JP2013243265A - Laminate and method for producing laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminate capable of bonding magnet and an attachment member without changing magnetism, and a method for producing a laminate.SOLUTION: A laminate comprises: a magnet member 10 including magnet; and a laminated member 11 made of a metal coating which is laminated on the magnet member (10) and is formed by accelerating powder including a metal material together with gas and spraying the powder on the surface of the magnet member 10 in a solid phase state to be deposited. Thereby, the magnet member 10 and the laminated member 11 can be bonded without changing magnetism.

Description

  The present invention relates to a laminate including a magnet used for a motor disposed in, for example, a device in an automobile or the like, or a household appliance, and a method for manufacturing the laminate.

  2. Description of the Related Art Conventionally, a magnet member having a magnet is used for a motor disposed in a device such as an automobile or a device for home appliances. Examples of the motor include those used in various devices such as IPM (Interior Permanent Magnet) motors, motors for precision devices such as hard disk drives, and vibration motors for mobile phones. The magnet member is also used for small speakers and the like. As the magnet, a rare earth magnet such as a neodymium magnet having a strong magnetism or a samarium cobalt magnet having excellent heat resistance is used.

  Generally, it is difficult to drill or cut a notch shape for rare earth magnets, so by forming a laminated body in which a mounting member made of resin or metal is laminated on a magnet member, the mounting property for mounting at a predetermined position of the device is improved. (For example, refer to Patent Document 1). In this technique, for example, a magnet member and a pure copper plate are heated to about 800 ° C., and a liquid phase is generated at a contact portion between the magnet and the pure copper plate to join them together.

JP-A-8-78231

  However, in the technique disclosed in Patent Document 1, since the joining temperature is as high as 800 ° C., the magnetism of the magnet may be lost during joining. For example, neodymium magnets and samarium cobalt magnets have inherent Curie temperatures, which are transition temperatures at which a ferromagnetic material transitions to a paramagnetic material, and are 310 ° C. and 830 ° C., respectively. When the magnet is heated above this Curie temperature, it is demagnetized. This demagnetization may change the performance of the magnet. In particular, in the case of a samarium cobalt magnet, since re-magnetization after demagnetization is impossible, once demagnetized, there is a possibility that it cannot be used as a laminate.

Further, as shown in Table 1, the magnet and the metal have different thermal expansion coefficients, and the magnet and the mounting member may be separated due to a difference in thermal expansion occurring before and after joining. In addition, since the magnet has thermal expansion anisotropy, it is not suitable for high-temperature bonding.

  This invention is made in view of the above, Comprising: It aims at providing the manufacturing method of a laminated body and a laminated body which can join a magnet member and an attachment member, without changing magnetism. .

  In order to solve the above-described problems and achieve the object, a laminate according to the present invention includes a magnet member having a magnet, and a magnetic material that is laminated on the magnet member and accelerates powder containing a metal material together with a gas. And a laminated member made of a metal film formed by spraying and depositing in a solid state on the surface of the member.

  Moreover, the laminate according to the present invention is characterized in that, in the above invention, the magnet member has a plating layer covering a surface of the magnet.

  In the laminate according to the present invention, the magnet is a rare earth magnet.

  In the laminate according to the present invention, the metal material is any one of copper and aluminum.

  Moreover, the manufacturing method of the laminated body concerning this invention is a manufacturing method of the laminated body which consists of a magnet member and the metal membrane | film | coat as a laminated member laminated | stacked on this magnet, Comprising: On the surface of the said magnet member, copper or The metal film is formed by accelerating a powder containing a metal material made of aluminum together with a gas and spraying and depositing the powder in a solid state on the surface.

  According to the present invention, a laminated member (mounting member) made of a metal film formed by accelerating a powder containing a metal material together with a gas and spraying and depositing the powder on the surface of the magnet in a solid phase state is provided as a magnet member. Thus, the magnet member and the mounting member can be joined without changing the magnetism.

