Method for producing large and/or complex permanent magnet structures

Claim 1

A method of producing a large and/or complex magnetized permanent magnet structure having a surface area greater than 4 square inches with predetermined magnetic properties and geometry and having a flux determined by its shape and consisting essentially of premagnetized modules comprising forming a powder consisting essentially of a permanent magnet type cobalt-rare earth alloy having an average particle size up to about 10 microns, subjecting said powder to a magnetic field to magnetically align it along its easy axis of magnetization, pressing the aligned powder into a compact having a density of at least 70%, coating said compact with a non-magnetic protective coating selected from the group consisting of a plastic or metal, and magnetizing said coated compact along its easy axis of magnetization producing a premagnetized module, said premagnetized module being characterized by an intrinsic coercive force H ci at least 30% higher than its ordinary coercive force H c , a demagnetization curve substantially in the form of a straight line and a recoil line substantially identical to its demagnetization curve when its remanent flux is driven to zero, producing a plurality of said premagnetized modules of substantially the same size and having substantially the same properties, and bonding together a plurality of said premagnetized modules to produce said magnetized permanent magnet structure, said premagnetized modules being bonded so that only north poles of bonded modules form the surface of the north pole of said magnetized permanent magnet structure and only south poles of bonded modules form the surface of the south pole of said magnetized permanent magnet structure, said bonding always including external physical means.

Claim 2

A method of producing a large and/or complex magnetized permanent magnet structure having a surface area greater than 4 square inches with predetermined magnetic properties and geometry and having a flux determined by its shape and consisting essentially of premagnetized modules comprising forming a powder consisting essentially of a permanent magnet type cobalt-rare earth alloy having an average particle size up to about 10 microns, subjecting said powder to a magnetic field to magnetically align it along its easy axis of magnetization, pressing the aligned powder into a compact having a density of at least 70%, coating said compact with a non-magnetic protective coating selected from the group consisting of a plastic or metal, and magnetizing said coated compact along its easy axis of magnetization producing a premagnetized module, said premagnetized module being characterized by an intrinsic coercive force H ci at least 30% higher than its ordinary coercive force H c , a demagnetization curve substantially in the form of a straight line and a recoil line substantially identical to its demagnetization curve when its remanent flux is driven to zero, producing a plurality of said premagnetized modules of substantially the same size and having substantially the same properties, and bonding together a plurality of said premagnetized modules to produce said magnetized permanent magnet structure, said premagnetized modules being bonded so that only north poles of bonded modules form the surface of the north pole of said magnetized permanent magnet structure and only south poles of bonded modules form the surface of the south pole of said magnetized permanent magnet structure, said bonding always including external physical means.

Claim 3

A method of producing a large and/or complex magnetized permanent magnet structure having a surface area greater than 4 square inches with predetermined magnetic properties and geometry and having a flux determined by its shape and consisting essentially of premagnetized modules comprising forming a powder consisting essentially of a permanent magnet type cobalt-rare earth alloy having an average particle size up to about 10 microns, subjecting said powder to a magnetic field to magnetically align it along its easy axis of magnetization, pressing the aligned powder into a compact having a density of at least 70%, sintering said compact to a density of at least 87%, and magnetizing the resulting sintered body along its easy axis of magnetization producing a premagnetized module, said premagnetized module being characterized by an intrinsic coercive force H ci at least 30% higher than its ordinary coercive force H c , a demagnetization curve substantially in the form of a straight line and a recoil line substantially identical to its demagnetization curve when its remanent flux is driven to zero, producing a plurality of said premagnetized modules of substantially the same size and having substantially the same properties, and bonding together a plurality said premagnetized modules to produce said magnetized permanent magnet structure, said premagnetized modules being bonded so that only north poles of bonded modules form the surface of the north pole of said magnetized permanent magnet structure and only south poles of bonded modules form the surface of the south pole of said magnetized permanent magnet structure, said bonding always including external physical means.

Claim 4

A method of producing a large and/or complex magnetized permanent magnet structure having a surface area greater than 4 square inches with predetermined magnetic properties and geometry and having a flux determined by its shape and consisting essentially of premagnetized modules comprising forming a powder consisting essentially of a permanent magnet type cobalt-rare earth alloy having an average particle size up to about 10 microns, subjecting said powder to a magnetic field to magnetically align it along its easy axis of magnetization, pressing the aligned powder into a compact having a density of at least 70%, sintering said compact to a density of at least 87%, and magnetizing the resulting sintered body along its easy axis of magnetization producing a premagnetized module, said premagnetized module being characterized by an intrinsic coercive force H ci at least 30% higher than its ordinary coercive force H c , a demagnetization curve substantially in the form of a straight line and a recoil line substantially identical to its demagnetization curve when its remanent flux is driven to zero, producing a plurality of said premagnetized modules of substantially the same size and having substantially the same properties, and bonding together a plurality said premagnetized modules to produce said magnetized permanent magnet structure, said premagnetized modules being bonded so that only north poles of bonded modules form the surface of the north pole of said magnetized permanent magnet structure and only south poles of bonded modules form the surface of the south pole of said magnetized permanent magnet structure, said bonding always including external physical means.