A RARE-EARTH PERMANENT MAGNET

Abstract: A rare-earth permanent magnet is coated with an organic resin material having a waterproof property.

Description: The present invention relates to a permanent magnet, and more particular, to a rare-earth permanent magnet. Broadly, there are three types of permanent magnets, that is hard ferrite magnets, alnico magnets and rare-earth magnets. With a recent growing demand for smaller-sized and more efficient electrical appliances for office automation (OA) and facsimile automation (FA), specifically the demand for rare-earth magnets has increased. It is well known that rare-earth magnets may be classified into three classes according to the production methods, that is, (1) sintered magnets, (2) bonded magnets and (3) cast magnets. Typical rare-earth magnets are further grouped into two groups according to their composition, that is, (1) rare-earth magnets comprising a rare-earth metal (hereinafter referred to as R) and cobalt, and (2) rare-earth magnets comprising a rare-earth metal and ferrite. By way of example, EP-B-108474 discloses a magnet which comprises a rare-earth metal and iron, obtained by a rapid-quenching method. EP-B-101552 describes a magnet also comprising a rare-earth metal and iron, obtained by a sintering method. In both cases the magnet mainly consists of Nd, Fe and B. With the rapid-quenching method, a ribbon-like material having a thickness of 20 µm is first made and is an aggregate of crystals having a diameter of 0.1 - 0.5 µm, which is smaller than the critical diameter of uniaxial particles. Therefore, this material is pulverized into a particle diameter of less than 177 µm but not less than 0.1 µm, while maintaining the coercive force, resulting in a material applicable especially for bonded type magnets. Having regard to the coercive force mechanism, rare-earth magnet materials are classified into two classes. One class is formed by the 1-5 system rare-earth magnetic materials comprising rare-earth transition metal compounds like e.g. SmCo₅, CeCo₅, Sm 0.5 Ce 0.5 Co₅, YCo₅, PrCo₅, Sm(CoCu)₅, or the nucleation-type comprising intermetallic compounds of at least one rare-earth metal and at least one transition metal including compounds based on R-Fe-B. The second class is formed by the 2-17 system rare-earth transistion metal compound magnetic materials (pinning type of 2-17 system magnets for precipitation hardening type), comprising a rare-earth transition metal intermetallic compound like e.g. Sm(Co bal Cu 0.05 Fe 0.02 Zr 0.02 ) 8.0 , Sm(Co Bal Cu 0.06 Fe 0.22 Ti 0.16 ) 7.6 , Sm 0.8 Y 0.2 (Co Bal Cu 0.06 Fe 0.20 Nb 0.018 ) 7.8 , Sm 0.7 Ce 0.3 (Co bal Cu 0.06 Fe 0.24 Zr 0.02 ) 7.4 , and Sm 0.5 Pr 0.5 (Co bal Fe 0.3 Cu 0.07 Zr 0.02 ) 7.6 . The above mentioned rare-earth transition metal intermetallic compounds comprise a rare-earth metal, a transition metal, and a semi-metal or semiconductor element. Such rare-earth transition compound magnets are very active to oxygen, if their surface is exposed to an oxidizing atmosphere. In particular, R-Fe-B magnets comprising a rare-earth metal, iron and boron as the main ingredients, cause many problems. For instance when an R-Fe-B magnet is used in a motor, a relay or the like, oxide is produced and torn off. This oxide may cause troubles to such an extent that those magnets cannot be used in practice. EP-B-101552 describes R-Fe-B permanent magnets manufactured by a sintering method, however, does not mention any problem with respect to rust. To prevent rust, it is well known from JP-A-56-81908 to coat a rare-earth magnet with resin such as an epoxy resin. It is also known, however, that in this case, subtle pin holes occur in the plating or coating layer, and there is no way to avoid this. Therefore, there is the disadvantage that despite of the coating, rust may be generated as water enters through the pin holes of the plating or coating layer. The pin holes occur mainly due to the following reasons: 1) Because the magnets do not have a uniform plain or mirror surface but a subtly uneven surface or spaces between particles, the pin holes are generated in the layer deposited on a magnet. 