US5164104A — Magnetic material containing rare earth element, …

Claim 1

Independent Claim 136 words

A magnetic material represented by the formula: R.sub.α Fe.sub.(100-α-β-γ-δ) N.sub.β H.sub.γ O.sub.67 (I) wherein R is at least one rare earth element inclusive of Y; α is from 5 to 20 atomic percent, β is from 5 to 25 atomic percent, γ is from 0.01 to 5 atomic percent and δ is from 3 to 15 atomic percent said magnetic material being in the form of particles, at least 50 percent by volume of which are single magnetic domain grains having a particle size of from 1 μm to 5 μm, at least 80 atomic percent of the oxygen, based on the total amount of the oxygen, being present in a surface portion of the particles, and said magnetic material exhibiting a higher (BH) max when fabricated into a magnet than said magnetic material without oxygen.

Claim 2

Dependent Claim 136 words

A magnetic material represented by the formula: R.sub.α Fe.sub.(100-α-β-γ-δ) N.sub.β H.sub.γ O.sub.67 (I) wherein R is at least one rare earth element inclusive of Y; α is from 5 to 20 atomic percent, β is from 5 to 25 atomic percent, γ is from 0.01 to 5 atomic percent and δ is from 3 to 15 atomic percent said magnetic material being in the form of particles, at least 50 percent by volume of which are single magnetic domain grains having a particle size of from 1 μm to 5 μm, at least 80 atomic percent of the oxygen, based on the total amount of the oxygen, being present in a surface portion of the particles, and said magnetic material exhibiting a higher (BH) max when fabricated into a magnet than said magnetic material without oxygen.

Claim 3

Dependent Claim 32 words

The magnetic material of claim 1, wherein at least 80 percent by volume of the particles are single magnetic domain grains having a particle size of from 1 μm to 5 μm.

Claim 4

Dependent Claim 76 words

The magnetic material of claim 1, having magnetic properties such that when the magnet material is fabricated into a bonded mass having a magnet material content of 80% by volume, followed by magnetization in a pulse magnetic field of at least 30 kOe, the resultant bonded magnet exhibits a residual magnetization (Br) of at least 7 kG, an intrinsic coercive force (iHc) of at least 5000 Oe and a loop rectangularity (Br/4πIs) of at least 85%.

Claim 5

Dependent Claim 160 words

A magnetic material represented by the formula: R.sub.α Fe.sub.(100-α-β-γ-δ) N.sub.β H.sub.γ O.sub.δ (I) 637 wherein R is at least one rare earth element inclusive of Y; α is from 5 to 20 atomic percent, β is from 5 to 25 atomic percent, γ is from 0.01 to 5 atomic percent, δ is from 3 to 15 atomic percent, and the Fe atoms are substituted by Co atoms in a substitution ratio of from 0.01 to 49 atomic percent of the Fe atoms, said magnetic material being in the form of particles, at least 50 percent by volume of which are single magnetic domain grains having a particle size of from 1 μm to 5 μm, at least 80 atomic percent of the oxygen, based on the total amount of the oxygen, being present in a surface portion of the particles, and said magnetic material exhibiting a higher (BH) max when fabricated into a magnet than said magnetic material without oxygen.

Claim 6

Dependent Claim 160 words

A magnetic material represented by the formula: R.sub.α Fe.sub.(100-α-β-γ-δ) N.sub.β H.sub.γ O.sub.δ (I) 637 wherein R is at least one rare earth element inclusive of Y; α is from 5 to 20 atomic percent, β is from 5 to 25 atomic percent, γ is from 0.01 to 5 atomic percent, δ is from 3 to 15 atomic percent, and the Fe atoms are substituted by Co atoms in a substitution ratio of from 0.01 to 49 atomic percent of the Fe atoms, said magnetic material being in the form of particles, at least 50 percent by volume of which are single magnetic domain grains having a particle size of from 1 μm to 5 μm, at least 80 atomic percent of the oxygen, based on the total amount of the oxygen, being present in a surface portion of the particles, and said magnetic material exhibiting a higher (BH) max when fabricated into a magnet than said magnetic material without oxygen.

Claim 7

Dependent Claim 32 words

The magnetic material of claim 4, wherein at least 80 percent by volume of the particles are single magnetic domain grains having a particle size of from 1 μm to 5 μm.

Claim 8

Dependent Claim 39 words

The magnetic material of claim 1 or 4, wherein R is at least one rare earth element selected from the group consisting of Nd, Pr, La, Ce, Tb, Dy, Ho, Er, Sm, Eu, Gd, Tm, Yb, Lu and Y.

Claim 9

Dependent Claim 10 words

The magnetic material of claim 6, wherein R is Sm.

Claim 10

Dependent Claim 10 words

The magnetic material of claim 6, wherein R is Ce.

Claim 11

Dependent Claim 10 words

The magnetic material of claim 6, wherein R is Nd.

Claim 12

Dependent Claim 10 words

The magnetic material of claim 6, wherein R is Gd.

