US4983232A
Expired / Lapsed
US
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Anisotropic magnetic powder and magnet thereof and method of producing same
Assignee: Proterial Ltd
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Filing: 1987-10-27
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Granted: 1991-01-08
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Expires: 2007-10-27
Abstract
Abstract A the magnetically anisotropic magnetic powder having an average particle size of 1-1000 μm and made from a magnetically anisotropic R-TM-B-Ga or R-TM-B-Ga-M alloy having an average crystal grain size of 0.01-0.5 μm, wherein R represents one or more rare earth elements including Y, TM represents Fe which may be partially substituted by Co, B boron, Ga gallium, and M one or more elements selected from the group consisting of Nb, W, V, Ta, Mo, Si, Al, Zr, Hf, P, C and Zn. This is useful for anisotropic resin-bonded magnet with high magnetic properties.
Inventors
- 👤 Minoru Endoh
- 👤 Yasuto Nozawa
- 👤 Katsunori Iwasaki
- 👤 Shigeho Tanigawa
- 👤 Masaaki Tokunaga
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 14:28
CPC Classifications
H; H01; H01F; H01F1/00; H01F1/01; H01F1/03; H01F1/032; H01F1/04; H01F1/047; H01F1/053; H01F1/055; H01F1/057; B; B61; B61C; B61C15/00; B61C15/08; B61C15/10; B61C15/102; H01F1/0571; H01F1/0575; H01F1/0577; H01F1/0578
Claims Analysis
Total Claims: 48
Claim 1
Independent Claim
106 words
A magnetically anisotropic magnetic powder of rare earth-iron-boron having improved thermal stability, having an average particle size of 1-1000 μm and made from a magnetically anisotropic R-TM-B-Ga alloy having an average crystal grain size of 0.01-0.5 μm, wherein R represents one or more rare earth elements including Y, TM represents Fe which may be partially substituted by Co, B represents boron and Ga represents gallium, wherein said R-TM-B-Ga alloy comprises 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga, and balance Fe which may be partially substituted by 30 at. % or less of Co, and inevitable impurities.
Claim 2
Dependent Claim
106 words
A magnetically anisotropic magnetic powder of rare earth-iron-boron having improved thermal stability, having an average particle size of 1-1000 μm and made from a magnetically anisotropic R-TM-B-Ga alloy having an average crystal grain size of 0.01-0.5 μm, wherein R represents one or more rare earth elements including Y, TM represents Fe which may be partially substituted by Co, B represents boron and Ga represents gallium, wherein said R-TM-B-Ga alloy comprises 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga, and balance Fe which may be partially substituted by 30 at. % or less of Co, and inevitable impurities.
Claim 3
Dependent Claim
47 words
The magnetically anisotropic magnetic powder according to claim 1, wherein said R-TM-B-Ga alloy powder consists essentially of 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga, and balance Fe which may be partially substituted by Co, and inevitable impurities.
Claim 4
Dependent Claim
36 words
The magnetically anisotropic magnetic powder according to claim 1, having a residual magnetic flux density of 8 KG or more in the direction of the axis of said magnetic powder along which it is easily magnetizable.
Claim 5
Dependent Claim
49 words
The magnetically anisotropic magnetic powder according to claim 1, wherein said anisotropic R-TM-B-Ga alloy powder is prepared by pressing flakes obtained from a melt having the composition of R-TM-B-Ga by a rapid quenching method to provide a pressed magnet, giving it anisotropy by plastic deformation and then pulverizing it.
Claim 6
Dependent Claim
19 words
The magnetically anisotropic magnetic powder according to claim 4, wherein the anisotropy is given by die upsetting while heating.
Claim 7
Dependent Claim
43 words
The magnetically anisotropic magnetic powder according to claim 1, wherein the ratio of the average dimension (c) of said crystal grains measured perpendicular to their C axis to the average dimension (a) thereof measured parallel to their C axes in 2 or more.
Claim 8
Dependent Claim
108 words
A magnetically anisotropic pressed powder magnet having improved thermal stability, made of magnetically anisotropic R-TM-B-Ga alloy having an average crystal grain size of 0.01-0.5 μm wherein R consisting essentially of Nd part of which may be substituted with Dy, TM represents Fe which may be partially substituted by Co, B represents boron, and Ga represents gallium, said magnetically anisotropic R-TM-B-Ga alloy having an axis of easy magnetization, wherein said R-TM-B-Ga alloy comprises 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga and balance Fe which may be partially substituted by 30 at % or less of Co, and inevitable impurities.
