Magnet regeneration to form ND-FE-B magnets with improved or restored magnetic performance.

Abstract

The present invention provides a method, system, and apparatus for regenerating magnetic materials to restore or improve their magnetic properties, including a computer program encoded on a computer storage medium. [Solution] One method includes the steps of: demagnetizing a magnetic material derived from a waste magnet assembly by periodic heating and cooling of the magnetic material, fragmenting the adhesive adhering to the magnetic material, cracking the coating layer of the magnetic material, and removing the coating layer by performing at least one of (a) mechanical treatment or (b) chemical treatment on the magnetic material to prepare an impurity-free magnetic material; fragmenting the demagnetized magnetic material to form a powder; and mixing the powder with a rare earth material R and elemental additive A to produce a homogeneous powder. The rare earth material R comprises at least one of Nd or Pr, and the elemental additive A comprises at least one of Nd, Pr, Dy, Co, Cu, and Fe.

Description

[Technical Field]

[0001] (background) This disclosure relates to the production of neodymium iron boron (Nd-Fe-B) sintered magnets from waste magnet materials. To relate to. [Background technology]

[0002] The global market for rare-earth permanent magnets (REPMs) is growing along with the range of applications for REPMs. REPMs are It possesses high magnetic performance characteristics and is used in electronics, energy, transportation, aerospace, and defense. Advances in highly efficient applications of advanced technologies in many industries, including medical devices and information and communication technology. It is used for [this purpose].

[0003] For example, applications using Nd-Fe-B permanent magnets include: starting motors and anti-lock brakes. Key system (ABS), fuel pump, fan, loudspeaker, microphone, telephone Ringers, switches, relays, hard disk drives (HDDs), stepping motors Servo motors, magnetic resonance imaging (MRI), wind turbine generators, robotics, sensors, magnetism Examples include sorting machines, guidance systems, satellites, and cruise missiles.

[0004] Nd-Fe-B type sintered magnets have a very finely tuned elemental composition, and this elemental composition is N In addition to d, it contains elements such as Dy, Tb, Ga, Co, Cu, Al, and other trace transition metal element additives. nothing. [Overview of the project] [Means for solving the problem]

[0005] (overview) In general, an innovative aspect of the subject matter described herein is the magnetic material derived from a discarded magnet assembly. Demagnetize the ferromagnetic material by periodic heating and cooling of the ferromagnetic material, fragment the adhesive attached to the ferromagnetic material, crack the coating layer of the ferromagnetic material, and subject the ferromagnetic material to at least one of (a) mechanical processing or (b) chemical processing to remove the coating layer to prepare a ferromagnetic material free of impurities; an action of fragmenting the demagnetized ferromagnetic material into powder ; and an action of mixing the powder with (a) rare earth material R and (b) elemental additive A to produce a homogeneous powder, wherein the rare earth material R can include at least one of (a) Nd or (b) Pr, and the elemental additive A can include at least one of (a) Nd, (b) Pr, (c) Dy, (d) Co , (e) Cu, and (f) Fe. The method can be embodied to include this action. Other embodiments of this aspect include corresponding computer systems, devices, and computer programs recorded on one or more computer storage devices configured to perform the actions of this method. One or more computer systems can be configured to perform specific operations or actions by having software, firmware, hardware, or combinations thereof installed on the system that cause the system to perform the actions during operation. One or more computer programs can be configured to perform specific operations or actions by including instructions that cause the device to perform the actions when executed by a data processing device. The foregoing and other embodiments can each optionally include one or more of the following features alone or in combination

[0006] It may be included. This method may include performing fragmentation and mixing simultaneously. Demagnetized magnetic material The step of fragmenting may include fragmenting the demagnetized magnetic material to an average particle size of 1 to 4 μm The step of fragmenting the demagnetized magnetic material may include removing particles of a particle fraction having a size larger than the average size of the particles in the demagnetized magnetic material from the demagnetized magnetic material to obtain a low oxygen concentration in the demagnetized magnetic material The step of removing particles of a particle fraction having a size larger than the average size of the particles in the demagnetized magnetic material from the demagnetized magnetic material to obtain a low oxygen concentration in the demagnetized magnetic material may include sieving to obtain a low oxygen concentration in the demagnetized magnetic material may include sieving The step of removing particles of a particle fraction having a size larger than the average size of the particles in the demagnetized magnetic material from the demagnetized magnetic material to obtain a low oxygen concentration in the demagnetized magnetic material may include sieving in the demagnetized magnetic material may include sieving

[0007] In some embodiments, this method may include mixing a homogeneous powder with another element selected from rare earth material R or elemental additive A This method may include removing a coating layer by at least one of (a) mechanical treatment or (b) chemical treatment of the magnetic material to prepare a magnetic material free of impurities to prepare a magnetic material free of impurities This method may include separating a waste magnet portion from a non-magnet portion included in the magnet assembly from one or more magnetic assemblies of the magnetic material and recovering the waste magnet portion by extracting the waste magnet portion from the non-magnet portion and recovering the waste magnet portion by extracting the waste magnet portion from the non-magnet portion The step of fragmenting the demagnetized magnetic material to form a powder may include fragmenting the demagnetized magnetic material to form a powder having an average particle size of about 1 μm to about 2 mm This method may include further fragmenting the powder to an average particle size of about 1 to about 4 μm and homogenizing the powder This method may include further fragmenting the powder to an average particle size of about 1 to about 4 μm and homogenizing the powder The step of homogenizing the powder may include homogenizing a powder that may have an average particle size of about 1 μm to about 2 mm and the powder may be (a) rare earth material R and (b) have an average particle size of about 1 μm to about 2 mm and the powder may be (a) rare earth material R and (b) The step of mixing with elemental additive A to produce a homogeneous powder has an average particle size of approximately 1 to 4 μm. The powder is mixed with (a) a rare earth material R and (b) elemental additive A to produce a homogeneous powder. It may contain p. The powder is mixed with (a) rare earth material R and (b) elemental additive A to produce a homogeneous powder. The steps involve (a) a rare earth material R and (b) a powder having an average particle size of approximately 1 μm to approximately 2 mm. The process may include a step of mixing with elemental additive A to produce a homogeneous powder, and further homogenizing the powder. The step may include homogenizing a powder that may have an average particle size of approximately 1 to 4 μm.

[0008] In some implementations, this method involves the step of fragmenting the demagnetizing magnetic material to form a powder. The process separately includes the step of fragmenting the rare earth material R and elemental additive A, wherein the powder is ( a) The step of mixing rare earth material R and (b) elemental additive A to produce a homogeneous powder is said to be The end is mixed with (a) the fragmented rare earth material R and (b) the fragmented elemental additive A and then equalized. The process may include a step of producing a high-quality powder.

[0009] In some implementations, this method involves sintering and magnetizing a homogeneous powder, and then discarding the magnet assembly. Recycled Nd-Fe-B magnet products having at least the same residual magnetism and coercivity as the original discarded magnet parts. This may include the step of forming a homogeneous powder by sintering and magnetizing it to form a recycled Nd-Fe-B magnet product. The step involves compressing the homogeneous powder to form a green compact. The steps are: 1) sintering the compacted powder at approximately 1000°C to approximately 1100°C, and 2) heating the sintered compacted powder at a temperature below 15°C. This method may include the step of magnetizing the regenerated Nd-Fe-B magnet product in an active atmosphere. This involves a step in which the sintered powder compact is heat-treated at approximately 490°C to approximately 950°C before magnetizing it. This method may include the step of exposing the compacted powder to an inert magnetic field at a temperature of less than 15°C. The atomic percentage of Co in recycled Nd-Fe-B magnet products can be 3% or less. Recycled Nd-F The atomic percentage of Cu in eB magnet products can be 0.3% or less. (Recycled Nd-Fe-B magnets) The total atomic percentage of Fe and Co in the product can be 77% or less. (Made from recycled Nd-Fe-B magnets) The total atomic percentage of Nd, Pr, and Dy in the product is the same as that of waste magnet parts derived from waste magnet assemblies. The total atomic percentage of Nd, Pr, and Dy can be greater than or equal to the total atomic percentage of Nd. The total atomic percentage of Dy and Pr can be 18 at% or less. This method produces a homogeneous mixture. The process may include adding a lubricant to the powder before compressing it to form a compact. The coercivity of raw Nd-Fe-B magnet products is higher than the coercivity of the waste magnet portion derived from the waste magnet assembly. It can be increased by approximately 0 to 20%.

[0010] In some implementations, this method involves sintering and magnetizing a homogeneous powder to obtain the final residual magnetism and final The steps may include forming a recycled Nd-Fe-B magnet product having coercivity, wherein the final residual magnetism is This is approximately 97% of the residual magnetism of the waste magnet portion derived from the waste magnet assembly, and the final coercivity. The degree is at least 30% higher than the coercivity of another part of the discarded magnet. This method uses homogeneous powder By sintering and magnetizing, recycled Nd-Fe-B magnet products with final residual magnetism and final coercivity are formed. This step may include determining whether the final residual magnetism is derived from the waste magnet assembly or from the waste magnet portion. It is approximately 95% of the residual magnetism, and the final coercivity is less than the coercivity of the other part of the discarded magnet. It is at least 80% higher. This method involves sintering and magnetizing a homogeneous powder to obtain the final residual magnetism and final The steps may include forming a recycled Nd-Fe-B magnet product having coercivity, wherein the final residual magnetism is It is approximately 5% higher than the residual magnetism of other waste magnet portions derived from the waste magnet assembly, and the final The magnetic field is at least the same as the coercivity of another part of the discarded magnet.

[0011] In some implementations, this method involves sintering and magnetizing a homogeneous powder, which is substantially W a R b A c composition The steps may include forming a recycled Nd-Fe-B magnet product having, where W is a waste magnet assembly. It may contain Nd-Fe-B material derived from buri, where subscripts a, b, and c represent the atomic hundredth of the corresponding component or element. This represents a fraction. The powder is mixed with (a) rare earth material R and (b) elemental additive A to produce a homogeneous powder. The step involves homogeneously distributing the rare earth material R and the elemental additive A within the demagnetizing magnetic material. The process may include steps such as sintering and magnetizing a homogeneous powder to form a recycled Nd-Fe-B magnet product. The step involves the primary Nd2Fe in the recycled NdFe-B magnet product. 14 The concentration of the rare earth material R around phase B and the step of forming a recycled Nd-Fe-B magnet product in which the concentration of elemental additive A has increased on average. This may include the step of forming a recycled Nd-Fe-B magnet product, which may spread throughout the recycled Nd-Fe-B magnet product. A step to restore the average concentration and elemental composition of the grain boundary phase in multiple grain boundary regions where the grain boundary is affected. This may include steps to change and steps to improve. 81≦a≦99.9, 0.1≦b≦19, 3- 81×a(Co)≦c(Co)≦3-99.9×a(Co), 0.3-81×a(Cu)≦c(Cu)≦0.3-99.9×a( Cu), 77-81×(a(Fe)+a(Co))≦c(Fe)≦77-99.9×(a(Fe)+a(Co)), a( Nd)+b(Nd)+c(Nd)+a(Pr)+b(Pr)+c(Pr)>0, a(Nd)+b(Nd)+c(Nd) +a(Pr)+b(Pr)+c(Pr)+a(Dy)+b(Dy)+c(Dy)≦18, a(Co)+b(Co)+c (Co)≦3, a(Cu)+b(Cu)+c(Cu)≦0.3, a(Fe)+b(Fe)+c(Fe)+a(Co)+b (Co)+c(Co)≦77, and b(Nd)+c(Nd)+b(Pr)+c(Pr)+b(Dy)+c(Dy)≧0 Recycled Nd-Fe-B magnet products are Nd[0.1-19at%×s(Nd), x]Pr[0.1-19at%×s( The equation can satisfy [Pr], [y]Dy[0.1-19%×s(Dy)], [z]Co[0, d]Cu[0, e]Fe[0, f], and formula In [m, n], the range is from the smallest m to the largest n; s(t) is the element in the initial composition. f(t) is the atomic percentage of element t in the final composition; x = 18 - [81, 99.9]at%×(s(Nd)+s(Pr)+s(Dy));y=18-[81, 99.9]at%×(s(Nd)+ s(Pr)+s(Dy));z=18-[81, 99.9]at%×(s(Nd)+s(Pr)+s(Dy));d=3 -[81, 99.9]at%×s(Co);e=0.3-[81, 99.9]at%×s(Cu);and f=77-[81, 99.9% at% × (s(Fe) + s(Co)).

[0012] In some implementations, magnetic materials derived from discarded magnet assemblies are subjected to periodic heating of the magnetic material and The step of demagnetizing by cooling demagnetizes the waste magnet portion derived from the waste magnet assembly. The adhesive used to bond the discarded magnetic portion, which may contain the magnetic material, to the non-magnetic portion is fragmented. The discarded magnet portion is coated with electrolytic black epoxy, Ni, Ni-Cu, Ni-Ni, Ni-Cu-Ni, or Zn. The process may include the step of cracking at least one coating layer selected from the layers. Periodic heating and cooling is a step of heating the magnetic material to the Curie temperature of the rare earth material R. And after the rare earth material R reaches its Curie temperature, the magnetic material is subjected to a ray at least 100°C / second. The step of cooling in a cooler may include mixing the powders with at least three of them. The step may include mixing with the elements: Pr, Nd, Dy, Co, Cu, or Fe. Elemental additive A is, It may contain pure Nd. Elemental additive A may contain pure Pr. This method fragments the demagnetizing magnetic material. The process may include the step of adding a lubricant to the powder before proceeding.

[0013] In general, an innovative aspect of the subject matter described herein is specific to a recycled Nd-Fe-B sintered magnet. It can be converted, and the recycled Nd-Fe-B sintered magnet is W a R b A c It may have the following composition, in which waste material W This may include materials derived from discarded Nd-Fe-B sintered magnets, and the rare earth material R is a small amount of (a) Nd or (b) Pr. It may contain at least one element, and elemental additive A is (a) Nd, (b) Pr, (c) Dy, (d) Co, (e (f)Cu or (f)Fe may comprise at least one of the above, and the subscripts a, b, and c are the corresponding components. This represents the atomic percentage of a fraction or element, and 81 ≤ a ≤ 99.9, 0.1 ≤ b ≤ 19, and 3 - 81 × a(Co) ≤ c(Co) )≦3-99.9×a(Co), 0.3-81×a(Cu)≦c(Cu)≦0.3-99.9×a(Cu), 77-81×(a (Fe) + a(Co) ≤ c(Fe) ≤ 77 - 99.9×(a(Fe) + a(Co)), a(Nd) + b(Nd) + c (Nd) + a(Pr) + b(Pr) + c(Pr) > 0, a(Nd) + b(Nd) + c(Nd) + a(Pr) + b(Pr ) + c(Pr) + a(Dy) + b(Dy) + c(Dy) ≤ 18, a(Co) + b(Co) + c(Co) ≤ 3, a(Cu ) + b(Cu) + c(Cu) ≤ 0.3, a(Fe) + b(Fe) + c(Fe) + a(Co) + b(Co) + c(Co) ≤ 77, and b(Nd) + c(Nd) + b(Pr) + c(Pr) + b(Dy) + c(Dy) ≥ 0 satisfy the values to have.

[0014] Generally, an innovative aspect of the subject matter described herein can be embodied in a recycled Nd-Fe-B sintered magnet, and the recycled Nd-Fe-B sintered magnet can have a composition of WR a R b A c where the waste material W can include materials derived from waste Nd-Fe-B sintered magnets, the rare earth material R can include at least one of (a) Nd or (b) Pr, and the elemental additive A can include at least one of (a) Nd, (b) Pr, (c) Dy, (d) Co, (e) Cu , or (f) Fe, and the subscripts a, b, and c represent the atomic percentages of the corresponding components or elements, and have values satisfying Nd[0.1 - 19 at%×s(Nd), x]Pr[0.1 - 19 at%×s(P r), y]Dy[0.1 - 19%×s(Dy), z]Co[0, d]Cu[0, e]Fe[0, f], where [m, n] means the range from the minimum m to the maximum n; s(t) is the atomic percentage of element t in the starting composition ; f(t) is the atomic percentage of element t in the final composition; x = 1 r), y]Dy[0.1 - 19%×s(Dy), z]Co[0, d]Cu[0, e]Fe[0, f] to have values satisfying, where [m, n] means the range from the minimum m to the maximum n; s(t) is the atomic percentage of element t in the starting composition ; f(t) is the atomic percentage of element t in the final composition; x = 1 8-[81, 99.9]at%×(s(Nd)+s(Pr)+s(Dy));y=18-[81, 99.9]at%×(s (Nd)+s(Pr)+s(Dy));z=18-[81, 99.9]at%×(s(Nd)+s(Pr)+s(Dy) );d=3-[81, 99.9]at%×s(Co);e=0.3-[81, 99.9]at%×s(Cu);and f=7 7 - [81, 99.9] at% × (s(Fe) + s(Co)).

