Rare earth bonded magnet, rare earth magnetic composition, and method for manufacturing rare earth bonded magnet

Abstract: A rare earth bonded magnet comprising a rare earth magnet powder bonded with a binder resin is manufactured by extrusion or injection molding. A rare earth bonded magnet manufactured by extrusion molding has a rare earth magnet powder content of 78.1 to 83.0 percent by volume. A rare earth bonded magnet manufactured by injection molding has a rare earth magnet powder content of 68.0 to 76.0 percent by volume. A rare earth bonded magnet is manufactured by kneading a rare earth magnetic composition comprising a rare earth magnet powder and a thermoplastic resin, and by extruding or injecting the mixture after kneading. A rare earth magnetic composition used for extrusion molding contains a rare earth metal powder of 77.6 to 82.5 percent by volume, and a rare earth magnetic composition used for injection molding contains a rare earth metal powder of 67.6 to 75.5 percent by volume. Thereby, a rare earth bonded magnetic showing excellent moldability and magnetic properties and high mechanical strength at a minimum binding resin can be obtained.

Description: The present invention relates to a rare earth bonded magnet comprising rare earth magnet powder bonded with a resin, a rare earth magnetic composition which is used for the production of the rare earth bonded magnet, and a method for manufacturing the rare earth bonded magnet using the rare earth magnetic composition. Generally, rare earth bonded magnets of various shapes are molded from compounds of rare earth magnet powders and binder resins or organic binders by applying pressure molding, such as compaction molding, injection molding, or extrusion molding. In compaction molding, a bonded magnet is produced by packing a compound into a mold, compacting it to form a green body, and then heating it to harden a thermosetting binder resin. Since the compaction molding method enables molding with a smaller amount of binder resin compared with other molding methods, the magnetic properties of the resulting magnet are enhanced. However, molding versatility with respect to the shape of the magnet is restricted and production efficiency is low. In injection molding, a bonded magnet is produced by melting a compound and then injecting the flowable melt into a mold of a specified shape. The molding versatility with respect to the shape of the magnet is high with this injection molding method, and magnets having irregular shapes can be easily produced. However, since injection molding requires a high level of melt fluidity, a large amount of binder resin must be added. Thus, the binder resin content in the magnet is correspondingly high, resulting in poorer magnetic properties. In extrusion molding, a bonded magnet is produced by melting a compound fed into an extruder, extruding and cooling the compound from a die of the extruder to a long molded body, and then cutting the long body into specified lengths. The extrusion molding method has advantages of both compaction molding and injection molding. That is, in extrusion molding, the shape of the magnet can be varied to some extent by using an appropriate die, and a thin-walled or long magnet can be easily produced. Further, the resulting magnet shows enhanced magnetic properties due to the reduced amount of binder resin because high fluidity of the melt is not required, unlike the injection molding. Thermosetting resins, such as epoxy resins, have been generally employed as binder resins in compounds, as disclosed in JP-B-56-31841 and JP-B-56-44561. The content of the thermosetting resins is low from 0.5 to 4.0 percent by weight due to its high fluidity. However, there are many points which are not clarified concerning optimum conditions for molding using thermoplastic resins as binder resins, e.g. the effect of the rare earth magnet powder content on the moldability, magnetic properties, and mechanical properties of the bonded magnet. Document EP-A-0 605 934 discloses that compositions of which the content of the magnetic material is 65% or more in volume ratio are desirable. This document, however, is silent about the void ratio being also relevant for achieving good modability. It is a first object of the present invention to provide a rare earth bonded magnet which can be easily manufactured in various shapes and which has excellent magnetic properties and a high mechanical strength, a rare earth magnetic composition for manufacturing the magnet, which shows excellent moldability while containing a minimum amount of thermoplastic binder resin and, and a method for manufacturing the magnet utilizing the above-mentioned advantages of the extrusion molding process. This object is achieved with the subject-matter as set forth in the claims. It is a second object of the present invention to provide a rare earth bonded magnet which can be easily manufactured in various shapes and which has excellent magnetic properties and a high mechanical strength, a rare earth magnetic composition for manufacturing the magnet, which shows excellent moldability while containing a minimum amount of thermoplastic binder resin and, and a method for manufacturing the magnet utilizing the above-mentioned advantages of the injection molding. Preferred embodiments of the invention are subject-matter of the dependent claims. A rare earth bonded magnet showing a small void ratio, a high mechanical strength, and excellent magnetic properties can be easily produced from