Claim 9
Dependent Claim
108 words
A magnetically anisotropic pressed powder magnet having improved thermal stability, made of magnetically anisotropic R-TM-B-Ga alloy having an average crystal grain size of 0.01-0.5 μm wherein R consisting essentially of Nd part of which may be substituted with Dy, TM represents Fe which may be partially substituted by Co, B represents boron, and Ga represents gallium, said magnetically anisotropic R-TM-B-Ga alloy having an axis of easy magnetization, wherein said R-TM-B-Ga alloy comprises 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga and balance Fe which may be partially substituted by 30 at % or less of Co, and inevitable impurities.
Claim 10
Dependent Claim
47 words
The magnetically anisotropic pressed powder magnet according to claim 7, wherein said R-TM-B-Ga alloy consists essentially of 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga and balance Fe which may be partially substituted by Co, and inevitable impurities.
Claim 11
Dependent Claim
50 words
The magnetically anisotropic pressed powder magnet according to claim 7, wherein said anisotropic R-TM-B-Ga alloy powder is prepared by pressing flakes obtained from a melt having the composition of R-TM-B-Ga by a rapid quenching method to provide a pressed magnet, giving it anisotropy by plastic deformation and then pulverizing it.
Claim 12
Dependent Claim
20 words
The magnetically anisotropic pressed powder magnet according to claim 9, wherein the anisotropy is given by die upsetting while heating.
Claim 13
Dependent Claim
115 words
A magnetically anisotropic resin-bonded magnet of rare earth-iron-boron having improved thermal stability composed of 15-40 volume % of a resin binder and balance R-TM-B-Ga alloy powder having an average crystal grain size of 0.01-0.5 μm, wherein R represents one or more rare earth elements including Y, TM represents Fe which may be partially substituted by Co, B represents boron and Ga represents gallium, said magnetically anisotropic R-TM-B-Ga alloy having an axis of easy magnetization, wherein said R-TM-B-Ga alloy comprises 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga, and balance Fe which may be partially substituted by 30 at % or less of Co, and inevitable impurities.
Claim 14
Dependent Claim
115 words
A magnetically anisotropic resin-bonded magnet of rare earth-iron-boron having improved thermal stability composed of 15-40 volume % of a resin binder and balance R-TM-B-Ga alloy powder having an average crystal grain size of 0.01-0.5 μm, wherein R represents one or more rare earth elements including Y, TM represents Fe which may be partially substituted by Co, B represents boron and Ga represents gallium, said magnetically anisotropic R-TM-B-Ga alloy having an axis of easy magnetization, wherein said R-TM-B-Ga alloy comprises 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga, and balance Fe which may be partially substituted by 30 at % or less of Co, and inevitable impurities.
Claim 15
Dependent Claim
46 words
The magnetically anisotropic resin-bonded magnet according to claim 11, wherein said R-TM-B-Ga alloy consists essentially of 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga and balance Fe which may be partially substituted by Co, and inevitable impurities.
Claim 16
Dependent Claim
44 words
The magnetically anisotropic resin-bonded magnet according to claim 11, wherein said anisotropic R-TM-B-Ga alloy powder is prepared by rapidly quenching a melt of the R-TM-B-Ga composition to form flakes which are pressed and then subjected to plastic deformation to have anisotropy and then pulverized.
Claim 17
Dependent Claim
19 words
The magnetically anisotropic resin-bonded magnet according to claim 13, wherein the anisotropy is given by die upsetting while heating.
Claim 18
Dependent Claim
139 words
A magnetically anisotropic magnetic powder of rare earth-iron-boron having improved thermal stability, the powder having an average particle size of 1-1000 μm, and composed of an R-TM-B-Ga-M alloy powder having an average crystal grain size of 0.01-0.5 μm, wherein R represents one or more rare earth elements including Y, TM represent Fe which may be partially substituted by Co, B represents boron, Ga represents gallium and M represents one or more elements selected from the group consisting of Nb, W, V, Ta, Mo, Si, Al, Zr, Hf, P, C and Zn, wherein said R-TM-B-Ga-M alloy comprises 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga, 3 atomic % or less of M and balance Fe which may be partially substituted by 30 at % or less of Co, and inevitable impurities.
