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US4834812A
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Method for producing polymer-bonded magnets from rare earth-iron-boron compositions
Assignee: Union Oil Company of California
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Filing: 1987-11-02
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Granted: 1989-05-30
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Expires: 2007-11-02
Abstract
Abstract Permanent magnets are prepared by a method comprising mixing a particulate rare earth-iron-boron alloy with a particulate additive metal powder, compacting the aligned mixture to form a shape, and heating the compacted shape at a temperature at least 150 DEG C. less than the sintering temperature of a rare earth-iron-boron alloy and usually in the range from about 700 DEG C. to less than 850 DEG C.
Inventors
- 👤 Mohammad H. Ghandehari
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 15:51
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; B; B22; B22F; B22F1/00; B22F1/09; H01F1/0578
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
107 words
A method for producing a permanent magnet, comprising the steps of: (a) mixing a particulate alloy, containing at least one rare earth metal, or in, and boron, with at least one particulate additive metal having a melting temperature less than about 800° C. (b) compacting the mixture to form a shape, (c) heating the compacted shape at a temperature in the range from about 700° C. to less than 850° C. to form a heat-treated compact composition having magnetic properties, and (d) crushing said heat-treated compact composition obtained from step (c) to produce a heat-treated compact powder composition having grain sizes of diameter less than 25 microns.
Claim 2
Independent Claim
107 words
A method for producing a permanent magnet, comprising the steps of: (a) mixing a particulate alloy, containing at least one rare earth metal, or in, and boron, with at least one particulate additive metal having a melting temperature less than about 800° C. (b) compacting the mixture to form a shape, (c) heating the compacted shape at a temperature in the range from about 700° C. to less than 850° C. to form a heat-treated compact composition having magnetic properties, and (d) crushing said heat-treated compact composition obtained from step (c) to produce a heat-treated compact powder composition having grain sizes of diameter less than 25 microns.
Claim 3
Dependent Claim
27 words
The method defined in claim 1 wherein said particulate additive metal is selected from the group consisting of aluminum, dysprosium, gallium, magnesium, terbium, thallium, tin and zinc.
Claim 4
Dependent Claim
21 words
The method defined in claim 1 wherein said heating temperature is in the range from about 725° C. to 825° C.
Claim 5
Dependent Claim
13 words
The method defined in claim 1 wherein said particulate additive metal is aluminum.
Claim 6
Dependent Claim
16 words
The method defined in claim 1 wherein said rare earth metal comprises a light rare earth.
Claim 7
Dependent Claim
13 words
The method defined in claim 5 wherein said rare earth metal comprises neodymium.
Claim 8
Dependent Claim
35 words
The method defined in claim 1 further comprising, prior to step (b), aligning magnetic domains of the mixture in a magnetic field and, after step (c), magnetizing said heat-treated compact composition obtained in step (b).
Claim 9
Dependent Claim
11 words
A permanent magnet prepared according to the method of claim 7.
Claim 10
Independent Claim
23 words
The method defined in claim, 1 wherein said heat-treated compact composition contains about 0.05 to about 1.0 weight percent of said additive metal.
Claim 11
Dependent Claim
33 words
The method defined in claim 1 wherein said heating temperature is at least 150° C. less than the temperature required to produce a sintered permanent magnet from said mixture obtained in step (a).
Claim 12
Dependent Claim
16 words
The method defined in claim 1 wherein said particulate alloy is sintered prior to step (a).
Claim 13
Dependent Claim
25 words
The method defined in claim 1 wherein said alloy further contains a ferromagnetic metal selected from the group consisting of nickel, cobalt, and mixtures thereof.
Claim 14
Dependent Claim
49 words
The method defined in claim 1 wherein, prior to step (a), said particulate alloy is prepared by mixing a rare earth-iron-boron alloy with at least one particulate rare earth oxide, rare earth metal or aluminum metal, followed by sintering the mixture to a temperature greater than about 1070° C.
Claim 15
Dependent Claim
26 words
The method defined in claim 13 wherein the rare earth oxide is selected from the group consisting of terbium oxide and dysprosium oxide and mixtures thereof.