[0015] Each of the above and other embodiments may optionally include one or more of the following features individually or in combination. It may contain both. The rare earth material R and elemental additive A are homogeneously distributed in the recycled Nd-Fe-B sintered magnet. This can be done, thereby the concentration of the rare earth material R and the concentration of the elemental additive A can be adjusted. Primary Nd2Fe in raw Nd-Fe-B sintered magnets 14 It rises on average in the mixture of waste material W surrounding phase B. The first atomic percentage of waste material W can be approximately 99.9 at% to approximately 81 at%, and rare earth material The second atomic percentage of the combination of R and elemental additive A can be set to approximately 0.1 at% to approximately 19 at%. Recycled Nd-Fe-B sintered magnets may have an average particle size of less than 5 μm. Recycled Nd-Fe-B sintered magnets It may have an average particle size of less than 2.5 μm. Recycled Nd-Fe-B sintered magnets have a density of approximately 7.56 g / cm³. 3 ~Approx. 7.6g / cm 3 It may have a density of .

[0016] In some implementations, recycled Nd-Fe-B sintered magnets may have an atomic percentage of Co of 3% or less. Nd-Fe-B sintered magnets may have an atomic percentage of Cu of 0.3% or less. Regenerated Nd-Fe-B sintered magnets are 7 It may have a total atomic percentage of Fe and Co of 7% or less. Recycled Nd-Fe-B sintered magnets have Nd of 18% or less. It may have a total atomic percentage of Dy and Pr. Elemental additive A may contain pure Nd. Elemental additive A This may include pure Pr.

[0017] In general, an innovative aspect of the subject matter described herein uses recycled Nd-Fe-B sintered magnets. This can be embodied in a system for recovering used products, and this system is used The system receives the product and defines a recess for aligning the used product with the positioning mechanism. The positioning mechanism wherein the used product includes a discarded Nd-Fe-B sintered magnet, The mechanism, and when the positioning mechanism passes each used product through the separation station, The portion of the used product containing the Nd-Fe-B sintered magnet is substantially separated from the rest of the used product. The separation station for separating the used products, and the positioning mechanism for transporting each used product, are located in a transport station. When moved to the positioning, the portion of the used product, including the discarded Nd-Fe-B sintered magnet, is positioned Includes the transport station that receives the transport from the organization.

[0018] Each of the above and other embodiments may optionally include one or more of the following features individually or in combination. This system may include loading stations and used products. The loading station can be equipped with a loading device for inserting the load into its positioning mechanism. The loading device separates the used product from the rest of the product at the separation station. The orientation of the used product is aligned with the positioning mechanism, and the used Nd-Fe-B sintered magnet is also used. The product parts can be positioned. The loading device is equipped with a robot. This is possible. The loading device can be equipped with a feeder. The transport station is , at least some of the used products, including the NdFe-B sintered magnets, are disposed of. It can be equipped with a recycling bin that receives from a placement mechanism.

[0019] In some implementations, the transport station handles used products, including discarded Nd-Fe-B sintered magnets. The device is equipped with an instrument for removing the min from the remaining portion of the used product. It can have a curved surface. This device can be equipped with an abrasive cutter. can.

[0020] In some implementations, the transport station is used equipment, including discarded Nd-Fe-B sintered magnets. Once the removal of the product portion from the rest of the used product is complete, at least one Recycling bins that accept used product parts, including Nd-Fe-B sintered magnets, for disposal of used products. The transport station is equipped with equipment for handling used products, including discarded Nd-Fe-B sintered magnets. Once the process of removing the min from the remaining portion of the used product is complete, at least a portion of the used The system includes a conveyor that receives used product parts, including discarded Nd-Fe-B sintered magnets. It is possible. The transport station is used products, including discarded Nd-Fe-B sintered magnets. Once the removal of that portion from the rest of the used product is complete, at least some Equipped with a chute to receive waste products, including Nd-Fe-B sintered magnets. It is possible to obtain it.

[0021] In some implementations, the system includes a base supporting the positioning mechanism and waste Nd-Fe-B sintered material. A transport station that allows parts of used products, including magnets, to fall into the recycling bin. The base of the unit has holes. The system uses at least some of the used products. A disposal station can be provided to remove the remaining portion of the used product from the positioning mechanism. The waste station may be equipped with waste bins. The positioning mechanism is the central axis It rotates to the center and moves used products between the separation station and the transport station. The system can include a base that supports the positioning mechanism. The system supports the positioning mechanism and reduces friction between the base and the positioning mechanism. It may include bearings positioned on the base.

[0022] In some implementations, the separation station uses a plasma cutter, water jet, and blade. It can be equipped with a cutter, a band saw, and a shearing machine. The positioning mechanism is a loading machine. A rotating platform is defined with multiple recesses that each receive one of the used products at the storage station. The system can be equipped with a filter vent to remove waste particles from the system. The system may be equipped with an inertial force filter to remove waste particles from the system. The system may be equipped with additional devices. The system is designed to discharge contaminants from the system. It can be equipped with a component. The system is a part of used products, including discarded Nd-Fe-B sintered magnets. The portion of the used product, including the discarded Nd-Fe-B sintered magnets, is received from the transport station. It can be equipped with a heater that heats the magnetic material to a temperature higher than its Curie temperature. The system rapidly cools the portion of the used product containing the waste Nd-Fe-B sintered magnet, and then disposes of the waste Nd-Fe-B Each sub-sub It can be equipped with a cooler that facilitates separation from Swertia japonica. The cooler is made of waste Nd-Fe-B A portion of the used product, including the sintered magnet, was heated to a temperature higher than the Curie temperature of the magnetic material. Later, the used product portion, including the discarded Nd-Fe-B sintered magnet, can be rapidly cooled to 5°C. ru.

[0023] In general, an innovative aspect of the subject matter described herein is a waste disposal system comprising multiple reaction vessels. This can be embodied in a gas mixing apparatus for fragmenting and mixing magnetic materials, and the multiple reactions Each container may have an inner liner with a plurality of openings defined, Each iner receives magnetic material and gases around the magnetic material through the multiple openings. The pump and valve assembly are configured to facilitate the circulation of the multiple reaction vessels. To control the introduction of gas into the reaction vessels and to control the transfer of gas between the multiple reaction vessels, the multiple It is operably coupled to several reaction vessels.

[0024] Each of the above and other embodiments may optionally include one or more of the following features individually or in combination. It may include multiple reaction vessels, each defined by a diffusion facilitator. The diffusion promoting device may be equipped with holes, and the diffusion promoting device may be equipped with a pump and a valve It is configured to be operably coupled to Swertia japonica and to facilitate the dispersion of the gas throughout the reaction vessel. Each of the multiple reaction vessels may be equipped with a removable lid. Pump and valve assembly: Evacuation of reaction vessels by vacuum pump; gas from one of the reaction vessels One or more of the following: discharge into the atmosphere; pressurization of the reaction vessel; and filling one or both of the reaction vessels with gas. To enable this, it can be operably coupled to multiple reaction vessels. The apparatus is gas Pumps and valve assemblies for automating the mixing process and the transfer of gases between reaction vessels. It may be equipped with a control device that is operably coupled.

[0025] In some implementations, the apparatus includes a gas storage chamber, which is a reaction vessel. Before transferring to the other side, the gas transferred from one side of the reaction vessel is configured to be stored. Yes. This gas can be hydrogen, or a mixture of hydrogen and an inert gas. One or more The reaction vessels are configured to facilitate the flow of gas into each of the reaction vessels. A circulation promoting device may be provided. The circulation promoting device may be an agitator, a fan, or a gas supply device. It may be equipped with one of the following: Each of the multiple reaction vessels may be a reaction vessel and a pump and valve A separate gas supply line may be provided connected to the assembly. The device can be configured to produce powder with a particle size of 1 to 10 μm from waste magnetic material.

[0026] In general, an innovative aspect of the subject matter described herein involves fragmenting and mixing waste magnets. This is embodied in a hydrogen mixing apparatus for forming the optimal powder and / or hydride blend. The apparatus can be configured to include a pair of reaction chambers, and connected to the pair of reaction chambers, The gas management component interconnects the pair of reaction chambers, The unit transfers gas between the pair of reaction chambers and presses one of the reaction chambers to a target pressure. It is configured to apply pressure to force.

[0027] Each of the above and other embodiments may optionally include one or more of the following features individually or in combination. It may include the following. The gas control component controls the introduction of gas into a pair of reaction chambers. Furthermore, in order to control the transfer of gas between the pair of reaction chambers, It may include a pump and valve assembly that is operably coupled. At the very least, one of the chambers may be equipped with a thermostat-controlled heater. The apparatus includes a trolley assembly configured to be received in one of a pair of reaction chambers. The trolley assembly may include one or more bottles containing waste magnetic material. This is possible. The trolley assembly may have a removable cover. The bottle is It may be equipped with a removable cover, which can be recovered after the hydrogen mixing process. It is configured to function as a funnel that allows the hydride magnetic particles to be guided through a chute. One or more of the bottles are equipped with a device that facilitates the diffusion of gas within the bottle. This device allows the gas to reach the waste magnetic material contained in the bottle. The device may include a cylinder with an opening on its side that allows for the diffusion of the gas.

[0028] The subject matter described herein is expressed in certain embodiments in order to achieve one or more of the following advantages. It can be implemented. In some implementations, the regeneration process has low energy consumption and Low consumption of unused materials. In some implementations, recycled Nd-Fe-B magnets are used in the final product, Fulden. Without reducing the magnetic performance and achievable values ​​of Nd-Fe-B sintered magnets, economically and / or environmentally friendly. Boundary costs can be reduced. In some implementations, recycled Nd-Fe-B magnet products are used instead of unused Nd-Fe-B magnets. It may have performance equivalent to or better than Fe-B magnets. In some implementations, recycled Nd-Fe-B magnet products This can contain as much as 99.9% of the waste-start magnetic material used to form recycled magnets.

[0029] Details of one or more embodiments of the subject matter of this specification are shown in the accompanying drawings and the following description. Other features, aspects, and advantages of the subject matter are evident from the description, drawings, and claims. It will probably happen. [Brief explanation of the drawing]

[0030] (Brief explanation of the drawing) [Figure 1A-C] Figures 1A to 1C show an example of a separator.

[0031] [Figure 2] Figure 2 shows an example of a furnace that processes a magnet or magnet assembly for demagnetization and removes the assembly from the EOL magnet.

[0032] [Figure 3A] Figure 3A shows an example of an abrasive jet cleaning device for cleaning magnets.

[0033] [Figure 3B] Figure 3B shows an example of a hydrogen mixing reactor that decomposes waste magnetic material into particles and mixes these particles.

[0034] [Figure 4A-EHJ] Figures 4A to 4E, 4H, and 4J show reaction bottles that can be mounted on a trolley to allow them to be moved in and out of the reaction chamber.

[0035] [Figure 4F-G] Figures 4F to 4G show an example of another hydrogen mixed reactor equipped with a pair of reaction chambers.

[0036] [Figure 4K] Figure 4K shows an example of a storage container for magnetic particles received from the bottle.

[0037] [Figure 5] Figure 5 shows an example of a process for recovering waste magnets and magnetic materials from products, such as "bulk" products (manufacturing "bulk"), failed / rejected / excess batches, and / or end-of-life products, to achieve target properties.

[0038] [Figure 6] Figure 6 is a graph showing an example of the characteristic range of starting materials for recycled magnets, available as bulk and / or EOL magnets.

[0039] [Figure 7] Figure 7 compares the composition of the original waste magnetic material, shown in the left bar, with the final recycled magnet product, shown in the right bar, which was formed by the process.

[0040] [Figure 8] Figure 8 shows various shapes and coatings of sintered magnets.

[0041] [Figure 9] Figure 9 is a block diagram of a computer system that can be used in connection with the computer implementation described herein. [Modes for carrying out the invention]

[0042] Similar reference numbers and symbols in various drawings indicate the same elements.

[0043] (Detailed explanation) According to some implementations, waste magnets, e.g., bulk magnetic materials and / or used (EOL:en A method for manufacturing full-density Nd-Fe-B sintered magnets using d-of-life magnets is described. A magnet is a magnet that has not undergone the final product finishing, especially one that has not been coated with any materials. This refers to the material. An example of bulk magnet material is material loss and scraps that occur during manufacturing. ), and magnetic materials that are discarded as a result of inefficiency. Another term used is "drop." End-of-Life (EOL) magnets are the final product. This refers to magnets and magnetic pieces that have been finished, particularly coated with a finishing material. EOL magnetic materials Examples include magnets or magnetic fragments recovered from discarded products. For example, magnetic rotation A magnetic field that can retain its coating even when separated from the circuit, assembly, or other substrates. Stone. Used products include products containing EOL magnets, such as hard disk drives.

[0044] The manufacturing method, compared to conventional Nd-Fe-B manufacturing, involves operations in the total value chain. The number can be reduced, for example, mining, concentration, oxide production, chloride production, alloy production Furthermore, the strip-casting procedure is not performed at all. The products obtained from the process described below have residual magnetism (Br) as described in the table below. Full This is a dense Nd-Fe-B sintered magnet. In some implementations, the residual material is equivalent to or greater than that of the material to be discarded. To manufacture products having magnetic field (Br), coercivity (iHc), and energy product (BHmax). This is possible. The new NdFeB product has an improved temperature profile compared to the waste-start material. And it may have corrosion resistance. The method reduces the amount of unused material required and the basic operating costs. This can be suppressed. The process involves 81-99.9% waste magnetic material and / or magnets and 0.1- It can be combined with 19% rare earth element additives, and all of the elements present in the waste magnets. High recovery of elements such as Nd, Dy, Pr, and Fe, Co, Cu, Al, Ti, Zr, Gd, Tb. It may have affinity and magnetic properties, such as Br, iHc, or BHmax.

[0045] Methods for manufacturing full-density Nd-Fe-B sintered magnets are: not limited to, but hard EO from product structures including disc drives, motors, generators, or speakers. Extraction of L magnet components (multiple possible); and prior to the method for manufacturing new Nd-Fe-B sintered magnet products, This includes the preparation of magnets and magnetic materials by mechanical and chemical measurements and treatments. Nd-Fe-B sintered magnet The method for manufacturing stone products involves the direct removal of the coating from extracted EOL magnet components. The method may include one or more mixing steps of the resulting uncoated material. It is possible, and at least one of the steps is, but is not limited to, a hydrogen mixing reactor. The method may include a mixture of uncoated magnetic materials using [a specific method]. A method can be used to achieve this. The method involves adding new rare elements in the range of 0.1-19% of the starting material. This may include the addition of earth materials. Further details and any characteristics of some implementations may be subject to the specific target of Nd -Includes a process for maintaining, improving, and / or imparting performance characteristics of Fe-B magnets. This refers to particle size, orientation, density, energy product (BHmax), coercivity (iHc), and / or remanent magnetism (B This may include any desired combination of r).

[0046] Some implementations require a supply of new rare earth elements when manufacturing recycled products with desired properties. The required amount can be reduced. Some implementations involve risks to the supply of rare earth elements and the price of rare earth elements. A more sustainable magnet supply that mitigates the end-user's susceptibility to stability. Plays an important role in the formation of the chain, or any two or more of these combinations It can be done. In some implementations, the input cost of the necessary materials is mined unused This is reduced by using recycled magnetic materials instead of new materials. Materials, waste, pollution The resource requirements, including those related to energy, can be mitigated by the benefits that arise simultaneously.

[0047] In some implementations, the method is included in or incorporated into the product structure, for example, an EOL product. This includes the recovery of Nd-Fe-B magnet components. This is the first process that can be characterized as a recovery stage. In sessing, the method is either included in the EOL product or a separate accessory assembly from the EOL product. This may include the recovery of EOL Nd-Fe-B magnets from the materials of the attached components. In some implementations, the first Lossing is a process that increases the magnet concentration relative to the total mass of a component containing EOL Nd-Fe-B magnets. This includes the integration of the materials and the separation of the EOL Nd-Fe-B magnet assembly from the initial process. The magnet is fixed on and / or to another material, such as a magnetic circuit or support housing. Remove, fragment, or disintegrate a coating on any material, such as adhesives. It is possible.