2) The solvent in the plating solution or the coating solution remains in the coating layer, and is volatilized during the drying process. As a result, portions where such volatilization occurred, become pin holes. Such pin holes are not a big problem with prior art magnets such as Sm-Co including only a small amount of iron. On the contrary, prior art magnets comprising a rare-earth metal and iron have a large amount of iron and, thus, are apt to rust. Therefore, when such a magnet is used in a rotating machine such as a motor, a VCM (voice coil motor), a speaker or a relay to provide a magnetic circuit, generation of rust lowers its magnetic performance. The object of the present invention is to eliminate the above mentioned problems and to provide a rare-earth magnet having a superior corrosion and weathering resistance and a high strength. Another object of the invention is to prevent the surface of a rare-earth magnet from losing particles and becoming damaged. This object is achieved with rare-earth permanent magnets as claimed. According to the invention a rare-earth permanent magnet is coated with an organic resin having a water-proof property. The organic resin material includes fluoro-plastics and preferably consists of a mixture of fluoroplastics and at least of one of epoxy resin, polyester resin and phenol resin. The coating has a thickness of approximately 1 µm - 50 µm. The proportion of fluoroplastics in the organic resin material is approximately 2 - 70% by weight of the organic resin. It is also possible to coat the magnet with fluoroplastics alone. By the coating water is repelled and prevented from entering into pin holes. In one embodiment of the present invention, a powder bonded rare-earth permanent magnet comprises particles of a rare-earth magnet material and a thermosetting resin as a bonding material. This magnet is coated with fluoroplastics in a thickness of 1 - 50 µm. In accordance with the present invention, the above described coating of the magnets with an organic resin material can be performed by a physical or a chemical method. A rare-earth permanent magnet according to the present invention comprises an intermetallic compound comprising at least one rare-earth metal R, iron Fe and boron B, like Nd₁₅Fe₇₇B₈, Nd₁₅Fe₇₃Co₄B₈, Pr₁₅Fe₇₇B₈, Pr₁₅Fe₈₀B₅. Magnets of this material have a large saturation magnetization (4πIs) and a large anisotropic magnetic field (Ha), therefore these magnets have the best performance of all the magnets. The composition includes 8 - 18% by atomic of a rare-earth metal, 73 - 88% by atomic of a transition metal, and 4 - 9% by atomic of submetal or semiconductor element such as As, Sb, Bi, B, C, Si, P, Se. H-OH in water and iron (Fe) of the magnet cause a substitution reaction to form Fe(OH)₃. To prevent this substitution reaction, an organic coating layer having a water-proof property is formed on the magnets. The preferable thickness of the organic coating layer is more than 1 µm. The fluoroplastics preferably used in the first and second embodiments of the present invention are: 4-fluorinated ethylene resin (PTFE) (-CF₂-CF₂), a copolymer resin (PFA) of 4-fluorinated ethylene and per-fluoroalkoxyethylene (R f is an alkyl group) a copolymer resin (FEP) of 4-fluorinated ethylene and 6-fluorinated propylene a copolymer resin (EPE) of 4-fluorinated ethylene, 6-fluorinated propylene and per-fluoroalkoxyethylene a copolymer resin (ETFE) of 4-fluorinated ethylene and ethylene (-CF₂-CF₂)m(-CH₂-CH₂)n, a copolymer resin (PCTFE) of 3-fluorinated ethylene chloride (-CF₂-CFCl)n, or a copolymer resin (ECTFE) of 3-fluorinated ethylene chloride and ethylene (-CF₂-CFCl)m(-CH₂-CH₂)n, fluorinated vinyliden resin (PVDF) (-CF₂-CH₂)n, and fluorinated vinyl resin (PVE) (-CHF-CH₂)n. When the proportion of fluoroplastics (flourine resin) in the organic resin which further includes at least one of epoxy resin, polyester resin and phenol resin is less than 2% by weight, it is not possible to have a superior weathering resistance. When the proportion is more than 70% by weight, it is impossible to obtain a uniform mixture of the components resulting in an organic resin layer with an uneven surface and a low strength. Therefore, according to the present invention, the preferable proportion of fluorine resin is approximately 2 - 70% by weight of the organic resin. If the thickness of the coating layer is less than 1 µm, it is difficult to obtain reliability since the layer becomes uneven. However, if the thickness of the coating layer is more than 50 µm, forming of the layer takes a long time and requires