JP6341115B2 - Polar anisotropic ring magnet and rotor using the same - Google Patents

Description

  The present invention relates to a polar anisotropic ring magnet using an R-T-B system sintered magnet, and a surface magnet type rotor using the same.

  In surface magnet type rotors having RTB polar anisotropic sintered ring magnets, various detent technologies have been disclosed to prevent idle rotation between the rotor shaft and the polar anisotropic sintered ring magnet. Yes.

  Patent Document 1 discloses that in an RTB polar anisotropic sintered ring magnet, an axial groove formed on the inner peripheral surface is fitted with an axial protrusion formed on the outer peripheral surface of the rotor yoke. Disclosed is a method for preventing idling of the rotor yoke, and the axial groove of the inner peripheral surface is sintered when a molded body that is polar-anisotropically oriented to have a pole on the outer peripheral surface side, It is described that the molded body shrinks and is formed by utilizing the deformation of the inner peripheral surface that occurs along with it.

  However, since the groove on the inner peripheral surface is provided by utilizing deformation during sintering accompanying polar anisotropic orientation formed on the outer peripheral surface side, the groove of the rotor yoke includes some manufacturing error. There is a possibility that the position of the strip and the groove of the sintered ring magnet may be shifted. Furthermore, in order to maintain the dimensional accuracy of the inner diameter of the sintered ring magnet, a step of polishing the inner peripheral surface other than the groove portion is necessary, and there is a problem that costs are increased. Further, since the rotor yoke is made of a magnetic metal, the inertia force is inevitably increased, which is not suitable for a rotor that frequently stops rotation.

Patent Document 2 discloses a ratio (inner / outer diameter) of the inner diameter (D ₁ ) and the outer diameter (D ₂ ) in order to prevent cracks caused by thermal stress in RTB sintered cylindrical magnets having polar anisotropy on the surface. Ratio: D ₁ / D ₂ ) is disclosed according to the number of magnetized poles, 0.35-0.85 for 4-pole, 0.45-0.85 for 6-pole, 0.55--for 8-pole It is 0.85, and when the number of poles P is 10 to 48, it is described that it is expressed by the formula: D ₁ / D ₂ = 1−K (π / P) [where K is a constant of 1.0 or more] .

However, Patent Document 2 only shows the inner / outer diameter ratio in a range as described above. When actually manufacturing a ring magnet, the number of the inner and outer diameter ratios is included in the range by trial and error. A ring magnet is produced under the conditions of point, and the work of selecting the one with the highest performance is necessary, and the efficiency is poor. In addition, for example, in the case of a 10-pole or 12-pole polar anisotropic magnet, the inner / outer diameter ratio D ₁ / D ₂ when the constant (K) in the above formula is 1.0 to 1.5 is 0.53 to 10 poles The range is 0.69, and in the case of 12 poles, the range is 0.61 to 0.74. Comparing the inner / outer diameter ratio from the 4-pole to the 8-pole and the inner-outer diameter ratio from the 10-pole to the 12-pole, the connection between the 8-pole and the 10-pole is poor and lacks linearity. In particular, the upper limit of the inner / outer diameter ratio in the case of multiple poles (10 poles or more) is smaller than that in the case of eight poles. As the number of magnetic poles described in Patent Document 2 increases, the inner / outer diameter ratio increases (thickness is thinner). Is inconsistent with the explanation.

JP 2005-304178 JP-A 64-27208

  Accordingly, an object of the present invention is to provide an RTB-type polar anisotropic sintered ring magnet having an inner peripheral surface of a polygonal cross section for preventing rotation and generating almost no cracking due to stress, and a shaft having a resin spacer in the magnet. And providing a rotor capable of reducing the inertial force.