[0048] After the initial recovery processing, the adhesive bond between the magnet and the magnet assembly is separated. Heating and cooling processes adapted to the requirements, as well as the initial or complete disassembly of the coating on the magnet. Further steps can be taken, including the recovery of magnet assemblies. The material is placed in a furnace and subjected to a periodic heating process. In such a process, the material becomes magnetic. To demagnetize the stone and weaken or burn all adhesives attached to the magnet or any part thereof. Furthermore, the Curie temperature of the Nd-Fe-B sintered magnet is, for example, the point at which the magnetic flux drops to zero, for example, 600°C. It can be heated to a higher temperature. For example, the first heating cycle may be at least 400°C or baked. A heating cycle in which the material is heated to a sufficiently high temperature and for a long time to demagnetize the magnetizing element. It is possible. The second heating cycle is performed until the adhesive is reliably weakened or destroyed. This can be done at a sufficiently high temperature, for example, 650°C and / or for a long time. Using rapid cooling at the end of the heating cycle, removal from all assemblies of the rare earth magnets. To assist in removal and to completely or partially fragment all coating layers covering the magnet. and / or can be peeled off. The heating and cooling process may affect other parts or assemblies. For example, the coating of an EOL magnet that has already been separated from the support housing, magnetic circuit, or other components. This may also include demagnetization and / or fragmentation and / or peeling.

[0049] In some implementations, another component, such as an assembly, magnetic circuit, support, or other part, is used. Repeated heating, in which the attached magnet is held at 650°C for 1 hour followed by rapid cooling to 5°C, is performed on the magnet. Remove the magnet from the assembly, weaken or destroy all adhesives, and all on the magnet It is effective in cracking the coating layer.

[0050] The heating process can be carried out in an air, argon, or other inert atmosphere. Heat can be generated by, for example, resistance heating, high-frequency heating, convection, microwave heating, gas combustion heating, or chemical heating. This can be done using any suitable technique, including immersion in a heating bath or other convection heating. Next, the magnets are separated using a separation device, collected, and then transported by an appropriate conveyor. It is possible.

[0051] A process whose primary purpose is the removal of a magnet coating is characterized as a surface removal process. This can be done by utilizing mechanical surface removal techniques, such as the use of abrasive jets. The surface removal process can be performed by centrifugation, grinding, or immersion in a chemical heat bath. It may include.

[0052] In some of the coating removal steps, for a 100kg mixed waste magnet, a diameter of 1mm of styrene was used. A 15-minute abrasive jet using a shot was used to extract NiCuNi, aluminum, and black enamel. Sufficient to remove the protective layer on magnets of various shapes coated with porcelain and zinc. It was found that this protective layer is collected by sieving for the purpose of reuse. The extracted magnets are then sent for further processing.

[0053] The atmosphere and temperature can be controlled during abrasive jet processing. In the department's implementation, abrasive jet processing, for example, shot blast processing The rinsing is performed in air, argon, or another inert atmosphere, preferably with a humidity in the range of 0-35%, 5 This can be done at temperatures between ℃ and 600℃. In some cases, the mass of waste sintered Nd-Fe-B material during this process is... The decrease was less than 1%. Processing period, granular material, e.g., shot speed, And / or other parameters can be selected to limit the mass reduction to 1% or less. In some implementations, the parameters ensure that the mass reduction is less than 10%, and in some implementations, 5 You can choose to make it less than or equal to a percent.

[0054] Magnets from which the coating has been mechanically removed are chemically treated in 1-5% diluted HCl or HNO3. This allows all oxide layers to be further removed from the surface of the discarded magnet. Implementation is possible with these These are not the only options; in some implementations, other active agents are used to remove oxides. It can be removed. For example, CuSO4. The mass reduction during this process is 0.1-5%. It can be maintained within the range. Preferably, the time, temperature, and concentration are such that the mass decrease is 10 The selection is made so that the percentage is less than or equal to 20%, especially less than or equal to 20%.

[0055] During the mixing stage, the bulk magnet achieves the desired final properties in the final product formed from the material. It is mixed with additional raw materials for this purpose. The mixing process involves crushing, grinding, pulverizing, or using hydrogen. This may include the decomposition of the material into a coarse powder. In some implementations, magnets, for example, Nd-Fe-B or 2 A 17-type magnet is processed into powder using a hydrogen mixing reactor, and this powder material is then added on-site. It is used in combination with other materials to restore or improve their residual magnetism, energy product, and / or density.

[0056] In some implementations, additional magnetic materials are added to discarded magnetic materials to restore or improve the performance of the magnets. It can be improved. Additional magnetic materials include rare earth elements, RE, for example, Nd, Pr, Dy, Gd, Tb, La Ce, Yb, Ho, or Eu and transition metals, e.g., TM, e.g., V, Cr, Mn, Fe, Co, Ni, Cu, Y , or can be combined with Zr. For example, a recycled magnet is given by the following formula (1) It may have a chemical formula that satisfies this condition. (1)Nd[0.1~19at%×s(Nd), x]Pr[0.1~19at%×s(Pr), y]Dy[0.1~19%×s (Dy), z]Co[0, d]Cu[0, e]Fe[0, f]

[0057] [m, n] represents the range from the smallest m to the largest n, and s(t) represents the element t in the initial composition. x = 18 - [81, 99.9]at%×(s(Nd)+s(Pr)+s(Dy)), y=18-[81, 99.9]at%×(s(Nd)+s (Pr)+s(Dy)), z=18-[81, 99.9]at%×(s(Nd)+s(Pr)+s(Dy)), d=3 -[81, 99.9]at%×s(Co), e=0.3-[81, 99.9]at%×s(Cu), and f=77-[81, 99.9% at% × (s(Fe) + s(Co)).

[0058] The additional requirements include one or more of the following: (a) the final product is in the range of 0.1 ≤ p + q + r ≤ 19 at % The additional unused material, NdpPrqDyr, in the formula, must be such that T ≥ minimum value (R, 18). , T=f(Nd)+f(Pr)+f(Dy) and R=s(Nd)+s(Pr)+s(Dy);(b)p+q+r≧X, In the formula, X is at% of RE(Nd, Pr, Dy) removed from the original magnet; (c) T ≤ 18%; (d (e)f(Nd)+f(Pr)>0, where f is the at% fraction of the final product; (e)f(Nd)+f(Pr )+f(Dy)≦18;(f)f(Co)≦3;(g)f(Cu)≦0.3;(h)f(Fe)+f(Co)≦77; Alternatively, (i) f(Dy) + f(Nd) + f(Pr) ≥ R.

[0059] The mixing process involves grinding, cutting, high-energy ball grinding, roller grinding, sawing, and jigging. Includes jet crushing, rolling, vibration, jaw crushing, and hydrogen mixing. In this process, hydrogen mixing is used to homogenize the waste magnets and new rare earth element additives in the initial material. This is the process. In the hydrogen mixing process, hydrogen is added to the φ phase, for example, Nd2Fe 14 B and waste magnet It enters the rare-earth-rich grain boundaries of the rock, reacts with the rare-earth elements, and traps hydrogen within the crystal structure. It forms a hydride. The crystal structure expands as a result of hydrogen absorption and hydride formation. This causes the brittle structure to break down. This result may be effective for mixing, and at the same time, waste magnetism It may also be effective in fragmenting stones and additive materials.

[0060] As used herein, the term "fragmentation" refers to mechanical processes, chemical processes, thermal processes, etc. Solid It encompasses all types of fragmentation of materials. The degree of fragmentation ranges from coarse division to complete decomposition. It can then be processed into a fine powder.

[0061] In some implementations, the method involves adding 0.1–19 wt% of one or more rare earth element additives to the composition. The present invention provides, or the method thereof. In another embodiment, the method is about 0.1 wt%, about 0.2 wt% , about 0.3wt%, about 0.4wt%, about 0.5wt%, about 1wt%, about 2wt%, about 3wt%, about 4wt%, about 5wt%, Additives of one or more rare earth elements in an amount of approximately 6 wt%, approximately 7 wt%, or approximately 8 wt%, or one or more rare earth elements The present invention provides methods for adding combinations of elemental additives to compositions, or for the methods described herein. In another embodiment, the method is approximately 0.1-0.5 wt%, approximately 0.1-1 wt%, approximately 0.5-1 wt%, approximately 1-2 wt%, approximately 1-3 wt%, approximately 1-5 wt%, approximately 1-8 wt%, approximately 2-4 wt%, approximately 2-6 wt%, approximately 3-5 wt%, or approximately Additives of one or more rare earth elements in amounts of 3-8 wt% or combinations of one or more rare earth elements. The present invention provides methods for adding to compositions or for methods described herein.

[0062] In some implementations, the method involves using a mixture of 0.1-1 at% or less, preferably 1%, with Pr at 25 wt% and Nd at 75 wt%. Contains % rare earth element additives. Essential rare earth element additives and / or new element hydrides. Along with the addition, the desired fine, impurity-free powder mixture can be produced in-situ using a hydrogen mixing reactor. This process may be effective in recovering or improving the magnetic properties of discarded Nd-Fe-B type sintered magnetic materials. The magnetic properties of the magnetic material include the addition of 0.1 wt% to 19 wt%, preferably 1%, of additive elements. And physical properties, such as density or corrosion resistance, can be restored or improved. Additives and waste The antimagnetic material is placed in a hydrogen mixing reactor, Pr 75 Nd 25 H x (In the formula, x is a mole fraction of 1 to 3) It forms a crude powder mixture containing rare earth elements.

[0063] The hydrogen mixing process is carried out under a hydrogen atmosphere at a temperature of 20-150°C and a pressure of 1-60 bar (100-6000 kPa). This can be done. Then, the material is preferably heated to 550-600°C on site to form a mixture. It can be partially degassed. The average particle size formed by the mixing step is 1 μm~ It can be in the range of 2000 mm. When a pressure of 50 bar (5000 kPa) is used, the average particle size is reduced. The particle size present in the antimagnetic material, for example, 2-8 μm, and the particles that did not react with hydrogen by oxidation. This can correspond to powders in the range of 500 μm to 2000 mm. This powder is sieved to separate the oxidized coarse It can remove rare earth powder.

[0064] In some implementations, the hydrogen mixing process ensures that the particles are small enough for the final magnet, and Use a sufficiently high pressure to eliminate the wet grinding process. In this example, A sieve that removes larger particles, and therefore removes particles with a higher oxygen concentration. This may be advantageous. Sieving is possible because oxides make up the hard parts of the material recovered from the magnet. Furthermore, it is effective in preventing further reduction to smaller particle sizes.

[0065] For further mixing and homogenization, the magnetic powder mixture, for further homogenization of the mixture It can be transferred to a roller mill. The crushed material can be, for example, crushed during roller crushing. It can be lubricated with 1% zinc stearate. After the roller grinding step, waste magnetic The powder can be sieved to further remove all remaining rare earth oxides. In the implementation, sieving can be selected to remove particles larger than 500 μm. .

[0066] Lubricants used in roller grinding may have a low oxygen content and / or a binder. It may include. Examples of lubricants include amides, for example, oleic acid amide or amide, Other low-carbon hydrogenated esters or fatty acids, such as oleic acid, are also included.

[0067] The powder can be further homogenized by jet grinding. In some implementations, jet grinding The structure can be formed using air or an inert gas, such as He, Ar, or N. Jet grinding, for example, homogenizes the mixture for 1 to 4 hours, breaking down the aggregates into single particles of 1 to 4 μm. This can be done at a speed that further breaks down the particles into individual particles. In some implementations, jet pulverization is It can be completed in less than 24 hours.

[0068] In some implementations, waste-derived Nd-Fe-B was used in comparison to jet grinding of Nd-Fe-B elemental additives. An 80% reduction in the time required for jet pulverization of powder can be observed. The average particle size of the waste magnet is The particle size can be in the range of 4-10 μm. During jet pulverization, the aggregates were broken down into single particles, The rare earth oxide powder remained coarse. Disposal began after removing the coarse rare earth oxide powder. The amount of oxygen contained in the magnetic material can be reduced, and more preferably, the final regenerated sintered magnet The amount of oxygen is suppressed. This step involves homogenization of the waste magnetic powder mixture, and (RE(TM) x ) For the addition of new elemental additives and the decomposition of separated single particles along grain boundaries, Preferably, this is done in an inert atmosphere completely free of oxygen contamination, for example, using Ar gas. This is possible. RE (Rare Earth) refers to any combination of Nd, Pr, Dy, Tb, Y, La, or Sm. Furthermore, TM (transition element-doped material) is any Co, Ni, V, Nb, Mo, Ti, Zr, Al, C This refers to a combination of u, Ga, or Fe.

[0069] After the particle reduction, mixing, and sieving are complete, the powder is oriented and compressed, and then air or It can form compacted powder in an inert atmosphere. Before compression and orientation, a lubricant is applied to the powder. It can be added to the compacted powder. The compacted powder can be compressed and oriented in a magnetic field. Then, the compacted powder The body can be directly subjected to sintering at a temperature in the range of 1050-1100°C for a holding time of 5 hours, after which This is followed by a heat treatment at 900°C for 5 hours and then at 550°C for 3 hours. The selection of sintering temperature depends on the hydrogenation / mixed sintering process. This can be determined by the total amount of rare earth additives added before the step.

[0070] Some implementations provide a cost-effective and measurable recovery process for waste magnetic materials. This can be done. The method may include a mechanical automated process for recovering the EOL magnet. This method can provide a recovery phase, in which other materials of EOL waste magnets can be collected. Effective and rapid separation from material assemblies and / or fixtures, and collection / integration of EOL magnets. The process is carried out. The separation method of the recovery process is to achieve separation of demagnetization and adhesive bonding. This may include periodic heating and cooling processes.

[0071] This process can be applied to EOL magnets that can retain their coating. The coating is removed by mechanical means to minimize contamination and achieve a high recovery concentration of magnetic material. It can be maintained. The high recovery concentration of the magnetic material from which the coating has been removed is primary CO2, CO SO2, NO x Because it can significantly reduce the use of energy and materials, it can reduce costs. This allows for the provision of a greener process using the method described above. It will be done.

[0072] This process involves the addition of elemental additives, hydrides, or other additives in a series of mixing stages. Therefore, the goal is to produce recycled sintered magnets that have the same or better magnetic performance as the discarded material. This allows for rapid restoration of magnetic performance. The process described is 0.1~19wt 81-99.9 wt%, preferably 99 wt%, of raw / unused / new additives, preferably 1 wt%, By using it in combination with bulk material or EOL magnets from which the coating has been stripped This prevents a decrease or deterioration in the magnetic performance of the starting material.

[0073] Some implementations facilitate homogenization of bulk materials and / or EOL magnets with new elemental additives. Hydrogen mixing can be advantageously used to achieve this. Jet pulverization is then performed. This jet grinding allows for cost-effective and measurable processing. In the process, it is used for further homogenization with auxiliary materials, such as rare earth oxides or Nd / Pr. Other methods include crushing, roller crushing, high-energy ball crushing, rolling, and may include other mixing steps.

[0074] Figures 1A to 1C show an example of the separator 100. This separator 100 is used for EOL products, for example, The separator receives the hard disk and creates a flow of material containing a high concentration of the desired magnetic material. The 100 may include a control unit 20 that controls the process of the separator 100. The turntable 4, driven by 12, rotates around the center 6 of the bearing 13 supported by the base 19. ru.

[0075] In some implementations, the hard disk drive (HDD) unit 14 is located in the loading bracket. It is fed in at 11 and then by the robot positioning device 16, feeder, conveyor, or operator It is attached to the turntable by one of the following manual operations. Loading and attachment are, for example, Cutting stationary equipment by plasma cutter, water jet, or blade cutter This is effective in aligning the orientation of the HDD unit 14 that is to be cut by the 21, and the plasma cutter The tar, the water jet, or the blade cutter is fixed to a specific point on the base 19. Through a small passage shielded by inert gas, which is delivered via a shielded gas transport pipe 5. Then a pressurized gas, for example, N, Ar, or O, is supplied. For example, the turntable 4 rotates around the center 6. Then, the HDD unit 14 is transferred from the loading station 11 to the cutting station 21, At the cutting station 21, the HDD unit is cut, and the magnetic material from the HDD unit 14 is removed. A section containing HDDs will be formed.

[0076] In some cases, a plasma cutter is used to remove HDD corners from the HDD unit. The HDD unit is equipped with a nozzle 17 positioned at the 2 o'clock position for releasing rasma. The nozzle 17 receives gas from the plasma control unit via the gas line 18. It is possible.

[0077] In some implementations, the separator 100 utilizes a band saw or shear at the cutting station. This is possible. The shearing process may limit the extraction of magnets, may damage the recovered magnets, HD The corner portion of unit D 14 may be crushed, or any combination of two or more of these may occur. The clamping force on the circuit board, which could potentially cause an elephant to break, can be modified to minimize this issue.

[0078] If not sufficiently separated by the cutter, the warped surface, for example, the corner of the recycling bin The downward-curving surface above the hole 8 of the base stand 19 on top of 7, the corner of the HDD unit Further force can be applied to the corner until it separates from the rest of the piece, The HDD corner can be dropped into the corner regeneration bin 7. abrasive cutter, or abrasive jet cutter, for example, water jet Using a cutting tool or other type of cutting tool, cut the corner away from the rest of the HDD unit 14. It can be separated.

[0079] For the control of fine particles, a filtration vent 1 equipped with a filter, such as a HEPA filter 2, is provided. Other particulate control devices, such as the inertial force separator 3, can be provided. Pollutants can be drawn in through the downdraft vent 15.

