JP2016207977A - 希土類磁石の製造方法及び希土類化合物の塗布装置 - Google Patents
希土類磁石の製造方法及び希土類化合物の塗布装置 Download PDFInfo
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Abstract
Description
請求項1:
R1−Fe−B系組成(R1はY及びScを含む希土類元素から選ばれる1種又は2種以上)からなる焼結磁石体に、R2の酸化物、フッ化物、酸フッ化物、水酸化物又は水素化物(R2はY及びScを含む希土類元素から選ばれる1種又は2種以上)から選ばれる1種又は2種以上を含有する粉末を溶媒に分散したスラリーを塗布し、乾燥させてスラリーの溶媒を除去することにより上記粉末を上記焼結磁石体表面に塗着させ、これを熱処理して上記R2を焼結磁石体に吸収させる希土類磁石の製造方法において、
上記スラリーの塗布前に上記焼結磁石体を加温ないし加熱することを特徴とする希土類磁石の製造方法。
請求項2:
上記焼結磁石体の加温ないし加熱の温度が、上記スラリーの溶媒の沸点から20℃を減じた温度以下である請求項1記載の希土類磁石の製造方法。
請求項3:
上記スラリーの溶媒が水であり、上記焼結磁石体を40〜80℃に加温ないし加熱した後にスラリーを塗布する請求項2記載の希土類磁石の製造方法。
請求項4:
上記焼結磁石体に赤外線を照射することにより、上記加温ないし加熱を行う請求項1〜3のいずれか1項に記載の希土類磁石の製造方法。
請求項5:
上記赤外線が、波長0.8〜5μmの近赤外線である請求項4記載の希土類磁石の製造方法。
請求項6:
スラリーの塗布がローラ塗布である請求項1〜5のいずれか1項に記載の希土類磁石の製造方法。
請求項7:
上記焼結磁石体を加温ないし加熱し、上記スラリーを塗布し、乾燥させる塗布プロセスを複数回繰り返して重ね塗りを行う請求項1〜6のいずれか1項に記載の希土類磁石の製造方法。
請求項8:
上記粉末を塗着させた焼結磁石体に対し、当該焼結磁石体の焼結温度以下の温度で、真空又は不活性ガス中で熱処理を施す請求項1〜7のいずれか1項に記載の希土類磁石の製造方法。
請求項9:
上記熱処理後、更に低温で時効処理を施す請求項1〜8のいずれか1項に記載の希土類磁石の製造方法。
請求項10:
R1−Fe−B系組成(R1はY及びScを含む希土類元素から選ばれる1種又は2種以上)からなる四角板状又は四角ブロック状の焼結磁石体に、R2の酸化物、フッ化物、酸フッ化物、水酸化物又は水素化物(R2はY及びScを含む希土類元素から選ばれる1種又は2種以上)から選ばれる1種又は2種以上を含有する粉末を溶媒に分散したスラリーを塗布し乾燥させて、上記粉末を上記焼結磁石体表面に塗着させ、これを熱処理して上記R2を焼結磁石体に吸収させ希土類永久磁石を製造するに際し、上記焼結磁石体に上記粉末を塗布する希土類化合物の塗布装置であって、
上記焼結磁石体を載せて搬送する搬送コンベアと、
該搬送コンベア上の焼結磁石体に上記スラリーを塗布するスラリー塗布手段と、
該塗布手段によるスラリー塗布位置の搬送方向上流側に設けられ、上記搬送コンベア上の焼結磁石体を所定温度に加温ないし加熱する事前加熱手段と、
上記塗布手段によるスラリー塗布位置の搬送方向下流側に設けられ、上記搬送コンベア上の焼結磁石体を加温して乾燥させる乾燥手段とを具備してなり、
上記搬送コンベアの上流側から上記焼結磁石体を供給して搬送し、この焼結磁石体を上記事前加熱手段により所定温度に加温ないし加熱し、この所定温度に加温ないし加熱された焼結磁石体に上記スラリー塗布手段により上記スラリーを塗布し、このスラリーが塗布された焼結磁石体を上記乾燥手段により加熱し乾燥させてスラリーの溶媒を除去することにより上記粉末を焼結磁石体表面に塗着させ、この焼結磁石体を上記搬送コンベアの下流側から回収することを特徴とする希土類化合物の塗布装置。
