturing method of the iron-type magnet alloy powder containing the rare earth elements in any one of 8-12.   The method for producing an iron-based magnet alloy powder containing a rare earth element according to any one of claims 8 to 13, wherein the amount of the coating treatment liquid added is 10 to 70 g per kg of the magnet alloy powder.   The iron-based magnet containing a rare earth element according to any one of claims 8 to 14, wherein the inorganic-organic composite coating formed on the magnet alloy powder is heated and dried at 60 to 250 ° C for 1 to 30 hours. Manufacturing method of alloy powder.   A resin composition for a bonded magnet comprising the iron-based magnet alloy powder containing the rare earth element according to any one of claims 1 to 7, and a thermoplastic resin or a thermosetting resin as a resin binder.   An injection molding method, compression molding method, injection compression molding method, extrusion molding of a resin composition for a bonded magnet comprising a rare earth element-containing iron-based magnet alloy powder and a thermoplastic resin or thermosetting resin as a resin binder. A bonded magnet obtained by any one of molding methods selected from the group consisting of an injection press molding method and an injection press molding method, a composite metal phosphate containing iron phosphate and a rare earth metal phosphate on the surface of the molded body, and a polyphenol A bonded magnet, wherein an inorganic-organic composite film made of an organic compound containing is formed.   The bonded magnet according to claim 17, wherein the iron-based magnet alloy is an iron-based magnet alloy powder containing the rare earth element according to claim 1.   A compacted magnet obtained by compacting an iron-based magnet alloy powder containing a rare earth element and having an apparent density of 85% or more of the true density. Iron compact and rare earth metal phosphate are formed on the surface of the compact. A compacted magnet, wherein an inorganic-organic composite coating composed of a composite metal phosphate containing and an organic compound containing polyphenol is formed.   A compacted magnet, wherein the iron-based magnet alloy is an iron-based magnet alloy powder containing the rare earth element according to any one of claims 1 to 7.

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