[0080] The HDD unit 14 is held by gravity in the recess 24 of the rotating base 4 shown in Figure 1C. Yes, it is possible. This is because the HDD unit 14 engages with the rotating base 4 within the recess 24. This is because it can be shaped in a way that allows for precise alignment. The recess 24 is a magnet Modify to suit the type of assembly, such as a motor or wind turbine assembly. The HDD unit 14 passes through the cutting station 21, and at this time, it is recovered. Corners with magnets can be completely or partially separated. - The HDD unit falls from the corner drop opening 8 into the corner regeneration bin 7, and the rest of the HDD unit The contents fall from opening 10 into waste bottle 9.

[0081] In some implementations, the HDD corner or other magnet assembly is not the corner regeneration bin 7. To transport the materials to a position for further processing, a chute or conveyor may be provided. This is possible. In some cases, the HDD corner is collected in batches and processed. It can be transported for that purpose.

[0082] Figure 2 shows the process of treating a magnet or magnet assembly for demagnetization and removing the assembly from the EOL magnet. An example of a furnace 40 for removal is shown. For example, the corner of the HDD unit is on the conveyor 47 It can be transported to the furnace 40 by the heater 43. The furnace 40 uses the heater 43 to heat the Curie magnetic material. It can reach temperatures higher than the indicated temperature, and the heater 43 is made of the ceramic shown in the figure. The heater is an electric or other suitable form, equipped with a heating element 44 within the sleeve 45. This can be done using resistance, radio frequency (RF), convection, microwave heating, gas combustion, or chemical heating. This includes immersion in a tank, other appropriate heating methods, or any two or more combinations thereof. Alternatively, alternative heating methods can be used. To further suppress the oxidation of the magnet, The atmosphere around heated HDD corners or other waste materials containing magnets, for example, an inert gas. A pipe 46 can be provided to control it.

[0083] The furnace 40 may be equipped with an insulating housing 42 having an outer wall 42'. For example, an insulating housing The zing 42 reduces the amount of heat escaping from the furnace 40 and / or protects objects outside the furnace 40. The internal seals 41 and 41' can reduce the amount of heat escaping from the furnace 40.

[0084] The furnace 40 separates the magnet from the partial assembly and other non-magnetic materials by removing the waste magnet and Any magnet assembly configured to directly heat without substantially polluting the air It can be used as a heater for the pipe. Heating combined with subsequent rapid cooling is magnetic assembly. This can play a role in facilitating the initial cracking of all magnetic coatings on the rim. Demagnetization involves heating the magnetic material to at least its Curie temperature, for example, 320°C, without applying a magnetic field. This can be made certain.

[0085] The furnace 40 is in fluid communication with piping 46 that provides a controlled inert atmosphere or air atmosphere. It may have an inner wall that defines the heating space. The Curie temperature depends on the composition of the magnetic material. The temperature can range from 310°C to 900°C. Maintaining a temperature of or above the Curie temperature, the magnet A For example, magnets in the corners of an HDD unit including magnetic circuit elements and / or supports. The adhesive holding the magnet in place can be reliably removed or destroyed. To further facilitate separation from the assembly, subsequent coating fracture, or both. Furthermore, after heating, it can be rapidly cooled to, for example, 5°C. Heating and cooling can be performed in multiple stages. It can be done repeatedly or just once.

[0086] Figure 3A shows an example of an abrasive jet cleaning device 60 for cleaning the magnet 79. The rapid jet cleaning device 60 supports an entry conveyor 63 that sends the magnet 79 into the rotating drum 64. It has a frame 67. The drum 64 rotates, and the surface of the magnet 79 is moved away from the jet nozzle 66. You are exposed to the jets of abrasives that come out.

[0087] Ensure that the magnet 79 and its separated parts are securely moved, and the material, such as adhesive and other magnetic coatings A belt grinding roll 75 can be provided to ensure that the finning is reliably removed from the magnet 79. The treatment of the magnet 79 by the abrasive jet cleaning device 60 is not limited to, but Ni It is useful for removing coating layers containing CuNi, Al, Zn, and electrolytically eluted black epoxy material. It may be effective. The roller 75 moves in the opposite direction to the direction of the surface of the drum 64, with the magnet adjacent surface moving in the opposite direction. The roller 75 can rotate in the same direction as the drum 64. Further material can be removed from the magnet. By using the roller 75 together with the drum 64... This allows the surface of the magnet 79 to be exposed more evenly to the shot blasting process of the jet nozzle 66. can.

[0088] The dust / shot collection groove 57 receives fine particles from shots and coatings, and then Then, the shot and the particles are sieved, or separated by other size or density processes. The process involves removing the coating material and then collecting abrasive particles, such as shi The nozzle can be reused, and the abrasive particles are released from the nozzle 66. - It is transported by a conveyor 68 to a feeder / generator 69 that generates a sibjet.

[0089] Once the excess material is separated from the magnet 79, the outlet conveyor 70 will jet-clean the magnet. Remove from 60. The air purifier 65 and the outlet conveyor 70 remove the magnets from the jet cleaning device. At that time, all loose material separated from the magnet 79 can be removed.

[0090] Abrasive jet cleaning equipment controls the environment of the jet cleaning equipment, for example, processing The control cabinet shown in 71 is provided for controlling time, atmosphere, speed, etc. It is possible.

[0091] The coating of the magnet is applied by ablation of part or all of its surface. It can be completely removed by washing with an abrasive jet. In some implementations, this abrasive jet is used with steel shots, tungsten shots, etc. It can be made of bit, ceramic, or steel grit. The particle size is approximately 1 m m can be used. The abrasive jet cleaning device 60 receives the waste magnet and the waste Before further processing of the discarded magnets, the discarded magnets are not subjected to oxygen contamination. The surface coating or protective coating can be substantially removed around the magnet. The atmosphere can be a controlled inert atmosphere, such as argon.

[0092] Magnet 79 operates in humidity levels of approximately 1-35% relative humidity (RH) and temperatures of approximately 5°C-600°C. - It can be processed with a sibjet cleaning device 60.

[0093] In some implementations, the surface removal process is effective in removing less than 5% of the magnet's mass. It can be done over a period of time. In some cases, the surface treatment takes approximately 15 minutes to 5 hours. It will continue over a period of time.

[0094] Figure 3B shows an example of a hydrogen mixing reactor that decomposes waste magnetic material into particles and mixes these particles. In some implementations, a hydrogen mixing reactor mixes elemental additives with particles. The reactor can form particles with a target average diameter of approximately 1 μm to 2 mm, or approximately 4 to 7 μm. The hydrogen mixing reactor consists of two vessels 102 and 124, respectively, located in the mixing chambers 122 and 124. Each of the containers is equipped with a magnetic material and has holes in the inner lining 110. The inner lining 110 facilitates the circulation of gas around the magnetic material. When one of the containers 102 or 104 containing the material is filled with hydrogen gas, the hydrogen mixture in the container creates magnetism. Material fragmentation occurs. Exposure to hydrogen gas can last for approximately 1 to 40 hours. The exposure may be for a shorter or longer period, and the pressure and temperature may vary depending on the process. Scientific requirements, other processing steps used to achieve the target particle size, target homogeneity Other processing steps used to achieve the mixing, or any two or more of these can be selected based on the combination.

[0095] Using a diffusion promotion device 112 with holes, such as a snorkel or a tube, by hydrogen mixing decompose the magnet within the reaction vessels 102, 104, and the accumulation of particulate matter can be such that it does not prevent the exposure of some magnetic materials to hydrogen gas. A circulation promotion device (not shown) , such as a stirrer, a fan, or a gas supply device, can help promote the flow of hydrogen gas within the vessels 102, 104. The magnetic material falling through the holes of the inner lining 110 can be stirred by a stirrer disposed at the bottom of each of the vessels 102, 104.

[0096] A removable lid 114 can be provided for introducing the magnet into the vessels 102, 104. For example, after the magnet 79 has been cleaned by the abrasive jet cleaning device 60 shown in FIG. 3A, the magnet can be placed into the vessels 102, 104 shown in FIG. 3B. For example, after the magnet has been cleaned by the abrasive jet cleaning device 60, the magnetic material can be transferred into the inner lining 110 by a conveyor or manually, with or without using a controlled environment. A very small amount of rare earth transition element additive material can be added to the inner lining 110 to make the properties of the final product formed from the magnet to the residual magnetism, energy product, and / or retention of predetermined specifications. In some examples, after mixing to adjust the properties of the final product, the additive can be added to the crushed waste magnet material. Some examples of the additive material can include Nd, Pr, Dy, Gd, Tb, La, Ce, Yb, Ho, or Eu. ​

[0097] Containers 102 and 104 can withstand a predetermined pressure. For example, a hydrogen mixing reactor is under vacuum. It can be equipped with a pump. In some implementations, the pressure can reach up to 60 bar (6000 kPa). It can be raised. Containers 102 and 104 can withstand low pressure. Containers 102 and 104 It may be equipped with a thermostat-controlled heater 116 and a pressure adjustment knob.

[0098] The hydrogen mixing reactor uses a pump assembly 128 and a valve assembly 133 to supply hydrogen or other gases. It is equipped with a gas source connection part 138 for introducing gas into containers 102 and 104. Pump assembly 128, The valve assembly 133, the gas management component 144, or any combination of two or more thereof In order to disperse the entire volume of magnetic material into containers 102 and 104, gas is directly transferred to the diffusion promoting device 112. It can supply. In some examples, the pump assembly 128 and the valve assembly 133 are Containers 102 and 104 can be connected, which allows for, for example, degassing or primary gas injection. For the purpose of evacuating the containers 102 and 104 with a vacuum pump, for example, one for regenerating hydrogen gas Gas transfer from one container to another, for example, to the outside air using the surrounding connection part 132. Discharge, pressurize the containers 102 and 104, fill one or both of the containers 102 and 104 with inert gas, etc. The regeneration process can be carried out, or a combination of two or more of these. The control device 140 The valve assembly 133 and the pump assembly 128 are connected to the hydrogen mixing process and the vessel 102 and 1 The transfer of hydrogen between 04 and 04 can be automated.

[0099] During the hydrogen mixing process, magnetic particles pass from containers 102 and 104 through chute 126 into chamber 1 It falls into 20. The magnetic particles are removed from chamber 102 for further processing. This is possible. In some implementations, a pressure-resistant valve is used at the opening between the chute 126 and the containers 102 and 104. It can be used.

[0100] In some implementations, one of the containers 102 or 104 is made airtight and a gas management component is used. The exhaust is performed using 144. Then, the selected containers 102 and 104 are removed from the gas source, for example, by using a piping bag. The pump assembly 138 is filled with hydrogen and selected for mixing and fragmenting of waste magnetic materials. Selected containers 102 and 104 can be prepared. After mixing and fragmentation, for example, hydrogen can be selected. By discharging from the selected containers 102 and 104 and transferring the hydrogen to the other containers 104 and 102, Then, hydrogen is transferred to the other containers 104 and 102 by the gas management component 144. Yes, it is possible. Since the contents of each container undergo hydrogen mixing, the hydrogen is recovered and transferred to the other containers 102 and 104. It can be transferred, and the hydrogen mixing process is repeated in the other container.

[0101] In some implementations, the gas storage chamber is included in the gas management component 144, and Hydrogen discharged from one of the containers 102, 104 is, for example, discharged into the other container 10 during the hydrogen mixing cycle. 2. Before being transferred to 104, it is temporarily stored in a gas storage chamber (not shown). The use of a chamber allows the hydrogen mixing reactor to consist of only one vessel. In the example, the hydrogen mixing reactor may have three or more vessels. The gas storage chamber is 、By minimizing the pressure drop or pressure rise during transfer, the chambers and vessels 102, 104 are selected to maximize the energy economy of gas transfer to and from them. Each stage of the volume can comprise a plurality of chambers.

[0102] FIG. 4A shows a set of four reaction bottles 212 on a cart 216, which cart 216 enables the transport of the reaction bottles 212 into and out of one of the reaction chambers, e.g., reaction chambers 202, 202' shown in FIG. 4F. The reaction chambers 202, 202' can be used with, or in place of, the hydrogen mixing reactor shown in FIG. 3B. In some examples, the reaction bottles 212 can be used with the hydrogen mixing reactor shown in FIG. 3B, e.g., like vessels 102, 104. For example, the gas management component 144 can fill the bottle 212, which will later be filled with magnets, with an inert gas, e.g., Ar or N. For example, the magnet 206 to be hydrogenated is introduced into the reaction bottle 212 from the transfer chute 208. Introducing the magnet 206 into the reaction bottle 212 in an inert atmosphere can prevent contamination of the magnet 206 by, for example, oxygen. The reaction chambers 202, 202' can be used with, or in place of, the hydrogen mixing reactor shown in FIG. 3B. In some examples, the reaction bottles 212 can be used with the hydrogen mixing reactor shown in FIG. 3B, e.g., like vessels 102, 104. For example, the gas management component 144 can fill the bottle 212, which will later be filled with magnets, with an inert gas, e.g., Ar or N. For example, the magnet 206 to be hydrogenated is introduced into the reaction bottle 212 from the transfer chute 208. Introducing the magnet 206 into the reaction bottle 212 in an inert atmosphere can prevent contamination of the magnet 206 by, for example, oxygen. <​​​​​​​​​​​​​​​​​​​​​​​​​ It is possible.

[0104] Each of the reaction bottles 212 has a snorkel 213 that facilitates the diffusion of gas within the reaction bottle. Alternatively, another device may be provided. For example, the snorkel 213 is located in the center of each bottle 212. A silicone mold with openings on its sides to allow gas diffusion so that the gas can reach the positioned magnets. It can be made into a runder.

[0105] Bottle 212 and snorkel 213 allow hydrogen gas to enter the bottle 212 and snorkel 213. This allows the magnet 206 contained within the bottle 212 to come into contact with and / or the magnet 206 The top can be opened to allow for insertion into bottle 212.

[0106] As shown in Figure 4B, once the magnet 215 is placed inside the bottle 212, the transfer cover 214 is moved. It can be attached to the trolley 216 to isolate the bottle 212 and its contents from the outside air. - The container formed by 214 and the trolley 216 cannot tolerate gas leakage, therefore The internal volume can maintain an inert gas atmosphere, and the ambient air comes into contact with the magnet 215. This is prevented. For example, after bottle 212 has been placed in an inert atmosphere, the bottle 212 is... The trolley 216 can be covered by the bar 214 and stored outside of a space with an inert atmosphere. For example, Figure 4E shows the placement of the filled bottles 212 onto the trolley 216 and the cover 214 of the filled bottles An example of the filled bottle 212 is shown before it is placed on top of the bottle 212. The container may be filled while it is on the trolley 216, or it may be filled first and then placed on the trolley 216. stomach.

[0107] Figures 4F and 4G show an example of another hydrogen mixing reactor equipped with a pair of reaction chambers 202, 202'. As shown, reaction chambers 202 and 202' are in contact with the gas control component 144 as described above. They are connected and interconnected by the gas management component 144. The gas source 138 is This allows for the provision of connection points for multiple gases, such as inert gas and hydrogen. The surrounding connection part 132 allows for exhaust to the atmosphere. The gas management component 144 is The reaction extends from one reaction chamber 202 to the other reaction chamber 202', rather than between containers 102 and 104. Conversely, in terms of transferring gas, it operates as described above, with reference to Figure 3B.

[0108] A covered trolley 260, for example, trolley 216, enters the first of the reaction chambers 202. Meanwhile, hydrogenation is occurring in the other reaction chamber 202'. The covered trolley 260 is in the reaction chamber Once inside the chamber 202, the cover 214 is removed from the trolley 260, and the reaction chamber 202 The hatch 252 is closed. Then, the chamber 202 can be filled with inert gas.

[0109] The gas management component 144 reacts hydrogen from a hydrogen source to achieve the required pressure. It can be supplied to chamber 202. For example, when hydrogenation is completed in reaction chamber 202'. Then, the gas management component 144 controls hydrogen from reaction chamber 202' into reaction chamber 202. Transfer and pressurize the reaction chamber 202 to the target pressure. The gas control component 144, Hydrogen gas, for example, pressurized hydrogen gas, is introduced from the reaction chamber 202 into the cover 232 or the other bottle 212. By introducing it into the bottle through the opening, hydrogenation is initiated in the reaction chamber 202. It is possible.

[0110] The hydrogen mixing process, for example, when a hydrogen mixing reactor performs the initial mixing process, is approximately 1 μm to approximately 2 mm, or, for example, when the hydrogen mixing reactor performs a second mixing process, approximately 4 Magnetic particles with an average diameter of μm to approximately 7 μm can be formed. In some examples, Figure 4F and The hydrogen mixing reactor shown in Figure 4G can perform both processes. A hydrogen mixing reactor can perform both processes. Or, one of the reactors can perform either process. However, one reactor can perform one process, and the other reactor can perform the other process. For example, the hydrogen mixing reactor shown in Figure 3B can perform the initial mixing process. Thus, the hydrogen mixing reactor shown in Figures 4F and 4G can carry out the second mixing process. can.