high costs. Therefore, the preferable thickness of the coating layer is within the range of 1 µm - 50 µm. Fluoroplastics are inferior as regards their adherence to metal (where the magnet comprises an intermetallic compound), compared to other resins. In general, when metal is coated with fluoroplastics, it is heat treated at 100°C - 900°C to improve the adherence. However, the heat treatment of the magnet impaires its magnetic property to a great extent. According to the present invention, by mixing fluoroplastics with another resin and keeping the water-proof property, it is possible to obtain a high-performance magnet and yet to achieve sufficient adherence and durability of the coating. Some specific effects of the present invention are as follows: (1) When a rare-earth permanent magnet according to the present invention is used with speakers, motors, meters, or the like, it is possible to obtain a sufficient reliability for a long time and a sufficient stability. (2) It is possible to provide a magnetic circuit having a high accuracy and high efficiency. (3) It is possible to use the magnet even in a high temperature or corrosion promoting surrounding, thus, to broaden the field of application. (4) It is possible to prevent any magnetic particles from separating from the magnet. (5) It is possible to prevent any cracking of the magnet. (6) It is possible to enhance the stability and the resistance of the magnet in heat. (7) It is possible to enhance the strength of a device in which the magnet is used. The above and other objects, features and advantages of the present invention will become clearer from the following description of preferred examples. The following examples relate to powder bonded rare-earth permanent magnets, but the invention is also applicable to sintered rare-earth permanent magnets and cast rare-earth permanent magnets. Example 1 As the basic material for the magnet, the composition Nd₁₄Fe₈₀B₆ represented by the compound in terms of percentage was used. A thin film of this material obtained by a rapid-quenching thin film producing process was pulverized in a ball mill to obtain magnetic particles having a diameter of about 177 µm. The magnetic particles were sufficiently milled after 1-3% by weight of epoxy resin had been added thereto and the mixture was then pressed to obtain a predetermined molded body. The molded body was cured at a temperature of approximately 155°C for approximately one hour to become hard. The resulting powder bonded permanent magnet was coated with the respective coating materials indicated in table 1. The magnetic properties were as follows: (BH) max =7.6 (1/4π)kTA/cm, Br=5.9 10⁻¹T, iHc=15.4 (10/4π)·kA/cm, bHc=5.3 (10/4π)·kA/cm, density=6.3 (g/cm³). The samples 1 to 11 were exposed to a constant temperature of 60°C and a constant humidity of 95% for approximately 1500h. The magnetic properties and the appearance of the samples after that treatment are shown in table 2. In addition, as a comparative example, table 2 shows a magnet which had not been coated with a coating layer. As shown in table 2, since the coating layer of sample 1 has an amount of PTFE of less than 2% by weight, and the sample 11 has an amount of PTFE of more than 70% by weight, both samples exhibit a poor corrosion resistance. Sample No. Br (10⁻¹T) Magnetic properties (BH)max ((1/4π)kTA/cm) corrosion condition bHc ((10/4π)kA/cm) iHc ((10/4π)kA/cm) 1 5.4 4.9 14.9 6.6 [III] 2 5.6 5.0 15.0 7.0 [II] 3 5.3 4.8 14.8 6.5 [II] 4 5.7 5.3 15.3 7.5 [I] 5 5.6 5.1 15.2 7.5 [I] 6 5.7 5.2 14.8 7.6 [I] 7 5.7 5.1 15.1 7.4 [I] 8 5.8 5.2 15.2 7.6 [I] 9 5.7 5.2 15.1 7.5 [I] 10 5.7 5.2 15.3 7.5 [I] 11 5.4 4.8 14.8 6.5 [III] * 5.0 4.6 14.5 5.9 [IV] *comparative example [I]: no corrosion [II]: minimal corrosion [III]: partial corrosion [IV]: complete corrosion Example 2 In the same way as in example 1, powder bonded magnets were produced. These magnets were repeatedly coated with a fluoroplastic to a thickness of 0.5 µm, 1 µm, 10 µm, 30 µm, 50 µm and 70 µm, respectively. In a corrosion resistance test, the coated magnets were exposed to an atmosphere of a temperatur of about 60°C and a humidity of about 90%. Table 3 shows the rust condition of the magnets after 10, 100 and 500 h, respectively. Thickness of coating film Time 10 h 100 h 500 h 0.5 µm [III] [IV] [IV] 1.0 µm [II] [III] [IV] 10 µm [I] [I] [II] 30 