JP5776275B2 - Composite magnet structure - Google Patents

Description

  The present invention relates to a composite magnet structure.

  For example, in application products such as various motors, motors incorporating magnets are the mainstream, and so far, magnets have been assembled alone. In recent years, products using magnets such as motors have been remarkably advanced in precision and characteristics, and magnets with higher characteristics are required. On the other hand, when the magnet is enlarged, heat generation or loss due to eddy current becomes a problem, and countermeasures are desired.

  From such a situation, a mode has been proposed in which a magnet is divided into a plurality of small magnets and these are handled together (see, for example, Patent Document 1 and Patent Document 2). In the technique shown in Patent Document 1, the magnet pieces are integrated with an adhesive to form a composite magnet structure. Moreover, in the technique shown in patent document 2, a magnet piece is integrated with an adhesive sheet to form a composite magnet structure.

  However, in the technique shown in Patent Document 1 or 2, since the magnet pieces are bonded via the adhesive or the adhesive sheet, the types of usable adhesives or adhesive sheets are limited depending on the surface treatment of the magnet pieces. There are issues such as. In particular, when Ni plating is performed as the surface treatment of the magnet piece, the adhesion strength may vary due to the influence of the degree of cleaning of the bonding surface.

  Moreover, in these prior arts, there is a problem that automation such as management of an adhesive or an adhesive sheet is difficult and manufacturing costs increase. In addition, there is a problem that the bonding accuracy is poor, it is difficult to align the magnet pieces, and the dimensional accuracy such as flatness of the composite magnet structure is deteriorated. When the dimensional accuracy deteriorates, it becomes difficult to attach the composite magnet structure to a predetermined attachment position.

  It has also been proposed to create a composite magnet structure by attaching a plurality of magnet pieces to a base such as a plastic plate by bonding or the like (Patent Document 3). In this structure, positioning of the magnet pieces is easy and dimensional accuracy such as flatness is improved. However, since a plastic plate or the like is arranged on the surface of the magnet pieces, there is a possibility that the magnetic characteristics are deteriorated.

JP 2008-253046 A Japanese Patent Laid-Open No. 2003-164083 JP 2007-266200 A

  The present invention has been made in view of such a situation, and the object thereof is a composite magnet structure having high dimensional accuracy such as flatness, good magnetic properties, little variation in strength, and low manufacturing cost. Is to provide.

In order to achieve the above object, a composite magnet structure according to the present invention comprises:
Two or more magnet pieces having a ridge line processed portion that is processed along at least a part of the sides;
And a resin frame for integrally fixing two or more of the magnet pieces by being arranged along the ridge line processed portion with a part of the main side surface of the magnet pieces exposed.

  In the present invention, the resin frame is disposed along the ridge line processed portion, whereby the two or more magnet pieces are integrated to form a composite magnet structure. The ridge line processing part is a part formed by chamfering or the like, for example, and is a space part removed from the magnet piece before the ridge line processing.

  In the present invention, a resin frame can be formed by using the removed space portion and pouring and curing the resin by, for example, injection molding. If the main sides of the magnet pieces are placed in contact with the inner wall of the cavity of the injection mold, and the magnet pieces are placed in contact with each other inside the mold cavity, the positions of the magnet pieces relative to each other The alignment is performed in a self-aligning manner, and a resin flow path corresponding to the ridge line processing portion is automatically formed. If injection molding (also referred to as insert molding) is performed in this state, the resin frame is integrally formed along the ridge line processed portion, and the magnet pieces are integrated with each other with the resin frame exposed. It becomes possible.

  For this reason, in the composite magnet structure of the present invention, since the main side surfaces of the magnet pieces are aligned in a self-aligning manner, the dimensional accuracy such as flatness is improved. Moreover, since the main side surface of each magnet piece is exposed, it has a favorable magnetic characteristic. Furthermore, even if the resin frame itself does not have an adhesive force, the resin frame is formed along the ridge line processed portion of the magnet piece, so that the magnet pieces can be held with a certain strength and integrated with an adhesive. There is less variation in strength compared to Furthermore, since the resin frame can be integrally formed by injection molding or the like, mass production is easy and the manufacturing cost is low.