Claim 19
Dependent Claim
139 words
A magnetically anisotropic magnetic powder of rare earth-iron-boron having improved thermal stability, the powder having an average particle size of 1-1000 μm, and composed of an R-TM-B-Ga-M alloy powder having an average crystal grain size of 0.01-0.5 μm, wherein R represents one or more rare earth elements including Y, TM represent Fe which may be partially substituted by Co, B represents boron, Ga represents gallium and M represents one or more elements selected from the group consisting of Nb, W, V, Ta, Mo, Si, Al, Zr, Hf, P, C and Zn, wherein said R-TM-B-Ga-M alloy comprises 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga, 3 atomic % or less of M and balance Fe which may be partially substituted by 30 at % or less of Co, and inevitable impurities.
Claim 20
Dependent Claim
53 words
The magnetically anisotropic magnetic powder according to claim 15, wherein said R-TM-B-Ga-M alloy consists essentially of 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga, 3 atomic % or less of M and balance Fe which may be partially substituted by Co, and inevitable impurities.
Claim 21
Dependent Claim
28 words
The magnetically anisotropic magnetic powder according to claim 16, wherein the residual magnetic flux density thereof in the direction of easy magnetization axis is 8 KG or more.
Claim 22
Dependent Claim
44 words
The magnetically anisotropic magnetic powder according to claim 15, wherein said anisotropic R-TM-B-Ga-M alloy powder is prepared by rapidly quenching a melt of the R-TM-B-Ga-M composition to form flakes which are pressed and then subjected to plastic deformation to have anisotropy and then pulverized.
Claim 23
Dependent Claim
19 words
The magnetically anisotropic magnetic powder according to claim 18, wherein the anisotropy is given by die upsetting while heating.
Claim 24
Dependent Claim
43 words
The magnetically anisotropic magnetic powder according to claim 15, wherein the ratio of an average dimension (c) of said crystal grains measured perpendicular to their C axes to an average dimension (a) thereof measured parallel to their C axes is 2 or more.
Claim 25
Dependent Claim
54 words
The magnetically anisotropic magnetic powder according to claim 20, wherein said R-TM-B-Ga-M alloy powder consists essentially of 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga, 3 atomic % or less of M and balance Fe which may be partially substituted by Co, and inevitable impurities.
Claim 26
Dependent Claim
28 words
The magnetically anisotropic magnetic powder according to claim 21, wherein the residual magnetic flux density thereof in the direction of easy magnetization axis is 8 KG or more.
Claim 27
Dependent Claim
140 words
A magnetically anisotropic pressed powder magnet having improved thermal stability made of magnetically anisotropic R-TM-B-Ga-M alloy having an average crystal grain size of 0.01-0.5 μm, wherein R consisting essentially of Nd part of which may be substituted by Dy, TM represents Fe which may be partially substituted by Co, B represents boron, Ga represents gallium, and M represents one or more elements selected from the group consisting of Nb, W, V, Ta, Mo, Si, Al, Zr, Hf, P, C and Zn, said magnetically anisotropic R-TM-B-Ga-M alloy having an axis of easy magnetization, wherein said R-TM-B-Ga-M alloy comprises 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga, 3 atomic % or less of M and balance Fe which may be partially substituted by 30 at % or less of Co, and inevitable impurities.
Claim 28
Dependent Claim
140 words
A magnetically anisotropic pressed powder magnet having improved thermal stability made of magnetically anisotropic R-TM-B-Ga-M alloy having an average crystal grain size of 0.01-0.5 μm, wherein R consisting essentially of Nd part of which may be substituted by Dy, TM represents Fe which may be partially substituted by Co, B represents boron, Ga represents gallium, and M represents one or more elements selected from the group consisting of Nb, W, V, Ta, Mo, Si, Al, Zr, Hf, P, C and Zn, said magnetically anisotropic R-TM-B-Ga-M alloy having an axis of easy magnetization, wherein said R-TM-B-Ga-M alloy comprises 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga, 3 atomic % or less of M and balance Fe which may be partially substituted by 30 at % or less of Co, and inevitable impurities.
Claim 29
Dependent Claim
53 words
The magnetically anisotropic pressed powder magnet according to claim 23, wherein R-TM-B-Ga-M alloy consists essentially of 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga, 3 atomic % or less of M and balance Fe which mat be partially substituted by Co, and inevitable impurities.
Claim 30
Dependent Claim
45 words
The magnetically anisotropic pressed powder magnet according to claim 23, wherein said anisotropic R-TM-B-Ga-M alloy powder is prepared by rapidly quenching a melt of the R-TM-B-Ga-M composition to form flakes which are pressed and then subjected to plastic deformation to have anisotropy and then pulverized.
Claim 31
Dependent Claim
20 words
The magnetically anisotropic pressed powder magnet according to claim 25, wherein the anisotropy is given by die upsetting while heating.