such a composition showing high fluidity, excellent moldability, and suppressed oxidation of the magnet powder in the extrusion molding process. These and other objects, features, and advantages of the invention will become more apparent from the following description of preferred embodiments. Fig. 1 is an isometric view of an embodiment of a rare earth bonded magnet in accordance with the present invention. A rare earth bonded magnet, a rare earth magnetic composition, and a method for manufacturing the rare earth bonded magnet in accordance with the present invention will now be described in detail with reference to the drawing. It should be understood that the description herein is intended for both extrusion molding and injection molding unless the molding method is specified. Examples of the rare earth bonded magnet in accordance with the present invention include a rod shaped bonded magnet 1 as shown in Fig. 1A, a cylindrical bonded magnet 2 as shown in Fig. 1B, and an arch shaped bonded magnet 3 as shown in Fig. 1C. The rare earth bonded magnets 1, 2, 3 comprise a rare earth magnet powder and a thermoplastic resin as set forth below, and further comprise an antioxidant if necessary. 1. Rare Earth Magnet Powder It is preferred that the rare earth magnet powder comprises an alloy of one or more rare earth elements and one or more transition metals. Preferable examples of such an alloy are as follows: [1] A Sm-Co alloy comprising, as main ingredients, Sm (one or more other rare earth elements may additionally be included in which case Sm has the highest proportion among the rare earth elements) and one or more transition metals including Co; [2] an R-Fe-B alloy comprising, as main ingredients, R (R represents at least one of rare earth elements including Y), Fe as transition metal (one or more other transition metals may additionally be included in which case Fe has the highest proportion among the transition metals), and B; [3] a Sm-Fe-N alloy comprising, as main ingredients, Sm (one or more other rare earth elements may additionally be included in which case Sm has the highest proportion among the rare earth elements), Fe (one or more other transition metals may additionally be included in which case Fe has the highest proportion among the transition metals), and N (one or more other interstitial elements may additionally be included in which case N has the highest proportion among the interstitial elements); [4] a nano-crystalline magnet comprising R wherein R is at least one rare earth element including Y and one or more transition metals containing Fe as the main ingredient and having magnetic phases in the size of nanometers; [5] a mixture of at least two of these alloys [1] through [4] set forth above. In this case, a rare earth magnet powder showing excellent magnetic properties can be easily obtained by a combination of advantages, and in particular, advantages on magnetic properties, of the mixed magnetic powders. The degree of orientation of the magnet improves by mixing at least two anisotropic magnet powders. Typical examples of Sm-Co alloy include SmCo 5 , Sm 2 TM 17 , wherein TM represents a transition metal. Typical examples of the R-Fe-B alloy include Nd-Fe-B, Pr-Fe-B, Nd-Pr-Fe-B, Ce-Nd-Fe-B, Ce-Pr-Nd-Fe-B, and modified alloys thereof in which Fe is partly substituted with other transition metals, such as Ni and Co. A typical example of the Sm-Fe-N alloy is Sm 2 Fe 17 N 3 prepared by nitriding a Sm 2 Fe 17 alloy. Examples of rare earth elements in the magnet powder include Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, and Mischmetal. The magnet powder may include one or more of these elements. Examples of transition metals include Fe, Co and Ni. The magnet powder may include one or more of these metals. The magnet powder may further comprise B, Al, Mo, Cu, Ga, Si, Ti, Ta, Zr, Hf, Ag and Zn, if necessary, to improve magnetic properties. Although the average particle diameter of the magnet powder is not restricted, it ranges preferably from approximately 0.5 to 50 µm and more preferably from approximately 1 to 30 µm. The particle diameter may be determined with a F.S.S.S. (Fischer Sub-Sieve Sizer), for example. It is preferred that the magnet powder has a relatively wide particle diameter distribution to achieve excellent moldability with a small amount of binder resin during injection molding or extrusion molding. In this case, the void ratio (ratio of voids to total volume) in the resulting bonded magnet can be decreased. In the mixture [5] set forth above, each constituent powder may have a different average particle diameter. When at least two kinds of magnetic powders having different average particle diameters are used, smaller diameter particles can be easily packed between larger diameter particles after thorough mixing and kneading of the powders. Thus, the packing rate of the magnet powder in the compound can be raised, resulting in improved magnetic properties. The magnet powder can be produced by any conventional methods, e.g. milling, followed by screening if necessary, of an alloy ingot prepared by melting and casting, into a proper particle size range; and milling, followed by screening if necessary, of a melt spun ribbon comprising a fine polycrystalline texture which is made with a melt spinning apparatus for the amorphous alloy production. The preferred content of magnetic powder in the bonded magnet depends on the molding method: In the rare earth bonded magnet manufactured by extrusion molding, the content