EP0101552B1
Expired / Lapsed
EP
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Magnetic materials, permanent magnets and methods of making those
Assignee: Proterial Ltd
•
Filing: 1983-07-05
•
Granted: 1989-08-09
•
Expires: 2003-07-05
Abstract
No abstract record available.
Inventors
- 👤 Masato Sagawa
- 👤 Setsuo Hanazonodanchi 14-106 Fujimura
- 👤 Yutaka Matsuura
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-10-27 10:43
CPC Classifications
H; H01; H01F; H01F1/00; H01F1/01; H01F1/03; H01F1/032; H01F1/04; H01F1/047; H01F1/053; H01F1/055; H01F1/057; H01F1/0571; H01F1/0575; H01F1/0577
Claims Analysis
Total Claims: 123
Claim 1
Independent Claim
44 words
An alloy comprising Fe-B-R characterized by containing at least one stable compound of the ternary Fe-B-R type, which compound can be magnetized to become a permanent magnet at room temperature and above, where R stands for at least one rare earth element inclusive yttrium.
Claim 2
Dependent Claim
44 words
An alloy comprising Fe-B-R characterized by containing at least one stable compound of the ternary Fe-B-R type, which compound can be magnetized to become a permanent magnet at room temperature and above, where R stands for at least one rare earth element inclusive yttrium.
Claim 3
Dependent Claim
12 words
The alloy of claim 1 wherein said compound has a tetragonal structure.
Claim 4
Dependent Claim
20 words
The alloy of claim 2 wherein the C o axis of the tetragonal structure is about 1,2 nm (12 A).
Claim 5
Dependent Claim
22 words
The alloy of claim 2 or 3 wherein the a o axis of the tetragonal structure is about 0,8 nm (8 A).
Claim 6
Dependent Claim
20 words
The alloy of one of the preceding claims, characterized by Curie points of 160 to 370°C, preferably of about 300°C.
Claim 7
Dependent Claim
21 words
The alloy of one of the preceding claims having crystals with a mean grain size of 1 µm to 80 µm.
Claim 8
Dependent Claim
18 words
The alloy of claim 6 having crystals with a mean grain size of 2 pm to 40 um.
Claim 9
Dependent Claim
29 words
The alloy of one of the preceding claims wherein the light rare earth elements amount to no less than 50 at % of the overall rare earth elements R.
Claim 10
Dependent Claim
21 words
The alloy of claim 8 wherein Nd and/or Pr amounts to no less than 50 at % of the overall R.
Claim 11
Dependent Claim
65 words
The alloy of one of the preceding claims further comprising additional elements M evident from the below list, the amounts of these elements being respectively limited to no more than the values specified hereinbelow by atomic percent wherein, when two or more of M are applied, the total amount of M is limited to the highest value of one of the individual metals M added.
Claim 12
Dependent Claim
17 words
The alloy of claim 10 having a mean crystal grain size of 1-90 pm, preferably 2--40 µm.
Claim 13
Dependent Claim
22 words
An alloy as defined in one of the preceding claims wherein R is 15 at % and B is 8 at %.
Claim 14
Dependent Claim
45 words
A process of preparing an alloy according to one of the preceding claims by melting and casting a composition containing 2-28 at % B, 8-30 at % R, where R stands for at least one rare earth element including yttrium and the balance being iron.
Claim 15
Dependent Claim
22 words
The process of claim 13 wherein as the starting materials iron, a ferroboron alloy for B and rare earth elements are used.
Claim 16
Dependent Claim
12 words
The process of claim 13 or 14 wherein the castings are pulverized.
Claim 17
Dependent Claim
12 words
The process of claim 15 wherein pulverization is effected to 3-10 pm.
Claim 18
Dependent Claim
31 words
Use of the alloys of one of claims 1 to 12 for being applied to magnetic recording media, as magnetic paints, temperature-sensitive materials and intermediaries for the production of permanent magnets.
Claim 19
Dependent Claim
44 words
A permanent magnet material comprising 8-30 at % of R, R being one or more rare earth elements including Y, Nd and/or Pr amounting to no less than 50 at % of R, 2 to 28 at % of B and the balance Fe.