  Furthermore, in the present invention, since a plurality of magnet pieces can be integrated to form a main surface having a large area, the magnetic characteristics are excellent and there are few harmful effects caused by eddy currents. Preferably, the main side surface is a magnetic pole surface.

  The ridge line processing part is formed by, for example, chamfering or ridge line processing in which the cross-sectional shape of the deleted portion at the time of ridge line processing is a quadrangle. The chamfering process includes not only a normal C chamfering process in which corners are removed in a triangular cross section, but also an R chamfering process or a process in which chamfering is performed by removing the shape into another shape. The R chamfering process is a process for rounding the corners.

Preferably, the resin frame has a first connecting part and a second connecting part,
The first connecting portion is disposed across two or more magnet pieces,
The second connecting part is disposed so as to connect two or more first connecting parts to each other. Since the resin frame has the first connection part and the second connection part, the resin frame for connecting the integrated magnet pieces to each other is structurally strong, and the strength of the composite magnet structure is improved.

  The composite magnet structure may have a rectangular parallelepiped shape, and may have a first connecting portion in the long side direction of the composite magnet structure. Or the said composite magnet structure may be a rectangular parallelepiped shape, Comprising: You may have a 1st connection part in the short side direction of the said composite magnet structure. It can change suitably according to the use for which a composite magnet structure is used.

  At least one of the magnet pieces may be different in magnetic characteristics from the other magnet pieces. All the magnet pieces to be integrated may have the same magnetic characteristics, but may be different depending on the application. For example, this is effective when it is desired to make the magnetic characteristics different between the central portion and the end portion of the composite magnet structure.

FIG. 1 is a perspective view of a composite magnet structure according to an embodiment of the present invention. 2A is a sectional view taken along the line IIa-IIa of the composite magnet structure shown in FIG. 1, and FIG. 2B is a sectional view taken along the line IIb-IIb of the composite magnet structure shown in FIG. is there. FIG. 3 is a sectional view taken along line III-III of the composite magnet structure shown in FIG. FIG. 4 is a perspective view of a magnet piece constituting the composite magnet structure shown in FIGS. FIG. 5A is a schematic diagram showing the ridge line processing portion of the magnet piece shown in FIG. 4, and FIG. 5B and FIG. 5C are schematic diagrams showing a modification of the ridge line processing portion. 6 is a perspective view showing a state in which the magnet pieces shown in FIG. 4 are arranged in a cavity (not shown) of a mold in order to manufacture the composite magnet structure shown in FIGS. FIG. 7 is a perspective view of a composite magnet structure according to another embodiment of the present invention. FIG. 8 is a sectional view taken along line VIII-VIII of the composite magnet structure shown in FIG. FIG. 9 is a cross-sectional view taken along line IX-IX of the composite magnet structure shown in FIG. FIG. 10 is a perspective view showing the arrangement of the magnet pieces excluding the frame of the composite magnet structure shown in FIG. FIG. 11 is a perspective view of a composite magnet structure according to still another embodiment of the present invention.

  Hereinafter, the present invention will be described based on embodiments shown in the drawings.

First Embodiment As shown in FIG. 1, in a composite magnet structure 2 according to a first embodiment of the present invention, two or more magnet pieces 4 are integrated and fixed by a resin frame 10. Although there is no restriction | limiting in particular in the shape of the composite magnet structure 2, For example, it is a flat rectangular parallelepiped shape as shown in figure.

  The magnet piece 4 constituting the composite magnet structure 2 has a flat rectangular parallelepiped shape that divides the composite magnet structure 2 into a plurality (for example, four) along the longitudinal direction. In this embodiment, for example, as shown in FIG. 4, each magnet piece 4 includes two main side surfaces 4 a having a relatively large area facing each other in the thickness direction, two end surfaces 4 b facing each other in the longitudinal direction, and a width. And two sub-side surfaces 4c facing each other in the direction.

  The length L0, the width W0, and the thickness T0 of each magnet piece 4 are not particularly limited. For example, L0 = 8 to 40 mm, W0 = 4 to 40 mm, and T0 = 3 to 15 mm. In the present embodiment, the longitudinal direction of each magnet piece 4 is the X axis, the width direction is the Z axis, and the thickness direction is the Y axis, which are perpendicular to each other.