of the rare earth magnet powder ranges from approximately 78.1 to 83 percent by volume, preferably from approximately 79.5 to 83 percent by volume, and more preferably from approximately 81 to 83 percent by volume. In the rare earth bonded magnet manufactured by injection molding, the content of the rare earth magnet powder ranges from approximately 68 to 76 percent by volume, preferably from approximately 70 to 76 percent by volume, and more preferably from approximately 72 to 76 percent by volume. In both cases, extrusion molding and injection molding, if the content of the rare earth magnet powder is too low the magnetic properties, especially the magnetic energy product, are not excellent, whereas if the content is too high the correspondingly low content of binder resin decreases the fluidity during extrusion/injection molding, rendering the molding difficult or even impossible. 2. Binder Resin Binder resins used in accordance with the present invention are thermoplastic resins. When thermosetting resins, e.g. epoxy resins, which are conventional binder resins, are used, the fluidity in the extrusion or injection molding process is poor, resulting in poor moldability, an increased void ratio of the magnet, low mechanical strength, and decreased corrosion resistance. In contrast, thermoplastic resins do not cause such problems. Examples of usable thermoplastic resins include polyamides, e.g. nylon 6, nylon 12, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, nylon 6-12, and nylon 6-66; liquid crystal polymers, e.g. thermoplastic polyimides, and aromatic polyesters; polyphenylene oxides; polyphenylene sulfides; polyolefins, e.g. polyethylenes, and polypropylenes; modified polyolefins; polycarbonates; polymethyl methacrylate; polyethers; polyether ketones; polyether imides; polyacetals; and copolymers, mixtures, and polymer alloys containing the above as the main ingredient. These resins may be used alone or in combination. Among them, thermoplastic resins containing polyamides, liquid crystal polymers and/or polyphenylene sulfides, as main ingredients, are preferably used, because they have excellent kneadability with the magnet powder, excellent moldability, and high mechanical strength. In particular, polyamides significantly improve moldability, and liquid crystal polymers and polyphenylene sulfide can improve heat resistance. A most suitable thermoplastic resin can be selected freely from the above resins by determining the kind of resin, and/or by copolymerizing the resin, for example, in consideration of moldability, heat resistance, or mechanical strength. Thermoplastic resins preferably used have a melting point of 400 °C or less, and more preferably, 300 °C or less. When thermoplastic resins having a melting point over 400 °C are used, the magnet powder is readily oxidized because of the higher molding temperature. It is preferred that thermoplastic resins used have an average molecular weight ranging from 10,000 to 60,000, and more preferably, from 12,000 to 30,000. 3. Antioxidant The antioxidant is an additive added to the composition in accordance with the present invention to prevent the oxidation, deterioration, or modification of the rare earth magnet powder, and the oxidation of the binder resin, which may be caused by a catalytic action of the metal component in the rare earth magnet powder, during kneading the rare earth magnetic composition. The addition of the antioxidant will result in the following advantages. First, the antioxidant can prevent the rare earth magnet powder and the binder resin from oxidizing. Thus, the excellent wettability between the rare earth magnet powder surface and binder resin can be maintained, resulting in an improved kneadability between the rare earth magnet powder and the binder resin. Second, since the antioxidant can prevent the rare earth magnet powder from oxidizing, it improves magnetic properties of the magnet, and thermal stability of the rare earth magnetic composition during kneading and molding, and excellent moldability can be achieved with a smaller amount of binder resin. Since the antioxidant is evaporated or decomposed during the kneading and molding steps of the rare earth magnetic composition, the manufactured rare earth bonded magnet contains a part of the antioxidant as a residue. Thus, the antioxidant content in the rare earth bonded magnet generally ranges from approximately 10 to 90 percent, and in particular from 20 to 80 percent of the amount added to the rare earth magnetic composition. The antioxidant also improves the corrosion resistance of the resulting magnet, in addition to preventing oxidation of the rare earth magnet powder and binder resin in the manufacturing process of the magnet. Any conventional antioxidants which can prevent or reduce the oxidation of the rare earth magnet powder and the binder resin, can be used. Examples of preferred antioxidants include chelating agents, such as amines, amino acids, nitrocarboxylic acids, hydrazines, cyanides, and sulfides, which inactivate the surface of the rare earth magnet powder. Such chelating agents have a significantly high antioxidant action. The kind and content of the antioxidant are not limited to the above. The rare earth bonded magnet may further comprise a plasticizer, e.g. stearate salts, and fatty acids, for plasticizing the binder resin; a lubricant, e.g. silicone oils, waxes, fatty acids, and inorganic lubricants such as alumina, silica and titania; and other additives, such as a molding activator. When