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- Nachgewiesen in: USPTO Patent Applications
- Sprachen: English
- Document Number: 20220139601
- Publication Date: May 5, 2022
- Appl. No: 17/509112
- Application Filed: October 25, 2021
- Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA (Toyota-shi, JP)
- Claim: 1. A rare earth magnet comprising: a main phase; and a grain boundary phase present around the main phase, wherein: an overall composition in terms of a molar ratio is represented by a formula (R1(1-x-y)LaxCey)u(Fe(1-z)Coz)(100-u-w-v)BwM1v (where R1 is one or more elements selected from the group consisting of Nd, Pr, Gd, Tb, Dy, and Ho; M1 is one or more elements selected from the group consisting of Ga, Al, Cu, Au, Ag, Zn, In, and Mn, and an unavoidable impurity element; and the followings are satisfied, 0.05≤x≤0.25, 0≤y/(x+y)≤0.50, 13.5≤u≤20.0, 0≤z≤0.100, 5.0≤w≤10.0, and 0≤v≤2.00); the main phase has a crystal structure of an R2Fe14B-type (where R is a rare earth element); an average grain size of the main phase is 1.0 μm to 20.0 μm; a volume fraction of the main phase is 80.0% to 90.0%; and the main phase and the grain boundary phase satisfy the following, (an existence proportion of La in the grain boundary phase)/(an existence proportion of La in the main phase)>1.30.
- Claim: 2. The rare earth magnet according to claim 1, wherein: the R1 is one or more elements selected from the group consisting of Nd and Pr; and the M1 is one or more elements selected from the group consisting of Ga, Al, and Cu, and an unavoidable impurity element.
- Claim: 3. The rare earth magnet according to claim 1, wherein the volume fraction of the main phase is 80.0% to 86.6%.
- Claim: 4. The rare earth magnet according to claim 1, wherein the main phase and the grain boundary phase satisfy the following, (the existence proportion of La in the grain boundary phase)/(the existence proportion of La in the main phase)≥1.56.
- Claim: 5. A manufacturing method for the rare earth magnet according to claim 1, the manufacturing method comprising: preparing a molten metal having a composition, in terms of a molar ratio, represented by a formula (R1(1-x-y)LaxCey)u(Fe(1-z)Coz)(100-u-w-v)BwM1v (where R1 is one or more elements selected from the group consisting of Nd, Pr, Gd, Tb, Dy, and Ho; M1 is one or more elements selected from the group consisting of Ga, Al, Cu, Au, Ag, Zn, In, and Mn, and an unavoidable impurity element; and the followings are satisfied, 0.05≤x≤0.25, 0≤y/(x+y)≤0.50, 13.5≤u≤20.0, 0≤z≤0.100, 5.0≤w≤10.0,and 0≤v≤2.00); cooling the molten metal at a rate of 1° C./sec to 104° C./Sec to obtain a magnetic alloy; pulverizing the magnetic alloy to obtain a magnetic powder; and sintering the magnetic powder without pressurization to obtain a sintered body.
- Claim: 6. The manufacturing method according to claim 5, wherein the magnetic powder is sintered without pressurization at 900° C. to 1,100° C.
- Claim: 7. The manufacturing method according to claim 5, wherein the sintered body after the sintering without pressurization is cooled at a rate of 1° C.:/min or less.
- Claim: 8. The manufacturing method according to claim 5, wherein: the R1 is one or more elements selected from the group consisting of Nd and Pr, and the M1 is one or more elements selected from the group consisting of Ga, Al, and Cu, and an unavoidable impurity element.
- Current International Class: 01; 01
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