Magnets made from rare earth elements and how to manufacture them.

Abstract

Rare Earth Magnets (500) including the principal phase (10) and the particle boundary phase (50). And the overall composition is represented by the formula (R2(lx)R1x)yFe(100-ywzv)CowBzM1v(R3(lp)M2)q. (R4(ls)M3s)t where R1 is a light rare earth element, R2 and R3 are medium rare earth elements, R4 is a rare earth element. Rare heavy metals, M1, M2, M3 are predetermined metallic elements. The main phase (10) includes the axial phase. (20), the first shell (30) and the second shell (40) contain proportions of medium-rare earth elements. In the first shell (30) the proportion is higher than in the core (20), the proportion of intermediate rare earth elements is higher. The second shell (40) is lower than the first shell (30). The second shell (40) contains heavy rare earth elements.

Claims

1. Rare earth magnets (500) are composed of a principal phase (10) and an edge phase of particles (50) surrounding the principal phase (10), where the overall composition in terms of molar ratio is represented by the formula (R2(1-x)R1x)yFe(100-ywzv)CowBzM1v(R3(lp)M2p)q(R4(ls)M3s)t, where R1 is one or more elements chosen from the group of Ce, La, Y, and Sc; R2 and R3 are one or more elements chosen from the group of Nd and Pr; R4 is a rare earth element, which includes one or more elements chosen from the group of Nd and Pr. M1 is an element or more from the group consisting of at least Gd, Tb, Dy, and Ho; M2 is a rare earth metal alloyed with R3 and unavoidable impurities; and M3 is a rare earth metal alloyed with R4 and unavoidable impurities, and conforms to the following specifications: 0.1 less than or equal to x less than or equal to 1.0, 12.0 less than or equal to y less than or equal to 20.0, 5.0 less than or equal to z less than or equal to 20.0, 0 less than or equal to w less than or equal to 8.0, 0 less than or equal to v less than or equal to 2.0, 0.05 less than or equal to p less than or equal to 0.40, 0.1 less than or equal to q less than or equal to 15.0, 0.05 less than or equal to s less than or equal to 0.40 and 0.1 less than or equal to t less than or equal to 5.

0. The principal phase (10) has a crystal structure of type R2Fe14B, in which R is a rare earth element. The average particle size of the principal phase (10) is 0.1 micrometer to 20 micrometers. The main phase (10) has a core (20), a first cladding (30) that surrounds the core (20), and a second cladding (40) that surrounds the first cladding (30). The sum of the molar ratios of Nd and Pr in the first cladding (30) is higher than the sum of the molar ratios of Nd and Pr in the core (20). The sum of the molar ratios of Nd and Pr in the second cladding (40) is lower than the sum of the molar ratios of Nd and Pr in the first cladding (30). The second cladding (40) contains one of the elements.

1. A rare earth magnet (500) according to claim 1 where x is 0.5 less than or equal to x is 1.

03.

2. A rare earth magnet (500) according to claim 1 where x is 0.5 less than or equal to x is 1.

03. 3.Rare earth magnets (500) under either claim 1 or 2, where R1 is one or more elements selected from the group of Ce and La, R2 and R3 are Nd, and R4 is one or more elements selected from the group of Tb and Nd.

4. Rare earth magnets (500) under either claim 1 to 3, where the sum of the molar ratios of Nd and Pr in the first cladding (30) is 1.2 to 3.0 times the sum of the molar ratios of Nd and Pr in the core (20). The sum of the molar ratios of Nd and Pr in the second cladding (40) is 0.5 to 0.9 times the sum of the molar ratios of Nd and Pr in the first cladding (30). The sum of the molar ratios of Gd, Tb, Dy and Ho in the second cladding (40) is at least 2.0 times the sum of the molar ratios of Gd, Tb, Dy and Ho in the core cladding (20), and the sum of the molar ratios of Gd, Tb, Dy and Ho in the second cladding (40) is at least 2.0 times the sum of the molar ratios of Gd, Tb, Dy and Ho in the first cladding (30).5.The manufacturing method for rare earth magnets (500) under claim1, in which the manufacturing method comprises the preparation of a rare earth magnet precursor (150) that includes the principal phase (10) and the peripheral phase of particles (50) present around the principal phase (10), and in which the overall composition in terms of molar ratio is represented by the formula (R2(lx)R1x)yFe(100-ywzv)CowBzM1v(R3(lp)M2p)q, where R1 is one or more elements chosen from the group consisting of Ce, La, Y and Sc; R2 and R3 are one or more elements chosen from the group consisting of Nd and Pr, M1 is one or more elements selected from a group consisting of Ga, Al, Cu, Au, Ag, Zn, In, and Mn and unavoidable impurities, and M2 is a rare earth metallic element alloyed with R3 and unavoidable impurities, and conforms to the following specifications: 0.1 less than or equal to x less than or equal to 1.0, 12.0 less than or equal to y less than or equal to 20.0, 5.0 less than or equal to z less than or equal to 20.0, 0 less than or equal to w less than or equal to 8.0, 0 less than or equal to v less than or equal to 2.0, 0.0.5 less than or equal to p less than or equal to 0.40 and 0.1 less than or equal to q less than or equal to 15.