  As shown in FIG. 4, in this embodiment, in each magnet piece 4, the corners of the main side surface 4 a and the sub-side surface 4 b (side or ridge line / the same applies hereinafter), the corners of the main side surface 4 a and the end surface 4 b, A ridge line machining process is performed at all corners of the corners of the sub-side surface 4c and the end surface 4b, and the ridge line machining part 20 is formed. That is, the magnet piece 4 according to the present embodiment includes the ridge line processing unit 20 in which all sides are subjected to ridge line processing along the sides.

  In the example shown in the drawing, the ridge line processing unit 20 is chamfered with a processing dimension α so that the deleted cross section by processing becomes a triangular shape in a cross section perpendicular to the ridge line as shown in FIG. Yes. However, in the present invention, as shown in FIG. 5B, the ridge line processing may be performed with the processing dimension α so that the deleted cross section by processing becomes a square shape, or as shown in FIG. As described above, the R processing may be performed so as to have a curvature radius (processing dimension) α.

  The chamfering process in which the deleted cross section by the process becomes a triangular shape is performed by, for example, a cutting process, a grinding process, a polishing process, or an electric discharge process. The R processing is processing for rounding corners, and is performed by barrel polishing, grinding processing, polishing processing, electric discharge processing, or the like, for example. The ridge line machining process in which the deleted cross section by the machining becomes a square shape is performed by, for example, cutting, grinding, polishing, electric discharge machining, or the like.

  The processing dimension α in the ridge line processing is not particularly limited, but is preferably 0.8 to 7.5 mm, and is expressed as a ratio (α / T0) to the minimum length (thickness T0) of the magnet piece 4. , Preferably 0.1 to 0.5.

  As shown in FIGS. 1 to 3, the resin frame 10 according to the present embodiment is arranged along the ridge line processing portion 20 of the magnet piece 4 so that two or more magnet pieces are integrated and fixed, and Z An elongated plate-like composite magnet structure 2 is formed along the axial direction. In this embodiment, the width direction Z of each magnet piece 4 is configured to coincide with the longitudinal direction of the structure 2.

  As shown in FIG. 1, the resin frame 10 includes a first connecting portion 10 a and a second connecting portion 10 b. The 1st connection part 10a is arrange | positioned ranging over the two or more magnet pieces 4 along the ridgeline process part 20 (refer FIG. 6) formed in the Z-axis direction. In the present embodiment, as shown in FIG. 2A, the first connecting portion 10b is formed so as to cover the end surface 4b of the magnet piece 4, and on the outer side in the X-axis direction, the first connecting portion 10b is formed. 10a and the reinforcement part 10c are integrally formed.

  As shown in FIG. 1, the reinforcing portion 10 c protrudes from the first connecting portion 10 a in the X-axis direction and is continuously formed along the Z-axis direction. The reinforcing portion 10c is formed on both sides in the X-axis direction of the composite magnet structure 2, but either one may be provided, or the reinforcing portion 10c is not necessarily provided.

  The second connecting portion 10b shown in FIG. 1 is formed along the ridge line processing portion 20 formed along the X-axis direction on the magnet piece 4 shown in FIG. As shown in FIG. 1, the 2nd connection part 10b is extended in the X-axis direction so that between the 1st connection parts 10a may be connected, the main side surface 4a of each magnet piece, and both ends of a Z-axis direction The sub-side surface 4 c of the magnet piece 4 located at the position is exposed, and the other part of the magnet piece 4 is covered with the resin frame 10. The thickness of the resin frame 10 corresponds to the processing dimension of the ridge line processing portion 20 shown in FIG. 5 in the second connecting portion 10b, and as shown in FIGS. 2A and 2B in the first connecting portion 10a. It can be set freely.

<Magnet piece>
The constituent material of the magnet piece 4 used for this embodiment is not specifically limited, For example, a R-Fe-B type composition is mentioned. By making the composition of the magnet pieces R-Fe-B-based, excellent magnet characteristics can be obtained, and the effect of improving corrosion resistance by forming a protective layer to be described later can be obtained more favorably.