Claim 32
Dependent Claim
145 words
A magnetically anisotropic resin-bonded magnet of rare earth-iron-boron having improved thermal stability composed of 15-40 volume % of a resin binder and balance R-TM-B-Ga-M alloy powder having an average crystal grain size of 0.01-0.5 μm, wherein R represents one or more rare earth elements including Y, TM represents Fe which may be partially substituted by Co, B represents boron, Ga represents gallium, and M represents one or more elements selected from the group consisting of Nb, W, V, Ta, Mo, Si, Al, Zr, Hf, P, c and Zn, said magnetically anisotropic R-TM-B-Ga-M alloy having an axis of easy magnetization, wherein said R-TM-B-Ga-M alloy comprises 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga, 3 atomic % or less of M and balance Fe which may be partially substituted by 30 at % of Co, and inevitable impurities.
Claim 33
Dependent Claim
145 words
A magnetically anisotropic resin-bonded magnet of rare earth-iron-boron having improved thermal stability composed of 15-40 volume % of a resin binder and balance R-TM-B-Ga-M alloy powder having an average crystal grain size of 0.01-0.5 μm, wherein R represents one or more rare earth elements including Y, TM represents Fe which may be partially substituted by Co, B represents boron, Ga represents gallium, and M represents one or more elements selected from the group consisting of Nb, W, V, Ta, Mo, Si, Al, Zr, Hf, P, c and Zn, said magnetically anisotropic R-TM-B-Ga-M alloy having an axis of easy magnetization, wherein said R-TM-B-Ga-M alloy comprises 11-18 atomic % of R, 4-11 atomic % of B, 5 atomic % or less of Ga, 3 atomic % or less of M and balance Fe which may be partially substituted by 30 at % of Co, and inevitable impurities.
Claim 34
Dependent Claim
53 words
The magnetically anisotropic resin-bonded magnet according to claim 27, wherein said R-TM-B-Ga-M alloy consists essentially of 11-18 atomic % of R, 4-11 atomic % or B, 5 atomic % or less of Ga, 3 atomic % or less of M and balance Fe which may be partially substituted by Co, and inevitable impurities.
Claim 35
Dependent Claim
43 words
The magnetically anisotropic resin-bonded magnet according to claim 27, wherein said anisotropic R-TM-B-Ga-M alloy powder is prepared by rapidly quenching a melt of the R-TM-B-Ga-M composition to form flakes which are pressed and subjected to plastic deformation to have anisotropy and then pulverized.
Claim 36
Dependent Claim
19 words
The magnetically anisotropic resin-bonded magnet according to claim 29, wherein the anisotropy is given by die upsetting while heating.
Claim 37
Dependent Claim
15 words
The magnetically anisotropic magnetic powder according to claim 1, wherein Ga is 0.01-3 atomic %.
Claim 38
Dependent Claim
16 words
The magnetically anisotropic pressed powder magnet according to claim 7, wherein Ga is 0.01-3 atomic %.
Claim 39
Dependent Claim
15 words
The magnetically anisotropic resin-bonded magnet according to claim 11, wherein Ga is 0.01-3 atomic %.
Claim 40
Dependent Claim
15 words
The magnetically anisotropic magnetic powder according to claim 15, wherein Ga is 0.01-3 atomic %.
Claim 41
Dependent Claim
16 words
The magnetically anisotropic pressed powder magnet according to claim 23, wherein Ga is 0.01-3 atomic %.
Claim 42
Dependent Claim
15 words
The magnetically anisotropic resin-bonded magnet according to claim 27, wherein Ga is 0.01-3 atomic %.
Claim 43
Dependent Claim
22 words
The magnetically anisotropic magnetic powder according to claim 1, wherein R consists of Nd part of which may be substituted with Dy.
Claim 44
Dependent Claim
23 words
The magnetically anisotropic pressed powder magnet according to claim 7, wherein R consists of Nd part of which may be substituted with Dy.
Claim 45
Dependent Claim
22 words
The magnetically anisotropic resin-bonded magnet according to claim 11, wherein R consists of Nd part of which may be substituted with Dy.
Claim 46
Dependent Claim
22 words
The magnetically anisotropic magnetic powder according to claim 15, wherein R consists of Nd part of which may be substituted with Dy.
Claim 47
Dependent Claim
23 words
The magnetically anisotropic pressed powder magnet according to claim 23, wherein R consists of Nd part of which may be substituted with Dy.
Claim 48
Dependent Claim
22 words
The magnetically anisotropic resin-bonded magnet according to claim 27, wherein R consists of Nd part of which may be substituted with Dy.
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