  As a result of diligent research in view of the above object, the present inventors have found that an RTB sintered ring magnet having a polar anisotropy having 4 to 14 poles on the outer peripheral surface and an inner peripheral surface having a polygonal cross section. The number of poles is an integral multiple of the number of vertices of the polygon, and the ratio (D1 / D2) of the number of poles (P) to the inner diameter (D1) and outer diameter (D2) of the ring magnet is expressed by the formula: D1 / D2 = 1-K (π / P) [However, when P = 4, the value of K is 0.51 to 0.70, when P = 6, the value of K is 0.57 to 0.86, and when P = 8, the value of K Is 0.59 to 0.97, when P = 10, the value of K is 0.59 to 1.07, when P = 12, the value of K is 0.61 to 1.18, and when P = 14, the value of K is 0.62 to 1.29. ], The occurrence of cracking due to stress is remarkably reduced, and at least one of the intermediate positions of two adjacent poles (magnetic poles) on the outer peripheral surface and the cross-sectional polygon forming the inner peripheral surface It was found that by matching at least one of the vertices in the circumferential direction, it is easy to obtain the inner diameter shape of the ring magnet following the shape of the die on the inner diameter side of the ring magnet at the time of forming the sintered magnet.

That is, the RTB sintered ring magnet of the present invention is an RTB sintered ring magnet having an outer peripheral surface having a circular cross section and an inner peripheral surface having a polygonal cross section, and having multipolar anisotropy on the outer peripheral surface. There,
The number of poles of the outer peripheral surface is an integral multiple of the number of vertices of the polygon;
When the number of poles is P, the ratio between the inner diameter (D1: diameter of the circle circumscribing the polygon) and the outer diameter (D2) is the formula:
D1 / D2 = 1-K (π / P)
[However, K is a numerical value satisfying 0.51 ≦ K ≦ 1.29]
And at least one of the intermediate positions of two adjacent poles on the outer peripheral surface and at least one vertex of a polygonal cross section constituting the inner peripheral surface coincide with each other in the circumferential direction. .

  The inner peripheral surface of the polygonal cross section is preferably unprocessed.

  The number of poles is preferably the same as the number of vertices of the polygon.

  The number of poles is preferably twice the number of vertices of the polygon.

In the above formula,
When P = 4, the value of K is 0.51 ~ 0.64,
When P = 6, the value of K is 0.57 ~ 0.76,
When P = 8, the value of K is 0.59 ~ 0.84,
When P = 10, the value of K is 0.59 to 0.91,
When P = 12, the value of K is 0.61 to 0.99, and
When P = 14, the value of K is 0.62 to 1.07
It is more preferable that

  The rotor of the present invention fills the space between the RTB sintered ring magnet, the columnar shaft inserted in the center of the RTB sintered ring magnet, and the shaft and the RTB sintered ring magnet. And a resin spacer for fixing the shaft to the RTB-based sintered ring magnet, and the shaft extends in the axial center of the polygonal column and the axial end of the polygonal column. The resin spacer is disposed so as to fill a space between the outer peripheral surface of the polygonal column and the inner peripheral surface of the RTB sintered ring magnet.

  The resin spacer is preferably made of a thermoplastic resin.

  The resin spacer is preferably injection molded.

  Since the RTB sintered ring magnet of the present invention has a polygonal inner peripheral surface, it is possible to reliably prevent idling of a columnar shaft having a cross section that fits into the polygon, and cracking due to stress is prevented. Because it hardly occurs, it shows high durability. The rotor of the present invention is a columnar shaft made of a relatively lightweight material, such as resin, by using an RTB sintered ring magnet having a polygonal inner peripheral surface. However, it is possible to reliably prevent idling, so that the inertial force can be kept low. Therefore, it is suitable for a rotor that frequently stops rotation.