  A protective layer may be formed on each of the magnet pieces 4. When the protective layer is a resin layer, the type of resin is not particularly limited, and both a layer made of a thermosetting resin or a layer made of a thermoplastic resin can be applied. Thermosetting resins include phenolic resin, epoxy resin, urethane resin, silicone resin, melamine resin, epoxy melamine resin, thermosetting acrylic resin, polyimide resin, polyamideimide resin, polyparaxylylene resin, polyurea resin, epoxy A silicone resin, an acrylic silicone resin, etc. are mentioned. Moreover, as a thermoplastic resin, the vinyl resin which uses vinyl compounds, such as acrylic acid, ethylene, vinyl chloride, vinyl acetate, as a raw material is mentioned.

  Moreover, when a protective layer is a metal layer, what combined Ni, Ni-P, Cu, Zn, Cr, Sn, Al, or the some layer which consists of these can be illustrated, for example.

  Further, when the protective layer is an inorganic layer, examples thereof include those composed of oxides such as alkali silicate, TiO2, ZrO2, SiO2, and Al2O3, and nitrides such as TiN and AlN.

<Resin frame>
The type of the resin constituting the resin frame 10 is not particularly limited, and both a layer made of a thermosetting resin or a layer made of a thermoplastic resin can be applied. Thermosetting resins include phenolic resin, epoxy resin, urethane resin, silicone resin, melamine resin, epoxy melamine resin, thermosetting acrylic resin, polyimide resin, polyamideimide resin, polyparaxylylene resin, polyurea resin, epoxy A silicone resin, an acrylic silicone resin, etc. are mentioned. Moreover, as a thermoplastic resin, the vinyl resin which uses vinyl compounds, such as nylon, polyester resin, acrylic acid, ethylene, vinyl chloride, vinyl acetate, as a raw material is mentioned. As the resin frame used in the composite magnet structure of the present embodiment, nylon, polyester resin, polybutylene terephthalate, and polyphenylene sulfide are particularly preferable. These resins can be easily injection-molded even in a narrow gap or have excellent heat resistance. Nylon and polyester resin have good fluidity and can be easily injection-molded in a narrow gap, and polybutylene terephthalate and polyphenylene sulfide are excellent in heat resistance.

<Method for producing composite magnet structure>
Below, the manufacturing method of the composite magnet structure which concerns on this embodiment is demonstrated.
First, prepare a plurality of rectangular parallelepiped magnet pieces of the same size, in the corner of the magnet piece, in a cross section perpendicular to the ridgeline of the corner, chamfered so that the deleted cross section by processing is triangular, The ridge line processing part 20 is formed.

  Next, a protective layer is formed on each magnet piece 4 as necessary. If the protective layer is a resin layer, prepare the coating solution by dissolving the resin described above in a solvent, and apply this to the surface of the magnet piece by dip coating, dip spin coating, spray coating, etc. Or can be formed by drying. The resin layer can also be formed by a so-called polymerization vapor deposition method in which a monomer for forming the resin layer is vaporized and vapor-deposited on the surface of the magnet piece and polymerized at the same time. Alternatively, the resin layer can be formed by electrodeposition coating.

  When the protective layer is a metal layer, it can be formed by performing electroplating, electroless plating or the like on the magnet piece. In addition, gas phase methods such as ion plating, sputtering, and vapor deposition can also be applied.

  In addition, when the protective layer is an inorganic layer, it can be formed by applying an alkali silicate solution such as water glass or a metal alkoxide solution to the surface of the magnet piece, followed by baking or drying. It can also be formed by using a vapor phase method such as a plating method or a CVD method, or a surface modification method by oxidation, nitridation, or chemical conversion treatment.

  Next, a mold for molding the resin frame 10 is prepared. The mold is composed of a first mold and a second mold, and a cavity is formed in the interior by combining the first mold and the second mold on a dividing surface.

  The magnet piece 4 shown in FIG. 4 is placed in the cavity of the injection mold not shown in the drawing so that the sub-side surfaces 4c of the magnet pieces 4 abut each other as shown in FIG. The pieces 4 are arranged in a line along the width direction Z of the pieces 4.

