Method of making an epoxy bonded rare earth-iron magnet

Claim 1

The method of making a bonded permanent magnet comprising the steps of: dissolving in a solvent an uncured epoxy resin having an incorporated catalyst which is inactive at a temperature of about 120° F.; adding particles of a rapidly quenched rare earth-iron-boron alloy to the epoxy resin solution; mixing said solution with said particles at a temperature of about 120° F. until said solvent is removed and said particles are substantially uniformly coated with said resin and are insubstantially free flowing powder form; cold pressing the epoxy resin coated particles into a compact to form a magnet; and curing said epoxy resin by heating said compact to a temperature of between about 250° F. and about 350° F. for a period of about 1-2 hours.

Claim 2

The method of making a bonded permanent magnet comprising the steps of: dissolving in a solvent an uncured epoxy resin having an incorporated catalyst which is inactive at a temperature of about 120° F.; adding particles of a rapidly quenched rare earth-iron-boron alloy to the epoxy resin solution; mixing said solution with said particles at a temperature of about 120° F. until said solvent is removed and said particles are substantially uniformly coated with said resin and are insubstantially free flowing powder form; cold pressing the epoxy resin coated particles into a compact to form a magnet; and curing said epoxy resin by heating said compact to a temperature of between about 250° F. and about 350° F. for a period of about 1-2 hours.

Claim 9

The method of making bonded permanent magnet comprising the steps of: dissolving in an acetone solvent an uncured thermally curable biphenol A epoxy resin having an incorporated catalyst which is inactive at a temperature of about 120° F.; adding magnetic particles of a rapidly quenched rare earth-iron-boron alloy having a size of from about 30μ to about 500μ to the epoxy resin solution whereby said resin equals about 1.3 to 3 weight percent of the final compact; mixing said solution with said magnetic particles at a temperature of about 120° F. and at a vacuum of about 25-29 inches of Hg until said solvent is removed and said magnetic particles are substantially uniformly coated with said resin and are in substantially free flowing powder from; cold pressing the epoxy resin coated particles at a pressure of about 100,000 psi into a compact having a density of about 5.0-6.0 gm/cc to form a magnet; and curing said epoxy resin by heating said compact to about 250° F. for one hour and then heating at 350° F. for an additional hour.

Claim 10

The method of making bonded permanent magnet comprising the steps of: dissolving in an acetone solvent an uncured thermally curable biphenol A epoxy resin having an incorporated catalyst which is inactive at a temperature of about 120° F.; adding magnetic particles of a rapidly quenched rare earth-iron-boron alloy having a size of from about 30μ to about 500μ to the epoxy resin solution whereby said resin equals about 1.3 to 3 weight percent of the final compact; mixing said solution with said magnetic particles at a temperature of about 120° F. and at a vacuum of about 25-29 inches of Hg until said solvent is removed and said magnetic particles are substantially uniformly coated with said resin and are in substantially free flowing powder from; cold pressing the epoxy resin coated particles at a pressure of about 100,000 psi into a compact having a density of about 5.0-6.0 gm/cc to form a magnet; and curing said epoxy resin by heating said compact to about 250° F. for one hour and then heating at 350° F. for an additional hour.