FIG. 2 is a cross-sectional view showing an example of an R-T-B based sintered ring magnet having an 8-pole polar anisotropy of the present invention. FIG. 6 is a cross-sectional view showing another example of an R—T—B based sintered ring magnet having polar anisotropy of 8 poles. It is sectional drawing for demonstrating the definition of the internal diameter of the ring magnet which has an internal peripheral surface of a cross-sectional polygon. FIG. 4A is a partial cross-sectional view taken along a plane including an axis showing an example of the rotor of the present invention, and FIG. 5B is a schematic diagram viewed from the axial direction. FIG. 5 shows (a) a front view and (b) a side view showing only the shaft of FIG. 4. It is the schematic diagram seen from the axial direction which shows another example of the rotor of this invention. It is the schematic diagram seen from the axial direction which shows another example of the rotor of this invention. It is the schematic diagram seen from the axial direction which shows another example of the rotor of this invention. It is the schematic diagram seen from the axial direction which shows another example of the rotor of this invention. It is the schematic diagram seen from the axial direction which shows another example of the rotor of this invention. FIG. 6 is a cross-sectional view showing a rotor including an R—T—B-based sintered ring magnet having 14 poles of polar anisotropy and an inner peripheral surface of a cross section of 10 squares. FIG. 5 is a cross-sectional view showing a rotor including an R-T-B sintered ring magnet having 14 poles of polar anisotropy and a heptagonal cross section. It is sectional drawing which shows typically an example of the shaping | molding apparatus in a magnetic field. FIG. 14 is a sectional view taken along line AA in FIG. It is a graph which shows the range of inner / outer diameter ratio.

[1] RTB polar anisotropy ring magnet The RTB polar anisotropy ring magnet of the present invention has a cross section having multipolar anisotropy of 4, 6, 8, 10, 12, or 14 poles. A circular outer peripheral surface and a polygonal inner peripheral surface, the number of poles of the outer peripheral surface is an integral multiple of the number of vertices of the polygon, and the inner diameter when the number of poles is P (D1 : The diameter of the circle circumscribing the polygon) and the outer diameter (D2) is the formula:
D1 / D2 = 1-K (π / P)
[However,
When P = 4, the value of K is 0.51 to 0.70,
When P = 6, the value of K is 0.57 ~ 0.86,
When P = 8, the value of K is 0.59-0.97,
When P = 10, the value of K is 0.59 ~ 1.07,
When P = 12, the value of K is 0.61 to 1.18, and
When P = 14, the value of K is 0.62 to 1.29. ]
And at least one of the intermediate positions of two adjacent poles on the outer peripheral surface and at least one vertex of a polygonal cross section constituting the inner peripheral surface coincide with each other in the circumferential direction. .

(1) Shape of Ring Magnet The RTB polar anisotropy ring magnet of the present invention will be described by taking the octupole anisotropic ring magnet shown in FIG. 1 as an example. The RTB polar anisotropy ring magnet 1 is multipolar anisotropy (eight poles in the figure) having a plurality of poles 2a to 2h on the outer circumferential surface 1a having a circular cross section. The cross section of the peripheral surface 1b is a polygon (an octagon in the figure). The number of poles of the ring magnet 1 is an integral multiple of the number of vertices 3a to 3h of the polygon, and is preferably the same as or twice the number of vertices. The number of poles of the RTB polar anisotropy ring magnet of the present invention is any of 4, 6, 8, 10, 12, 12, and 14. In particular, when the number of poles is 10, 12, or 14, the thickness in the radial direction of the magnet can be reduced as compared with the conventional case. How to set the number of vertices of the polygon may be appropriately adjusted according to the number of poles. The polygon is preferably a regular polygon. The fact that the cross section of the inner peripheral surface 1b is a regular polygon means that it may include some manufacturing errors, and is not limited to a mathematically exact regular polygon.