  In the mold cavity, the main side surface 4a of the magnet piece 4 is arranged in contact with the inner wall surface of the mold cavity, and each magnet piece 4 is arranged in contact with the sub-side surfaces 4c, and The sub-side surfaces 4c of the magnet pieces 4 located at both ends in the Z-axis direction are also arranged in contact with the cavity inner wall surface of the mold. The end face 4b of each magnet piece 4 is disposed with a predetermined gap with respect to the cavity inner wall surface of the mold.

  The alignment of the magnet pieces 4 in the mold cavity in the X-axis direction can be achieved by, for example, arranging a plurality of spacers having a predetermined thickness and a shape capable of securing a passage in the cavity between the end surface 4b and the cavity inner wall surface. good. The spacer may be made of the same resin as the resin to be injection-molded, may be made of other resins or other materials, and is integrated with the resin to be injection-molded.

  In the state shown in FIG. 6, if resin is injected from the end face 4b direction (X-axis direction) of the magnet piece 4 and injection-molded, the resin flows through the gap between the cavity inner wall surface and the ridge line processing portion 20 and is cured. As a result, the resin frame 10 shown in FIGS. 1 to 3 is formed.

  In the present embodiment, the resin frame 10 is arranged along the ridge line processing portion 20, whereby the composite magnet structure 2 is configured by integrating two or more magnet pieces 4. The ridge line processing portion 20 is a portion formed by chamfering or R processing, and is a space portion removed from the magnet piece 4 before the ridge line processing.

  In the present embodiment, the resin frame 10 can be formed by pouring and curing the resin by injection molding using the removed space portion. If the main side surface 4a of the magnet piece 4 is arranged in contact with the inner wall surface of the cavity of the injection mold, and the magnet pieces 4 are arranged in contact with each other inside the mold cavity, the magnet piece The four mutual alignments are performed in a self-aligning manner, and a resin flow path corresponding to the ridge line processing portion 20 is automatically formed. If injection molding (also referred to as insert molding) is performed in this state, the resin frame 10 is integrally molded along the ridge line processed portion 20, and the magnet side piece 4 is exposed by the resin frame 10 in a state where the main side surface 4 a of the magnet piece 4 is exposed. 4 It becomes possible to integrate each other.

  For this reason, in the composite magnet structure 2 of this embodiment, since the main side surfaces 4a of the magnet pieces 4 are aligned with each other in a self-aligning manner, dimensional accuracy such as flatness is improved. Moreover, since the main side surface 4a of each magnet piece 4 is exposed, it has a favorable magnetic characteristic. Furthermore, even if the resin frame 10 itself has no adhesive force, the resin frame 10 is formed along the ridge line processing portion 20 of the magnet piece 4, so that the magnet pieces 4 can be held with a certain strength. There is less variation in strength compared to integration with an adhesive. Furthermore, since the resin frame 10 can be integrally formed by injection molding or the like, mass production is easy and the manufacturing cost is low.

  Furthermore, in this embodiment, since the several magnet piece 4 can be integrated and the main surface 4a of a large area can be formed, while being excellent in a magnetic characteristic, there are few bad effects by an eddy current.

  Moreover, in this embodiment, since the resin frame 10 has the 1st connection part 10a and the 2nd connection part 10b, the resin frame 10 which connects the mutually integrated magnet pieces 4 becomes structurally strong, The strength of the composite magnet structure 2 is improved.

Second Embodiment As shown in FIGS. 7 to 10, the composite magnet structure 2A according to the second embodiment of the present invention is compared with the composite magnet structure 2 according to the first embodiment shown in FIGS. And the formation position of the ridgeline processing part 20 currently formed in magnet piece 4A1 and 4A2 differs, and the structure of 10 A of resin frames obtained as a result differs. The other configurations and functions and effects of the composite magnet structure 2A according to the second embodiment are the same as those of the composite magnet structure 2 according to the first embodiment, and thus redundant description is omitted.

  As shown in FIGS. 7-10, in this embodiment, magnet piece 4A1 arrange | positioned at the both ends of a Z-axis direction, and magnet piece 4A2 arrange | positioned in the middle are the formation position of the ridgeline process part 20. As shown in FIG. Is different. That is, in the magnet piece 4A1, the ridge line processing portion 20 is formed only on one of the sub-side surfaces 4c, and the ridge line processing portion 20 is not formed on the other sub-side surface 4c. A ridge line processing portion 20 is formed on both end faces 4b of the magnet piece 4A1. Further, in the magnet piece 4A2, the ridge line processed portion 20 is not formed on both the sub-side surfaces 4c, and the ridge line processed portion 20 is formed only on the both end surfaces 4b.