Claim 20
Dependent Claim
44 words
A permanent magnet material comprising 8-30 at % of R, R being one or more rare earth elements including Y, Nd and/or Pr amounting to no less than 50 at % of R, 2 to 28 at % of B and the balance Fe.
Claim 21
Dependent Claim
17 words
A permanent magnet material of claim 18 comprising 12-20 at % R and 4-24 at % B.
Claim 22
Dependent Claim
28 words
The permanent magnet material of claim 18 or 19 which contains more than 50% of a phase containing at least one stable Fe-B-R compound having a tetragonal structure.
Claim 23
Dependent Claim
22 words
The permanent magnet material of claim 20 wherein the C o axis of the tetragonal structure is about 1,2 nm (12 A).
Claim 24
Dependent Claim
24 words
The permanent magnet material of claim 20 or 21 wherein the a o axis of the tetragonal structure is about 0,8 nm (8 A).
Claim 25
Dependent Claim
20 words
The permanent magnet material of one of claims 20 to 22 having a mean crystal grain size of 1-80 µm.
Claim 26
Dependent Claim
16 words
The permanent magnet material of claim 23 having a mean crystal grain size of 2-40 µm.
Claim 27
Dependent Claim
33 words
The permanent magnet material of one of claims 20 to 22 wherein the fine particles of the phase containing at least one stable Fe-B-R compound are separated from one another by nonmagnetic phases.
Claim 28
Dependent Claim
23 words
The permanent magnet material of claim 25 wherein the nonmagnetic phases have a high content of R of 1 to 45 vol %.
Claim 29
Dependent Claim
72 words
A permanent magnet material of one of claims 18 to 26 further comprising additional elements M evident from the below list, the amounts of these elements being respectively limited to no more than the values specified hereinbelow by atomic percent: wherein, when two or more of M are applied, the total amount of M shall be no more than the maximum value among the values specified hereinabove of the M actually added.
Claim 30
Dependent Claim
23 words
The permanent magnet material of claim 27 having a mean crystal grain size of 1 to 90 pm, preferably 2 to 40 pm.
Claim 31
Dependent Claim
21 words
The permanent magnet material of one of the preceding claims wherein R is 15 at % and B 8 at %.
Claim 32
Dependent Claim
47 words
A process for making a permanent magnetic material by providing a melt comprising 8-30 at % of R, R being one or more rare earth elements including Y, 2-28 at % of boron, the balance being Fe, cooling the melt to crystallize and powderizing the crystalline product.
Claim 33
Dependent Claim
47 words
A process for making a permanent magnetic material by providing a melt comprising 8-30 at % of R, R being one or more rare earth elements including Y, 2-28 at % of boron, the balance being Fe, cooling the melt to crystallize and powderizing the crystalline product.
Claim 34
Dependent Claim
61 words
The process of claim 30 wherein the balance is Fe and one or more of the following specified elements in amounts limited to no more than the values specified hereinbelow by atomic percent wherein, when two or more of M are applied, the total amount of M is limited to the highest value of one of the individual metals M added.
Claim 35
Dependent Claim
16 words
The process of claims 30 or 31 wherein the crystalline product is pulverized to 3-10 µm.
Claim 36
Dependent Claim
15 words
The process of one of claims 30 or 32 wherein the pulverized product is sintered.
Claim 37
Dependent Claim
17 words
The process of claim 33 wherein the sintering is effected at a temperatur of 1000 to 1200°C.
Claim 38
Dependent Claim
14 words
The process of claim 34 wherein the sintering is effected in an argon atmosphere.
Claim 39
Dependent Claim
34 words
A magnetic material comprising at least 50 vol % of a phase comprising at least one Fe-B-R type compound having a tetragonal structure, wherein R is at least one rare earth element including Y.
Claim 40
Dependent Claim
34 words
A magnetic material comprising at least 50 vol % of a phase comprising at least one Fe-B-R type compound having a tetragonal structure, wherein R is at least one rare earth element including Y.
Claim 41
Dependent Claim
21 words
The magnetic material of claim 36 wherein the C o axis of the tetragonal structure is about 1,2 nm (12 A).