FIG. 1 is a perspective view schematically showing a configuration of a laminate according to an embodiment of the present invention. 2 is a cross-sectional view taken along line AA in FIG. Drawing 3 is a mimetic diagram showing the outline of the cold spray device used for manufacture of the layered product concerning an embodiment of the invention.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the drawings. In addition, this invention is not limited by the following embodiment. The drawings referred to in the following description only schematically show the shape, size, and positional relationship so that the contents of the present invention can be understood. That is, the present invention is not limited only to the shape, size, and positional relationship illustrated in each drawing.

  First, the laminated body concerning embodiment of this invention is demonstrated in detail with reference to drawings. FIG. 1 is a perspective view schematically showing the configuration of the laminate according to the present embodiment. 2 is a cross-sectional view taken along line AA in FIG. A laminated body 1 shown in FIGS. 1 and 2 includes a plate-like magnet member 10 having at least a magnet 10 a which is a rare earth magnet such as a neodymium magnet or a samarium cobalt magnet, and a laminated member laminated on one main surface of the magnet member 10. 11. The laminated body 1 is used for a motor disposed in a device in an automobile or the like, a home appliance, or the like.

  As shown in the cross-sectional view of FIG. 2, the magnet member 10 includes a magnet 10a and a plating layer 10b in which the surface of the magnet 10a is plated. In the present embodiment, the description will be made assuming that the plating layer 10b is made of copper plating. By covering the surface of the magnet 10a with the plating layer 10b made of copper plating, the plating layer 10b functions as an antioxidant for the magnet 10a.

  The magnet 10a is a plate-like permanent magnet, and is a rare earth magnet such as a neodymium magnet having strong magnetism or a samarium cobalt magnet having excellent heat resistance. Neodymium magnets and samarium cobalt magnets have the inherent Curie temperature and thermal expansion anisotropy (see Table 1) as described above. In addition, neodymium magnets generate a very strong magnetic field, but are easily broken mechanically, and the temperature change of the magnetic force is large. Samarium cobalt magnets have excellent heat resistance and can be used up to about 350 ° C., while the strength of the magnetic field is smaller than that of neodymium magnets of the same shape. The magnet 10a can be selected according to the use to be used.

  The laminated member 11 is formed using, for example, copper (including a copper alloy), aluminum (including an aluminum alloy), or the like. The laminated member 11 is attached to a predetermined position of the motor.

  Here, the laminated member 11 is a metal film formed by a cold spray method described later. As the metal film (film material), any metal or alloy having conductivity in addition to the above-described copper and aluminum can be applied.

  Next, formation of the laminated member 11 (metal film) will be described with reference to FIG. The laminated member 11 is formed by, for example, a cold spray method. FIG. 3 is a schematic diagram showing an outline of a cold spray apparatus used for forming a metal film. The metal film formation by the cold spray method is performed by, for example, a cold spray apparatus 20 shown in FIG.

  The cold spray device 20 contains a gas heater 21 that heats a compressed gas, a powder supply device 22 that contains powder (powder, such as copper or aluminum) that is sprayed on the sprayed object, and supplies the powder to the spray gun 24. A gas nozzle 23 that injects material powder mixed with the compressed gas heated by the spray gun 24 toward the surface of the magnet 10 is provided.

  As the compressed gas, helium, nitrogen, air or the like is used. The supplied compressed gas is supplied to the gas heater 21 and the powder supply device 22 by valves 25 and 26, respectively. The compressed gas supplied to the gas heater 21 is heated to, for example, 50 to 900 ° C. and then supplied to the spray gun 24. More preferably, the compressed gas is heated so that the upper limit temperature of the powder sprayed onto the surface of the magnet member 10 is kept below the melting point of the coating material. By keeping the heating temperature of the powder below the melting point of the coating material, the oxidation of the coating material can be suppressed.