  At least one of the intermediate positions of two adjacent poles on the outer peripheral surface (for example, the intermediate position 200) and at least one of apexes 3a to 3h of the polygonal cross section constituting the inner peripheral surface (for example, the apex 3b) Are preferably the same in the circumferential direction. By setting it as such a structure, formation of a cross-sectional polygon can be performed easily. The magnetic flux inside the polar anisotropic ring magnet 1 is, for example, as indicated by an arrow A in FIG. 1, from the one vertex (for example, the pole 2a) to the adjacent pole (for example, the pole 2b). It flows in an arc shape across the 3h part. Although it seems that the magnetic flux flowing between the poles is obstructed by the apexes 3a to 3h, in the polar anisotropic magnet, most of the magnetic flux flows in the vicinity of the outer peripheral surface, so that the magnetic efficiency is hardly lowered. In particular, in the range of the inner / outer diameter ratio shown in the present invention, the efficiency decrease is extremely slight.

  The sintered ring magnet of the present invention is less likely to be deformed in the inner diameter shape during sintering, and tends to have a shape that follows the mold shape on the inner diameter side during molding. In other words, an inner diameter polygon having the same number of vertices as the number of poles of the polar anisotropic ring magnet is produced by compression molding in a magnetic field, and the intermediate position between two adjacent poles on the outer peripheral surface and the vertex of the polygon are surrounded. When matched in the direction, the inner diameter shape after sintering becomes a shape and tendency following the inner diameter shape at the time of molding. This is due to the fact that the degree of shrinkage during sintering differs between the orientation direction during molding of the R-T-B system sintered magnet and the direction orthogonal to the orientation direction. In the present invention, an intermediate position between two adjacent poles is a position derived from a design pole position, and is referred to as an intermediate position including variations occurring in manufacturing.

  As shown in FIG. 2, when the polar anisotropic ring magnet 11 having eight poles 12a to 12h on the outer peripheral surface 11a has an inner peripheral surface 11b having a regular triangular section (having three apexes 13a to 13c) ( Even if the number of poles is not an integral multiple of the number of vertices of the polygon, it has a detent effect, but the thickness of the polar anisotropic ring magnet 11 is increased and the magnet material must be used efficiently. I can't. Furthermore, since the weight increases and the inertial force increases, it is not suitable as a rotor of a rotating machine that frequently stops rotation.

  The inner peripheral surface of the R-T-B sintered ring magnet is preferably unprocessed. By making the inner peripheral surface unprocessed, polishing of the inner peripheral surface can be omitted, which can greatly contribute to cost reduction.

(2) Ratio of inner diameter to outer diameter (inner / outer diameter ratio)
The ratio D1 / D2 between the inner diameter (D1) and the outer diameter (D2) of the ring magnet of the present invention depends on the number of poles P of the ring magnet:
D1 / D2 = 1-K (π / P)
[However,
When P = 4, the value of K is 0.51 to 0.70,
When P = 6, the value of K is 0.57 ~ 0.86,
When P = 8, the value of K is 0.59-0.97,
When P = 10, the value of K is 0.59 ~ 1.07,
When P = 12, the value of K is 0.61 to 1.18, and
When P = 14, the value of K is 0.62 to 1.29. ]
It is represented by Here, as shown in FIG. 3, the inner diameter D1 is a diameter of a circle 1c circumscribing a polygonal cross section of the inner peripheral surface 1b. As the value of K increases, the inner / outer diameter ratio decreases, and as the value of K decreases, the inner / outer diameter ratio increases.

  When the value of K falls below the lower limit of the above range for each pole number, the thickness of the ring magnet becomes thin, and the strength of the sintered body loses the stress generated by anisotropy, and during sintering (the sintered body is There is a risk that the sintered body may crack during the cooling process) or may be cracked due to heat generated when the ring magnet is used. On the other hand, it is possible to manufacture a magnet even if the value of K exceeds the upper limit, but if the ring magnet is too thick, it will only increase the amount of magnets that are unnecessary (not necessary for magnetic properties). In addition, since an inertial force is increased due to an increase in weight, it is not preferable for a rotor such as a motor.

  Table 1 shows the range of D1 / D2 values obtained from the K value using the formula: D1 / D2 = 1−K (π / P) at each pole number.