Claim 42
Dependent Claim
23 words
The magnetic material of claim 36 or 37 wherein the a o axis of the tetragonal structure is about 0,8 nm (8 A).
Claim 43
Dependent Claim
22 words
The magnetic material of one of claims 36 to 38 comprising 2-28% of B, 8-30% of R, and the balance being Fe.
Claim 44
Dependent Claim
24 words
The magnetic material of one of claims 36 to 38 wherein the mean crystal grain size ranges, preferably from 1.0 pm to 80 pm.
Claim 45
Dependent Claim
19 words
The magnetic material of claim 40 wherein the mean crystal grain size ranges from 2 µm to 40 pm.
Claim 46
Dependent Claim
32 words
The magnetic material of one of claims 36 to 41 wherein the particles of the phase comprising at least one Fe-B-R type compound having tetragonal structure are separated individually by nonmagnetic phases.
Claim 47
Dependent Claim
25 words
The magnetic material of one of claims 36 to 42 comprising nonmagnetic phases of 1 vol % to 45 vol % containing much of R.
Claim 48
Dependent Claim
82 words
The magnetic material of one of claims 36 to 43 comprising 2-28% of B, 8 to 30% of R and the balance being Fe and M, M being one or more of the elements specified hereinbelow, the amounts of these elements being limited to no more than the values specified hereinbelow by atomic percent wherein, when two or more of M are applied, the total amount of M is limited to the highest value of one of the individual metals M added.
Claim 49
Dependent Claim
23 words
The magnetic material of claim 44, wherein the mean crystal grain size ranges from 1 to 90 pm, preferably 1.5 to 80 um.
Claim 50
Dependent Claim
24 words
The magnetic material of one of claims 36 to 43 wherein the light rare earth elements are used for the rare earth element R.
Claim 51
Dependent Claim
18 words
The magnetic material of claim 46 wherein Nd and/or Pr are used for the rare earth elements R.
Claim 52
Dependent Claim
38 words
A sintered magnetic material consisting of a magnetic material powder comprising 8-30% at % of R, R being one or more of the rare earth elements including Y, 2-28 at % of B and the balance being Fe.
Claim 53
Dependent Claim
38 words
A sintered magnetic material consisting of a magnetic material powder comprising 8-30% at % of R, R being one or more of the rare earth elements including Y, 2-28 at % of B and the balance being Fe.
Claim 54
Dependent Claim
68 words
A process of making a magnetic material powder showing a tetragonal structure comprising 8-30 at % of R, R being one or more of the rare earth elements including Y, 2-28 at % of B and the balance being Fe, by heating a powdery rare earth oxide R 2 0 3 as raw material for R, with powdery Fe, powdery FeB and a reducing agent for direct reduction.
Claim 55
Dependent Claim
68 words
A process of making a magnetic material powder showing a tetragonal structure comprising 8-30 at % of R, R being one or more of the rare earth elements including Y, 2-28 at % of B and the balance being Fe, by heating a powdery rare earth oxide R 2 0 3 as raw material for R, with powdery Fe, powdery FeB and a reducing agent for direct reduction.
Claim 56
Dependent Claim
14 words
The process of claim 49 including a further step of sintering the powder alloys.
Claim 57
Dependent Claim
28 words
A permanent magnet comprising at least one stable ternary compound of the Fe-B-R type where R stands for at least one of the rare earth elements including Y.
Claim 58
Dependent Claim
28 words
A permanent magnet comprising at least one stable ternary compound of the Fe-B-R type where R stands for at least one of the rare earth elements including Y.
Claim 59
Dependent Claim
33 words
The permanent magnet of claim 51 comprising 8-30 at % R, R being one or more of the rare earth elements including Y, 2-28 at % of B and the balance being Fe.
Claim 60
Dependent Claim
20 words
The permanent magnet of claim 52 comprising 12-20 at % R and 4-24 at % B, the balance being Fe.
Claim 61
Dependent Claim
21 words
The permanent magnet of one of claims 51 to 53, having anisotropic properties obtainable by sintering a powder of said material.
Claim 62
Dependent Claim
38 words
A permanent magnet comprising 8-30 at % R, R being one or more of the rare earth elements including Y, 2-28 at % of B and the balance being Fe, obtainable by sintering a powder of said material.
