Abstract: A method of recovering magnetic powder from rare earth bond magnet comprising a process of soaking the rare earth bond magnet in a decomposing solution, or holding it in a gas phase of the decomposing solution, containing at least one solvent selected from a group comprising tetralin, naphthalene, 1,4-hydroxynaphthalene, naphthol, biphenyl, 2-hexanone, acetonylacetone, phorone cyclohexanone and methlcyclohexanone, and heating at a temperature not lower than 230° C. A method of recycling recovered magnetic powder by substituting at least a part or all of magnetic powder in the molding compound of a second rare earth bond magnet. For preventing deterioration of magnetic powder from oxidation at surface, air in the decomposition vessel is substituted with nitrogen gas, helium gas and argon gas or is reduced to a pressure not higher than 10−2 Torr.

Abstract: The method of manufacturing rare earth thick film magnet comprising a step of forming an alloy layer of 30-100 &mgr;m thick having a general formula RXBYTMZ on a substrate by a physical deposition process, and a step of heat-treating the alloy layer to form a thick film magnetic layer having R2TM14B phase as a main phase. In the general formula, R is at least one of rare earth elements, B is boron, TM is iron or its alloy partly substituted by cobalt. X is 0.1-0.2, Y is 0.05-0.2 and Z=1−X−Y. Further, the method of the present invention includes a step of laminating a plurality of alloy layers formed on a substrate together with the substrate. A motor comprising rare earth thick film magnet of the present invention is extremely small while obtaining high output.

Abstract: There is provided a process of producing a ring shaped resin bonded magnetic member by molding a feed mixture 24 which contains a lubricant and a magnetic powder composite made of magnetic powder and a heat curable resin composition which is in a solid state at a room temperature. The process is characterized in that (1) heating an inner peripheral surface of the annular cavity 20 so as to transfer heat to the feed mixture 24 whereby heating the feed mixture to a temperature not lower than a softening temperature and below a curing temperature of the resin composition, and compressing the filled feed mixture after or during the heating; and (ii) cooling the inner peripheral surface so as to transfer heat from the heated and compressed feed mixture through the inner peripheral surface, whereby cooling the feed mixture to a temperature below the softening temperature of the resin composition so as to obtain a green compact having a ring shape.

Abstract: Fine powder out of adequate particle size range discharged in a manufacturing process of resin magnet compound comprising step 1 of mixing magnet powder such as neodymium-iron-boron system quenched alloy and an organic solvent solution of a thermal polymerizing resin in wet process, and step 2 of solvent removal-pulverizing-sorting into adequate particle size range is processed again in step 1 and step 2, and resin magnet compound within adequate particle size range is obtained again, and moreover the green matter obtained by strong compression of the resin magnet compound into a desired magnet shape is processed again at step 2 to obtain fine powder, which is processed again at step 1 and step 2, so that resin magnet compound within adequate particle size is obtained again.

Abstract: A magnet having a maximum energy product at 20° C. of 18 MGOe or more, and an extremely excellent magnetic performance is obtained. A magnet stable in the magnetic performance in practical temperature range is obtained. A magnet having an excellent recycling performance is obtained. A magnet motor using such rare earth resin magnet generates a potent static magnetic field in the space with the armature core. The motor output is enhanced, and the current consumption is lowered. The rare earth resin magnet comprises at least one resin of thermoplastic resin and thermoplastic elastomer, pentaerythritol stearic acid triester, and rare earth magnetic powder. The rare earth magnetic powder, resin, and pentaerythritol stearic acid triester form a mutually mixed resin magnet composition, and this resin magnet composition has a predetermined shape. A magnet rotor has this rare earth resin magnet.

Abstract: There is provided a process of producing a ring shaped resin bonded magnetic member by molding a feed mixture 24 which contains a lubricant and a magnetic powder composite made of magnetic powder and a heat curable resin composition which is in a solid state at a room temperature. The process is characterized in that (1) heating an inner peripheral surface of the annular cavity 20 so as to transfer heat to the feed mixture 24 whereby heating the feed mixture to a temperature not lower than a softening temperature and below a curing temperature of the resin composition, and compressing the filled feed mixture after or during the heating; and (ii) cooling the inner peripheral surface so as to transfer heat from the heated and compressed feed mixture through the inner peripheral surface, whereby cooling the feed mixture to a temperature below the softening temperature of the resin composition so as to obtain a green compact having a ring shape.