[0111] The gas management component 144 removes gas from chamber 202', for example, completely. The gas is introduced into the chamber 202 for use during processing within the chamber 202. Alternatively, it can be placed in a storage chamber or container. (Figure 4G shows a chamber) The thermostat-controlled heater 257 in 202 is controlled by the control unit to provide the target temperature. It can be controlled in that way.

[0112] As the hydrogenation process proceeds within the reaction chamber 202, the gas control component 144 controls the reaction The chamber 202' is filled with an inert gas. Then, as shown in Figure 4G, the reaction chamber The hatch 252' to the ba 202' is opened, and the cover 214' is placed over the bogie 260'. The stone material is reduced to particles at this time, and then removed from the reaction chamber 202' on the trolley 260'. It can be done.

[0113] Once hydrogenation is complete in chamber 202, the gas management component 144 controls the excess hydrogen gas. The contents are discharged from the chamber 202. For example, the hydrogenation process is carried out in the chamber 202'. It can be restarted for one or more bottles 212.

[0114] In some implementations, bottle 212 is covered 232, as shown in Figures 4C, 4D, and 4J. The cover 232 can be closed, for example, when the bottle 212 is in an upside-down position, and the valve 23 When 4 is open, it allows the collected hydride magnet particles to be guided through the chute 237. It functions as a container. Cover 232 allows, for example, the magnet 206 to enter the bottle 212. It can be removed for this purpose and then attached to each bottle 212.

[0115] Referring to Figure 4J, in an inert atmosphere, the cover 232 is positioned on top of the bottle 212. The bottle can be sealed and removed from an inert atmosphere without the need for cover 214. The bottles 212 can be transported by trolley 216, or they can be transported individually. can.

[0116] Figure 4K shows an example of a storage container 240 for magnetic particles received from bottle 212. The valve 234 of bottle 212 receives the nozzle 265 provided in the storage container 240, and the manifold Install the rod 267 into the snorkel 213 inside the bottle 212. The blower 266 will then... The manifold 267 supplies the magnetic particles into the snorkel 213, and the magnetic particles are released from the bottle 212. Remove and place in storage container 240. The inert gas is stored after being placed in one of bottles 212. It can return to chamber 240 and circulate.

[0117] The inert gas is as shown in Figure 4H, a cross-sectional view of bottle 212 and snorkel 213. The water can then flow out of the snorkel 213 in a tangential / radial flow. The arrows indicate the flow of the snorkel 213. This shows the tangential pattern of inert gas discharged through slots oriented tangentially. The tangential pattern of the inert gas flow helps to remove particles from the inner wall of bottle 212. This can facilitate the complete removal of magnetic particles from the bottle 212.

[0118] The valve 234 has a gate structure, for example, to allow the nozzle 265 to enter the bottle 212. It can have the following: When the bottle 212 is removed, the cover 268 is attached to the nozzle 265. It can be attached to seal the storage container 240.

[0119] Figure 5 shows how waste magnets and magnetic materials are treated as products, for example, "bulk" products, failed / unacceptable / surplus products. In an example of process 500 for recovering and / or EOL products to achieve target characteristics Yes, process 500 can be performed using one or more of the above systems.

[0120] In S10, the conveyor aligns the product with the cutter and brings the product to the cutter. To pass through. The magnet-containing portion or cut portion of the product is separated from the rest of the product. , the magnet-containing portion together with other magnet-containing portions "recovered" from the same or similar equipment They can be grouped into one batch.

[0121] In S20, the magnet-containing portion or the cut portion is separated, demagnetized, and initially coated. It is transported to a system that crushes it, in this first crushing, the magnet-containing part is heated, and then The magnets are cooled and attached to each substrate, for example, to the components of a magnetic circuit or assembly. All adhesive used to attach the magnet-containing portion is separated from the magnetic material. This process can substantially recover all magnets from the magnet-containing portion or assembly. Furthermore, the recovered magnets do not need to be destroyed any further.

[0122] In some implementations, heating and cooling are sometimes used on coatings, such as Nd-Fe-B magnets. It may be effective in breaking or partially shattering nickel-copper-nickel coatings. Some coatings, such as phosphates, lacquers, or polymers, may not completely dissolve during heating. It can be destroyed.

[0123] The heating and cooling cycle may be repeated multiple times, or it may be repeated only once. The magnet-containing portion is heated to a temperature of approximately 600°C, and then the magnet-containing portion is heated to a temperature of approximately 5°C. It can be cooled. Other target temperatures may be used. The heating temperature is included in the magnet-containing part. The Curie temperature of a magnetic material, for example, the temperature at which the magnetization of the magnet disappears. A temperature higher than the Lie temperature can be used for selection.

[0124] The magnet-containing portions of a single batch that the system heats simultaneously have different Curie temperatures. It may include magnets of multiple formulations. The selected heating temperature is of any type. The highest Curie temperature among all magnetic formulations ensures that the magnetization of the magnetic material is completely extinguished. It can be made to be equivalent to or higher than a certain degree.

[0125] In some implementations, both heating and cooling are rapid. In some examples, the temperature of the magnetic material To demagnetize, the temperature is kept above the Curie temperature for a predetermined minimum time. In some implementations, The magnet-containing portion is heated to a temperature higher than the Curie temperature, and that temperature is maintained for a predetermined minimum time. The magnet-containing portion is then held and rapidly cooled. The magnet-containing portion is then again It can be heated, maintained at a lower temperature for a shorter period of time, and then rapidly cooled again. If demagnetization occurs during the initial heating and cooling cycle, the same temperature or holding rate will be maintained in subsequent cycles. It is not necessary to reach a certain time, but this heating and cooling cycle is necessary for the adhesive of the magnetic material to break down. This may be advantageous for removal and / or coating breakage. In some implementations, the system The magnet-containing portion is heated at a rate of 10°C / second or more, preferably 50-100°C / second. For example, the magnet-containing portion is rapidly heated at a rate of 100°C / second, preferably about 200 to 1000°C / second. It can be cooled down.

[0126] Process 500 involves completely removing non-magnetic material from magnetic material in a furnace for approximately one hour. This can be done for batches containing magnets weighing approximately 50 to 1000 kg. The larger the mass of the batch, the longer the holding time in the furnace will be due to convection, for example. The holding time in the furnace can be the total time of all heating and cooling cycles, for example. The furnace performs both heating and cooling of the magnet-containing portion.

[0127] An inert atmosphere may be used inside the furnace, or heating may be carried out in air. In this process, the processing of the magnetic material is carried out in such a way that even a slight separation or removal of the coating from the magnetic material occurs. Once removed, the magnetic material can be protected from excessive oxidation by utilizing an inert atmosphere. ru.

[0128] In S30, the entire coating is removed from the magnetic material. The coating is removed by mechanical or chemical means. It can be removed by scientific and / or other methods. In some cases, the coating The coating is removed by shot blasting or abrasive jetting. The chemical bath is then used. This can be done after shot blasting or abrasive jetting. For example, oxide Diluted hydrochloric acid, nitric acid, or other active substances effective in removing it can be used. The bath can remove oxides from the surface of magnetic materials.

[0129] In S40, the magnetic material is placed in a mixing apparatus after mechanical and chemical treatment. The apparatus exposes magnetic materials to a pressurized hydrogen atmosphere for a predetermined period, at a specified temperature and rotation speed. This can be done. For example, magnetic materials are shown in the hydrogen mixed reactor shown in Figure 3B and in Figure 4G. By using a hydrogen mixing reactor, or both hydrogen mixing reactors, or another suitable mixing device It can be processed.

[0130] In some cases, rare earth transition element additives are added to the magnetic material before or after mixing. This can be done. In some implementations, Nd-Fe-B magnets, for example, waste magnets and rare earth transition elements are added. Things, for example, Nd 1-x Pr xHowever, they are put together in a mixing device in a ratio of 99.9:0.1 to 81:19, They are mixed together homogeneously. After S40, the rare earth transition element additive material is separately fragmented and discarded. It can be added to magnetic materials.

[0131] Rare earth transition element-doped materials were analyzed using elemental analysis of the composition of waste magnetic materials, as well as experimentally. Therefore, an extrapolation method or other suitable method for achieving the predetermined target formulation and magnetic performance. Database of restoration formulas determined by any suitable method It can be selected using S. For example, this database shows the resulting sintered regenerated magnets. Rare earth transition element additives added to the starting material to achieve the desired properties of the product and This may include historical data showing the compositional characteristics of discarded magnetic materials.

[0132] The magnetic and physical properties of the initial magnetic material are changed when mixed, for example, after processing and re-sintering. During or after the reduction of the initial magnetic material by mixing hydride powder or crushed powder to make a raw magnet. This is restored or improved by adding specific rare earth transition element additive materials in a predetermined proportion. This is possible. An example of this formulation is 99 parts of waste Nd-Fe-B magnets, with Pr at 25 wt% and Nd at 75 wt%. It is a partial elemental additive of t%, and in the case of a 2:17 type magnet, it is Sm2Co 17 , includes some Sm. Examples include 99 parts of waste Nd-Fe-B magnets and 1 part of Nd, Dy, Co, Cu, and Fe elemental additives. In some implementations, this combination is combined with very small amounts of rare earth transition element additives or elements. Most of these are single waste rare earth magnets. In some implementations, rare earth transition elements are added. The additive is a combination of Nd, a lanthanide, and another transition metal. In some implementations, elemental doping is used. The material is used in combination with the initial magnetic material in less than 2% of cases. In some implementations, lanthanides are used. It can be replaced with this.

[0133] In S50, the powder is fragmented and homogenized by appropriate means. In some implementations This is achieved by jet grinding to a target particle size of approximately 1 to 4 μm. , fragmentation using any suitable fragmentation apparatus, for example, the fragmentation apparatus described in detail above It can be done by homogenizing, or both. In some implementations, step S40 And S50 can be performed simultaneously. In some implementations, only a small amount is added to the batch to be hydrogenated. Instead of adding rare earth transition element additives, the rare earth material is hydrogenated separately in S50. They are mixed together. In some cases, the rare earth transition element additives are discarded after, for example, S50. The magnetic material can be added after being crushed separately, and during this time, the initial waste magnetic material is... For example, using a high pressure of 60 bar (6000 kPa), a powder in the range of approximately 1 to 50 μm is formed. It is preferable that it be divided sufficiently into these parts.

[0134] In S60, for example, larger particles of about 1 mm are sieved from the fragmented material. For example, powder The oxidized portion is separated from the fine powder by sieving larger particles, such as particles of approximately 500 μm to 2 mm. This process prevents the oxidized particles from fragmenting and breaking down into pieces. Due to the hardness of the oxides on most of the recovered rare earth magnet material, the oxidized portion must be removed. It is effective for this purpose. For example, hydrogenation, pulverization, jet pulverization, crushing, or another suitable method Furthermore, it is possible that it does not decompose oxides that have a large size distribution, and the proportion of them in the fine powder is It is possible to eliminate or reduce the amount of the mixture by sieving.

[0135] In S70, the fine powder is compressed by filling it into a press and generating a magnetic field inside the press. The powder is then oriented and formed into a compact, and in S80, the compact is sintered and heat-treated and then re-treated. A raw sintered magnet product is formed.

[0136] Figure 6 shows the properties of starting materials for recycled magnets, which are available as bulk magnets and / or EOL magnets. This graph shows an example of a range. The ellipse 302 drawn on the graph represents the application of process 500. This represents the approximate range of starting materials that can be used. Process 500 is outside the ellipse 302. This can also be applied to other starting materials.

[0137] Figure 7 shows the composition of the original waste magnetic material, indicated by the bar on the left, as formed by process 500. This is a diagram comparing the initial magnetic material with the final regenerated magnet product shown in the bar on the right. The rare earth metal component, indicated by the "R" region of the left bar, is low even if it is higher than 18 at%. It is not necessary. The amount of rare earth metal "X" is removed from the starting magnetic material during processing. To ensure that recycled NdFe-B products have a composition similar to the original magnets, new rare earth elements are added. Materials, specifically unused materials, must be added.

[0138] In Figure 7, unused material is represented by the "V" region and is removed during processing. The amount of rare earth metals is approximately equal to "X". In the final recycled product, the final percentage of rare earth metals is , at least the percentage in the initial magnetic material, but less than 18 at%. The percentage of earth element material "R" is lower as the lower dashed line of the two dashed lines on the left bar approaches, for example, 18 at%. If the value is full, the final rare earth atom percentage in the final recycled magnet product shown in the bar on the right is: As indicated by the extended lower dashed line, it is at least equal to the same percentage. However, However, even if the percentage of rare earth metals in the initial magnetic material is higher than 18 at%, the final regenerated magnetic The atomic percentages in the stone are shown by the upper dashed line at the 18% position on the bar to the right. , limited to 18%

[0139] In the final recycled product, the final rare earth atom percentage is determined by the composition of each component of the unused material: Nd, Pr, Dy, Gd. The percentages of Tb, La, Ce, Yb, Ho, and / or Eu are within the range of 0.1 to 19% of their respective percentages in the original magnet. The atomic percentage is the percentage of each element, and the combined atomic percentage of Nd and Pr is greater than 0.

[0140] In addition to rare earth metals, the remaining parts of both the initial magnetic material and the final regenerated magnet are Fe, Co, and Cu. It is composed of aluminum and other elements. The following limitations apply to the final recycled product. (1) The atomic percentage of Co is 3% or less; (2) The atomic percentage of Cu is 0.3% or less; and (3) The total atomic percentage of Fe and Co is 77% or less.

[0141] Figure 8 shows various shapes and coatings of the sintered magnet 800. It can be used during the regeneration process 500. As an example of coating for sintered magnets 800, Examples include phosphate 802, A1 804, NiCuNi 806, epoxy 808, and Zn 810. For example, see Figure The abrasive jet cleaning apparatus 60 shown in 3A is used to coat the surface from the sintered magnet 800. It can be removed.

[0142] The following examples show uniform grade and performance, such as residual magnetism (Br) and coercivity (iHc). Discarded magnets from bulk and EOL sources, either one or a mixture, are aggregated and processed to create the original starting magnetic material. A new Nd-F with properties corresponding to the desired magnetic performance, which is equivalent to or better than the properties shown by [the specified method]. This demonstrates that it is possible to form regenerated eB magnets. [Examples]

[0143] (Example 1) The waste magnets were subjected to inductively coupled plasma (ICP) analysis and oxygen / carbon elemental analysis as shown in Table 1A below. The mass ratio of the components is determined by the analytical apparatus. Using a magnetic permeability meter, the following Table 1B is obtained. The magnetic properties of the mixed waste magnets, such as residual magnetism and retention, were determined. (Table) Tables 1A and 1B characterize the waste magnet materials.

[0144] Approximately 300 kg of mixed-grade EOL magnets are held in a muffle furnace at temperatures higher than the Curie temperature. The EOL magnet was demagnetized by heating it at 650°C for 4 hours. The demagnetized magnet was then rapidly cooled in water and coated. The material was crushed and then heated to 200°C in a furnace and dried. The demagnetizing magnet was coated with Ni-Cu-Ni. For further removal of the fumes, it was shot blasted for 15 minutes and then held in an inert atmosphere. The mass reduction of the demagnetizing magnet due to the removal of the coating was less than 5%. The magnets were chemically treated with diluted HCl.

[0145] 100 kg of waste material, free of impurities and with the coating removed, is placed in a rotary reaction mixing vessel. It was added, and then 1% Nd(0.55x+1)Pr(0.45x+1) additive was added. The coating peeled off. The waste materials and additives, free of impurities, were left at room temperature, for example, approximately 20-25°C, for 4 hours. The reaction was maintained in a rotary mixing vessel at a hydrogen pressure of 2 bar (2000 kPa). Then, the obtained hydrogen The hydride mixture was partially degassed by heating it to 550-600°C on-site. 1% Zinc stearate was mixed with degassed powder using a roller mill for 30 minutes, and the degassed The powder was lubricated. The degassed powder was further homogenized until it reached an average particle size of approximately 2.5 μm or less. For the purpose of pulverization, the particles were jet-milled under an argon atmosphere for 1.5 hours. The resulting particles were then oriented and compressed. The material was then sintered, annealed, and demagnetized. The demagnetization temperature was maintained at approximately 1050°C to 1100°C for 5 hours. Next, it was heat-treated at 600°C for 3 hours.

[0146] ICP, elemental analysis, and permeability testing were performed on the new Nd-Fe-B sintered product. The composition and magnetic properties of the Nd-Fe-B sintered products are shown in Tables 2A and 2B, respectively.

