Abstract: The present disclosure relates to coating formulations for neodymium-iron-boron type magnetic powders manufactured from rapid solidification processes for the purpose, inter alia, of corrosion and oxidation resistance when exposed to aggressive environments. The coating formulation preferably contains an epoxy binder, curing agent, an accelerating agent, and a lubricant. By incorporating coupling agents and optionally, other specialty additives with the magnetic powder and the organic epoxy components, additional oxidation and corrosion prevention, enhanced adhesion and dispersion between the filler and matrix phases can be achieved. This disclosure relates to all such rare earth-transition metal-boron (RE-TM-B) powders produced by rapid solidification and encompasses both the bonded magnet products that include combinations of the materials mentioned and the application processes.

Abstract: The present disclosure relates to coating formulations for neodymium-iron-boron type magnetic powders manufactured from rapid solidification processes for the purpose, inter alia, of corrosion and oxidation resistance when exposed to aggressive environments. The coating formulation preferably contains an epoxy binder, curing agent, an accelerating agent, and a lubricant. By incorporating coupling agents and optionally, other specialty additives with the magnetic powder and the organic epoxy components, additional oxidation and corrosion prevention, enhanced adhesion and dispersion between the filler and matrix phases can be achieved. This disclosure relates to all such rare earth-transition metal-boron (RE-TM-B) powders produced by rapid solidification and encompasses both the bonded magnet products that include combinations of the materials mentioned and the application processes.

Abstract: The present disclosure relates to coating formulations for neodymium-iron-boron type magnetic powders manufactured from rapid solidification processes for the purpose, inter alia, of corrosion and oxidation resistance when exposed to aggressive environments. The coating formulation preferably contains an epoxy binder, curing agent, an accelerating agent, and a lubricant. By incorporating coupling agents and optionally, other specialty additives with the magnetic powder and the organic epoxy components, additional oxidation and corrosion prevention, enhanced adhesion and dispersion between the filler and matrix phases can be achieved. This disclosure relates to all such rare earth-transition metal-boron (RE-TM-B) powders produced by rapid solidification and encompasses both the bonded magnet products that include combinations of the materials mentioned and the application processes.

Abstract: The present invention relates to highly quenchable Fe-based rare earth magnetic materials that are made by rapid solidification process and exhibit good magnetic properties and thermal stability. More specifically, the invention relates to isotropic Nd—Fe—B type magnetic materials made from a rapid solidification process with a lower optimal wheel speed and a broader optimal wheel speed window than those used in producing conventional magnetic materials. The materials exhibit remanence (Br) and intrinsic coercivity (Hci) values of between 7.0 to 8.5 kG and 6.5 to 9.9 kOe, respectively, at room temperature. The invention also relates to process of making the materials and to bonded magnets made from the magnetic materials, which are suitable for direct replacement of anisotropic sintered ferrites in many applications.

Abstract: The present invention relates to highly quenchable Fe-based rare earth magnetic materials that are made by rapid solidification process and exhibit good magnetic properties and thermal stability. More specifically, the invention relates to isotropic Nd—Fe—B type magnetic materials made from a rapid solidification process with a lower optimal wheel speed and a broader optimal wheel speed window than those used in producing conventional magnetic materials. The materials exhibit remanence (Br) and intrinsic coercivity (Hci) values of between 7.0 to 8.5 kG and 6.5 to 9.9 kOe, respectively, at room temperature. The invention also relates to process of making the materials and to bonded magnets made from the magnetic materials, which are suitable for direct replacement of anisotropic sintered ferrites in many applications.

Abstract: The invention relates to a flywheel magneto generator having a rotor assembly and a stator assembly. The rotor assembly includes a non-ferromagnetic flywheel and a plurality of magnetic poles that are positioned in spaced relationship around the circumference of the flywheel. The stator assembly includes an E-shaped core with a single magnet mounted on the center leg and coils associated with at least the outer legs. The poles and core may be formed of a bonded iron material. The poles may be joined to the flywheel by press fitting or integral molding, among other methods.

Abstract: An improved magnet for use in voice coil actuators is disclosed. The improved magnet includes first and second ends and a top surface, which includes one or more reversed slope notches. Each reversed slope notch may be located in proximity to the ends of the magnet, and may be located such that the magnet is shaped symmetrically about its center. The reversed slope notch is generally characterized in that it includes a notch surface which slopes downward towards the associated end of the magnet. The reversed slope notch or notches minimize the drop-off of force of the voice coil actuator near the ends of the actuator's stroke. In one embodiment, the magnet is part of a linear voice coil actuator that includes a return structure enclosing a magnet and an air gap. In this embodiment, the top surface of the magnet is located adjacent the air gap, and a current-carrying coil travels through the air gap.

Abstract: The invention relates to a flywheel magneto generator having a rotor assembly and a stator assembly. The rotor assembly includes a non-ferromagnetic flywheel and a plurality of magnetic poles that are positioned in spaced relationship around the circumference of the flywheel. The stator assembly includes an E-shaped core with a single magnet mounted on the center leg and coils associated with at least the outer legs. The poles and core may be formed of a bonded iron material. The poles may be joined to the flywheel by press fitting or integral molding, among other methods.

Abstract: An improved magnet for use in voice coil actuators is disclosed. The improved magnet includes first and second ends and a top surface, which includes one or more reversed slope notches. Each reversed slope notch may be located in proximity to the ends of the magnet, and may be located such that the magnet is shaped symmetrically about its center. The reversed slope notch is generally characterized in that it includes a notch surface which slopes downward towards the associated end of the magnet. The reversed slope notch or notches minimize the drop-off of force of the voice coil actuator near the ends of the actuator's stroke. In one embodiment, the magnet is part of a linear voice coil actuator that includes a return structure enclosing a magnet and an air gap. In this embodiment, the top surface of the magnet is located adjacent the air gap, and a current-carrying coil travels through the air gap.

Abstract: The invention relates to magnets, particularly bonded magnets, of the Re—Fe—B type made from atomized magnetic powders and to methods of producing the powders and the magnet. The magnetic powders comprise, by weight, about 15% to 25% of RE; about 0.8% to 2.0% of B; about 1% to 10% of T; and balanced with Fe, Co, or mixtures thereof; wherein RE is one or more rare earth elements selected from the group consisting of Y, La, Ce, Pr, Nd, Sm, Er, Gd, Tb, Dy, Ho, Tm, Yb and Lu, and T is one or more elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, and W. To produce bonded magnets, the atomized powders are heat treated, combined with a binder, pressed or molded, and cured to produce the bonded magnets.

Abstract: Isotropic magnetic alloy powder having an intrinsic magnetic induction of at least two third of its magnetic remanence and method for making same are provided. The powder is made from an alloy having a composition comprising, by weight percentage, approximately 15 to 35 percent of one or more rare earth metals, approximately 0.5 to 4.5 percent of boron, and approximately 0 to 20 percent of cobalt, balanced with iron. The alloy powder is made by a process wherein an amount of the alloy is melt and spun in an inert environment, preferably at a distance between an orifice and a wheel being less than one and one half inches, into ribbons, followed by crushing the ribbons into powder and annealing the powder.

Abstract: A process is disclosed for producing rare earth-iron-boron alloys and magnets with reduced oxygen content and improved yield. Such a reduction in oxygen content and improvement in yield are achieved by including copper in a melt having a composition comprising a rare earth, boron, and iron, and subsequently solidifying the melt.