Claim 63
Dependent Claim
38 words
A permanent magnet comprising 8-30 at % R, R being one or more of the rare earth elements including Y, 2-28 at % of B and the balance being Fe, obtainable by sintering a powder of said material.
Claim 64
Dependent Claim
19 words
The permanent magnet of claim 54 or 55 having anisotropic properties obtainable by additional alignment in a magnetic field.
Claim 65
Dependent Claim
31 words
The permanent magnet of one of claims 51 to 56 wherein the light rare earth elements amount to no less than 50 at % of the overall rare earth elements R.
Claim 66
Dependent Claim
22 words
The permanent magnet of claim 57 wherein Nd and/or Pr amounts to no less than 50 at % of the overall R.
Claim 67
Dependent Claim
22 words
The permanent magnet of one of claims 54 to 58 wherein the mean crystal grain size is 1-80 µm, preferably 2-40 µm.
Claim 68
Dependent Claim
67 words
The permanent magnet of one of claims 52 to 58 further comprising additional elements M evident from the below list, the amounts of these elements being respectively limited to no more than the values specified hereinbelow by atomic percent wherein, when two or more of M are applied, the total amount of M is limited to the highest value of one of the individual metals M added.
Claim 69
Dependent Claim
18 words
The permanent magnet of claim 60 having a mean crystal grain size of 1-90 µm, preferably 2-40 pm.
Claim 70
Dependent Claim
19 words
The permanent magnet of claims 52 to 61 wherein R is 15 at % and B 8 at %.
Claim 71
Dependent Claim
22 words
The permanent magnet of one of claims 51 to 62 wherein the at least one stable ternary compound has a tetragonal structure.
Claim 72
Dependent Claim
21 words
The permanent magnet of claim 63 wherein the C o axis of the tetragonal structure is about 1,2 nm (12 A).
Claim 73
Dependent Claim
23 words
The permanent magnet of claim 63 or 64 wherein the a o axis of the tetragonal structure is about 0,8 nm (8 A).
Claim 74
Dependent Claim
28 words
The permanent magnet of one of claims 54 to 65 comprising nonmagnetic phases separating the fine particles of the at least one stable ternary compound from one another.
Claim 75
Dependent Claim
21 words
The permanent magnet of claim 66 wherein the nonmagnetic phases contain much of R and are present between 1-45 vol %.
Claim 76
Dependent Claim
35 words
A sintered permanent magnet comprising at least 50 vol % of a phase comprising at least one Fe-B-R type compound having a tetragonal structure wherein R is at least one rare earth element including Y.
Claim 77
Dependent Claim
35 words
A sintered permanent magnet comprising at least 50 vol % of a phase comprising at least one Fe-B-R type compound having a tetragonal structure wherein R is at least one rare earth element including Y.
Claim 78
Dependent Claim
18 words
The sintered permanent magnet of claim 68 containing nonmagnetic phases of 1-45 vol % containing much of R.
Claim 79
Dependent Claim
17 words
The sintered permanent magnet of claim 69 wherein the nonmagnetic phases are present in 2-10 vol %.
Claim 80
Dependent Claim
36 words
The sintered permanent magnet of one of claims 68 to 70 comprising 8-30 at % R, wherein R is at least one rare earth element including Y, 2-28 at % B and the balance being Fe.
Claim 81
Dependent Claim
19 words
The sintered permanent magnet of claim 71 wherein R is 12-20 at % and B is 4-24 at %.
Claim 82
Dependent Claim
32 words
The sintered permanent magnet of one of claims 68 to 72 wherein the light rare earth element(s) amounts to no less than 50 at % of the overall rare earth elements R.
Claim 83
Dependent Claim
26 words
The sintered permanent magnet of claim 73 wherein Nd and/or Pr amounts to no less than 50 at % of the overall rare earth elements R.
Claim 84
Dependent Claim
27 words
The sintered permanent magnet of one of claims 71 to 74 wherein R amounts to about 15 at % and B amounts to about 8 at %.
Claim 85
Dependent Claim
20 words
The sintered permanent magnet of one of claims 68 to 75 wherein the mean crystal grain size is 1-80 µm.