請求項11:
上記事前加熱手段が、赤外線ヒータにより赤外線照射して加温ないし加熱を行うものである請求項10記載の希土類化合物の塗布装置。
請求項12:
上記乾燥手段が、焼結磁石体に赤外線を照射して加熱する赤外線ヒータと、赤外線照射によって気化した溶媒を焼結磁石体周囲から除去する排気手段とを具備したものである請求項10又は11記載の希土類化合物の塗布装置。
請求項13:
上記事前加熱手段及び上記乾燥手段のいずれか一方又は両方の赤外線ヒータが、波長0.8〜5μmの近赤外線を照射するものである請求項11又は12記載の希土類化合物の塗布装置。
請求項14:
上記スラリー塗布手段が、塗布ローラにより上記焼結磁石体表面に上記スラリーを塗布するものである請求項10〜13のいずれか1項に記載の希土類化合物の塗布装置。
請求項15:
上記スラリー塗布手段によるスラリー塗布位置の搬送方向上流側に設けられ、エアナイフからシート状薄層気流を吹き付けて上記焼結磁石体表面をクリーニングするクリーニング手段を具備する請求項10〜14のいずれか1項に記載の希土類化合物の塗布装置。
Ndが14.5原子%、Cuが0.2原子%、Bが6.2原子%、Alが1.0原子%、Siが1.0原子%、Feが残部からなる薄板状の合金を、純度99質量%以上のNd、Al、Fe、Cuメタル、純度99.99質量%のSi、フェロボロンを用いてAr雰囲気中で高周波溶解した後、銅製単ロールに注湯するいわゆるストリップキャスト法により薄板状の合金とした。得られた合金を室温にて0.11MPaの水素化に曝して水素を吸蔵させた後、真空排気を行ないながら500℃まで加熱して部分的に水素を放出させ、冷却してから篩いにかけて、50メッシュ以下の粗粉末とした。
また、実施例3と同様にしてフッ化ディスプロシウム粉末の薄膜を形成した磁石体をAr雰囲気中、900℃で5時間熱処理して吸収処理を施し、更に500℃で1時間時効処理して急冷することにより希土類磁石を得た。図4に示された9点の場所から2mm×2mm×2mmに磁石体を切り出し、その保磁力を測定した。結果を表2に示す。
2 スラリー塗布手段
21 塗布ローラ
211 水平軸
212 鉛直軸
22 スラリー供給機構部
221 スラリー流出槽
222 スラリー受入槽
223 スラリー供給バット
224 ポンプ
225 返送管
23 超音波洗浄器
3 事前加熱手段
31 赤外線ヒータ
32 反射シート
4 クリーニング手段
41 エアナイフ
42 集塵ダクト
5 乾燥手段
51 赤外線ヒータ
52 排気ダクト
m 焼結磁石体
s スラリー
Claims (15)
- R1−Fe−B系組成(R1はY及びScを含む希土類元素から選ばれる1種又は2種以上)からなる焼結磁石体に、R2の酸化物、フッ化物、酸フッ化物、水酸化物又は水素化物(R2はY及びScを含む希土類元素から選ばれる1種又は2種以上)から選ばれる1種又は2種以上を含有する粉末を溶媒に分散したスラリーを塗布し、乾燥させてスラリーの溶媒を除去することにより上記粉末を上記焼結磁石体表面に塗着させ、これを熱処理して上記R2を焼結磁石体に吸収させる希土類磁石の製造方法において、
上記スラリーの塗布前に上記焼結磁石体を加温ないし加熱することを特徴とする希土類磁石の製造方法。 - 上記焼結磁石体の加温ないし加熱の温度が、上記スラリーの溶媒の沸点から20℃を減じた温度以下である請求項1記載の希土類磁石の製造方法。
- 上記スラリーの溶媒が水であり、上記焼結磁石体を40〜80℃に加温ないし加熱した後にスラリーを塗布する請求項2記載の希土類磁石の製造方法。