at least one of a plasticizer and lubricant is added, the fluidity further improves during kneading of the rare earth magnetic composition and molding the rare earth bonded magnet. It is preferred that the void ratio of the rare earth bonded magnet in accordance with the present invention is 2 percent by volume or less, and more preferably, 1.5 percent by volume. An excessive void ratio may cause a decrease in mechanical strength and corrosion resistance, depending on the composition and content of the thermoplastic resin, the composition and particle size of the magnet powder, and the like. Both isotropic and anisotropic rare earth bonded magnets in accordance with the present invention show excellent magnetic properties, due to the composition of the magnet powder and a high content of the magnet powder. The rare earth bonded magnet manufactured by extrusion molding has a magnetic energy product (BH) max of 8 MGOe (64 kJ/m 3 ) or more, and in particular, 9.5 MGOe (76 kJ/m 3 ) or more, when it is molded with no magnetic field applied, or a magnetic energy product (BH) max of 12 MGOe (96 kJ/m 3 ) or more, and in particular, 14 MGOe (112 kJ/m 3 ) or more, when it is molded under a magnetic field. The shape and size of the rare earth bonded magnet in accordance with the present invention are not limited. For example, the rare earth bonded magnet can have a variety of shapes, such as hollow or solid prismatic or plate shape, as well as a rod, cylindrical or arch shape as shown in Fig. 1. The size can be varied from a large size to an ultra small size. Rare Earth magnetic Composition The rare earth magnetic composition in accordance with the present invention comprises the rare earth magnet powder and the thermoplastic resin which are set forth above. Preferably, the rare earth magnetic composition further comprises the antioxidant set forth above. The rare earth magnet powder content in the rare earth magnetic composition is determined in consideration of magnetic properties of the resulting rare earth bonded magnet and the fluidity of the melt composition during molding. In the rare earth magnetic composition used for extrusion molding, the content of the rare earth magnet powder in the composition ranges preferably from approximately 77.6 to 82.5 percent by volume, and more preferably from approximately 79 to 82.5 percent by volume. In the rare earth magnetic composition used for injection molding, the content of the rare earth magnet powder in the composition ranges preferably from approximately 67.6 to 75.5 percent by volume, and more preferably from approximately 69.5 to 75.5 percent by volume. In both cases, extrusion molding and injection molding, if the content of the rare earth magnet powder is too low the magnetic properties, especially the magnetic energy product, are not excellent, whereas if the content is too high the correspondingly low content of binder resin decreases the fluidity during extrusion/injection molding, rendering the molding difficult or even impossible. The rare earth magnetic composition discussed herein results in the magnets discussed above. The slightly higher magnet powder content of the magnets compared to that of the composition is due to some loss of additives during manufacturing, in particular evaporation during kneading. The contents of the thermoplastic resin and antioxidant in the rare earth magnetic composition may vary with the kind and composition of the resin and antioxidant, molding conditions such as temperature and pressure, and the shape and size of the molded body. In order tp enhance magnetic properties of the resulting rare earth bonded magnet, it is preferred that the thermoplastic resin is added in an amount as small as possible but enough for the kneading and molding to be carried out. The antioxidant content in the rare earth magnetic composition ranges preferably from approximately 2.0 to 12.0 percent by volume, and more preferably from approximately 3.0 to 10.0 percent by volume. Preferably, the antioxidant is added in an amount of 10 to 150 percent of the binding resin added, and more preferably 25 to 90 percent. However, in the present invention, an antioxidant content of less than the lower limit set forth above can be allowable, and the addition of the antioxidant is not always essential. When the thermoplastic resin content in the rare earth magnetic composition is too low, the viscosity of the mixture of the rare earth magnetic composition increases, resulting in increased torque during kneading and accelerated oxidation of the magnet powder due to heat generation. Thus, the oxidation of the magnet powder cannot be suppressed at a low antioxidant content. Further, since the moldability is not so good due to the increased viscosity of the mixture (resin melt), a magnet having a small void ratio and a high mechanical strength cannot be obtained. On the other hand, when the thermoplastic resin content is too high, the magnetic properties decrease, although moldability improves. When the antioxidant content in the rare earth magnetic composition is too low, the antioxidant action is insufficient at a high magnet powder content to suppress the oxidation of the magnet powder. On the other hand, too high an antioxidant content may decrease the mechanical strength of the molded body due to the relatively low resin content. As set forth above, the antioxidant content can be reduced when a relatively high amount of thermoplastic resin is added, whereas the antioxidant content must increase at a lower