Abstract: A molding composition containing an unsaturated alkyd resin and an unsaturated polyester containing a crosslinking monomer, which may be 2-hydroxyethyl acrylate or 2-hydroxyethyl methacrylate. A molded part is manufactured by (a) covering the surrounding of a stator part having a heat generating coil with the molding composition, (b) feeding power to the coil for generating heat in the stator part, and (c) curing the molding composition by the heat generated in the stator part. The curing time is shortened, the molding cycle is improved, and, as a result, a molding composition excellent in productivity is presented, and by using this molding composition, molded parts are manufactured at excellent productivity.

Abstract: Fine powder out of adequate particle size range discharged in a manufacturing process of resin magnet compound comprising step 1 of mixing magnet powder such as neodymium-iron-boron system quenched alloy and an organic solvent solution of a thermal polymerizing resin in wet process, and step 2 of solvent removal-pulverizing-sorting into adequate particle size range is processed again in step 1 and step 2, and resin magnet compound within adequate particle size range is obtained again, and moreover the green matter obtained by strong compression of the resin magnet compound into a desired magnet shape is processed again at step 2 to obtain fine powder, which is processed again at step 1 and step 2, so that resin magnet compound within adequate particle size is obtained again.

Abstract: There is provided a process of recovering copper from winding composed of an enameled copper wire having a polyester and/or a polyurethane based insulating coating thereon, and the process includes the steps of immersing the winding into an alkali solution, removing alkali attaching to the winding, and melting the winding using high frequency heating.

Abstract: A motor bearing device includes a bearing member, and a rotary shaft made of steel into which ions of metal element and carbon ions are implanted via a surface of the rotary shaft. The rotary shaft is slidable relative to the bearing member. The metal element is selected from the group consisting of metal elements in the IVa, Va, and VIa groups of the periodic system. Lubricant is provided between the bearing member and the rotary shaft. The surface of the rotary shaft opposes the bearing member.

Abstract: A method for disposal of a thermosetting resin containing a material, at least part of which is affected by an alkaline aqueous solution, is disclosed. It comprises at least two steps of including a step of immersing the molded product in an alkaline aqueous solution and a subsequent step of immersing the molded product in water. This method does not require a high temperature as required in a thermal decomposition and does not generate any exhaust gas, and consumes only small energy.

Abstract: A method of recovering resources in a resin-molded electrical rotating device (1,2) in which electromagnetic members (1a,1b,2a) are molded with resin molding (1c,2c) with fine voids so as to be integrally made into a solid body, and a resin for molding of the rotating device (1,2). The method has the steps of disintegrating the resin molding (1c,2c) by chemically decomposing and/or eluting so as to remove the resin molding (1c,2c) from the electromagnetic members (1a,1b,2a) and separating and recovering at least metal components in the electromagnetic members (1a,1b,2a) as the resources.

Abstract: A process for producing a magnet in which the content of anisotropic magnet powder is from 95 to 50% by weight. The process includes the following steps. A powder mixture composed of the anisotropic magnet powder and solder powder containing isotropic magnet powder as a main constituent thereof is charged in a compacting mold. The powder mixture in a cavity is orientated in a magnetic field. It is compressed and Joule heated. Thus, the powder mixture is fixed. When the powder mixture is fixed into a magnet, the ratio (Po/Lo) of the average grain size Po of the anisotropic magnet powder to the size of the magnet Lo which size is measured in the orientation direction is preferably 0.6 or more.

Abstract: A method of manufacturing an inorganic bonding type rapidly solidified magnet, which is formed by energizing and sintering, after an instantaneous mutual attractive force has been applied intermittently in accordance with the electromagnetic force upon a thin piece shaped rapidly solidified magnet powder in a mold. A thin piece shaped inorganic glass having a thermal expansion ratio 9.times.10.sup.-6 /.degree. C. or less is used as the inorganic coupling agent. The magnet of the present invention having a ring shape, is effective to improve reliability as a rotor magnet in consideration of size, safety, mechanical strength, etc. of the present magnet formed in a ring shape. The electric resistance of the magnet is 10.sup.-3 through 10.sup.-1 .OMEGA.cm and is desirable as a rotor magnet of a PWM driving brushless electric motor.