µm [I] [I] [II] 50 µm [I] [I] [I] 70 µm [I] [I] [I] (Temperature: 60°C, Humidity: 90%) As apparent from Table 3, when the thickness of the coating layer is not more than 1 µm, it is impossible to obtain a corrosion resistance sufficient for practical use. If the thickness of the coating layer is more than 50 µm, it is possible to obtain a sufficient corrosion resistance without any corrosion. Example 3 Two solutions of fluoroplastics with different densities were prepared. A first powder bonded permanent magnet was coated with the solution having a higher density one time to obtain a coating layer having a higher thickness of about 10 µm . A second powder bonded permanent magnet was coated with the other solution three times to obtain a coating layer structure having a total thickness of about 10 µm. In a corrosion resistance test both magnets were exposed to an atmosphere of approximately 60°C and a humidity of approximately 95%. The rust condition of the magnets after 10, 100 and 500 h, respectively, revealed that by a repeated coating process a more superior corrosion resistance is achieved. Example 4 As the basic material for the magnet in this case, the composition Nd₁₃Fe₇₇Co₄B₈ represented by the compound in terms of percentage was used. A thin film of this material obtained by a rapid-quenching thin film producing process was pulverized in a ball mill to obtain magnetic particles having a diameter of less than 100 µm. The magnetic particles were sufficiently milled after 1-3% by weight of epoxy resin had been added thereto and the mixture was then pressed to obtain a predetermined molded body. The molded body was cured at a temperature of approximately 125°C for approximately one hour to obtain a powder bonded permanent magnet. The resulting powder bonded permanent magnet was coated with the respective coating materials indicated in Table 4. The magnetic properties were as follows: (BH) max =11.0 (1/4π)kTA/cm, Br=7.2 10⁻¹T iHc=9.8 (10/4π)·kA/cm, bHc=5.0 (10/4π)·kA/cm, density=6.4 (g/cm³). Samples 21 - 32 were exposed for about 1500 h to an atmosphere of a constant temperature of 60°C and a constant humidity of 95%. The magnetic properties and the appearance (corrosion condition) of the exposed samples after that treatment are shown in Table 5. In addition, a magnet which had not been coated is shown in Table 5 as a comparative example. Sample No. Br (10⁻¹T) Magnetic properties (BH)max ((1/4π)kTA/cm) corrosion condition bHc ((10/4π)kA/cm) iHc ((10/4π)kA/cm) 21 6.8 4.6 9.4 8.6 [III] 22 6.8 4.8 9.7 8.9 [II] 23 6.9 4.8 9.6 9.2 [II] 24 7.1 5.0 9.8 10.7 [I] 25 7.2 4.9 9.7 10.9 [I] 26 7.1 5.1 9.9 11.0 [I] 27 7.1 4.8 10.0 10.9 [I] 28 7.2 4.9 9.8 10.9 [I] 29 7.2 4.8 9.8 10.8 [I] 30 7.2 5.0 9.8 10.9 [I] 31 6.9 4.8 9.5 8.5 [III] * 6.5 4.5 9.2 7.9 [IV] *comparative example (Temperature: 60°C, Humidity: 95%) As shown in Table 4, the coating material of sample 21 has an PTFE content of less than 2% by weight whereas the coating material of sample 31 has an PTFE content of more than 70% by weight. As shown in Table 5, both samples 21 and 31 have a poor corrosion resistance. Example 5 In the same way as in example 4, powder bonded magnets were produced. These magnets were repeatedly coated with a fluoroplastic layer of a thickness of 0.5 µm, 1 µm, 10 µm, 30 µm, 50 µm and 70 µm, respectively. In a corrosion resistance test, the coated magnets were exposed to an atmosphere of a temperatur of about 60°C and a humidity of about 90%. Table 6 shows the rust condition of the magnets after 10, 100 and 500 h, respectively. Thickness of coating film Time 10 h 100 h 500 h 0.5 µm [III] [IV] [IV] 1.0 µm [II] [III] [IV] 10 µm [I] [I] [II] 30 µm [I] [I] [II] 50 µm [I] [I] [I] 70 µm [I] [I] [I] (Temperature: 60°C, Humidity: 90%) As apparent from Table 6, when the thickness of the coating layer is not more than 1 µm, it is impossible to obtain a corrosion resistance sufficient for practical use. If the thickness of the coating layer is more than 50 µm, it is possible to obtain a sufficient corrosion resistance without any corrosion. Example 6 As the basic material for the magnet in this case, the composition Nd₁₃Fe₇₄Co₇B₆ represented by the compound in terms of percentage was used. A thin film of this material obtained by a rapid-quenching thin film producing process was pulverized in a ball mill to obtain magnetic particles having a