  Therefore, as shown in FIG. 7, the second connecting portion 10b is not formed between the magnet piece 4A1 and the magnet piece 4A2, and the exposed area of the main side surface 4a of the magnet piece 4 is increased. The main side surface 4a of the magnet piece is a portion to be a magnetic pole surface, and the magnetic characteristics are improved by increasing the area.

Third Embodiment As shown in FIG. 11, the composite magnet structure 2B according to the third embodiment of the present invention is compared with the composite magnet structure 2 according to the first embodiment shown in FIGS. The magnet pieces 4B1 and 4B2 have different sizes, and the magnet pieces 4B1 and 4B2 have different magnetic characteristics. Furthermore, the composite magnet structure 2B according to the third embodiment has a resin frame 10B in which the reinforcing portion 10c shown in FIG. 1 is not formed.

  In the composite magnet structure 2B according to the third embodiment, unlike the composite magnet structure 2 according to the first embodiment, the longitudinal direction X of each magnet piece 4 coincides with the longitudinal direction of the composite magnet structure 2b. The first connecting portion 10a is formed in the short side direction of the composite magnet structure 2B. Moreover, the 2nd connection part 10b is formed in the long side direction of the composite magnet structure 2B.

  Moreover, in the composite magnet structure 2b of the present embodiment, the sub-side surface 4c of the magnet piece 4 located at the end in the Z-axis direction is exposed, and the end face 4b of the magnet piece 4 located at the end in the X-axis direction is exposed. Exposed. Since the configuration and operational effects of the composite magnet structure 2B according to the third embodiment other than those described above are the same as those of the composite magnet structure 2 according to the first embodiment, overlapping description will be omitted.

  In this embodiment, the magnet piece 4B1 is different in magnetic characteristics from the other magnet pieces 4B2. This embodiment is effective when it is desired to make magnetic characteristics such as coercive force and saturation magnetic flux density different between the central portion and the end portion of the composite magnet structure 2B.

The present invention is not limited to the above-described embodiment, and can be variously modified within the scope of the present invention.
For example, the shape and number of the magnet pieces constituting the composite magnet structure are not limited to the illustrated example, and can be variously modified.

  Hereinafter, although this invention is demonstrated based on a more detailed Example, this invention is not limited to these Examples.

Example 1
First, the rectangular parallelepiped magnet pieces 4 having the dimensions L0 × W0 × T0 = 24 mm × 18 mm × 8 mm shown in FIG. 4 are prepared for each sample 1 to 6 in the number of 4 × 10 samples. In the cross section perpendicular to the ridgeline of the corner, chamfering was performed so that the cross section to be deleted by processing became a triangular shape, and the ridgeline processing portion 20 was formed. Table 1 shows the processing dimension α during chamfering. In Table 1, the symbol C for the chamfering method means chamfering in which the deleted cross section shown in FIG. 5A is triangular, and the symbol □ indicates that the deleted cross section shown in FIG. The symbol R is the R processing shown in FIG. 5 (c).

  Next, a protective layer was formed on each magnet piece 4 as necessary. In the case of a protective layer, epoxy resin, or phenol resin, the resin was dissolved in a solvent to prepare a coating solution, which was applied to the surface of the magnet piece 4 by a dip coating method and then dried. When the protective layer was a Ni metal layer, the magnet piece 4 was formed by electroplating.

  Next, a mold for molding the resin frame 10 was prepared. The magnet pieces 4 shown in FIG. 4 are placed in the cavity of the mold not shown in the drawing so that the sub-side surfaces 4c of the magnet pieces 4 come into contact with each other as shown in FIG. They were arranged in a line along the width direction Z.

