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AssigneeSeiko Epson Corporation
InventorsAkira Arai, Hiroshi Kato
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A magnetic material manufacturing method, a ribbon-shaped magnetic material manufactured by the method, a powdered magnetic material formed from the ribbon-shaped magnetic material and a bonded magnet manufactured using the powdered magnet material are disclosed. The method and the magnetic materials can provide magnets having excellent magnetic properties and reliability. A melt spinning apparatus 1 is provided with a tube 2 having a nozzle 3 at the bottom thereof, a coil 4 for heating the tube and a cooling roll 5 having a circumferential surface 53 on which dimple correcting means is provided. A melt spun ribbon 8 is formed by injecting the molten alloy 6 from the nozzle 3 so as to be collided with the circumferential surface 53 of the cooling roll 5 in an inert gas atmosphere (ambient gas) such as helium gas, so that the molten alloy 6 is cooled and then solidified. In this process, dimples to be produced on a roll contact surface of the melt spun ribbon are divided by the dimple correcting means, thereby preventing formation of huge dimples.
A magnetic material manufacturing method for manufacturing a ribbon-shaped magnetic material by colliding a molten alloy to a circumferential surface of a cooling roll so as to cool and then solidify it, the ribbon-shaped magnetic material having an alloy composition represented by the formula of Rx(Fe1-yCoy)100-x-zBz(where R is at least one rare-earth element, x is 10-15 at %, y is 0-0.30 and z is 4-10 at %), wherein the circumferential surface of the cooling roll has dimple correcting means for dividing dimples to be produced on a roll contact surface of the ribbon-shaped magnetic material which is in contact with the circumferential surface of the cooling roll.
A ribbon-shaped magnetic material which is manufactured by colliding a molten alloy to a circumferential surface of a cooling roll so as to cool and then solidify it, the ribbon-shaped magnetic material having an alloy composition represented by the formula of Rx(Fe1-yCoy)100-x-yBz (where R is at least one rare-earth element, x is 10-15 at %, y is 0-0.30 and z is 4-10 at %), wherein the circumferential surface of the cooling roll has dimple correcting means for dividing dimples to be produced on a roll contact surface of the ribbon-shaped magnetic material which is in contact with the circumferential surface of the cooling roll.
A powedered magnetic material which is obtained by milling a ribbon-shaped magnetic material which is manufactured by colliding a molten alloy to a circumferential surface of a cooling roll so as to cool and then solidify it, the ribbon-shaped magnetic material having an alloy composition represented by the formula of Rx(Fe1-yCOy)100-x-zBz (where R is at least one rare-earth element, x is 10-15 at %, y is 0-0.30 and z if 4-10 at %), wherein the circumferential surface of the cooling roll has dimple correcting means for dividing dimples to be produced on a roll contact surface of the ribbon-shaped magnetic material which is in contact with the circumferential surface of the cooling roll.
A bonded magnet manufactured by binding a powdered magnetic material which is obtained by milling a ribbon-shaped magnetic material which is manufactured by colliding a molten alloy to a circumferential surface of a cooling roll so as to cool and then solidify it, the ribbon-shaped magnetic material having an alloy composition represented by the formula of Rx(Fe1-yCoy)100-x-zBz (where R is at least one rare-earth element, x is 10-15 at %, y is 0-0.30 and z if 4-10 at %), wherein the circumferential surface of the cooling roll has dimple correcting means for dividing dimples to be produced on a roll contact surface of the ribbon-shaped magnetic material which is in contact with the circumferential surface of the cooling roll.
Dependencies are inferred from the claim text.