Claim 86
Dependent Claim
18 words
The sintered permanent magnet of claim 76 wherein the mean crystal grain size is 2 to 40 pm.
Claim 87
Dependent Claim
63 words
The sintered permanent magnet of one of claims 68 to 75 containing at least one additional element M selected from the group given below in the amounts of no more than the values specified below, wherein, when two or more of M are applied, the total amount of M is limited to the highest value of one of the individual metals M added.
Claim 88
Dependent Claim
16 words
The sintered permanent magnet of claim 78 wherein the mean crystal grain size is 1-90 um.
Claim 89
Dependent Claim
18 words
The sintered permanent magnet of claim 79 wherein the mean crystal grain size is 2 to 40 µm.
Claim 90
Dependent Claim
23 words
The permanent magnet of claim 52 or 71 wherein the maximum energy product (BH)max is no less than 32 kJ/m 3 (4 MGOe).
Claim 91
Dependent Claim
23 words
The permanent magnet of claim 53 or 72 wherein the maximum energy product (BH)max is no less than 80 kJ/m l (10 MGOe).
Claim 92
Dependent Claim
21 words
The permanent magnet of claim 82 wherein the maximum energy product (BH)max is no less than 160 kJ/m 3 (20 MGOe).
Claim 93
Dependent Claim
21 words
The permanent magnet of claim 82 wherein the maximum energy product (BH)max is no less than 240 kJ/m 3 (30 MGOe).
Claim 94
Dependent Claim
21 words
The permanent magnet of claim 82 wherein the maximum energy product (BH)max is no less than 280 kJ/m 3 (35 MGOe).
Claim 95
Dependent Claim
16 words
The permanent magnet of one of claims 51 to 85 obtainable by a powder metallurgical process.
Claim 96
Dependent Claim
50 words
A process of making a permanent magnet by providing a melt comprising 8-30 at % R, R being one or more rare earth element including Y, 2-28 at % of boron, the balance being Fe, cooling the melt to crystallize, powdering the crystallized product, pressing and sintering the powdered product.
Claim 97
Dependent Claim
50 words
A process of making a permanent magnet by providing a melt comprising 8-30 at % R, R being one or more rare earth element including Y, 2-28 at % of boron, the balance being Fe, cooling the melt to crystallize, powdering the crystallized product, pressing and sintering the powdered product.
Claim 98
Dependent Claim
104 words
The process for making a permanent magnet by providing a melt comprising 8-30 at % R, R being one or more rare earth element including Y, 2-28 at % of boron, the balance being Fe and M, M being at least one additional element selected from the group given below in the amounts of no more than the values specified below, wherein, when two or more of M are applied, the total amount of M is limited to the highest value of one of the individual metals M added, cooling the melt to crystallize, powdering the crystallized product, pressing and sintering the powdered alloy.
Claim 99
Dependent Claim
104 words
The process for making a permanent magnet by providing a melt comprising 8-30 at % R, R being one or more rare earth element including Y, 2-28 at % of boron, the balance being Fe and M, M being at least one additional element selected from the group given below in the amounts of no more than the values specified below, wherein, when two or more of M are applied, the total amount of M is limited to the highest value of one of the individual metals M added, cooling the melt to crystallize, powdering the crystallized product, pressing and sintering the powdered alloy.
Claim 100
Dependent Claim
18 words
The process of claim 87 or 88 wherein the pressed powdered product is oriented in a magnetic field.
Claim 101
Dependent Claim
18 words
The process of one of claims 87 to 89 wherein the compacts are sintered at 1000 to 1200°C.
Claim 102
Dependent Claim
14 words
The process of claim 90 wherein the sintering is effected in an argon atmosphere.
Claim 103
Dependent Claim
18 words
The process of one of claims 88 to 91 wherein a step of aging is effected after sintering.
Claim 104
Dependent Claim
40 words
Legierung mit einem Gehalt an Fe-B-R, dadurch gekennzeichnet, daß sie mindestens eine stabile Verbindung des ternären Typs Fe-B-R enthält, die magnetisiert werden kann, um bei Raumtemperatur und daruber ein Permanentmagnet zu werden, wobei R mindestens ein Seltenerdelement einschließlich Yttrium bedeutet.
