A magnet material of an embodiment includes a composition represented by a formula 1: (Fe.sub.1-x-yCo.sub.xT.sub.y).sub.2(B.sub.1-aA.sub.a).sub.b, and a metallic structure having a CuAl.sub.2 crystal phase as a main phase. T is at least one element selected from V, Cr, and Mn. A is at least one element selected from C, N, Si, S, P, and Al. An atomic ratio x of Co and an atomic ratio y of the element T satisfy 0.01≤y≤0.5 and x+y≤0.5. When the element T includes at least one element selected from V and Cr, a total atomic ratio of V and Cr is 0.03 or more. When the element T includes Mn, an atomic ratio of Mn is 0.3 or less. An atomic ratio a of the element A satisfies 0≤a≤0.4. A total atomic ratio b of B and the element A satisfies 0.8≤b≤1.2.

The present invention relates to a composite component including a metal component having a substantially cylindrical shape or a substantially annular shape, and a ring-shaped bonded magnet disposed on the outer periphery of the metal component, the ring-shaped bonded magnet containing a thermoplastic resin, magnetic particles, and rubber particles.

A sintered magnet body is held in a grounded jig exhibiting excellent electrical conductivity, a rare-earth-compound powder is charged and sprayed on the sintered magnet body to electrostatically coat the sintered magnet body with the powder, and thus apply the powder to the sintered magnet body. The sintered magnet body having the powder applied thereto is heat treated to produce a rare-earth magnet. As a result, the rare-earth-compound powder can be uniformly applied to the surface of the sintered magnet body, and the application operating can be performed extremely efficiently.

This invention provides for a rare-earth permanent magnet-forming sintered body obtained by integrally sintering magnet material particles containing a rare-earth substance while shaping the magnet material particles, a rare-earth permanent magnet obtained by magnetizing the sintered body, and a rotary machine in which the permanent magnet is embedded.

A compression molded core contains a plurality of soft magnetic material powders. A first powder and a second powder in the plurality of powders satisfy D1>D2, 0.23≤(D1−D2)/D1<0.6, D1≤7 μm, and 3 μm≤DT≤5.7 μm. D1 is the median diameter, which is a particle size at which the integrated particle diameter distribution from the small particle size side is 50% in a volume-based particle size distribution measured by a laser diffraction/scattering method, of the first powder and is maximum among median diameters; D2 is the median diameter D2 of the second powder and is minimum among median diameters; and DT is determined using the weight rate R1 of the first powder and the weight rate R2 of the second powder by R1×D1+R2×D2.

A compression molded core contains a plurality of soft magnetic material powders. A first powder and a second powder in the plurality of powders satisfy D1>D2, 0.23≤(D1−D2)/D1<0.6, D1≤7 μm, and 3 μm≤DT≤5.7 μm. D1 is the median diameter, which is a particle size at which the integrated particle diameter distribution from the small particle size side is 50% in a volume-based particle size distribution measured by a laser diffraction/scattering method, of the first powder and is maximum among median diameters; D2 is the median diameter D2 of the second powder and is minimum among median diameters; and DT is determined using the weight rate R1 of the first powder and the weight rate R2 of the second powder by R1×D1+R2×D2.

A hybrid rotor assembly is provided. The assembly utilizes two different types of magnets within the lamination cavities of the lamination stack: sintered permanent magnets and bonded magnets.

A FeNi ordered alloy includes a plurality of particles having a L1.sub.0 type ordered structure. A size of the particles is in a range between 200 nm and 500 nm. A volume fraction of a pore in the particles with respect to a volume of the particles having an unit of vol. % is 5% or less.

A multipole permanent magnet may be provided with a magnetic-field shunt. The multipole permanent magnet may be formed from compression-molded magnetic particles such as magnetically anisotropic rare-earth particles in an elastomeric polymer. The magnetic-field shunt may be formed from magnetic members in a polymer binder that are separated by gaps to allow the shunt to flex or from magnetic particles in a polymer binder. The magnetic particles in the polymer binder may be ferrite particles or other magnetic particles. The polymer binder may be formed from an elastomeric material and may be integral with the elastomeric polymer of the multipole permanent magnet or separated from the elastomeric polymer of the multipole permanent magnet by a polymer separator layer. Conductive particles may be formed in polymer such as the elastomeric polymer with the magnetic particles. The conductive particles may be configured to form electrical connector contacts and other signal paths.

A hybrid rotor assembly is provided. The assembly utilizes two different types of magnets within the lamination cavities of the lamination stack: sintered permanent magnets and bonded magnets.