[0147] In this example, a rare earth element additive, such as Nd / Pr, is prepared on-site and then disposed of. A hydride powder blend was formed using the materials. The addition of RE is explained, for example, by referring to Figure 5. Rare earth oxides removed from the waste initiation material during the revealed steps S20, S30, S40, and S50. Alternatively, the calculated reduction in the grain boundary surface area phase was compensated for. The addition of partially degassed rare earth hydrides leads to the formation of a selectively increased grain boundary phase. During sintering, the diffusion of solid-state oxygen can be assisted, and / or the amount of oxygen in the hydride powder. This can reduce the initial material. In other words, the microstructure of the newly formed magnet is the starting material. It will be changed compared to the previous one. For example, the regeneration process will change if rare earth element additives are added, for example, NdPr By utilizing the recovery and improvement of grain boundaries when absorbing the H2 component of the process gas that generates H3, After absorption, the NdPrH3 is converted back to oxygen-free NdPr during sintering. Therefore, Grain boundary restoration and Nd2Fe 14 The reaction with component B constitutes the newly formed microstructure and elemental composition. As a result, the resulting Nd-Fe-B sintered magnet will contain Br, iHc, BHmax, or two or more of these. Combinations of these materials may possess properties equivalent to or better than those of discarded materials.

[0148] In some cases, the rare earth RE additive component results in an Nd-Fe-B magnet that consists solely of an Nd-rich phase. By restoring and forming a grain boundary-rich phase, diffusion along the grain boundaries is possible, as shown in Table 3B. The coercivity and residual magnetic force decrease, as explained in more detail by referring to [reference].

[0149] The proportion of rare earth elements (RE) from discarded magnets is determined by the main element, Nd2Fe. 14 A new approach to the B matrix phase. It can be replaced by additives. In some implementations, rare earth RE additives are used in waste magnets. By sintering together with the material, rare earth RE components are diffused and selectively along the grain boundaries. It can be driven into the target. The coercivity equivalent to the coercivity of the original discarded magnet starting material is very By using small amounts of new rare earth materials, regenerated sintered magnets can be restored or improved. For example, a new recycled Nd-Fe-B product with superior properties compared to the original waste material can be manufactured. It can be made.

[0150] The magnetic properties are shown in the table as BHmax (energy product), iHc (coercivity), and Br (remanent magnetism). List them. [Table 1] [Table 2] [Table 3] [Table 4]

[0151] (Example 2) The EOL magnet initiation material was supplied in magnetized form. The EOL magnet was initially supplied to the Fe substrate within the EOL product. It was installed. The magnet was demagnetized, and the periodic heating process described in more detail above It was separated from the Fe substrate using the regeneration step disclosed in Example 1. The stones were processed to form new fuldensity Nd-Fe-B sintered magnet products.

[0152] 1% additive, for example, Nd x / Pr y These are shown in the columns of additives in Tables 3A and 3C. It was added to the waste magnets as described. The waste magnets were specially analyzed by ICP, elemental analysis, and permeability meter. The composition and magnetic properties of the initial waste material and the new Nd-Fe-B sintered product were identified. Table 3 shows these properties, respectively. This is shown in A and Table 3B, as well as in Tables 3C and 3D.

[0153] The magnetic properties and corresponding densities are expressed as BHmax (energy product), iHc (coercivity), and Br (residual density). The magnetic fields are listed in Tables 3A to 5B. [Table 5] [Table 6] [Table 7] [Table 8]

[0154] (Example 3) The magnets in the waste material were characterized using ICP and permeability measurement. Please refer to Tables 4A and 4B, respectively. Additives of 0.5-8% Nd, Dy, Co, Cu, and Fe New Nd-Fe-B was added to the discarded magnets as shown in the Additives column of Tables 5A and 5B. The composition and magnetic properties of the sintered products are shown in Tables 5A and 5B, respectively. [Table 9] [Table 10] [Table 11] [Table 12]

[0155] From Tables 2B and 3B, it is possible to control the recovery of residual magnetism using Nd / Pr elemental additives and obtain It can be seen that the retention of regenerated sintered magnets can be improved. Specifically, elemental addition The lower the purity of Nd in the additive, the higher the retention rate of the resulting regenerated sintered magnet will be. As more Pr is added to the elemental additive, the percentage of Nd present in the elemental additive decreases. Conversely, the coercivity of the resulting regenerated sintered magnet increases, but the residual magnetism decreases slightly.

[0156] Similarly, the coercivity and remanent magnetism of regenerated sintered magnets are as shown in Table 5B, Nd, Dy, This can be manipulated by changing the percentages of Co, Cu, and Fe additives. For example, Table 5B shows that as the percentage of additives increases, the residual magnetism decreases in accordance with the increase in coercivity. It can be seen that a low percentage of additives, for example 0.5%, results in the regeneration. It is possible to completely restore the residual magnetism of sintered magnets, but with a high percentage of additives, for example, 8% additives. The substance can reduce residual magnetism. If the percentage of additives is high, compared to the discarded material in Table 4B... As a result, the coercivity value increases by at least approximately 30% to approximately 80% (see Table 5B), and this increase is due to the new This can be achieved with recycled sintered Nd-Fe-B products.

[0157] The recycled waste magnets will conform to a range of possible compositions. For example, the composition of the waste magnets is small At least 72% Fe, 7-20% Nd, at least 2% Pr, at least 5.6% B, and The first magnet waste material may contain at least 0.1% Al. In some implementations, the first magnet waste The materials are: 0-5% Dy; 0-4% Co; 0-0.3% Cu; 0-2.07% Tb; 0-0.19% Ga; 0-1 It contains at least one of 0.25% Gd; 0-0.14% Ti; 0-0.3% Zr; and 0-0.3% Ni. In some implementations, the first magnet waste material consists of 0-5% Dy; 0-4% Co; 0-0.3% Cu; 0-2%. 0.7% Tb; 0-0.19% Ga; 0-1.25% Gd; 0-0.14% Ti; 0-0.3% Zr; and 0-0.3 Contains at least two % Ni. In some implementations, the first magnet waste material contains 0-5% Dy;0 ~4% Co; 0~0.3% Cu; 0~2.07% Tb; 0~0.19% Ga; 0~1.25% Gd; 0~0.14% It contains at least three elements: Ti; 0-0.3% Zr; and 0-0.3% Ni.

[0158] In some implementations, the first magnet waste material is 0-5% Dy; 0-4% Co; 0-0.3% Cu; 0- 2.07% Tb; 0-0.19% Ga; 0-1.25% Gd; 0-0.14% Ti; 0-0.3% Zr; and 0-0. Contains at least four 3% Ni. In some implementations, the first magnet waste material contains 0-5% Dy;0 ~4% Co; 0~0.3% Cu; 0~2.07% Tb; 0~0.19% Ga; 0~1.25% Gd; 0~0.14% It contains at least five of the following: Ti; 0-0.3% Zr; and 0-0.3% Ni. In some implementations, the first Magnet waste materials consist of 0-5% Dy; 0-4% Co; 0-0.3% Cu; 0-2.07% Tb; 0-0.19% At least six elements: Ga; 0-1.25% Gd; 0-0.14% Ti; 0-0.3% Zr; and 0-0.3% Ni. Includes.

[0159] In some implementations, the first magnet waste material is 0-5% Dy; 0-4% Co; 0-0.3% Cu; 0- 2.07% Tb; 0-0.19% Ga; 0-1.25% Gd; 0-0.14% Ti; 0-0.3% Zr; and 0-0. Contains at least 7 units of 3% Ni. In some implementations, the first magnet waste material contains 0-5% Dy;0 ~4% Co; 0~0.3% Cu; 0~2.07% Tb; 0~0.19% Ga; 0~1.25% Gd; 0~0.14% It contains at least eight of the following: Ti; 0-0.3% Zr; and 0-0.3% Ni. In some implementations, the first Magnet waste materials consist of 0-5% Dy; 0-4% Co; 0-0.3% Cu; 0-2.07% Tb; 0-0.19% At least nine elements: Ga; 0-1.25% Gd; 0-0.14% Ti; 0-0.3% Zr; and 0-0.3% Ni. Includes.

[0160] In some implementations, some of the above implementations use 0-5% Dy; 0-4% Co; 0-0.3% Cu; 0-2.07% Tb; 0-0.19% Ga; 0-1.25% Gd; 0-0.14% Ti; 0-0.3% Zr; and 0 Contains at least one Ni at ~0.3%. In some implementations, some of the above implementations contain 0-5% Dy; 0-4% Co; 0-0.3% Cu; 0-2.07% Tb; 0-0.19% Ga; 0-1.25% Gd; 0- It contains at least one of 0.14% Ti, 0-0.3% Zr, and 0-0.3% Ni.

[0161] In some implementations, the magnet waste material consists of 0.1-5% Dy; 0.1-4% Co; 0.1-0.3% Cu; 0. 1-2.07% Tb; 0.01-0.19% Ga; 0.01-1.25% Gd; 0.01-0.14% Ti; 0.01-0.3% It contains Zr and at least one of 0.01-0.3% Ni. In some implementations, magnet waste material is 0.1-5% Dy; 0.1-4% Co; 0.1-0.3% Cu; 0.1-2.07% Tb; 0.01-0.19% Ga; 0 A small amount of 0.01-0.3% Gd, 0.01-0.14% Ti, 0.01-0.3% Zr, and 0.01-0.3% Ni. Both include two. In some implementations, the magnet waste material is 0.1-5% Dy; 0.1-4% Co; 0.1- 0.3% Cu; 0.1-2.07% Tb; 0.01-0.19% Ga; 0.01-1.25% Gd; 0.01-0.14% Ti It contains at least three components: 0.01-0.3% Zr and 0.01-0.3% Ni.

[0162] In some implementations, the magnet waste material consists of 0.1-5% Dy; 0.1-4% Co; 0.1-0.3% Cu; 0. 1-2.07% Tb; 0.01-0.19% Ga; 0.01-1.25% Gd; 0.01-0.14% Ti; 0.01-0.3% It contains at least four Zr and 0.01-0.3% Ni. In some implementations, magnet waste material is 0.1-5% Dy; 0.1-4% Co; 0.1-0.3% Cu; 0.1-2.07% Tb; 0.01-0.19% Ga; 0 A small amount of 0.01-0.3% Gd, 0.01-0.14% Ti, 0.01-0.3% Zr, and 0.01-0.3% Ni. It includes five of each. In some implementations, the magnet waste material is 0.1-5% Dy; 0.1-4% Co; 0.1- 0.3% Cu; 0.1-2.07% Tb; 0.01-0.19% Ga; 0.01-1.25% Gd; 0.01-0.14% Ti It contains at least six components of 0.01-0.3% Zr and 0.01-0.3% Ni.

[0163] In some implementations, the magnet waste material consists of 0.1-5% Dy; 0.1-4% Co; 0.1-0.3% Cu; 0. 1-2.07% Tb; 0.01-0.19% Ga; 0.01-1.25% Gd; 0.01-0.14% Ti; 0.01-0.3% It contains at least seven Zr and 0.01-0.3% Ni. In some implementations, magnet waste material is 0.1-5% Dy; 0.1-4% Co; 0.1-0.3% Cu; 0.1-2.07% Tb; 0.01-0.19% Ga; 0 A small amount of 0.01-0.3% Gd, 0.01-0.14% Ti, 0.01-0.3% Zr, and 0.01-0.3% Ni. Both include 8. In some implementations, the magnet waste material is 0.1-5% Dy; 0.1-4% Co; 0.1- 0.3% Cu; 0.1-2.07% Tb; 0.01-0.19% Ga; 0.01-1.25% Gd; 0.01-0.14% Ti It contains at least nine elements of 0.01-0.3% Zr and 0.01-0.3% Ni.

[0164] In some implementations, the composition of the waste magnets described herein is Dy, Co, Cu, Tb, Ga, Gd, Ti, Contains trace amounts of Zr, Ni, or one or more combinations thereof. In some implementations, as described herein. The composition of the waste magnets used is Dy, Co, Cu, Tb, Ga, Gd, Ti, Zr, Ni, or a combination thereof. It contains one or more impurities. In some implementations, the composition of the waste magnets described herein is about 0.1 Dy, Co, Cu, Tb, Ga, Gd, Ti, Zr, Ni in amounts of %, 0.2%, 0.3%, 0.4%, 0.5%, or less than 1%. , or one or more combinations thereof. In some implementations, the waste magnetization described herein The composition of the stone is one or more of Dy, Co, Cu, Tb, Ga, Gd, Ti, Zr, Ni, or a combination thereof. Does not include. In some implementations, the composition of the waste magnets described herein is as shown herein. Including all ranges, substantially derived from all ranges, or consisting of all ranges.

[0165] Table 6 shows material combinations that define other possible recycled magnet materials by some implementations. It is. [Table 13]

[0166] In some implementations, the waste magnet material, whose composition range is defined in the table above, is mixed with the most During or after the process, a certain amount of rare earth element additives are added, resulting in approximately 0. An optimal magnetic powder mixture containing 5 to approximately 8 at% magnetic powder can be produced. So, the amount of elemental additives is such that at least one of the elemental components of the rare earth element additive is the first pro The elements lost during the sessing step are the same elements as those lost from the waste magnet initiation material, and the amount lost. The amount is at least the same as that of rare earth elements. In some implementations, the amount of elemental additives is the same as that of rare earth elements. At least one of the elemental components of the elemental additive is present in the first processing step and further processing. The same elements lost from the discarded magnet initiation material during the set step, and the amount of this loss. It is a quantity that is equal to the amount of the other. To determine the amount of lost material, the waste magnet starter The material sample is processed and analyzed using ICP to determine the changes in the composition of rare earth elements. This is possible. For example, the decrease in the concentration of element Nd may be 0.7%. In this case, 1% added Nd (0.70)Pr(0.25)(0.05 is another substance) elemental additives are the original elements of recycled Nd-Fe-B sintered magnet products. This would be effective in restoring the grain boundary-rich phase. In some cases, the decrease in Nd concentration was 0.7%. In some cases, the total amount of Nd, Pr, and Dy in the resulting Nd-Fe-B sintered product should not exceed 18%. In addition, twice the amount of elemental additives, for example, 2%, can be added.

[0167] The following equation further illustrates some implementations: R = s(Nd) + s(Pr) + s in the starting material of the discarded magnet (Dy); As defined in paragraph 19, in the final Nd-Fe-B product, T = f(Nd) + f(Pr) + f( Dy); and the unused material added V = Nd[p] + Pr[q] + Dy[r], where 0.1 of the final product ≤ p + q + r ≤ 19 at% of the final product, and T ≥ minimum value (R, 18 at%). For illustrative purposes, Consider the following example: the atomic percentage values ​​of Nd, Pr, and Dy in the discarded magnet starting material are as follows: If the values ​​are 9.77, 2.96, and 0.92, then the corresponding values ​​are given in the formula R=s(Nd)+s(Pr)+s(Dy). Substituting these values, we get R = 9.77 + 2.96 + 0.92, or R = 13.65. In the same example, a new recycled Nd-Fe- The atomic percentage values ​​of Nd, Pr, and Dy in the B sintered magnet are 10.74, 3.26, and 0.91, respectively. It is possible. Substituting the values ​​of the new recycled Nd-Fe-B sintered magnet into the equation T=s(Nd)+s(Pr)+s(Dy), , T=10.74+3.26+0.91 or T=14.91. In the same example, unused material during the recycling process When added, the unused material has an atomic percentage value of 0.2, 0.3, and 0.4, respectively. Including d, Pr, and Dy, the formula V = Nd[p] + Pr[q] + Dy[r] gives V = 0.2 + 0.3 + 0.4, or V = 0.9. The formula for unused material, or V, is subject to two constraints: 0.1% ≤ p+ of the final product. q+r ≤ 19% of the final product, and T ≥ minimum value (R, 18 at%). In our example, p +q+r=0.9%, which means the first constraint: the value of p+q+r must be 0.1% or greater and 19% or less. The condition that it must not be true is satisfied. This example is the second constraint of the formula for unused materials: T is a series of R or 18 It also satisfies the condition that it is greater than or equal to the minimum value of R or 18. In this example, T is 14.91, and the minimum value of a series of R or 18 The smallest value is R, and since R is 13.65, T is greater than or equal to the minimum value of the series of R or 18.

[0168] In some implementations, V = Nd[p] + Pr[q] + Dy[r], where 0.1 ≤ p + q for the final product. +r ≤ 15 at% of the final product, and T ≥ minimum value (R, 18 at%). In some implementations, V = Nd [p]+Pr[q]+Dy[r], where in the formula, 0.1 ≤ p+q+r ≤ 12 at% of the final product. Yes, T ≥ minimum value (R, 18 at%). In some implementations, V = Nd[p] + Pr[q] + Dy[r] In the equation, 0.1 ≤ p + q + r ≤ 8 at % of the final product, and T ≥ minimum value (R, 18 at %). In some implementations, V = Nd[p] + Pr[q] + Dy[r], where the final product 0.1 ≤ p + q + r ≤ 5 at% of the final product, and T ≥ minimum value (R, 18 at%). V = Nd[p] + Pr[q] + Dy[r], where 0.1 ≤ p + q + r ≤ final product It is 3 at%, and T ≥ minimum value (R, 18 at%). In some implementations, V = Nd[p] + Pr[q] + Dy[r] is given by the formula where 0.1 ≤ p + q + r ≤ 2at% of the final product, and T ≥ minimum value (R , 18 at%). In some implementations, V = Nd[p] + Pr[q] + Dy[r], and in the formula, the final The product's product yields 0.1 ≤ p + q + r ≤ 1 at% of the final product, and T ≥ minimum value (R, 18 at%).