- 上記焼結磁石体に赤外線を照射することにより、上記加温ないし加熱を行う請求項1〜3のいずれか1項に記載の希土類磁石の製造方法。
- 上記赤外線が、波長0.8〜5μmの近赤外線である請求項4記載の希土類磁石の製造方法。
- スラリーの塗布がローラ塗布である請求項1〜5のいずれか1項に記載の希土類磁石の製造方法。
- 上記焼結磁石体を加温ないし加熱し、上記スラリーを塗布し、乾燥させる塗布プロセスを複数回繰り返して重ね塗りを行う請求項1〜6のいずれか1項に記載の希土類磁石の製造方法。
- 上記粉末を塗着させた焼結磁石体に対し、当該焼結磁石体の焼結温度以下の温度で、真空又は不活性ガス中で熱処理を施す請求項1〜7のいずれか1項に記載の希土類磁石の製造方法。
- 上記熱処理後、更に低温で時効処理を施す請求項1〜8のいずれか1項に記載の希土類磁石の製造方法。
- R1−Fe−B系組成(R1はY及びScを含む希土類元素から選ばれる1種又は2種以上)からなる四角板状又は四角ブロック状の焼結磁石体に、R2の酸化物、フッ化物、酸フッ化物、水酸化物又は水素化物(R2はY及びScを含む希土類元素から選ばれる1種又は2種以上)から選ばれる1種又は2種以上を含有する粉末を溶媒に分散したスラリーを塗布し乾燥させて、上記粉末を上記焼結磁石体表面に塗着させ、これを熱処理して上記R2を焼結磁石体に吸収させ希土類永久磁石を製造するに際し、上記焼結磁石体に上記粉末を塗布する希土類化合物の塗布装置であって、
上記焼結磁石体を載せて搬送する搬送コンベアと、
該搬送コンベア上の焼結磁石体に上記スラリーを塗布するスラリー塗布手段と、
該塗布手段によるスラリー塗布位置の搬送方向上流側に設けられ、上記搬送コンベア上の焼結磁石体を所定温度に加温ないし加熱する事前加熱手段と、
上記塗布手段によるスラリー塗布位置の搬送方向下流側に設けられ、上記搬送コンベア上の焼結磁石体を加温して乾燥させる乾燥手段とを具備してなり、
上記搬送コンベアの上流側から上記焼結磁石体を供給して搬送し、この焼結磁石体を上記事前加熱手段により所定温度に加温ないし加熱し、この所定温度に加温ないし加熱された焼結磁石体に上記スラリー塗布手段により上記スラリーを塗布し、このスラリーが塗布された焼結磁石体を上記乾燥手段により加熱し乾燥させてスラリーの溶媒を除去することにより上記粉末を焼結磁石体表面に塗着させ、この焼結磁石体を上記搬送コンベアの下流側から回収することを特徴とする希土類化合物の塗布装置。 - 上記事前加熱手段が、赤外線ヒータにより赤外線照射して加温ないし加熱を行うものである請求項10記載の希土類化合物の塗布装置。
- 上記乾燥手段が、焼結磁石体に赤外線を照射して加熱する赤外線ヒータと、赤外線照射によって気化した溶媒を焼結磁石体周囲から除去する排気手段とを具備したものである請求項10又は11記載の希土類化合物の塗布装置。
- 上記事前加熱手段及び上記乾燥手段のいずれか一方又は両方の赤外線ヒータが、波長0.8〜5μmの近赤外線を照射するものである請求項11又は12記載の希土類化合物の塗布装置。
- 上記スラリー塗布手段が、塗布ローラにより上記焼結磁石体表面に上記スラリーを塗布するものである請求項10〜13のいずれか1項に記載の希土類化合物の塗布装置。
- 上記スラリー塗布手段によるスラリー塗布位置の搬送方向上流側に設けられ、エアナイフからシート状薄層気流を吹き付けて上記焼結磁石体表面をクリーニングするクリーニング手段を具備する請求項10〜14のいずれか1項に記載の希土類化合物の塗布装置。
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