  In the mold cavity, the main side surface 4a of the magnet piece 4 is arranged in contact with the inner wall surface of the mold cavity, and each magnet piece 4 is arranged in contact with the sub-side surfaces 4c, and The sub-side surfaces 4c of the magnet pieces 4 located at both ends in the Z-axis direction are also disposed in contact with the cavity inner wall surface of the mold. The end face 4b of each magnet piece 4 was arranged with a predetermined gap with respect to the inner wall surface of the mold cavity.

The alignment of each magnet piece 4 in the X-axis direction in the cavity of the mold was performed by arranging a plurality of spacers between the end face 4b and the inner wall surface of the cavity. In the state shown in FIG. 6, injection molding was performed by injecting resin from the end face 4 b direction (X-axis direction) of the magnet piece 4. The resin flowed through the gap between the cavity inner wall surface and the ridge line processed portion 20 and hardened, and the resin frame 10 shown in FIGS. 1 to 3 was formed.
With respect to the molded composite magnet structure 2 (see FIG. 1), the flatness of the main side surface 4a, which is the magnetic pole surface, the flatness of the end surface in the X-axis direction, the variation in strength, and the magnetic characteristics were measured. The flatness is measured by measuring the positional deviation of the main side surface 4a of the composite magnet structure 2 or the side surface of the reinforcing portion 10c using a digimatic indicator (model number ID-C1012X (B), manufactured by Mitutoyo Corporation). Table 1 shows the value (unit: mm) having the largest difference in positional deviation. The flatness is 0.03 or less.

  Further, the variation in strength was obtained by conducting a three-point bending test (JIS R 1601) of the composite magnet structure 2 and expressing the variation in strength by a value obtained by subtracting the minimum value from the maximum value and dividing the average value. . The number of samples for each sample is ten. The strength variation is preferably 1.00 or less.

  Furthermore, the magnetic characteristics were measured by measuring the total flux per composite magnet structure with a flux meter 480 (manufactured by LakeShore), and taking the surface magnetic flux of the assembly of magnet pieces when there is no ridge line machining part as 100% Indicated. The magnetic properties are preferably 95% or more, but 92% or more may be good depending on the chamfering method.

  The results are shown in Table 1. As shown in Table 1, when the chamfering dimension α is 0.8 to 2.0 mm and α / T0 = 0.1 to 0.25, the flatness, strength variation, and magnetic properties are improved. It was confirmed.

Example 2
Samples 10 to 15 were produced in the same manner as in Example 1 except that the size of the magnet piece 4 was L0 × W0 × T0 = 18 mm × 12 mm × 6 mm, and each sample was evaluated in the same manner as in Example 1. went.

  The results are shown in Table 1. As shown in Table 1, when the chamfering dimension α is 0.8 to 2.0 mm and α / T0 = 0.133 to 0.333, the flatness, strength variation, and magnetic properties are improved. It was confirmed.

Example 3
Samples 20 to 25 were prepared in the same manner as in Example 1 except that the ridge line processing portion 20 of the magnet piece 4 was R-processed, and the same evaluation as in Example 1 was performed for each sample.

  The results are shown in Table 1. As shown in Table 1, when the chamfering dimension α is 1 to 2.0 mm and α / T0 = 0.125 to 0.250, the flatness, strength variation, and magnetic characteristics may be improved. confirmed.

Example 4
Samples 30 to 35 were prepared in the same manner as in Example 1 except that the ridge line processing portion 20 of the magnet piece 4 was chamfered with a square cross section, and the same evaluation as in Example 1 was performed for each sample. It was.

  The results are shown in Table 1. As shown in Table 1, when the chamfering dimension α is 0.8 to 2.0 mm and α / T0 = 0.1 to 0.250, the flatness, strength variation, and magnetic properties are improved. It was confirmed. In this embodiment, the magnetic characteristics are preferably 92% or more. A chamfering method may be selected according to the target magnetic characteristics.

Example 5
As shown in FIGS. 7 to 9, samples 40 to 45 were prepared in the same manner as in Example 4 except that the ridge line processing portion 20 of the magnet piece 4 was formed only in part, and for each sample, The same evaluation as in Example 4 was performed.

  The results are shown in Table 1. As shown in Table 1, when the chamfering dimension α is 0.8 to 2.0 mm and α / T0 = 0.1 to 0.250, the flatness, strength variation, and magnetic properties are improved. It was confirmed.