[0169] In some implementations, X is at% of RE(Nd, Pr, Dy) removed from the original magnet, and p+q+ r≧X. In some implementations, the additive is f(Nd)+f(P) in the final recycled Nd-Fe-B sintered product. The additive is such that r)>0, where f is the at% percentage of the recycled Nd-Fe-B sintered product. In some implementations, f(Nd)+f(Pr)+f(Dy)≦18. In some implementations, f(Co)≦ The answer is 3. In some implementations, f(Cu)≦0.3. In some implementations, f(Fe)+f(Co)≦7 The answer is 7. In some implementations, f(Dy)+f(Nd)+f(Pr)≧R.

[0170] In some implementations, the elemental additive is Nd[0.1-19at%×s(Nd), x]Pr[0.1-19at%×s (Pr), y]Dy[0.1-19%×s(Dy), z]Co[0, d]Cu[0, e]Fe[0, f], in the formula [m, n] represents the range from the smallest m to the largest n; s(t) represents the element t in the initial composition. x = 18 - [81, 99.9]at%×(s(Nd)+s(Pr)+s(Dy));y=18-[81, 99.9]at%×(s(Nd)+s (Pr)+s(Dy));z=18-[81, 99.9]at%×(s(Nd)+s(Pr)+s(Dy));d=3 -[81, 99.9]at%×s(Co);e=0.3-[81, 99.9]at%×s(Cu);f=77-[81, 99. 9]at% × (s(Fe) + s(Co)).

[0171] In some implementations, (i) the final product is in the range of 0.1 ≤ p + q + r ≤ 19 at %, and T ≥ minimum value Unused material that must be (R, 18), for example, Nd p Pr q Dy r In the equation, T = f(Nd) + f(Pr) +f(Dy) and R=s(Nd)+s(Pr)+s(Dy); (ii) p+q+r≧X, where X is the original magnet or (iii) T ≤ 18%; (iv) f(Nd) + f(Pr) >0, where f is the at% percentage of the final product; (v)f(Nd)+f(Pr)+f(Dy)≦18;( vi) f(Co)≦3; (vii) f(Cu)≦0.3; (viii) f(Fe)+f(Co)≦77; and (ix) f( Dy) + f(Nd) + f(Pr) ≥ R.

[0172] In some implementations, the method involves adding 0.1–19 wt% of one or more rare earth element additives to the composition. The present invention provides, or the method thereof. In another embodiment, the method is about 0.1 wt%, about 0.2 wt% , about 0.3wt%, about 0.4wt%, about 0.5wt%, about 1wt%, about 2wt%, about 3wt%, about 4wt%, about 5wt%, Approx. 6wt%, approx. 7wt%, approx. 8wt%, approx. 9wt%, approx. 10wt%, approx. 11wt%, approx. 12wt%, approx. 13wt%, approx. 14 Additives of one or more elements in amounts of wt%, approximately 15wt%, approximately 16wt%, approximately 17wt%, approximately 18wt%, or approximately 19wt%. Addition of additives or a combination of one or more elemental additives to a composition, or as described herein. The method is provided. In another embodiment, the method is approximately 0.1-0.5 wt%, approximately 0.1-1 wt%, and approximately 0.5-1 wt %, about 1-2wt%, about 1-3wt%, about 1-5wt%, about 1-8wt%, about 1-12wt%, about 1-15wt%, about 1-19 wt%, approximately 2-4 wt%, approximately 2-6 wt%, approximately 2-12 wt%, approximately 2-19 wt%, approximately 3-5 wt%, approximately 3-8 wt% t%, approximately 3-15 wt%, and approximately 3-19 wt% of one or more elemental additives or one or more elemental additives The invention provides a combination of additions to a composition, or the method described herein.

[0173] In some implementations, unavoidable impurities can be combined with specific substances.

[0174] The subjective and functional process embodiments described herein are based on the structures and functional processes disclosed herein. Digital electronic circuits, including their structural equivalents, and tangible computer software. Alternatively, firmware, computer hardware, or one or more of these. It can be implemented as a set. Embodiments of the subject matter described herein may be one or more composites. For execution by a computer program, i.e., a data processing device, or said data processing device A tangible non-transitor program carrier for controlling the operation of One or more modules of computer program instructions encoded in the program carrier. It can be implemented as follows. Or, in addition to the above, program instructions can be artificially The generated propagation signal, for example, is transmitted to a suitable receiving device and processed by a data processing device. To encode the information to be encoded, a machine-generated electrical signal, optical signal, or electromagnetic signal is generated. It can be encoded. Computer storage media include machine-readable storage devices and machine-readable memory devices. A board, random or serial access memory elements, or a combination of one or more of these. It can be done this way.

[0175] The term "data processing device" refers to data processing hardware, for example, a programmer Multiprocessor, computer, or multiprocessor or multicomputer This includes all kinds of devices, equipment, and machines for data processing. Furthermore, dedicated logic circuits, such as FPGAs (Field-Programmable Gate Arrays), or This can also be an ASIC (Application-Specific Integrated Circuit), or it may further include these. This device can optionally provide a computer program execution environment in addition to the hardware. Code that generates, for example, processor firmware, protocol stack, database A system management system, an operating system, or one or more combinations thereof. It may include code that performs the task.

[0176] Programs, software, software applications, modules, software A module, script, or code, or what is described as such A certain computer program may use a compiled or interpreted language, or a descriptive language. It can be written in any form of programming language, including verbal or procedural languages. The computer program may be used as a standalone program or as a modular program. Suitable for use in a code, component, subroutine, or computer environment. It can be deployed in any format, including as other units. The program can be mapped to files in the file system, but it is not always possible to map them. There is no need to do so. The program is not compatible with other programs or data, such as markup languages. Documents, a single file dedicated to the program, or multiple integrated files, for example , in a file that stores one or more modules, subprograms, or parts of code. It can be saved in a part of a file that holds one or more saved scripts. A computer program may reside on one computer or on one site, or multiple computers may be located on multiple sites. On multiple computers distributed across several sites and interconnected by a communication network It can be deployed to run in [a specific location].

[0177] The processes and logical flows described herein are implemented by one or more computer programs. One or more programs perform their function by manipulating input data and generating output. This can be executed by a Grammatical processor. This process and logical flow is: Dedicated logic circuits, such as FPGAs (Field-Programmable Gate Arrays), or AS It can also be implemented by an IC (Application-Specific Integrated Circuit), and the device can be configured using the dedicated logic circuit. It can also be implemented as follows.

[0178] A computer suitable for running computer programs is, for example, a general-purpose microprocessor. A processor, a dedicated microprocessor, or both, or other types of central processing. Examples of such devices include: Generally, a central processing unit stores instructions and data in read-only memory. It receives from random access memory, or both. Essential elements of a computer are: A central processing unit for implementing or executing commands, and for storing commands and data. It is one or more memory elements. Generally, computers also have one to store data. One or more mass storage devices, for example, magnetic disks, magneto-optical disks, or optical disks It is equipped with, or receives data from the mass storage device, and stores data in the mass storage device. The mass storage device is operably connected to perform either transmission or both transmission and reception. However, computers do not necessarily need such devices. Furthermore, computers can connect to other devices, for example, a couple of other examples, such as mobile phones and mobile information services. Terminals (PDAs), portable audio or video players, game consoles, Global Positioning System (G PS) Receiver or portable storage device, e.g., Universal Serial Bus (USB) It can also be integrated into a flash drive.

[0179] Computer-readable media suitable for storing computer program instructions and data. Examples include semiconductor memory elements, such as EPROM, EEPROM, and flash memory elements. Magnetic disks, for example, internal hard disks or removable disks; magneto-optical disks Screens; and all forms of non-volatile memory, media, and CD-ROM and DVD-ROM discs. It includes memory elements. This processor and memory can also be complemented by dedicated logic circuits. It is possible, or it can be incorporated into the dedicated logic circuit.

[0180] To provide user interaction, embodiments of the subject matter described herein are provided to the user Display devices for displaying information, such as CRT (cathode ray tube) or LCD (liquid crystal display). Monitor, as well as keyboard and pointing that allow the user to input into the computer. This can be performed on a computer having a gaming device, such as a mouse or trackball. It is possible to provide interaction with users using other types of devices. For example, the feedback supplied to the user can be any form of sensory feedback. For example, visual feedback, auditory feedback, or tactile feedback. It is possible; and user input may include acoustic input, voice input, or haptic input. It can be received in any format. In addition, computers are used by the user. By sending and receiving documents to the receiving device; for example, from a web browser. Send a web page to the user's device's web browser in response to a requested message. This allows interaction with the user.

[0181] Embodiments of the subject matter described herein can be implemented on a computer system, Computer systems have back-end components, such as data servers. Include as, or middleware components, such as an application server including, or front-end components, for example, the implementation of the subject matter described herein and A graphical user interface or This includes client computers with web browsers, or such backend computers. • Components, middleware components, or front-end components Includes one or any combination of the following components. The components of this system are Digital data communication in any form or medium, for example, interconnected by a communication network. It is possible. An example of a communication network is a local area network (LAN). ) and wide area networks (WANs), such as the Internet.

[0182] A computer system may include clients and servers. The bars are generally located remotely from each other and typically communicate via a communication network. The relationship between the client and the server is that they operate on their respective computers and interact with each other. It is caused by computer programs that have a client-server relationship. In this embodiment, the server, for example, receives data from a user acting as a client. To display to the user interacting with the device, and to receive user input from the user. To do this, data, for example, an HTML page, is sent to the user's device. The server processes the data generated on the user device as a result of the interaction with the user. It can receive data from other devices.

[0183] One example of this type of computer is the general computer system 900. A schematic diagram is shown in Figure 9. System 900 is performed according to one implementation, as already described. It can be used for the tasks described in relation to any of the computer implementation methods. The 900 includes a processor 910, memory 920, storage device 930, and input / output device 940. The components 910, 920, 930, and 940 are each interconnected using the system bus 950. The processor 910 can process instructions for execution within the system 900. In practice, the 910 processor is a single-threaded processor. In another practice, Processor 910 is a multithreaded processor. Processor 910 has memory 920 or storage The device 930 processes the instructions stored therein and displays the graphic information of the user interface. This can be displayed on the input / output device 940.

[0184] Memory 920 stores information within System 900. In one implementation, Memory 920 is used by the computer It is a readable medium. In one implementation, memory 920 is a volatile memory unit. In another implementation In this system, memory 920 is a non-volatile memory unit.

[0185] The storage device 930 can realize the large-capacity storage of the system 900. In one embodiment, the storage Device 930 is a computer-readable medium. In various different implementations, the storage device 930 is a flow This may be a disc drive, hard disk drive, optical disk drive, or tape drive. It is possible.

[0186] The input / output device 940 enables input / output operations of the system 900. In one implementation, the input / output device 940 This includes a keyboard and / or a pointing device. In another implementation, input / output device 940 This is a display unit for displaying a graphical user interface. Includes.

[0187] This specification includes numerous specific details of implementation, but these do not constitute part of the scope of any invention or request It should not be interpreted as a limitation on the scope that can be sought, but rather as a limitation on the specific practical aspects of a particular invention. This should be interpreted as a description of features that may be specific to the method of implementation. Certain features described in the specification may also be implemented in combination in a single embodiment. Yes, it is possible. Conversely, various features described in relation to a single embodiment may be described separately in multiple embodiments. It can also be implemented individually or in any appropriate partial combination. Furthermore, the features can be specially As stated above, it functions in a specific combination, and is initially claimed as such. It is even possible, but one or more of the features of the requested combination may, in some cases, be this combination Any combination that can be removed from the set and is requested may be a partial combination or part This approach can address variations in the combination of different components.

[0188] Similarly, although the process is described in a drawing in a specific order, this means that such a process is... To achieve the desired result, the steps must be carried out in the specific order or sequential order shown in the diagram. It should not be interpreted that all of the steps listed or exemplified must be performed. In this situation, multitasking and parallel processing may be advantageous. Furthermore, in the above embodiment The separation of various system modules and components is in all embodiments such separation It should not be interpreted that this is necessary, and the components and systems of the program described are Generally, these are combined into a single software product, or packaged into multiple software products. This should be interpreted as meaning that it can be caged.

[0189] Specific embodiments of the subject matter have been described so far. Other embodiments are described in the following claims. It is within the box. For example, the actions described in the claim may still be performed in a different order as desired. The desired result can be achieved. As an example, the process shown in the attached drawing can be used to achieve the desired result. To achieve the desired result, neither a specific illustrated order nor a sequential order is necessarily required. In some cases, multitasking and parallel processing may be advantageous.