  The compressed gas supplied to the powder supply device 22 is supplied to the spray gun 24 so that, for example, a material powder having a particle size of about 10 to 100 μm in the powder supply device 22 has a predetermined discharge amount. The heated compressed gas is accelerated to a supersonic speed (about 340 m / s or more) by a gas nozzle 23 having a tapered wide shape. The powder supplied to the spray gun 24 is accelerated by the injection of the compressed gas into the supersonic flow, and collides with the surface of the magnet member 10 at a high speed in the solid state to form a film.

  By covering the surface of the magnet member 10 with a metal film by the above-described treatment, the laminate 1 in which the laminate member 11 is joined to the magnet member 10 can be formed. In addition, you may adjust the surface shape by performing surface processing processes, such as cutting, after film formation.

  According to the above-described embodiment, the attachment member (laminate member) joined to the magnet member is made of a metal film formed by the cold spray method, so that the magnetism is changed below the Curie temperature of the magnet. The magnet member and the attachment member can be joined without causing them. For this reason, no phase transition occurs in the magnet, and there is no need to perform re-magnetization after the laminate is manufactured. Therefore, this process can be reduced and the manufacturing cost can be reduced.

  Further, according to the above-described embodiment, since the joining process is performed at a low temperature by the cold spray method, a metal having a low melting point (for example, aluminum) can be used as the laminated member. Moreover, it becomes possible to obtain a laminated body excellent in conductivity by using copper or aluminum as a laminated member.

  Further, according to the above-described embodiment, the cold spray method can form a dense metal film as compared with welding, thermal spraying, and the like that are processed at a high temperature, so that the electrical conductivity of the laminated member is improved. . Therefore, a laminate having good electrical conductivity can be produced.

  In the present embodiment, the laminated member has been described as covering one surface of the columnar magnet member 10. However, the laminated member may cover a part of the surface of the magnet member 10, or one or more It may cover an arbitrarily selected surface.

  Further, when the plating layer 11 includes nickel plating, the nickel plating has high hardness, and it is difficult to laminate copper or aluminum by the cold spray method with respect to the nickel plating. It is preferable that a two-layer structure in which copper plating or silver plating is exposed on the outer surface of the magnet member 10 is preferable.

  When copper or aluminum can be laminated on the surface of the magnet 10a by the cold spray method, a metal film (laminated member) may be formed on the surface of the magnet 10a.

  Further, in the present embodiment, the main surface of the magnet member 10 has been described as a rectangular plate shape, but not limited to this shape, the main surface may be a circle or an ellipse, It may be spherical. A laminate can be produced by forming a metal film on the surface of each shaped magnet member.

  As described above, the laminate and the manufacturing method thereof according to the present invention are useful for joining the magnet member and the attachment member without changing the magnetism.

DESCRIPTION OF SYMBOLS 1 Laminated body 10 Magnet member 10a Magnet 10b Plating layer 11 Laminated member 20 Cold spray apparatus 21 Gas heater 22 Powder supply apparatus 23 Gas nozzle 24 Spray gun 25, 26 Valve

Claims (5)

A magnet member having a magnet;
A laminated member made of a metal film that is laminated on the magnet member and is formed by accelerating a powder containing a metal material together with a gas and spraying and depositing the powder on the surface of the magnet member in a solid state;
A laminate comprising:   The laminate according to claim 1, wherein the magnet member has a plating layer that covers a surface of the magnet.   The laminate according to claim 1, wherein the magnet is a rare earth magnet.   The said metal material is either copper or aluminum, The laminated body as described in any one of Claims 1-3 characterized by the above-mentioned. A method for producing a laminate comprising a magnet member and a metal film as a laminate member laminated on the magnet,
The metal film is formed on the surface of the magnet member by accelerating a powder containing a metal material made of copper or aluminum together with a gas and spraying and depositing the powder in the solid state on the surface. A manufacturing method of a layered product.

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