thermoplastic resin content. When it is used for extrusion molding, it is preferred that the total content of the thermoplastic resin and antioxidant ranges from 15.0 to 22.4 percent by volume, more preferably from 15.0 to 20.5 percent by volume, and most preferably from 15.0 to 18.5 percent by volume of the rare earth magnetic composition. When it is used for injection molding, it is preferred that the total content of the thermoplastic resin and antioxidant ranges from 24.5 to 32.4 percent by volume, more preferably from 24.5 to 30.5 percent by volume, and most preferably from 24.5 to 28.0 percent by volume of the rare earth magnetic composition. In such ranges, fluidity, moldability, and the antioxidant effect of the magnetic composition improve, resulting in a magnet having a small void ratio, a high mechanical strength, and excellent magnetic properties, in both extrusion and injection molding. The rare earth magnetic composition may contain various additives set forth above, if necessary. The plasticizer and lubricant are preferably added to improve fluidity during molding and to achieve excellent properties with a smaller binder resin content. Preferably, the plasticizer content ranges from 0.1 to 2.0 percent by volume and the lubricant content ranges from 0.2 to 2.5 percent by volume, to maximize advantages by the addition of such additives. The rare earth magnetic composition can have various forms, for example, a mixture of a rare earth magnet powder and a thermoplastic resin, a mixture of the above with other additives such as an antioxidant, as-kneaded mixtures thereof, and pelletized mixture thereof having a pellet size of 1 to 12 mm. When these mixtures or pellets thereof are used, moldability further improves in extruding and injection molding. Moreover, the use of pellets causes improved handling. The mixtures set forth above can be kneaded with a roll mill, kneader, or twin-screw extruder, for example. The kneading temperature can be determined depending on the composition and characteristics of the thermoplastic resin used, and preferably is a temperature higher than its thermal deformation temperature or softening temperature (softening point or glass transition temperature). When using a thermoplastic resin having a relatively low melting point, the kneading temperature is preferably a temperature near or higher than the melting point of the thermoplastic resin. When kneading is carried out at such a temperature, the mixture can be homogeneously kneaded at a shorter time period due to the enhanced kneading efficiency. Further, in order to decrease the void ratio of the rare earth bonded magnet, the kneading process is very critical because the rare earth magnet powder particles are completely surrounded by the thermoplastic resin through this process. Preferred examples for manufacturing the rare earth bonded magnet in accordance with the present invention will now be explained. The rare earth bonded magnet in accordance with the present invention can be manufactured using the rare earth magnetic composition set forth above by extrusion or injection molding as set forth below. [I] Extrusion Molding A rare earth magnetic composition (mixture) comprising a rare earth magnet powder, a thermoplastic resin and, optionally, an antioxidant is kneaded thoroughly with a kneading machine set fort above to prepare the kneaded mixture. The kneading temperature can be determined to be 150 to 350 °C, for example, in consideration of the parameters set forth above. The kneaded mixture may be pelletized before the use. The rare earth magnetic composition after kneading is melted in a cylinder in an extruder by heating it up to a temperature higher than the melting point of the thermoplastic resin, and is extruded from an extruding die under a magnetic field (for example, under an alignment field of 10 to 20 kOe (8 to 16 kA/cm)) or no magnetic field. Preferably, the temperature of the material in the cylinder ranges from approximately 20 to 330 °C, the extruding speed ranges from approximately 0.1 to 10 mm/sec, and the temperature of the mold ranges from approximately 200 to 350 °C. The molded body is cooled to solidify while being extruded from the die, for example. The long molded body is then cut into a rare earth bonded magnets having a specified shape and size. The cross-sectional shape of the rare earth bonded magnet is determined by the shape of the extruding die (inside die and outside die), and rare earth bonded magnets having a thin-walled or irregular shape can be easily manufactured. Further, a long rare earth bonded magnet can be manufactured by adjusting the cutting length. A rare earth bonded magnet suitable for mass production can be continuously produced with high versatility on shape, excellent fluidity and moldability even at a smaller resin content, and a high dimensional precision. [II] Injection molding A rare earth magnetic composition (mixture) comprising a rare earth magnet powder, a thermoplastic resin and, optionally, an antioxidant is kneaded thoroughly with a kneading machine set forth above to prepare the kneaded mixture. The kneading temperature can be determined to be 150 to 350 °C, for example, in consideration of the parameters set forth above. The kneaded mixture may be pelletized before the use. The rare earth magnetic composition after kneading is melted in a cylinder in an injection molding machine by heating to a temperature higher than the melting point of the thermoplastic resin, and injected into a mold under