In order to further prevent the occurrence of cracking due to stress in the polar anisotropic sintered ring magnet and to suppress the increase in inertial force,
When the number of poles is 4, the value of K is 0.51 to 0.64,
When the number of poles is 6, the value of K is 0.57 to 0.76,
When the number of poles is 8, the value of K is 0.59 to 0.84.
If the number of poles is 10, the value of K is 0.59 to 0.91,
When the number of poles is 12, the value of K is preferably 0.61 to 0.99, and when the number of poles is 14, the value of K is preferably 0.62 to 1.07.

  Table 2 shows a preferable range of D1 / D2 values obtained by using the formula: D1 / D2 = 1−K (π / P) from the preferable range of K values at each pole number.

  FIG. 15 shows a graph in which the range of these D1 / D2 values and the preferable range of D1 / D2 values are plotted against the number of poles. The upper limit of the D1 / D2 value is indicated by a line A, and the lower limit of the D1 / D2 value is indicated by a line B. The upper limit of the preferred D1 / D2 value is indicated by line A, and the lower limit of the preferred D1 / D2 value is indicated by line C. That is, the range between the line A and the line B is the range of the inner / outer diameter ratio D1 / D2 in the ring magnet of the present invention, and the range between the line A and the line C is the range of the inner / outer diameter ratio D1 / D2. This is a preferred range. As can be seen from FIG. 15, the preferable inner / outer diameter ratio D1 / D2 is a range on the larger value side of the range of D1 / D2 values, that is, a range on the side where the thickness of the ring magnet is thin, By setting the inner / outer diameter ratio D1 / D2 within this range, it is possible to suppress the occurrence of cracking due to stress, and to produce a ring magnet that can exhibit sufficient magnetic properties with as little magnet quantity as possible and does not increase inertia force. Can be obtained.

  However, when a ring magnet having a relatively small outer diameter (outer diameter of 20 mm or less) is formed, if the preferred K value is adopted, there may be a problem in manufacturing efficiency. For example, even when the inner / outer diameter ratio is the same, when forming a ring magnet with a small outer diameter, the absolute value of the wall thickness of the ring magnet is reduced compared to forming a ring magnet with a large outer diameter. The clearance of the mold cavity becomes thin, and it becomes difficult to supply magnetic powder to the clearance. For this reason, the problem that production efficiency falls very much arises. In the production of a ring magnet having a small outer diameter, the inner / outer diameter ratio is made smaller (the value of K is larger on the larger side in the above range) because it is necessary to perform the molding operation at regular time intervals in consideration of the manufacturing cost for industrial production. The thickness of the ring magnet, that is, the clearance of the mold cavity is preferably set thick. When forming a ring magnet with a relatively small outer diameter in this way, not only is it intended to prevent cracking of the ring magnet, but also a large K value is set to ensure the clearance of the cavity and to move to the magnetic powder cavity. It is necessary to facilitate the supply of.

  The present invention is applicable not only to polar anisotropic ring magnets whose magnetic poles are parallel to the axis of the ring magnet, but also to polar anisotropic ring magnets whose magnetic poles have an angle (skewed) with respect to the axis as a countermeasure against cogging torque. it can.

[2] Rotor As shown in FIGS. 4 and 5, the rotor 20 of the present invention includes the RTB sintered ring magnet 1 (in FIG. 4, an 8-pole pole having an octagonal inner peripheral surface). A ring-shaped ring magnet), a columnar shaft 21 inserted into the RTB sintered ring magnet 1, and a space between the shaft 21 and the RTB sintered ring magnet 1 are filled. And a resin spacer 22 for fixing to the system sintered ring magnet 1. The shaft 21 has a polygonal column portion 21a and cylindrical portions 21b extending at both axial ends of the polygonal column portion 21a, and the axial length of the polygonal column portion 21a is the RTB sintered ring magnet. The axial length of 1 and the axial length of the resin spacer 22 are preferably substantially the same. The resin spacer 22 is disposed so as to fill a space between the outer peripheral surface of the polygonal column portion 21 a of the shaft 21 and the inner peripheral surface 1 b of the RTB sintered ring magnet 1.