Claim 13

Dependent Claim 154 words

A bonded magnet comprising: particles of at least one magnetic material represented by the formula: R.sub.α Re .sub.(100-α-β-γ-δ) N.sub.β H.sub.65 O.sub.67 (I) wherein R is at least one rare earth element inclusive of Y; α is from 5 to 20 atomic percent, β is from 5 to 25 atomic percent, γ is from 0.01 to 5 atomic percent and δ is from 3 to 15 atomic percent, at least 50 percent by volume of the particles being single magnetic domain grains having a particle size of from 1 μm to 5 μm, at least 80 atomic percent of the oxygen, based on the total amount of the oxygen, being present in a surface portion of the particles, and a binder interspersed between the particles to bond the particles together, and said bonded magnet exhibiting a higher (BH) max than a bonded magnet as defined above, but where oxygen is absent from said magnetic material.

Claim 14

Dependent Claim 154 words

A bonded magnet comprising: particles of at least one magnetic material represented by the formula: R.sub.α Re .sub.(100-α-β-γ-δ) N.sub.β H.sub.65 O.sub.67 (I) wherein R is at least one rare earth element inclusive of Y; α is from 5 to 20 atomic percent, β is from 5 to 25 atomic percent, γ is from 0.01 to 5 atomic percent and δ is from 3 to 15 atomic percent, at least 50 percent by volume of the particles being single magnetic domain grains having a particle size of from 1 μm to 5 μm, at least 80 atomic percent of the oxygen, based on the total amount of the oxygen, being present in a surface portion of the particles, and a binder interspersed between the particles to bond the particles together, and said bonded magnet exhibiting a higher (BH) max than a bonded magnet as defined above, but where oxygen is absent from said magnetic material.

Claim 15

Dependent Claim 32 words

The bonded magnet of claim 11, wherein at least 80 percent by volume of the particles are single magnetic domain grains having a particle size of from 1 μm to 5 μm.

Claim 16

Dependent Claim 38 words

The bonded magnet of claim 11, wherein R is at least one rare earth element selected from the group consisting of Nd, Pr, La, Ce, Tb, Dy, Ho, Er, Sm, Eu, Gd, Pm, Tm, Yb, Lu and Y.

Claim 17

Dependent Claim 70 words

The bonded magnet of claim 11, having magnetic properties such than when the bonded magnet has a magnetic material content of 80% by volume and is magnetized in a pulse magnetic field of at least 30 kOe, the resultant bonded magnet exhibits a residual magnetization (Br) of at least 7 kG, an intrinsic coercive force (iHc) of at least 5000 Oe and a loop rectangularity (Br/4πIs) of at least 85%.

Claim 18

Dependent Claim 10 words

The bonded magnet of claim 14, wherein R is Sm.

Claim 19

Dependent Claim 176 words

A bonded magnet comprising: particles of at least one magnetic material represented by the formula: R.sub.α Fe.sub.(100-α-β-γ-δ) N.sub.β H.sub.γ O.sub.δ (I) wherein R is at least one rare earth element inclusive of Y; α is from 5 to 20 atomic percent, β is from 5 to 25 atomic percent, γ is from 0.01 to 5 atomic percent, δ is from 3 to 15 atomic percent, and the Fe atoms are substituted by Co atoms in a substitution ratio of from 0.01 to 49 atomic percent of the Fe atoms, at least 50 percent by volume of the particles being single magnetic domain grains having a particle size of from 1 μm to 5 μm, at least 80 atomic percent of the oxygen, based on the total amount of the oxygen, being present in a surface portion of the particles, and a binder interspersed between the particles to bond the particles together, and said bonded magnet exhibiting a higher (BH) max than a bonded magnet as defined above, but where oxygen is absent from said magnetic material.

Claim 20

Dependent Claim 176 words

A bonded magnet comprising: particles of at least one magnetic material represented by the formula: R.sub.α Fe.sub.(100-α-β-γ-δ) N.sub.β H.sub.γ O.sub.δ (I) wherein R is at least one rare earth element inclusive of Y; α is from 5 to 20 atomic percent, β is from 5 to 25 atomic percent, γ is from 0.01 to 5 atomic percent, δ is from 3 to 15 atomic percent, and the Fe atoms are substituted by Co atoms in a substitution ratio of from 0.01 to 49 atomic percent of the Fe atoms, at least 50 percent by volume of the particles being single magnetic domain grains having a particle size of from 1 μm to 5 μm, at least 80 atomic percent of the oxygen, based on the total amount of the oxygen, being present in a surface portion of the particles, and a binder interspersed between the particles to bond the particles together, and said bonded magnet exhibiting a higher (BH) max than a bonded magnet as defined above, but where oxygen is absent from said magnetic material.

Claim 21

Dependent Claim 38 words

The bonded magnet of claim 16, wherein R is at least one rare earth element selected from the group consisting of Nd, Pr, La, Ce, Tb, Dy, Ho, Er, Sm, Eu, Gd, Pm, Tm, Yb, Lu and Y.

Claim 22

Dependent Claim 32 words

The bonded magnet of claim 16, wherein at least 80 percent by volume of the particles are single magnetic domain grains having a particle size of from 1 μm to 5 μm.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1995-11-17	1996-05-18	1996-11-17	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1999-11-17	2000-05-18	2000-11-17	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2003-11-17	2004-05-18	2004-11-17	$7700.00	Window Closed / Lapsed

Magnetic material containing rare earth element, iron, nitrogen, hydrogen and oxygen and bonded magnet containing the same

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