a magnetic field or no magnetic field (for example, an alignment field of 6 to 18 kOe (5 to 10 kA/cm)). It is preferred that the temperature in the cylinder ranges from approximately 220 to 350 °C, the injection pressure ranges from approximately 30 to 100 kgf/cm 2 (3 to 10 MPa), and the mold temperature ranges from approximately 70 to 100 °C. The molded body is cooled to solidify to obtain a rare earth bonded magnet having a specified shape and size. Preferably the molded body is cooled for approximately 5 to 30 seconds. The shape of the rare earth bonded magnet is determined by the injection mold, and the rare earth bonded magnet having a thin wall thickness or irregular shape can be readily manufactured by selecting the shape of the mold. A rare earth bonded magnet suitable for mass production can be continuously produced with a short molding cycle, higher versatility on shape than that in extrusion molding, excellent fluidity and moldability even at a smaller resin content, and a high dimensional precision. Mixing conditions and molding conditions other than those set forth above can be employed in the method for manufacturing the rare earth bonded magnet in accordance with the present invention. EXAMPLES The present invention will now be illustrated with reference to Examples. EXAMPLES 1 to 13 and COMPARATIVE EXAMPLES 1 and 2 Various mixtures having the compositions set forth in Table 1 were obtained from seven kinds of rare earth magnet powders, (1) through (7), each having a composition set forth below, three thermoplastic binder resins A, B and C, N,N-diphenyl oxamide as an antioxidant or chelating agent, a metal soap as a plasticizer and a fatty acid as a lubricant. Each mixture was kneaded with a screw kneader under the conditions set forth in Tables 2 and 3, and the resulting rare earth magnetic composition (compound) was subjected to a molding process under the conditions set forth in Tables 2 and 3 to obtain a rare earth bonded magnet. The shape, size, composition, visual appearance, and various properties of each resulting magnet are summarized in Tables 4 through 6. Rare Earth Magnet Powders (1) Quenched Nd 12 Fe 82 B 6 powder (average diameter: 18 µm) (2) Quenched Nd 8 Pr 4 Fe 82 B 6 powder (average diameter: 17 µm) (3) Quenched Nd 12 Fe 78 Co 4 B 6 powder (average diameter: 19 µm) (4) Sm(Co 0.604 Cu 0.06 Fe 0.32 Zr 0.016 ) 8.3 powder (average diameter: 21 µm) (5) Sm 2 Fe 17 N 3 powder (average diameter: 2 µm) (6) Anisotropic Nd 13 Fe 69 Co 11 B 6 Ga 1 powder by H.D.D.R. method (average diameter: 28 µm) (7) Nano-crystalline Nd 5.5 Fe 66 B 18.5 Co 5 Cr 5 powder (average diameter: 15 µm) Thermoplastic Binder Resins A. Polyamide (nylon 12), melting point: 175 °C B. Liquid crystal polymer, melting point: 180 °C C. Polyphenylene sulfide (PPS), melting point: 280 °C The mechanical strength in Tables 4 through 6 was determined by a shearing-by-punching method using a test piece of 15 mm in outside diameter and 3 mm in height, which was molded by an extrusion molding process under the conditions set forth in Tables 2 and 3, under no magnetic field. The corrosion resistance in Tables 4 through 6 was evaluated by accelerated test of the resulting rare earth bonded magnet at 80 °C and 90% RH. Results were classified into four grades, i.e., A (excellent), B (good), C (not so good), and D (no good), based on the time period after which rust was first observed. COMPARATIVE EXAMPLE 3 A rare earth bonded magnet was prepared as follows: The magnet powder (1) set forth above and an epoxy resin as a thermosetting resin were mixed in amounts as shown in Table 1, the mixture was kneaded at room temperature, the resulting compound was subjected to a compaction molding process under conditions shown in Table 3, and the molded body was heated at 150 °C for 1 hour to cure the thermosetting resin. The shape, size, composition, visual appearance, and various properties of resulting magnet are shown in Table 6. The mechanical strength shown in Table 6 was evaluated by a shearing-by-punching method of a test piece having an outer diameter of 15 mm and a height of 3 mm, which is obtained by compaction molding under the conditions in Table 6 under no magnetic field. The corrosion resistance was evaluated by a method identical to the one explained above. EXAMPLES 14 to 26, and COMPARATIVE EXAMPLES 4 to 6 Various mixtures having the compositions set forth in Table 7 were obtained from seven kinds of rare earth magnet powders, (1) through (7) each having a composition set forth below, the three thermoplastic binder resins A, B and C set forth above, a hydrazine antioxidant or chelating agent, zinc stearate as a plasticizer and a silicone oil as a lubricant. Each mixture was kneaded with a screw kneader under the conditions set forth in Tables 8 and 9, and the resulting rare earth magnetic composition (compound) was subjected to a molding process under the conditions set forth in Tables 8 and 9 to obtain a rare earth bonded magnet. The shape, size, composition, visual appearance, and various properties of each resulting magnet are summarized in Tables 10 through 12. Rare Earth Magnet Powders (1) Quenched Nd 12 Fe 82 B 6 powder (average diameter: 19 µm) (2) Quenched Nd 8 Pr 4 Fe 82 B 6 powder (average diameter: 18 µm) (3) Quenched Nd 12 Fe 78 Co 4 B 6 powder (average diameter: 20 µm) (4) Sm(Co 0.604 Cu 0.06 Fe 0.32 Zr 0.016 ) 8.3 powder (average diameter: 22 µm) (5) Sm 2 Fe 17 N 3 powder (average diameter: 2 µm) (6) Anisotropic Nd 13 Fe 69 Co 11 B 6 Ga 1 powder by