Abstract: A method of manufacturing a permanent magnet which comprises applying one directional pressure and an electric current to an aggregate through a pair of electrodes to cause the aggregate to undergo a plastic deformation thereby to expand an axially projected surface area. The aggregate used is of a type containing alloy flakes interlocked with each other. The alloy flakes are those made of at least one rare earth metal and a ferrous component by the use of a melt quenching process.

Abstract: A resin bonded magnet which comprises a resinous binder and melt quenched magnetically isotropic ferromagnetic alloy particles having a coercive force of 8 to 12 KOe of the formula: Fe.sub.100-x-y-z Co.sub.x R.sub.y B.sub.z wherein R is at least one of Nd and Pr, x is an atomic % of not less than 15 and not more than 30, y is an atomic % of not less 10 and not more than 13 and z is an atomic % of not less than 5 and not more than 8; the ferromagnetic alloy particles uniformly dispersed in the binder.

Abstract: A process for producing a rare earth element-iron-boron anisotropic magnet that may generate a strong static magnetic field in vacant spaces of a magnetic circuit mounted in a motor is disclosed. The process comprises the steps of placing a billet produced of rapid solidification powder of a rare earth element-iron-boron alloy into a mold cavity, applying a primary pressure to said billet, while allowing a primary current to pass through said billet, applying to said billet a secondary pressure which is increased up to at least five times as much as the primary pressure, and applying a secondary current greater than the primary current through said billet, wherein the billet is finally subjected to plastic deformation at the temperature between the crystalline temperature and 750.degree. C.

Abstract: A process for producing a rare earth-iron-boron magnet, which includes the steps of: (1) charging a melt spun powder of a rare earth-iron-boron magnet into at least one cavity, which is confined by a pair of electrodes inserted into a hole of an electrically non-conductive ceramic die; (2) subjecting the melt spun powder to a non-equilibrium plasma treatment, under a reduced atmosphere of 10.sup.-1 to 10.sup.-3 Torr, while applying a uniaxial pressure of 200 to 500 kgf/cm.sup.2 to the melt spun powder in the direction connecting the electrodes interposed between a pair of thermally insulating members, thereby fusing the melt spun powder; and (3) heating the fused melt spun powder to a temperature higher than or equal to its crystallization temperature by transferring a Joule's heat generated in the thermally insulating members by passing a current through the members to the melt spun powder thereby causing the plastic deformation of the melt spun powder to form a rare earth-iron-boron magnet.

Abstract: A process for producing resin bonded magnet structures is disclosed which includes the steps of: (a) adding a solid epoxy resin of at least one epoxy oligomer and a microcapsule which contains at least one liquid epoxy resin to a melt spun powder of a rare earth element-iron alloy to form a granulated intermediate material, wherein the epoxy oligomer has alcoholic hydroxyl groups in the molecular chain thereof and the solid epoxy resin has a softening temperature (Durran's melting point) of 65.degree. C. to 85.degree. C.; (b) mixing the granulated intermediate material with a powdered curing agent and a lubricant to form a compound; (c) forming a green body of a resin bonded magnet by compressing the compound, and then integrating the green body directly with a supporting member; and (d) curing the solid and liquid epoxy resins in the green body by application of heat to form a rigid structure of the resin bonded magnet integrated with the supporting member.

Abstract: A method for manufacturing permanent magnets from a plurality of thin flakes of a rare earth-Fe-B alloy metal, comprising the steps ofsubjecting the thin flakes to a discharge electric field, the thin flakes being comprised of an R-Fe-B alloy metal; and R-Fe-B-M alloy metal; an R-Fe(Co)-B alloy metal comprising 11 to 18 atom % R, 4 to 11 atom % B, 30 atom % Co, the balance being Fe; and/or an R-Fe(Co)-M-B alloy metal,generating Joule heat on the contacting interfaces of the thin flakes by applying pressure to the gathered body of thin flakes and by supplying a current thereto, andbonding the gathered body integrally by making the thin flakes deform plastically in a warm state.R is one or more rare earth elements and M is one or more members selected from the group consisting of Si, Al, Nb, Zr, Hf, Mo, Ga, P and C. The thin flakes are in a nonequilibrium state such that the R.sub.2 Fe.sub.14 B phases and amorphous phases are coexistent.