US4931092A
Expired / Lapsed
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Method for producing metal bonded magnets
Assignee: Dow Chemical Co
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Filing: 1988-12-21
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Granted: 1990-06-05
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Expires: 2008-12-21
Abstract
Abstract A metal-metal matrix composite magnet including a magnetic material such as a neodymium-iron-boron magnetic phase bonded by a metal matrix, preferably copper an a method of making the magnet which involves plating a thin metal layer, for example, a layer having a thickness of less than 1000 angstrom average, from a magnetic phase, pressing the powder, with or without magnetic alignment, into the desired shape and then sintering the pressed powder at a temperature below about 400° C.
Inventors
- 👤 Alan J. Cisar
- 👤 Calvin F. Brooks
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 21:35
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; B22F1/17; H01F1/0578; Y; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12014; Y10T428/12028; Y10T428/12049; Y10T428/12056; Y10T428/12181
Claims Analysis
Total Claims: 37
Claim 1
Independent Claim
95 words
A process for producing a metal bonded magnet composite, said process comprising: depositing a metal layer onto at least a portion of the surface of a plurality of particles of a magnetic material: forming a shaped body from the particles; and heating said shaped body sufficient to sinter the particles together whereby a metal-metal matrix composite magnet is formed, wherein said magnetic material comprises a phase of NdFeB; said deposited metal layer comprises a nonmagnetic ductile metal, said deposition being performed by chemical-plating of dissolved ductile metal onto the magnetic particles in a non-aqueous medium.
Claim 2
Dependent Claim
95 words
A process for producing a metal bonded magnet composite, said process comprising: depositing a metal layer onto at least a portion of the surface of a plurality of particles of a magnetic material: forming a shaped body from the particles; and heating said shaped body sufficient to sinter the particles together whereby a metal-metal matrix composite magnet is formed, wherein said magnetic material comprises a phase of NdFeB; said deposited metal layer comprises a nonmagnetic ductile metal, said deposition being performed by chemical-plating of dissolved ductile metal onto the magnetic particles in a non-aqueous medium.
Claim 3
Dependent Claim
41 words
The process of claim 1 wherein the metal chemically plated onto the particles of magnetic material is at least one selected from the group consisting of copper, cobalt, nickel, tin lead, mercury, silver, gold, palladium, iridium, rhodium, rhenium, bismuth, and platinum.
Claim 4
Dependent Claim
15 words
The process of claim 1 wherein the shaped body is formed by a pressing process.
Claim 5
Dependent Claim
14 words
The process of claim 3 wherein the pressing is carried out by uniaxial pressing.
Claim 6
Dependent Claim
15 words
The process of claim 3 wherein the pressing is carried out by rapid omnidirectional compaction.
Claim 7
Dependent Claim
20 words
The process of claim 1 wherein the heating is carried out at a temperature of less than about 400° C.
Claim 8
Dependent Claim
25 words
The process of claim 1 wherein the heating is carried out at a temperature of from about 300° C. to less than about 400° C.
Claim 9
Dependent Claim
23 words
The process of claim 1 wherein the plating is carried out at a temperature of from about -20° C. to about 30° C.
Claim 10
Dependent Claim
23 words
The process of claim 1 wherein the plating is carried out at a temperature of from about -10° C. to about 10° C.
Claim 11
Dependent Claim
19 words
The process of claim 1 wherein the layer of ductile metal is less than about 1000 angstroms in thickness.
Claim 12
Dependent Claim
16 words
The process of claim 1 wherein the layer is less than about 500 angstroms in thickness.
Claim 13
Dependent Claim
19 words
The process of claim 1 including the step of coating the sintered shaped body with a corrosive protection coating.
Claim 14
Dependent Claim
16 words
The process of claim 1 wherein the metal layer is selected from copper, nickel and cobalt.
Claim 15
Dependent Claim
15 words
The process of claim 1 wherein the magnetic material is Nd 2 Fe 14 B.
Claim 16
Dependent Claim
18 words
The process of claim 1 wherein the magnetic material particles are less than about 100 mesh in size.
Claim 17
Dependent Claim
18 words
The process of claim 1 wherein the magnetic material particles are less than about 270 mesh in size.
Claim 18
Dependent Claim
75 words
A process for producing composite metal bonded magnets comprising: chemically plating a ductile metal layer onto the surface of a magnetic powder material comprising NdFeB by using a non-aqueous solution containing at least one metal of the group consisting of copper, cobalt, nickel, tin, lead, mercury, silver, gold, palladium, iridium, rhodium, rhenium, bismuth, and platinum: pressing the metal-plated powder into a desired shape; and sintering the pressed powder at a temperature below about 400° C.
Claim 19
Dependent Claim
75 words
A process for producing composite metal bonded magnets comprising: chemically plating a ductile metal layer onto the surface of a magnetic powder material comprising NdFeB by using a non-aqueous solution containing at least one metal of the group consisting of copper, cobalt, nickel, tin, lead, mercury, silver, gold, palladium, iridium, rhodium, rhenium, bismuth, and platinum: pressing the metal-plated powder into a desired shape; and sintering the pressed powder at a temperature below about 400° C.
Claim 20
Dependent Claim
15 words
The process of claim 17 wherein the pressing step is carried out with magnetic alignment.
Claim 21
Dependent Claim
15 words
The process of claim 17 wherein the pressing step is carried out without magnetic alignment.
Claim 22
Dependent Claim
28 words
A composition for a metal bonded magnet comprising a dense assembly of Nd 2 Fe 14 B particles bonded together by a continuous phase of a softer metal.
Claim 23
Dependent Claim
28 words
A composition for a metal bonded magnet comprising a dense assembly of Nd 2 Fe 14 B particles bonded together by a continuous phase of a softer metal.
Claim 24
Dependent Claim
16 words
The composition of claim 20 wherein the softer metal is selected from copper, nickel and cobalt.
Claim 25
Dependent Claim
30 words
The composition of claim 20 wherein the softer metal is present in an amount of from about 4 to about 15 volume percent based on the amount of material used.
Claim 26
Dependent Claim
25 words
The process of claim 17 wherein the sintering is carried out at a temperature of from about 300° C. to less than about 400° C.
Claim 27
Dependent Claim
23 words
The process of claim 17 wherein the plating is carried out at a temperature of from about -20° C. to about 30° C.
Claim 28
Dependent Claim
23 words
The process of claim 17 wherein the plating is carried out at a temperature of from about -10° C. to about 10° C.
Claim 29
Dependent Claim
19 words
The process of claim 17 wherein the layer of ductile metal is less than about 1000 angstroms in thickness.
Claim 30
Dependent Claim
16 words
The process of claim 17 wherein the layer is less than about 5000 angstroms in thickness.
Claim 31
Dependent Claim
19 words
The process of claim 17 including the step of coating the sintered shaped body with a corrosive protection coating.
Claim 32
Dependent Claim
20 words
The process of claim 17 wherein the metal layer is selected from the group consisting of copper, nickel and cobalt.
Claim 33
Dependent Claim
15 words
The process of claim 17 wherein the magnetic material is Nd 2 Fe 14 B.
Claim 34
Dependent Claim
18 words
The process of claim 17 wherein the magnetic material particles are less than about 100 mesh in size.
Claim 35
Dependent Claim
18 words
The process of claim 17 wherein the magnetic material particles are less than about 270 mesh in size.
Claim 36
Dependent Claim
8 words
The composite prepared in accordance with claim 17.
Claim 37
Dependent Claim
8 words
The composite prepared in accordance with claim 1.
References Cited (Backward Citations)
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