H.D.D.R. method (average diameter: 30 µm) (7) Nano-crystalline Nd 5.5 Fe 66 B 18.5 Co 5 Cr 5 powder (average diameter: 15 µm) The mechanical strength in Tables 10 through 12 was determined by a shearing-by-punching method using a test piece of 15 mm in outside diameter and 3 mm in height, which was molded by an injection molding process under the conditions set forth in Tables 8 and 9, under no magnetic field. The corrosion resistance was evaluated by a method identical to the one explained above. Discussion of Results As shown in Tables 4 through 6 and 10 through 12, rare earth bonded magnets of EXAMPLES 1 through 26 showed excellent moldability, a small void ratio, a high mechanical strength, excellent magnetic properties such as magnetic energy product, and high corrosion resistance. In contrast, in COMPARATIVE EXAMPLES 1 and 4, the respective rare earth magnetic compositions were not able to be kneaded because of excessive rare earth magnet powder contents. In COMPARATIVE EXAMPLES 2 and 5, the respective rare earth magnetic compositions were not able to be molded because of an excessive rare earth magnet powder content, although kneading was successfully carried out. In COMPARATIVE EXAMPLE 3, the resin discharged on the surface of the magnet. In COMPARATIVE EXAMPLE 6, the rare earth bonded magnet showed a poor magnetic energy product because of an extremely small amount of the rare earth magnet powder, although molding was successfully carried out. As set forth above, a rare earth bonded magnet in accordance with the present invention showing excellent moldability, high corrosion resistance and mechanical strength, and excellent magnetic properties at a minimum binder resin content can be provided, while utilizing advantages of the extrusion molding process, i.e., high versatility of magnet shape and size, a high size precision, and high productivity suitable for mass production. Further, a rare earth bonded magnet in accordance with the present invention showing excellent moldability, high corrosion resistance and mechanical strength, and excellent magnetic properties at a minimum binder resin content can be provided, while utilizing advantages of the injection molding process, i.e., high versatility on magnet shape and size, a high size precision, and a short molding cycle. Composition [vol%] Composition [vol%] Example 1 Magnetic powder (1) 77.6 Example 9 Magnetic powder (4): 40 Polyamide 22.4 Magnetic powder (6): 40 Polyamide: 12.5 Antioxidant: 6.1 Lubricant: 1.4 Example 2 Magnetic powder (2) 79 Example 10 Magnetic powder (3): 81.5 Polyamide 16 PPS 9.7 Antioxidant 5.0 Antioxidant: 7.0 Lubricant: 1.4 Plasticizer: 0.4 Example 3 Magnetic powder (3) 80.5 Example 11 Magnetic powder (4): 40 Polyamide 12.3 Magnetic powder (5): 20 Antioxidant 6.0 Magnetic powder (6): 20 Lubricant 1.2 PPS 12.1 Antioxidant: 6.5 Lubricant: 1.4 Example 4 Magnetic powder (3) 82.5 Example 12 Magnetic powder (4): 42 Polyamide 9.0 Magnetic powder (5): 20 Antioxidant 6.5 Magnetic powder (6): 20 Lubricant 1.5 Liquid crystal polymer: Plasticizer 0.5 Antioxidant: 10 Lubricant: 6.4 1.6 Example 5 Magnetic powder (4) 82.5 Example 13 Magnetic powder (1): 60 Polyamide 11.5 Magnetic powder (7): 22.5 Antioxidant 4.5 Polyamide: 9.0 Lubricant 1.2 Antioxidant: 6.5 Plasticizer 0.3 Lubricant: 1.5 Plasticizer: 0.5 Example 6 Magnetic powder (5) 81 Comparative Magnetic powder (1): 84 Polyamide 10 Example 1 Polyamide: 16 Antioxidant 6.5 Lubricant 1.8 Plasticizer 0.7 Example 7 Magnetic powder (4) 60 Comparative Magnetic powder (1): 84 Magnetic powder (5) 22.5 Example 2 Polyamide: 10 Polyamide 10.3 Antioxidant: 5 Antioxidant 5.5 Lubricant: 1.0 Lubricant 1.2 Plasticizer 0.5 Example 8 Magnetic powder (2) 80 Comparative Magnetic powder (1): 80 Liquid crystal polymer 12.5 Example 3 Epoxy resin: 20 Antioxidant 6.0 Lubrican 1.5 Kneading Conditions Molding Conditions Temperature [°C] Length [cm] Method Material Temperature in Cylinder [°C] Die Temperature [°C] Alignment Field [kOe] (x0.8kA/cm) Example 1 230 25 Extrusion 240 250 none Example 2 230 25 Extrusion 240 250 none Example 3 230 30 Extrusion 240 250 none Example 4 230 35 Extrusion 240 250 none Example 5 230 35 Extrusion 240 250 15 Example 6 230 30 Extrusion 240 250 15 Example 7 230 35 Extrusion 240 250 15 Example 8 250 35 Extrusion 270 275 none Kneading Conditions Molding Conditions Temperature [°C] Length [cm] Method Material Temperature in Cylinder [°C] Die Temperature [°C] Alignment Field [kOe] (x0.8kA/cm) Example 9 230 30 Extrusion 240 250 18 Example 10 300 35 Extrusion 320 320 none Example 11 300 35 Extrusion 320 320 18 Example 12 250 30 Extrusion 270 275 18 Example 13 230 35 Extrusion 240 250 none Comparative Example 1 230 40 Extrusion 240 - none Comparative Example 2 230 40 Extrusion 240 250 none Comparative Example 3 Room temperature - Compaction Pressure: 7t/cm 2 (69kN/cm 2 ) Room temperature none Composition [vol%] Composition [vol%] Example 14 Magnetic powder (1) 67.6 Example 22 Magnetic powder (4) 50 Polyamide 32.4 Magnetic powder (6) 25 Polyamide 18 Antioxidant 6 Lubricant 1.0 Example 15 Magnetic powder (2) 70 Example 23 Magnetic powder (3) 72 Polyamide 24 PPS 18 Antioxidant 6 Antioxidant 7.5 Lubricant 1.7 Plasticizer 0.8 Example 16 Magnetic powder (3) 72 Example 24 Magnetic powder (4) 55 Polyamide 20 Magnetic powder (5) 10 Antioxidant 6.5 Magnetic powder (6) 5 Lubricant 1.5 PPS 22.5 Antioxidant 7.5 Example 17 Magnetic powder (3) 75 Example 25 Magnetic powder (4) 50 Polyamide 15.5 Magnetic powder (5) 12 Antioxidant 7 Magnetic powder (6) 10 