[0190] This application provides an invention having the following configuration: (Composition 1) A method for manufacturing recycled Nd-Fe-B permanent magnets: Magnetic material derived from a discarded magnet assembly, the inert magnetic material of the discarded magnet assembly. A step of demagnetizing by periodic heating and cooling in an atmosphere; The steps include: fragmenting the demagnetizing magnetic material to form a first or second recycled Nd-Fe-B powder; The first or second recycled Nd-Fe-B powder is (a) a powder of at least one rare earth material R, and (b) Mix the powder of at least one elemental additive A with the resulting powder mixture, optionally. A step of homogenizing to produce a homogeneous powder mixture, wherein the rare earth material R is Nd or Pr It comprises at least one of the elements, and the elemental additive A contains at least one of Dy, Co, Cu, and Fe. Including the aforementioned steps; The homogeneous powder mixture is sintered and magnetized to produce regenerated Nd-F containing oxygen at a level of 1.98 at% or less. The steps of forming an eB permanent magnet and This includes, here The first recycled Nd-Fe-B powder has an average particle size of about 1 μm to about 2 mm, and The second recycled Nd-Fe-B powder has an average particle size of about 1 μm to about 4 μm; and the recycled Nd-Fe-B Permanent magnets: (a) The residual magnetism and coercivity of the waste magnet material derived from the waste magnet assembly are at least the same as The same residual magnetism and coercivity; or (b) Approximately 0 to approximately 20% higher than the coercivity of the waste Nd-Fe-B magnet material derived from the waste magnet assembly. Coercivity; or (c) Residual magnetism of the discarded Nd-Fe-B magnet, which is approximately 97% of the residual magnetism of the discarded Nd-Fe-B magnet, and the discarded magnet assembly Coercivity at least 30% higher than that of the waste Nd-Fe-B magnet material derived from the same; or (d) Residual magnetism of the discarded Nd-Fe-B magnet, which is approximately 95% of the residual magnetism of the discarded Nd-Fe-B magnet, and the discarded magnet assembly Coercivity at least 80% higher than that of the waste Nd-Fe-B magnet material derived from the same; or (e) Residual magnetism approximately 5% higher than that of the discarded Nd-Fe-B magnet, and the discarded magnet assembly Coercivity that is at least the same as that of the waste Nd-Fe-B magnet material derived from yellowtail. The method described above, which demonstrates this. (Configuration 2) The regenerated Nd-Fe-B is the first regenerated Nd-Fe-B powder having an average particle size of about 1 μm to about 2 mm. The powder of the rare earth material R and the powder of the elemental additive A are mixed together to form a homogeneous powder mixture. The method described in Configuration 1 for generating [the specified value]. (Composition 3) The regenerated Nd-Fe-B is the second regenerated Nd-Fe-B powder having an average particle size of about 1 μm to about 4 μm. Yes, it is mixed with the powder of the rare earth material R and the powder of the elemental additive A to form a homogeneous powder mixture. A method for generating an object, as described in Configuration 1. (Composition 4) The demagnetizing magnetic material is fragmented from the aforementioned waste Nd-Fe-B magnet to obtain a first or second recycled Nd-Fe-B powder. The forming step involves forming a first regenerated Nd-Fe-B powder having an average particle size of approximately 1 μm to approximately 2 mm. The first recycled Nd-Fe-B powder is further fragmented and homogenized, and the first recycled N The present invention provides a second regenerated Nd-Fe-B powder having a lower oxygen content than that of d-Fe-B powder. To that end, the fraction of particles larger than the average particle size of the first recycled Nd-Fe-B powder is obtained by sieving. By removing the material, a second regenerated Nd-Fe-B powder having an average particle size of approximately 1 μm to 4 μm is formed. The method described in Configuration 3, including the steps to accomplish. (Composition 5) Removing the fraction of particles larger than the average particle size of the first recycled Nd-Fe-B powder is an inactivation process. The method described in Section 4, performed in a sexual atmosphere. (Composition 6) The method according to configuration 5, wherein the inert atmosphere includes argon. (Composition 7) The homogeneous powder mixture is a powder of another element selected from the elemental additive A, or the The process includes the step of mixing it with a powder of another element selected from the rare earth material R, or both. The method described in Configuration 1. (Composition 8) The recycled Nd-Fe-B permanent magnet has multiple grain boundary regions that extend throughout the entire recycled Nd-Fe-B permanent magnet. The region includes the grain boundary region, and the multiple grain boundary regions are located within the corresponding grain boundary regions of the discarded Nd-Fe-B magnet. The method according to configuration 1, wherein the concentrations of the rare earth material R and elemental additive A are higher than the concentration of the rare earth material R. (Composition 9) The rare earth material R contains NdPrH3, which is converted to oxygen-free NdPr during sintering, according to configuration 1. Method of loading. (Composition 10) The powder of the rare earth material R is present at a level of 0.1 atomic% to 1 atomic% relative to the overall homogeneous powder mixture. The method described in Configuration 1 exists. (Composition 11) The powder of the rare earth material R contains Nd and Pr in a ratio of 25 wt% Nd and 75 wt% Pr, and configuration 1 Method of description. (Composition 12) The powder of the rare earth material R and the powder of the elemental additive A are continuously mixed with the recycled Nd-Fe-B powder. The method according to configuration 1, wherein the materials are mixed together to produce a homogeneous powder mixture. (Composition 13) The powder of the rare earth material R, the powder of the elemental additive A, and the recycled Nd-Fe-B powder are simultaneously The method according to configuration 1, wherein the mixture is mixed to produce a homogeneous powder mixture. (Composition 14) The method according to configuration 1, wherein the fragmentation step and the mixing step are performed simultaneously. (Composition 15) The method according to configuration 1, wherein the homogeneous powder has an average particle size of 1 to 4 μm. (Composition 16) The first regenerated Nd-Fe-B powder having an average particle size of approximately 1 μm to approximately 2 mm, The powder of the rare earth material R and the powder of the elemental additive A The step of mixing to produce a homogeneous powder mixture having an average particle size of approximately 1 μm to approximately 4 μm. Including the method described in Configuration 1. (Composition 17) The second regenerated Nd-Fe-B powder having an average particle size of approximately 1 μm to approximately 4 μm, The powder of the rare earth material R and the powder of the elemental additive A The step of mixing to produce a homogeneous powder mixture having an average particle size of approximately 1 μm to approximately 4 μm. Including the method described in Configuration 1. (Composition 18) A lubricant is added to the homogeneous powder mixture, and the homogeneous powder mixture is compressed to form a compacted powder. The steps to form; The steps include: sintering the compacted powder at a temperature of approximately 1000°C to approximately 1100°C; The sintered powder body is heat-treated at approximately 490°C to approximately 950°C; The heat-treated compacted material is magnetized in an inert atmosphere below 15°C to produce a regenerated Nd-Fe-B permanent magnet. The method according to configuration 1, further comprising the step of forming. (Composition 19) The method according to configuration 1, wherein the recycled Nd-Fe-B permanent magnet contains 1.32 to 1.98 at% oxygen. (Composition 20) The recycled Nd-Fe-B permanent magnet has at least the same residual magnetism and coercivity as the discarded Nd-Fe-B magnet. A method for indicating the degree, as described in Configuration 1. (Composition 21) The recycled Nd-Fe-B permanent magnet is (a) A coercivity approximately 0 to approximately 20% higher than that of the discarded Nd-Fe-B magnet; or (b) Residual magnetism of the discarded Nd-Fe-B magnet, which is approximately 97% of the residual magnetism of the discarded Nd-Fe-B magnet A coercivity at least 30% higher than the coercivity of; or (c) Residual magnetism of the discarded Nd-Fe-B magnet, which is approximately 95% of the residual magnetism of the discarded Nd-Fe-B magnet, and the discarded Nd-Fe-B magnet A coercivity at least 80% higher than the coercivity of; or (d) A residual magnetism that is about 5% higher than the residual magnetism of the discarded Nd-Fe-B magnet, and the discarded Nd-Fe-B magnet Coercivity that is at least the same as that of the stone. The method described in Configuration 1, which demonstrates this. (Composition 22) The method according to configuration 1, wherein the recycled Nd-Fe-B permanent magnet has an average particle size of less than 5 μm. (Composition 23) The method according to configuration 1, wherein the recycled Nd-Fe-B permanent magnet has an average particle size of less than 2.5 μm. (Composition 24) The recycled Nd-Fe-B permanent magnet has a density of approximately 7.56 g / cm³. 3 ~Approx. 7.6g / cm 3 The density of the configuration described in 1 method. (Composition 25) The method according to configuration 1, wherein the recycled Nd-Fe-B permanent magnet contains Co at a concentration of 3 atomic percent or less. (Composition 26) The method according to configuration 1, wherein the recycled Nd-Fe-B permanent magnet contains Cu at a concentration of 0.3 atomic percent or less. (Composition 27) The recycled Nd-Fe-B permanent magnet contains Fe and Co in a total concentration of 77 atomic percent or less, as described in Configuration 1. The method. (Composition 28) The recycled Nd-Fe-B permanent magnet contains Nd, Dy, and Pr in a total concentration of 18 atomic percent or less. Method described in 1. (Composition 29) The recycled Nd-Fe-B permanent magnet is substantially W a R b A c It is characterized by having the following composition: Here, W is the composition of the Nd-Fe-B material corresponding to the demagnetizing Nd-Fe-B material derived from the discarded Nd-Fe-B magnet. Including minutes; The subscripts a, b, and c correspond to the atomic percentages of the corresponding components or elements; a(t) is the atomic percentage of element t in W relative to the composition of the regenerated Nd-Fe-B permanent magnet; b(t) is the atomic value of element t in the rare earth-containing material R relative to the composition of the recycled Nd-Fe-B permanent magnet. It is a percentage; c(t) is the atomic percentage of element t in the elemental additive A relative to the composition of the recycled Nd-Fe-B permanent magnet. It is a rate; and a, b, c, a(t), b(t), and c(t) are 81at% ≤ a ≤ 99.9at%, 0.1at% ≤ b ≤ 19at%, 3at%-99.9%×a(Co)≦c(Co)≦3at%-81%×a(Co), 0.3at%-99.9%×a(Cu)≦c(Cu)≦0.3at%-81%×a(Cu), 77at%-99.9%×(a(Fe)+a(Co))≦c(Fe)≦77at%-81%×(a(Fe)+a(Co)), a(Nd)+b(Nd)+c(Nd)+a(Pr)+b(Pr)+c(Pr)>0at%, a(Nd)+b(Nd)+c(Nd)+a(Pr)+b(Pr)+c(Pr)+a(Dy)+b(Dy)+c(Dy)≦18at%, a(Co) + b(Co) + c(Co) ≤ 3at%, a(Cu)+b(Cu)+c(Cu)≦0.3at%, a(Fe)+b(Fe)+c(Fe)+a(Co)+b(Co)+c(Co)≦77at%, and b(Nd)+c(Nd)+b(Pr)+c(Pr)+b(Dy)+c(Dy)≧0at% The method according to configuration 1, having a value that satisfies the requirements. (Composition 30) The recycled Nd-Fe-B permanent magnet is substantially W a R b A c It is characterized by having the following composition: Here, W includes Nd-Fe-B material derived from the discarded Nd-Fe-B magnet, and subscripts a, b, and c This includes the atomic percentage of the corresponding component or element, and the rare earth material R and the elemental additive A are : Nd[0.1-19%×s(Nd), x], Pr[0.1-19%×s(Pr), y], Dy[0.1-19%×s(Dy), z] Co[0at%, d], Cu[0at%, e], Fe[0at%, f] Satisfying the conditions, During the ceremony: [m, n] represents the range from the first value in the smallest interval m to the second value in the largest interval n; s(t) is the atomic percentage of element t in the initial composition; x=18at%-[81, 99.9]%×(s(Nd)+s(Pr)+s(Dy)); y=18at%-[81, 99.9]%×(s(Nd)+s(Pr)+s(Dy)); z=18at%-[81, 99.9]%×(s(Nd)+s(Pr)+s(Dy)); d = 3at% - [81, 99.9]% × s(Co); e=0.3at%-[81, 99.9]%×s(Cu); and The method described in Construction 1, where f = 77at% - [81, 99.9]% × (s(Fe) + s(Co)). (Composition 31) Steps to recover demagnetizing magnetic material from one or more discarded Nd-Fe-B magnet assemblies as follows: The method described in configuration 1, further including the following: Each discarded Nd-Fe-B magnet assembly is physically separated into discarded Nd-Fe-B magnets and non-magnetic materials. Step; The steps of removing any residual coating or adhesive from each discarded NdFe-B magnet; and Each discarded Nd-Fe-B magnet is demagnetized, and a demagnetized magnetic material is formed from the discarded Nd-Fe-B magnet. Pu. (Composition 32) The step of removing the residual coating or adhesive is performed on the discarded NdFe-B magnet. , applying at least one of mechanical fragmentation or cracking treatment, or chemical treatment. The method described in configuration 31, including the method described in configuration 31. (Composition 33) The aforementioned coating is made of electrolytic black epoxy, Ni, Ni-Cu, Ni-Ni, and N from the discarded Nd-Fe-B magnet. The method according to configuration 32, selected from an i-Cu-Ni or Zn coating layer. (Composition 34) The step of demagnetizing each of the aforementioned discarded Nd-Fe-B magnets is a periodic, curvilinear process of the discarded Nd-Fe-B magnets. - Including heating to a temperature and cooling each waste Nd-Fe-B magnet at a rate of at least 100°C / second. , the method described in configuration 31. (Composition 35) The aforementioned periodic heating and cooling, The steps include: heating each waste Nd-Fe-B magnet to the Curie temperature of the waste Nd-Fe-B magnet; Next, the discarded Nd-Fe-B magnet is cooled at a rate of at least 100°C / second. The method described in Configuration 1, including the above. (Composition 36) The total atomic percentage of Nd, Pr, and Dy in the recycled Nd-Fe-B permanent magnet is the same as that of the discarded Nd-Fe-B magnet. The method according to composition 1, wherein the total atomic percentage of Nd, Pr, and Dy in the stone is greater than or equal to the percentage of Nd, Pr, and Dy. (Composition 37) (a) The powder of the rare earth material R is present in the homogeneous powder, based on the entire homogeneous powder mixture. It exists at a level of 0.1at% to 1at%, (b) The rare earth material R is composed of 75 wt% Nd and 25 wt% Pr, (i)Nd or (ii) comprising at least one of Pr, and (c) The residual magnetism and coercivity are less than those of the waste magnet portion derived from the waste magnet assembly. The method described in Configuration 1 is not necessary; it is the same as not having it. (Composition 38) The first or second recycled Nd-Fe-B powder contains oxygen at a level of 1.98 at% or less, according to the description in Configuration 1. Method of loading. (Composition 39) The first recycled Nd-Fe-B powder contains oxygen at a level of 1.98 at% or less, as described in configuration 16. Law. (Composition 40) The method according to configuration 17, wherein the second recycled Nd-Fe-B powder contains oxygen at a level of 1.98 at% or less. Law. The claims are as follows:

Claims

1. A method for producing recycled Nd-Fe-B sintered magnets, comprising sintering particles of waste material containing Nd-Fe-B material recovered from waste Nd-Fe-B sintered magnets together with a rare earth-containing material containing Nd and Pr in a ratio of 75 wt% Nd to 25 wt% Pr.

2. The rare earth-containing material is combined with elemental additives, and the concentration of the rare earth-containing material and the concentration of the elemental additives are such that the main Nd in the recycled Nd-Fe-B sintered magnet is Nd 2 Fe 14 The method according to claim 1, wherein the B phase is uniformly distributed at the grain boundaries throughout the entire thickness of the recycled Nd-Fe-B sintered magnet, such that it is higher on average in the mixture of waste materials surrounding the B phase.

3. The recycled Nd-Fe-B sintered magnet has a density of 7.56 g / cm³. 3 ~7.6g / cm³ 3 The method according to claim 1, including the density in the range.

4. The discarded Nd-Fe-B sintered magnet exhibits coercivity and residual magnetism, and the recycled Nd-Fe-B sintered magnet exhibits: (a) Residual magnetism and coercivity that are at least the same as those of the discarded Nd-Fe-B sintered magnet; (b) Coercivity in the range of 0% to 20% higher than that of the discarded Nd-Fe-B sintered magnet; (c) Residual magnetism that is approximately 97% of the residual magnetism of the discarded Nd-Fe-B sintered magnet, and coercivity that is at least 30% higher than the coercivity of the discarded Nd-Fe-B sintered magnet; (d) a residual magnetism that is approximately 95% of the residual magnetism of the discarded Nd-Fe-B sintered magnet, and a coercivity that is at least 80% higher than the coercivity of the discarded Nd-Fe-B sintered magnet; and (e) A residual magnetism that is about 5% higher than that of the discarded Nd-Fe-B sintered magnet, and a coercivity that is at least the same as that of the discarded Nd-Fe-B sintered magnet. The method according to claim 1, which shows at least one of the following.

5. The method according to claim 1, wherein the total atomic percentage of Nd, Pr, and Dy in the recycled Nd-Fe-B sintered magnet is equal to or greater than the total atomic percentage of Nd, Pr, and Dy in the discarded Nd-Fe-B sintered magnet.

6. The method according to claim 1, wherein the recycled Nd-Fe-B sintered magnet contains 1.98 at% or less of oxygen.

7. The method according to claim 1, wherein the recycled Nd-Fe-B sintered magnet contains 1.32 to 1.98 at% oxygen.

8. The method according to claim 1, wherein the elemental additive contains Dy.

9. The method according to claim 1, wherein the elemental additive includes the rare earth-containing material.

10. A method for producing recycled Nd-Fe-B sintered magnets, comprising sintering waste material particles containing Nd-Fe-B material recovered from waste Nd-Fe-B sintered magnets together with a rare earth-containing material containing 0.1 to 1 at% Nd and Pr in a ratio of 75 wt% Nd to 25 wt% Pr, and elemental additives containing at least one of a) Nd, b) Pr, c) Dy, d) Co, e) Cu, or f) Fe.

11. The rare earth-containing material and the elemental additives, the concentration of the rare earth-containing material and the concentration of the elemental additives, are the main Nd in the recycled Nd-Fe-B sintered magnet. 2 Fe 14 The method according to claim 10, wherein the grain boundaries are uniformly distributed throughout the thickness of the recycled Nd-Fe-B sintered magnet such that they are higher on average in the mixture of waste materials surrounding the B phase.

12. The method according to claim 10, wherein the first atomic percentage of the waste material in the recycled Nd-Fe-B sintered magnet is in the range of 99.9 at% to 81 at%, and the second atomic percentage of the combination of the rare earth-containing material and the elemental additive in the recycled Nd-Fe-B sintered magnet is in the range of 0.1 at% to 19 at%.

13. The recycled Nd-Fe-B sintered magnet has a density of 7.56 g / cm³. 3 ~7.6g / cm³ 3 The method according to claim 10, including a density in the range of.

14. The method according to claim 10, wherein the recycled Nd-Fe-B sintered magnet contains an atomic percentage of Co of 3 at% or less.

15. The method according to claim 10, wherein the recycled Nd-Fe-B sintered magnet contains an atomic percentage of Cu of 0.3 at% or less.

16. The method according to claim 10, wherein the recycled Nd-Fe-B sintered magnet contains a total atomic percentage of Fe and Co of 77 at% or less.

17. The method according to claim 10, wherein the regenerated Nd-Fe-B sintered magnet contains a total atomic percentage of Nd, Dy, and Pr of 18 at% or less.

18. The method according to claim 10, wherein the elemental additive includes the rare earth-containing material.

19. The method according to claim 10, wherein the elemental additive contains Dy.

20. The method according to claim 10, wherein the recycled Nd-Fe-B sintered magnet contains 1.98 at% or less of oxygen.

21. The method according to claim 10, wherein the recycled Nd-Fe-B sintered magnet contains 1.32 to 1.98 at% oxygen.

22. A method for manufacturing a device or system comprising a recycled Nd-Fe-B magnet, comprising manufacturing the recycled Nd-Fe-B magnet according to the method described in any one of claims 1 to 21, wherein the device or system is a starter motor, an anti-lock braking system (ABS), a fuel pump, a fan, a loudspeaker, a microphone, a telephone ringer, a switch, a relay, a hard disk drive (HDD), a stepping motor, a servo motor, a magnetic resonance imaging apparatus (MRI), a wind turbine generator, a robotic device, a sensor, a magnetic separator, a guidance system, or a satellite.

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