Claim 16
Dependent Claim
88 words
The method defined in claim 1 further comprising the steps of: (e) aligning magnetic domains of the heat-treated compact powder composition obtained from step (d), (f) mixing said heat-treated compact powder composition with a polymer-containing bonding agent having particle sizes of diameter less than 25 microns, (g) compacting the mixture obtained from step (f), and (h) treating the compact obtained from step (g) to effect bonding of the particles of the heat-treated compact powder composition with the polymer contained in said polymer-containing bonding agent and magnetizing said compact.
Claim 17
Dependent Claim
12 words
A polymer-bonded permanent magnet prepared according to the method of claim 15.
Claim 18
Dependent Claim
16 words
The magnet defined in claim 16 wherein said polymer-bonded magnet comprises flexible-bonded magnets or rigid-bonded magnets.
Claim 19
Dependent Claim
32 words
The method defined in claim 1 further comprising the step of: (e) aligning magnetic domains of the heat-treated compact powder composition obtained in step (d) and magnetizing said heat-treated compact powder composition.
Claim 20
Dependent Claim
11 words
A permanent magnet prepared according to the method of claim 18.
Claim 21
Independent Claim
96 words
A method for producing a permanent magnet, comprising the steps of: (a) mixing a particulate alloy containing neodymium, iron and boron, with a particulate additive metal selected from the group consisting of aluminum, dysprosium, gallium, magnesium, terbium, thallium, tin and zinc, (b) compacting the mixture to form a shape, (c) heating the compacted shape at a temperature in the range from about 700° C. to less than 850° C., and (d) crushing the heat-treated compact composition obtained in step (c) to form a heat-treated compact powder composition having grain sizes of diameter less than 25 microns.
Claim 22
Independent Claim
96 words
A method for producing a permanent magnet, comprising the steps of: (a) mixing a particulate alloy containing neodymium, iron and boron, with a particulate additive metal selected from the group consisting of aluminum, dysprosium, gallium, magnesium, terbium, thallium, tin and zinc, (b) compacting the mixture to form a shape, (c) heating the compacted shape at a temperature in the range from about 700° C. to less than 850° C., and (d) crushing the heat-treated compact composition obtained in step (c) to form a heat-treated compact powder composition having grain sizes of diameter less than 25 microns.
Claim 23
Dependent Claim
22 words
The method defined in claim 20 wherein said additive metal is selected from the group consisting of aluminum, gallium, tin and zinc.
Claim 24
Dependent Claim
13 words
The method defined in claim 20 wherein said rare earth metal comprises neodymium.
Claim 25
Dependent Claim
23 words
The method defined in claim 20 wherein said heat-treated compact composition contains about 0.05 to about 1.0 weight percent of said additive metal.
Claim 26
Dependent Claim
33 words
The method defined in claim 20 wherein said heating temperature is at least 150° C. less than the temperature required to produce a sintered permanent magnet for said mixture obtained in step (a).
Claim 27
Dependent Claim
16 words
The method defined in claim 20 wherein said particulate alloy is sintered prior to step (a).
Claim 28
Dependent Claim
25 words
The method defined in claim 20 wherein the alloy further contains a ferromagnetic metal selected from the group consisting of nickel, cobalt, and mixtures thereof.
Claim 29
Dependent Claim
49 words
The method defined in claim 20 wherein, prior to step (a), said particulate alloy is prepared by mixing a rare earth-iron-boron alloy with at least one particulate rare earth oxide, rare earth metal or aluminum metal followed by sintering the mixture to a temperature greater than about 1070° C.
Claim 30
Dependent Claim
88 words
The method defined in claim 20 further comprising the steps of: (e) aligning magnetic domains of the heat-treated compact powder composition obtained from step (d), (f) mixing said heat-treated compact powder composition with a polymer-containing bonding agent having particle sizes of diameter less than 25 microns, (g) compacting the mixture obtained from step (f), and (h) treating the compact obtained in step (g) to effect bonding of the particles of said heat-treated compact powder composition with the polymer contained in said polymer-containing bonding agent and magnetizing said compact.
Claim 31
Dependent Claim
12 words
A polymer-bonded permanent magnet prepared according to the method of claim 28.
Claim 32
Dependent Claim
16 words
The magnet defined in claim 29 wherein said polymer-bonded magnet comprises flexible-bonded magnets or rigid-bonded magnets.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-05-29 | 1992-11-28 | 1993-05-30 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-05-29 | 1996-11-28 | 1997-05-30 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-05-29 | 2000-11-28 | 2001-05-30 | $7700.00 | Window Closed / Lapsed |