Lubricant 1.8 Liquid crystal polymer 19.5 Plasticizer 0.7 Antioxidant 7.5 Plasticizer 1.0 Example 18 Magnetic powder (4) 75 Example 26 Magnetic powder (3) 55 Polyamide 18 Magnetic powder (7) 20 Antioxidant 5 Polyamide 15.5 Lubricant 1.5 Antioxidant 7 Plasticizer 0.5 Lubricant 1.8 Plasticizer 0.7 Example 19 Magnetic powder (5) 72 Comparative Magnetic powder (1) 80 Polyamide 19 Example 4 Polyamide 20 Antioxidant 6 Lubricant 2.0 Plasticizer 1.0 Example 20 Magnetic powder (4) 57 Comparative Magnetic powder (1) 78 Magnetic powder (5) 18 Example 5 Polyamide 16 Polyamide 17 Antioxidant 6 Antioxidant 5.5 Lubricant 1.0 Lubricant 1.8 Plasticizer 0.7 Example 21 Magnetic powder (2) 70 Comparative Magnetic powder (2) 55 Liquid crystal polymer 23.5 Example 6 Polyamide 45 Antioxidant 5.5 Lubricant 1.0 Kneading Conditions Molding Conditions Tempe rature [°C] Length [cm] Method Cylinder Temperature [°C] Injection Pressure [kgf/cm 2 ] (x0.1MPa) Mold Temperature [°C] Alignment Field [kOe] (x0.8kA/cm) Example 14 230 20 Injection 260 50 90 none Example 15 230 20 Injection 260 50 90 none Example 16 230 25 Injection 260 50 90 none Example 17 230 30 Injection 260 60 90 none Example 18 250 30 Injection 300 60 90 15 Example 19 240 35 Injection 270 60 90 15 Example 20 250 25 Injection 290 60 90 15 Example 21 250 25 Injection 280 70 90 15 Kneading Conditions Molding Conditions Tempe rature [°C] Length [cm] Method Cylinder Temperature [°C] Injection Pressure [kgf/cm 2 ] (x0.1MPa) Mold Temperature [°C] Alignment Field [kOe] (x0.8kA/cm) Example 22 240 25 Injection 290 60 90 18 Example 23 300 30 Injection 320 80 90 none Example 24 300 30 Injection 320 80 90 18 Example 25 250 25 Injection 280 70 90 18 Example 26 230 20 Injection 260 50 90 none Comp. Example 4 230 30 Injection Keading impossible none Comp. Example 5 230 30 Injection Molding impossible none Comp. Example 6 230 10 Injection 260 40 90 none

Claims: A rare earth bonded magnet comprising a rare earth magnet powder and a thermoplastic resin, wherein the content of the rare earth magnet powder in the rare earth bonded magnet ranges from 78.1 to 83 percent by volume, and wherein the rare earth bonded magnet has a void ratio of 2 percent by volume or less, and said rare earth magnet powder comprises at least one selected from the group consisting of: a first composition comprising, as main ingredients, one or more rare earth elements mainly including Sm and one or more transition metals mainly including Co; a second composition comprising, as main ingredients, R (representing at least one of rare earth elements including Y), one or more transition metals mainly including Fe, and B; and a third composition comprising, as main ingredients, one or more rare earth elements mainly including Sm, one or more transition metals mainly including Fe, and one or more interstitial elements mainly Including N. The magnet according to claim 1, wherein either the magnet is magnetically isotropic and the magnetic energy product (BH)max is 8 MGOe (64 kJ/m 3 ) or more, or the magnet is magnetically anisotropic and the magnetic energy product (BH)max is 12 MGOe (96 kJ/m 3 ) or more. The magnet according to any one of the preceding claims, wherein said thermoplastic resin has a melting point of 400 °C or less. The magnet according to any one of the preceding claims, wherein said thermoplastic resin is a resin selected from polyamide resins, liquid crystal polymers, and polyphenylene sulfide resins. The magnet according to any one of the preceding claims, wherein said rare earth magnet powder comprises at least two rare earth magnet powders having different compositions and/or different average particle diameters. A method of manufacturing a rare earth bonded magnet as defined in claim 1, comprising preparing a rare earth magnetic composition comprising a rare earth magnet powder, an antioxidant, and a thermoplastic resin, wherein the content of said rare earth magnet powder ranges from 77.6 to 82.5 and the content of said antioxidant from 2.0 to 12.0 percent by volume of said rare earth magnetic composition, and extrusion molding the rare earth magnetic composition, wherein said rare earth magnet powder comprises at least one selected from the group consisting of: a first composition comprising, as main ingredients, one or more rare earth elements mainly including Sm and one or more transition metals mainly including Co; a second composition comprising, as main ingredients, R (representing at least one of rare earth elements including Y), one or more transition metals mainly including Fe, and B; and a third composition comprising, as main ingredients, one or more rare earth elements mainly including Sm, one or more transition metals mainly including Fe, and one or more interstitial elements mainly including N. The method according to claim 7, wherein said antioxidant is a chelating agent for inactivating the surface of the magnet powder. The method according to claim 7 or 8, wherein said rare earth magnetic composition further comprises at least one of a plasticizer and a lubricant. The method according to claim 7, 8 or 9, wherein the total content of said thermoplastic resin and said antioxidant ranges from 15.0 to 22.4 percent by volume of said rare earth magnetic composition.

Inventors: AKIOKA KOJI, IKUMA KEN, NAKAMURA YOSHIKI, SHIRAI HAYATO, TAKEI MITSURU, AKIOKA, KOJI, IKUMA, KEN, NAKAMURA, YOSHIKI, SHIRAI, HAYATO, TAKEI, MITSURU
Applicants: SEIKO EPSON CORP, SEIKO EPSON CORPORATION
Application year: 1996
Main classification: H01F41
IPC codes: H01F1