diameter of less than 120 µm. The magnetic particles were sufficiently milled after 1-3% by weight of epoxy resin had been added thereto and the mixture was then pressed to obtain a predetermined molded body. The molded body was cured at a temperature of approximately 160°C for approximately one hour to obtain a powder bonded permanent magnet. The resulting powder bonded permanent magnet was coated with the respective coating materials indicated in Table 7. The magnetic properties were as follows: (BH) max =11.5 (1/4π)kTA/cm, Br=7.4 10⁻¹T, iHc=9.4 (10/4π)·kA/cm, bHc=4.8 (10/4π)·kA/cm, density=6.6(g/cm³). Samples 41 - 51 were exposed for about 1500 h to an atmosphere of a constant temperature of 60°C and a constant humidity of 95%. The magnetic properties and the appearance (corrosion condition) of the exposed samples after that treatment are shown in Table 8. In addition, a magnet which had not been coated is shown in Table 8 as a comparative example. Sample No. Br (10⁻¹T) Magnetic properties (BH)max ((1/4π)kTA/cm) corrosion condition bHc ((10/4π)kA/cm) iHc ((10/4π)kA/cm) 41 6.9 4.7 8.5 9.6 [III] 42 7.0 4.7 8.9 10.0 [II] 43 6.9 4.7 8.8 10.4 [II] 44 7.4 4.9 9.1 11.4 [I] 45 7.3 4.8 9.0 11.5 [I] 46 7.4 4.8 8.9 11.3 [I] 47 7.4 4.9 9.2 11.3 [I] 48 7.4 4.9 9.1 11.2 [I] 49 7.4 4.8 9.1 11.4 [I] 50 7.4 4.8 9.2 11.4 [I] 51 7.1 4.7 8.9 10.5 [III] * 6.6 4.7 8.0 8.9 [IV] *comparative example (Temperature: 60°C, Humidity: 95%) As shown in Table 7, the coating material of sample 41 has an PTFE content of less than 2% by weight whereas the coating material of sample 51 has an PTFE content of more than 70% by weight. As shown in Table 8, both samples 41 and 51 have a poor corrosion resistance.

Claims: A rare-earth permanent magnet of the general formula R-Fe-B wherein R represents a rare earth metal, said magnet being coated with a waterproof organic resin coating having a thickness of more than 1 µm, characterized in that the organic resin of the coating includes a fluorine resin the amount of which being 2 to 70% by weight of the total resin composition. The magnet of claim 1, wherein the fluorine resin is selected from the group consisting of 4-fluorinated ethylene resin; a copolymer resin of 4-fluorinated ethylene and perfluoroalkoxyethylene; a copolymer resin of 4-fluorinated ethylene and 6-fluorinated propylene; a copolymer resin of 4-fluorinated ethylene, 6-fluorinated propylene and per-fluoroalkoxyethylene; a copolymer resin of 4-fluorinated ethylene and ethylene; a copolymer resin of 3-fluorinated ethylene chloride; a copolymer resin of 3-fluorinated ethylene chloride and ethylene; fluorinated vinylidene resin; fluorinated vinyl resin and mixtures thereof. The magnet of claim 1 or 2, wherein the organic resin of the coating includes said fluorine resin mixed with a second organic resin selected from the group consisting of epoxy resins, polyester resins, acrylic resins, phenol resins and mixtures thereof. The magnet of any of claims 1 to 3, wherein the coating has a thickness of no more than 50 µm. The magnet of any of claims 1 to 4, wherein the permanent magnet member is a powder bonded magnet. The magnet of any of claims 1 to 4, wherein the permanent magnet member is a sintered magnet. The magnet of any of claims 1 to 4, wherein the permanent magnet member is a cast magnet. The magnet of claim 5, wherein the powder bonded permanent magnet is selected from the group consisting of rare-earth transition metal intermetallic compounds; and intermetallic compounds including at least one rare-earth metal in an amount between about 8 and 18 atomic percent, iron or other transition metal in an amount between about 73 and 88 atomic percent and boron or other sub-metal or semiconductor element in an amount between about 4 and 9 atomic percent. The magnet of claim 5, wherein the powder bonded permanent magnet member is obtainable by: pulverizing a magnetic alloy composition to obtain magnetic particles; mixing the magnetic particles with a thermosetting resin to obtain a mixture; press molding the mixture to obtain a bonded magnet; and hardening the powder bonded magnet. The magnet of claim 9, wherein the thermosetting resin is an epoxy resin.

Inventors: OKONOGI, ITARU, OTA, MASAHIRO, SAKURAI, MITSURU, SHIOHARA, YUKIHIKO
Applicants: SEIKO EPSON CORPORATION
Application year: 1988
Main classification: H01F1
IPC codes: H01F41, H01F1