Claim 105
Dependent Claim
40 words
Legierung mit einem Gehalt an Fe-B-R, dadurch gekennzeichnet, daß sie mindestens eine stabile Verbindung des ternären Typs Fe-B-R enthält, die magnetisiert werden kann, um bei Raumtemperatur und daruber ein Permanentmagnet zu werden, wobei R mindestens ein Seltenerdelement einschließlich Yttrium bedeutet.
Claim 106
Dependent Claim
12 words
Legierung nach Anspruch 1, worin die genannte Verbindung eine tetragonale Struktur aufweist.
Claim 107
Dependent Claim
12 words
Legierung nach Anspruch 1, worin die genannte Verbindung eine tetragonale Struktur aufweist.
Claim 108
Dependent Claim
18 words
Legierung nach Anspruch 2, worin die c o- Achse der tetragonalen Struktur etwa 1,2 nm (12 Å) beträgt.
Claim 109
Dependent Claim
18 words
Legierung nach Anspruch 2, worin die c o- Achse der tetragonalen Struktur etwa 1,2 nm (12 Å) beträgt.
Claim 110
Dependent Claim
20 words
Legierung nach Anspruch 2 oder 3, worin die a o -Achse der tetragonalen Struktur etwa 0,8 nm (8 A) betragt.
Claim 111
Dependent Claim
20 words
Legierung nach Anspruch 2 oder 3, worin die a o -Achse der tetragonalen Struktur etwa 0,8 nm (8 A) betragt.
Claim 112
Dependent Claim
16 words
Legierung nach einem dervorstehenden Ansprüche, gekennzeichnet durch Curie-Punkte von 160 bis 370°C, vorzugsweise von etwa 300°C.
Claim 113
Dependent Claim
16 words
Legierung nach einem dervorstehenden Ansprüche, gekennzeichnet durch Curie-Punkte von 160 bis 370°C, vorzugsweise von etwa 300°C.
Claim 114
Dependent Claim
16 words
Legierung nach einem der vorstehenden Ansprüche, mit Kristallen, deren mittlere Korngröße 1 bis 80 µm beträgt.
Claim 115
Dependent Claim
16 words
Legierung nach einem der vorstehenden Ansprüche, mit Kristallen, deren mittlere Korngröße 1 bis 80 µm beträgt.
Claim 116
Dependent Claim
14 words
Legierung nach Anspruch 6, mit Kristallen, deren mittlere Korngröße 2 bis 40 µm betragt.
Claim 117
Dependent Claim
14 words
Legierung nach Anspruch 6, mit Kristallen, deren mittlere Korngröße 2 bis 40 µm betragt.
Claim 118
Dependent Claim
20 words
Legierung nach einem der vorstehenden Ansprüche, worin die leichten Seltenerdelemente nicht weniger als 50 Atom-% der gesamten Seltenerdelemente R betragen.
Claim 119
Dependent Claim
20 words
Legierung nach einem der vorstehenden Ansprüche, worin die leichten Seltenerdelemente nicht weniger als 50 Atom-% der gesamten Seltenerdelemente R betragen.
Claim 120
Dependent Claim
18 words
Legierung nach Anspruch 8, worin Nd und/oder Pr nicht weniger als 50 Atom-% der gesamten Komponente R betragen.
Claim 121
Dependent Claim
18 words
Legierung nach Anspruch 8, worin Nd und/oder Pr nicht weniger als 50 Atom-% der gesamten Komponente R betragen.
Claim 122
Dependent Claim
28 words
Legierung nach einem der vorstehenden Ansprüche, die außerdem zusätzliche Elemente M gemäß der nachfolgenden Liste enthält, deren Menge jeweils nicht mehr als die nachstehenden Werte in Atomprozent betragen,
Claim 123
Dependent Claim
28 words
Legierung nach einem der vorstehenden Ansprüche, die außerdem zusätzliche Elemente M gemäß der nachfolgenden Liste enthält, deren Menge jeweils nicht mehr als die nachstehenden Werte in Atomprozent betragen,
References Cited (Backward Citations)
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