0. The main phase (10) has a crystal structure of type R2Fe14B, in which R is a rare earth element. The average particle size of the main phase (10) is 0.1 μm to 20 μm. The main phase (10) includes the core (20) and the first cladding (30) which exists around the core (20), and the sum of the molar ratios of Nd and Pr in the first cladding (30) is higher than the sum of the molar ratios of Nd and Pr in the core (20). The preparation of the first modifier (300) containing the element The composition is represented by the formula R4(ls)M3s in terms of molar ratio, where R4 is a rare earth element, which includes at least one or more of the elements selected from the group consisting of Gd, Tb, Dy and Ho, M3 is a rare earth metallic element, which is alloyed with R4 and the inevitable impurities and conforms to the following specifications: 0.05 less than or equal to s less than or equal to 0.40 and the first modifier material (300) diffuses and permeates into the first rare earth magnetic substrate (150)6.The manufacturing method under claim 5, which incorporates the preparation of a second (100) rare earth magnetic precursor, includes the principal phase (10) and the peripheral phase of particles (50) present around the principal phase (10), and in which the overall composition in terms of molar ratio is represented by the formula (R2(lx)R1x)yFe(100-ywz)CowB1M1v, where R1 is one or more elements chosen from the group consisting of Ce, La, Y and Sc; R2 is one or more elements chosen from the group consisting of Nd and Pr; M1 is one or more elements. More than one selected from a group consisting of Ga, Al, Cu, Au, Ag, Zn, In and Mn and unavoidable impurities and according to the following specifications: 0.1 less than or equal to x less than or equal to 1.0, 12.0 less than or equal to y less than or equal to 20.0, 5.0 less than or equal to z less than or equal to 20.0, 0 less than or equal to w less than or equal to 8.0 and 0 less than or equal to v less than or equal to 2.0 and the principal phase (10) has a crystal structure of type R2Fe14B, where R is a rare earth element and the average particle size of the principal phase (10) is 0.1 micrometer to 20 micrometers, preparation of a second modifier material (200) with an element represented by the formula R3(lp)M2p in terms of molar ratio, where R3 is one or more elements chosen from the group consisting of Nd and Pr; M2 is a rare earth metallic element, which is alloyed with R3 and unavoidable impurities and conforms to the following specifications 0.05 less than or equal to P less than or equal to 0.40, and the diffusion and permeation of the second rare earth magnetic substrate (100) to obtain the first rare earth magnetic substrate (150).7.The manufacturing method under claim 5, which incorporates the preparation of a second rare earth magnetic precursor powder, includes a principal phase (10) and an edge phase of particles (50) surrounding the principal phase (10), and whose overall composition in terms of molar ratio is represented by the formula (R2(lx)R1x)yFe(100-ywz)CowBzM1v, where R1 is one or more elements chosen from the group consisting of Ce, La, Y and Sc; R2 is one or more elements chosen from the group consisting of Nd and Pr; M1 is one or more elements. Or more, selected from a group consisting of Ga, Al, Cu, Au, Ag, Zn, In and Mn and unavoidable impurities and according to the following specifications: 0.1 less than or equal to x less than or equal to 1.0, 12.0 less than or equal to y less than or equal to 20.0, 5.0 less than or equal to z less than or equal to 20.0, 0 less than or equal to w less than or equal to 8.0 and 0 less than or equal to v less than or equal to 2.0 and the principal phase (10) has a crystal structure of type R2Fe14B, where R is a rare earth element and the average particle size of the principal phase (10) is 0.1 micrometer to 20 micrometers. Preparation of a second modified powder containing an element represented by the formula R3(lp)M2p in terms of molar ratio, where R3 is one or more elements chosen from the group of Nd and Pr; M2 is a metallic element other than a rare earth element, which is alloyed with R3 and unavoidable impurities and conforms to the following specifications 0.05 less than or equal to p less than or equal to 0.40, and mixing of the second rare earth magnetic precursor powder with the second modified powder and sintering of the mixture to obtain the first rare earth magnetic precursor (150).

8. Production method according to claim 6 or 7 where the diffusion and permeation temperature of the first modified material (300) is lower than the diffusion and permeation temperature of the second modified material (200) or the diffusion and permeation temperature of the second modified powder.

9. Production method according to one of claims 5 to 8 where x conforms to 0.5 less than or equal to x less than or equal to 1.

01. 0.The production method shall be based on one of claims 5 through 9, where R1 is one or more elements selected from a group containing Ce and La; R2 and R3 are Nd; and R4 is one or more elements selected from a group containing Tb and Nd.