# US 10,770,208 B2 · Permanent magnet, motor, and generator > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,770,208 B2 - Document ID: US10770208B2 - Status: Granted - Kind: B2 - Application number: 14/661,122 - Filed: 2015-03-18 - Published: 2015-09-24 - Granted: 2020-09-08 - Earliest claimed: 2014-03-18 - Assignees: Kabushiki Kaisha Toshiba - Applicants: Kabushiki Kaisha Toshiba - Inventors: Yosuke Horiuchi; Shinya Sakurada; Keiko Okamoto; Masaya Hagiwara; Tsuyoshi Kobayashi; Masaki Endo; Tadahiko Kobayashi; Naoyuki Sanada - Web page: https://patentgrep.com/patent/US10770208B2 ## CPC - H01F 1/055: and magnetic transition metals, e.g. SmCo5 - C22C 19/07: based on cobalt - C22C 30/02: containing copper - H01F 1/0551: {in the form of particles, e.g. rapid quenched powders or ribbon flakes} - H01F 1/0557: {sintered} - H02K 1/02: characterised by the magnetic material - B22F 9/08: by casting, e.g. through sieves or in water, by atomising or spraying (using electric discharge B22F9/14) - B22F 2009/041: {by mechanical alloying, e.g. blending, milling} - B22F 2009/043: {by ball milling} - B22F 2009/044: {by jet milling} - B22F 2009/048: {by pulverising a quenched ribbon} - B22F 2998/10: Processes characterised by the sequence of their steps - B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy - H01F 7/0226: {PM with variable field strength (H01F7/0284 takes precedence)} - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES - C22C: ALLOYS (treatment of alloys C21D, C22F) - H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53}) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER ## Abstract A high performance permanent magnet is provided. The permanent magnet includes a composition represented by a composition formula: RpFeqMrCutCo100-p-q-r-t, and a metallic structure including cell phases having a Th2Zn17 crystal phase and Cu-rich phases having higher Cu concentration than the cell phases. An average diameter of the cell phases is 220 nm or less, and in a numeric value range from a minimum diameter to a maximum diameter of the cell phases, a ratio of a number of cell phases having a diameter in a numeric value range of less than upper 20% from the maximum diameter is 20% or less of all the cell phases. ## Claims ### Claim 1 A permanent magnet, comprising: a composition expressed by a composition formula: RpFeqMrCutCo100-p-q-r-t where R is at least one element selected from the group consisting of rare earth elements, M is at least one element selected from the group consisting of Zr, Ti, and Hf, p is a number satisfying 10.5≤p≤12.5 atomic %, q is a number satisfying 26≤q≤29.4 atomic %, r is a number satisfying 0.88≤r≤4.5 atomic %, and t is a number satisfying 5.23≤t≤10.7 atomic %, and a total of p, q and r is 41.02 atomic % or less; and a metallic structure including cell phases having a Th2Zn17 crystal phase and Cu-rich phases having higher Cu concentration than the cell phases, an average diameter of the cell phases being 220 nm or less, the cell phases having diameter of a numeric value range from a minimum diameter to a maximum diameter, a ratio of a number of cell phases having diameters in a numeric value range of upper 20% from the maximum diameter being 20% or less of all the cell phases, a squareness ratio of the magnet being 93.5% or more and 94.5% or less, and a residual magnetization of the magnet being 1.185 T or more and 1.215 T or less. ### Claim 2 (depends on 1) The magnet of claim 1, wherein the Cu-rich phases are provided to surround the cell phases. ### Claim 3 (depends on 1) The magnet of claim 1, wherein the Cu-rich phases have a CaCu5 crystal phase. ### Claim 4 (depends on 1) The magnet of claim 1, wherein the Cu concentration of the Cu-rich phases is 45 atomic % or more. ### Claim 5 (depends on 1) The magnet of claim 1, wherein a full width at half maximum of a concentration profile of Cu in the Cu-rich phases is 5 nm or less. ### Claim 6 (depends on 1) The magnet of claim 1, wherein 50 atomic % or more of a total amount of the element R in the composition formula is Sm, and wherein 50 atomic % or more of the element M in the composition formula is Zr. ### Claim 7 (depends on 1) The magnet of claim 1, wherein r is a number satisfying 0.88≤r≤3.11 atomic %. ### Claim 8 (depends on 1) A motor comprising the permanent magnet of claim 1. ### Claim 9 (depends on 1) A generator comprising the permanent magnet of claim 1. ### Claim 10 (depends on 8) A vehicle comprising the motor of claim 8. ### Claim 11 (depends on 9) A vehicle comprising the generator of claim 9. ### Claim 12 A permanent magnet, comprising: a composition expressed by a composition formula: RpFeqMrCut(Co100-xAx)100-p-q-r-t where R is at least one element selected from the group consisting of rare earth elements, M is at least one element selected from the group consisting of Zr, Ti, and Hf, A is at least one element selected from the group consisting of Ni, V, Cr, Mn, Al, Ga, Nb, Ta, and W, p is a number satisfying 10.5≤p≤12.5 atomic %, q is a number satisfying 26≤q≤29.4 atomic %, r is a number satisfying 0.88≤r≤4.5 atomic %, t is a number satisfying 5.23≤t≤10.7 atomic %, x is a number satisfying x≤20 atomic %, and a total of p, q and r is 41.02 atomic % or less; and a metallic structure including cell phases having a Th2Zn17 crystal phase and Cu-rich phases having higher Cu concentration than the cell phases, an average diameter of the cell phases being 220 nm or less, the cell phases having diameter of a numeric value range from a minimum diameter to a maximum diameter, a ratio of a number of cell phases having diameters in a numeric value range of upper 20% from the maximum diameter being 20% or less of all the cell phases, a squareness ratio of the magnet being 93.5% or more and 94.5% or less, and a residual magnetization of the magnet being 1.185 T or more and 1.215 T or less. ### Claim 13 A permanent magnet, comprising: a composition expressed by a composition formula: RpFeqMrCutCo100-p-q-r-t where R is at least one element selected from the group consisting of rare earth elements, M is at least one element selected from the group consisting of Zr, Ti, and Hf, p is a number satisfying 10.5≤p≤12.5 atomic %, q is a number satisfying 26≤q≤40 atomic %, r is a number satisfying 0.88≤r≤4.5 atomic %, and t is a number satisfying 5.23≤t≤10.7 atomic %; and a metallic structure including cell phases having a Th2Zn17 crystal phase and Cu-rich phases having higher Cu concentration than the cell phases, an average diameter of the cell phases being 220 nm or less, the cell phases having diameter of a numeric value range from a minimum diameter to a maximum diameter, a ratio of a number of cell phases having diameters in a numeric value range of upper 20% from the maximum diameter being 20% or less of all the cell phases, a squareness ratio of the magnet being 93.5% or more and 94.5% or less, and a residual magnetization of the magnet being 1.185 T or more and 1.215 T or less.