Patent ID: 6978533

Claim:
A method for manufacturing an arc-shaped rare earth-iron bond magnet having a weight of not more than 0.5 g and a thickness of less than 1 mm, the method comprising the steps of: (1) grinding rare earth-iron melt-spun flakes to a diameter not greater than 150 μm; (2) forming a granular compound by blending the rare earth-iron melt-spun flakes not greater than 150 μm in diameter with an epoxy oligomer and a stabilized isocyanate curing agent; (3) grinding and classifying the granular compound to have a particle diameter of less than 250 μm; (4) dry blending the granular compound having a particle diameter of less than 250 μm with fatty acid metallic soap powder; (5) compressing a powder comprising the blend of the granular compound and the fatty acid metallic soap powder in a an arc-shaped mold to form a compressed powder; and (6) heat-treating the compressed powder to form the arc-shaped rare earth-iron bond magnet having a weight of not more than 0.5 g and a thickness of less than 1 mm.