Example 6
Samples 50 to 52 were prepared in the same manner as in Example 1 except that the surface treatment of the magnet piece was changed as shown in Table 1 and the chamfering dimension was fixed at 1.5 mm. The same evaluation as in Example 1 was performed.

  The results are shown in Table 1. As shown in Table 1, it was confirmed that the flatness, the intensity variation, and the magnetic characteristics were improved regardless of the surface treatment method.

Comparative Example 1
Samples 60 to 62 were prepared in the same manner as in Example 1 except that the magnet pieces were not subjected to ridge line processing at all, and the magnet pieces were fixed with an adhesive made of an epoxy adhesive without forming a resin frame. The same evaluation as Example 1 was performed about each sample.

  The results are shown in Table 1. As shown in Table 1, it was confirmed that the fixing method using an adhesive was inferior to the examples in terms of flatness and strength variation.

2, 2A, 2B ... Composite magnet structure 4, 4A1, 4A2, 4B1, 4B2 ... Magnet piece 4a ... Main side surface 4b ... End surface 4c ... Sub-side surface 10, 10A, 10B ... Resin frame 10a ... First connecting portion 10b ... First 2 connection part 10c ... reinforcement part 20, 20a, 20c ... ridgeline processing part

Claims (8)

A flat plate shape having a main side and a secondary side and the end face, have a ridge machining portion being ridgeline processed along at least a portion of the sides, two or more of dividing a flat composite magnet structure into a plurality With magnet pieces,
Wherein while exposing a portion of the major sides of the magnet pieces, have a, a resin frame for fixing by integrating two or more of the magnet pieces by being arranged along the edge line processing unit,
The ridge line processing part is
All corners of the main side and end face of each magnet piece;
Corner portions present at least at both ends of the composite magnet structure among the corner portions of the main side surface and the sub-side surface of each magnet piece,
Formed at least at both ends of the composite magnet structure among the corners of the sub-side surface and the end surface of each magnet piece,
The resin frame has a first connecting part and a second connecting part,
The first connecting portion covers the end face of the magnet piece, and is disposed across the two or more magnet pieces along the ridge line processing portion,
The said 2nd connection part is a composite magnet structure arrange | positioned so that two or more said 1st connection parts may be connected mutually along a ridgeline process part . The ridge line processing part is
All corners of the main side and end face of each magnet piece;
All corners of the main side and the sub-side of each magnet piece;
The composite magnet structure according to claim 1, wherein the composite magnet structure is formed on all the corners of the sub-side surface and the end surface of each magnet piece. 2 or more which is a flat plate shape having a main side surface, a sub-side surface, and an end surface, has a ridge line processing portion processed along at least a part of the side, and divides the flat plate-like composite magnet structure into a plurality of pieces With magnet pieces,
A resin frame that unifies and fixes two or more of the magnet pieces by being arranged along the ridge line processing portion in a state in which a part of the main side surface, the sub-side surface, and the end surface of the magnet piece are exposed. Have
The ridge line processing part is
All corners of the main side and end face of each magnet piece;
All corners of the main side and the sub-side of each magnet piece;
It is formed at all corners of the sub-side surface and end surface of each magnet piece,
The resin frame has a first connecting part and a second connecting part,
The first connecting portion is disposed across two or more magnet pieces along the ridge line processing portion in the short side direction of the composite magnet structure,
The said 2nd connection part is a composite magnet structure arrange | positioned so that two or more said 1st connection parts may be connected mutually along a ridgeline process part. The composite magnet structure according to any one of claims 1 to 3, wherein the main side surface is a magnetic pole surface. Hybrid magnet structure according to any one of claims 1-4, wherein the ridge processing unit is formed by chamfering. The composite magnet structure according to any one of claims 1 to 5, wherein a cross-sectional shape of the deleted portion at the time of processing the ridgeline is a quadrangular shape. The composite magnet structure is a rectangular parallelepiped shape, the composite magnet structure as claimed in any one of claims 1,2,4～6 having said first connecting portion in the longitudinal direction of the composite magnetic structure.   The composite magnet structure according to claim 1, wherein at least one of the magnet pieces has a magnetic property different from that of the other magnet pieces.

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