Method of fabricating rare earth-transition metal magnets

Claim 1

A method of making a rare earth-transition metal permanent magnet having a thin, curved shape by sintering a green, rare earth-transition metal powder compact formed substantially in the shape of said magnet with allowance for shrinkage upon subsequent densification and wherein the powder particles of said compact are magnetically aligned substantially radially with respect to its curvature, said method comprising positioning a said green powder compact between a first die having a curved working surface substantially matching the concave side of said curved compact and a second die having a curved working surface substantially matching the convex side of said curved compact, heating said compact between said dies to a sintering temperature for said powder, restraining said compact between said dies during said heating such that the concave side of said compact shrinks contiguously with the working surface of said first die, said first and second dies serving to prevent said compact from distorting without inhibiting its shrinkage, and continuing to heat and restrain said compact until it reaches the desired density of said magnet, whereby a freestanding permanent magnet is formed having substantially the same inside radius as said green compact, the magnetic domains of said magnet being substantially radially oriented with respect to its curvature.

Claim 2

A method of making a rare earth-transition metal permanent magnet having a thin, curved shape by sintering a green, rare earth-transition metal powder compact formed substantially in the shape of said magnet with allowance for shrinkage upon subsequent densification and wherein the powder particles of said compact are magnetically aligned substantially radially with respect to its curvature, said method comprising positioning a said green powder compact between a first die having a curved working surface substantially matching the concave side of said curved compact and a second die having a curved working surface substantially matching the convex side of said curved compact, heating said compact between said dies to a sintering temperature for said powder, restraining said compact between said dies during said heating such that the concave side of said compact shrinks contiguously with the working surface of said first die, said first and second dies serving to prevent said compact from distorting without inhibiting its shrinkage, and continuing to heat and restrain said compact until it reaches the desired density of said magnet, whereby a freestanding permanent magnet is formed having substantially the same inside radius as said green compact, the magnetic domains of said magnet being substantially radially oriented with respect to its curvature.

Claim 3

A method of forming a sintered permanent rare earth-transition metal magnet having a thin, curved shape, the magnetic domains of said magnet being substantially radially oriented with respect to its curvature, comprising forming a green powder compact in substantially the shape of said magnet with allowance for shrinkage upon subsequent densification, the powder particles of said compact being magnetically aligned substantially radially with respect to its curvature, heating said compact to a sintering temperature for said powder between a first die having a curved working surface matching the concave side of said compact and a second die having a curved working surface matching the convex side of said compact, said die surfaces being smooth and nonadherent to said compact so that it does not bind with the dies as it shrinks during said heating, restraining said compact between said dies during said heating with a force of at least about 0.3 kPa, the magnitude of said force being sufficient to prevent said compact from warping without inhibiting its circumferential or radial shrinkage so that the radial magnetic alignment of the powder in the densified compact is substantially undisturbed, and continuing to heat and restrain said compact until it reaches the desired density of said magnet.

Claim 4

A method of forming a sintered permanent rare earth-transition metal magnet having a thin, curved shape, the magnetic domains of said magnet being substantially radially oriented with respect to its curvature, comprising forming a green powder compact in substantially the shape of said magnet with allowance for shrinkage upon subsequent densification, the powder particles of said compact being magnetically aligned substantially radially with respect to its curvature, heating said compact to a sintering temperature for said powder between a first die having a curved working surface matching the concave side of said compact and a second die having a curved working surface matching the convex side of said compact, said die surfaces being smooth and nonadherent to said compact so that it does not bind with the dies as it shrinks during said heating, restraining said compact between said dies during said heating with a force of at least about 0.3 kPa, the magnitude of said force being sufficient to prevent said compact from warping without inhibiting its circumferential or radial shrinkage so that the radial magnetic alignment of the powder in the densified compact is substantially undisturbed, and continuing to heat and restrain said compact until it reaches the desired density of said magnet.