Bonded rare earth-iron magnets

Claim 2

A bonded, magnetically isotropic permanent magnet comprising a bonding agent interspersed with melt-spun, finely crystalline particles comprising, on an atomic percent basis, at least about 10 to about 40 percent of one or more rare earth elements taken from the group consisting of neodymium and praseodymium, at least about 0.5 to about 10 percent boron, and at least about 50 to about 90 percent iron.

Claim 3

A bonded, magnetically isotropic permanent magnet comprising a bonding agent interspersed with magnetically isotropic particles comprising, on an atomic percent basis, at least about 50 to about 90 percent iron, at least 10 to about 40 percent of one or more rare earth elements taken from the group consisting of neodymium and praseodymium, and at least about 0.5 to about 18 percent boron.

Claim 4

A bonded, magnetically isotropic permanent magnet comprising a bonding agent interspersed with magnetically isotropic particles comprising, on an atomic percent basis, at least about 50 to about 90 percent iron, at least 10 to about 40 percent of one or more rare earth elements taken from the group consisting of neodymium and praseodymium, and at least about 0.5 to about 18 percent boron.

Claim 5

A bonded, magnetically isotropic permanent magnet comprising a bonding agent and magnetically isotropic alloy particles comprising, on an atomic percent basis, up to about 40 percent of one or more rare earth elements where neodymium and/or praseodymium comprise at least about 10 percent of the total composition, up to about 90 percent of one or more transition metals taken from the group consisting of iron, nickel and cobalt including at least about 50 percent iron based on the total alloy composition, and from about 0.5 to 10 percent boron.

Claim 6

A bonded, magnetically isotropic permanent magnet comprising a bonding agent and magnetically isotropic alloy particles comprising, on an atomic percent basis, up to about 40 percent of one or more rare earth elements where neodymium and/or praseodymium comprise at least about 10 percent of the total composition, up to about 90 percent of one or more transition metals taken from the group consisting of iron, nickel and cobalt including at least about 50 percent iron based on the total alloy composition, and from about 0.5 to 10 percent boron.

Claim 7

A bonded, magnetically isotropic permanent magnet comprising a compact of an organic polymeric bonding agent and fractured melt-spun, magnetically isotropic alloy particles comprising, on an atomic percent basis, at least about 50 to 90 percent iron, at least about 10 to about 40 percent of one or more rare earth elements taken from the group consisting of neodymium and praseodymium, and at least about 0.5 to about 18 percent boron, the density of the alloy particles.

Claim 8

A bonded, magnetically isotropic permanent magnet comprising a compact of an organic polymeric bonding agent and fractured melt-spun, magnetically isotropic alloy particles comprising, on an atomic percent basis, at least about 50 to 90 percent iron, at least about 10 to about 40 percent of one or more rare earth elements taken from the group consisting of neodymium and praseodymium, and at least about 0.5 to about 18 percent boron, the density of the alloy particles.

Claim 9

A bonded permanent magnet comprising magnetically isotropic ribbon particles of a melt-spun alloy containing at least about 10 to about 40 atomic percent neodymium and/or praseodymium, at least about 0.5 to about 18 percent boron and at least about 50 to about 90 atomic percent iron, said particles being bonded together by means of an organic or inorganic bonding agent; and said particles having a substantially brick-like shape and being spatially oriented substantially parallel to each other within regions of the compact to achieve high compact densities and compact green strength; said magnet being equally susceptible to magnetization in any direction in an applied magnetic field such that at a compact density of 80 percent of said alloy the magnet has a magnetic remanence of at least about 6 kiloGauss.

Claim 10

A bonded permanent magnet comprising magnetically isotropic ribbon particles of a melt-spun alloy containing at least about 10 to about 40 atomic percent neodymium and/or praseodymium, at least about 0.5 to about 18 percent boron and at least about 50 to about 90 atomic percent iron, said particles being bonded together by means of an organic or inorganic bonding agent; and said particles having a substantially brick-like shape and being spatially oriented substantially parallel to each other within regions of the compact to achieve high compact densities and compact green strength; said magnet being equally susceptible to magnetization in any direction in an applied magnetic field such that at a compact density of 80 percent of said alloy the magnet has a magnetic remanence of at least about 6 kiloGauss.