  For example, as shown in FIG. 6, the rotor 20 of the present invention includes a four-pole (or eight-pole or twelve-pole) polar anisotropic ring magnet 1 having a rectangular inner peripheral surface, a columnar shaft 21, For example, as shown in FIG. 7, a 6-pole (or 12-pole) polar anisotropic ring magnet 1 having a hexagonal cross section and a columnar shaft 21 The resin spacer 22 may be used.

(1) Shaft As shown in FIG. 5, the shaft 21 includes a polygonal column portion 21a and cylindrical portions 21b extending at both ends of the polygonal column portion 21a in the axial direction. The polygonal column portion 21a is formed in the central portion in the axial direction of the shaft 21, and has a polygonal cross section so as to have a detent effect with the resin spacer 22. The cross-sectional shape of the polygonal column portion 21a is not particularly limited, and for example, a quadrangle, pentagon, or hexagon can be adopted. The cross-sectional shape may be the same as or different from the cross-sectional shape of the inner peripheral surface 1b of the RTB sintered ring magnet 1. For example, as shown in FIG. 8, a combination of an 8-pole polar anisotropic ring magnet 1 having an inner peripheral surface with an octagonal cross section and a shaft 21 having a polygonal column portion 21a having a square cross section may be used. As shown in FIG. 4, a combination of an 8-pole polar anisotropic ring magnet 1 having an inner peripheral surface with an octagonal cross section and a shaft 21 having a polygonal column portion 21a having a hexagonal cross section may be used.

  The cylindrical portion 21b is a portion for connecting the rotor 20 to another device. A cylindrical shape is preferred. The polygonal column portion 21a and the columnar portion 21b may be formed integrally, or may be formed by inserting the columnar portion 21b into a hole provided at the axial center of the polygonal column portion 21a.

  The shaft 21 is preferably configured with a diameter as small as possible as compared with the inner diameter of the ring magnet 1 because the inertial force can be reduced. However, since the anti-rotation effect cannot be obtained if the shaft 21 is made too thin, it is necessary to set appropriately considering the anti-rotation effect.

  The material of the shaft 21 may be any material as long as the required strength is obtained, and a non-magnetic material or a magnetic material can be adopted. For example, when the magnetic flux penetrates to the inner diameter side like a radial ring magnet, it is better to use a magnetic shaft in terms of magnetic circuit. There is no need to consider magnetism. Further, even when an iron material is used from the viewpoint of cost and strength, the inertia force can be reduced by reducing the outer diameter of the shaft 21.

(2) Resin spacer The resin spacer 22 fills the space between the outer peripheral surface of the polygonal column 21a and the inner peripheral surface 1b of the RTB sintered ring magnet 1, and is lighter than the shaft 21. By using this, the inertia force of the rotor can be greatly reduced, and the resin spacer 22 absorbs the difference in thermal expansion between the shaft 21 and the ring magnet 1 during heating, thereby preventing the magnet from cracking. Can do. For example, as shown in FIG. 10, when the shaft 21 having the polygonal column portion 21a having a relatively large diameter is used, the thickness (wall thickness) in the radial direction of the resin spacer 22 becomes thin, so that the thermal expansion difference is absorbed. The effect is reduced. The radial thickness of the resin spacer 22 may be determined by appropriately setting the diameter of the shaft 21 in consideration of the diameter of the ring magnet.

  The resin spacer 22 may be formed by injection molding a thermoplastic resin in a state where the shaft 21 is inserted into the RTB sintered ring magnet 1. You may fix by the method of adhere | attaching on the prism part 21a and the internal peripheral surface 1b of the said RTB type sintered ring magnet 1 with an adhesive agent.

  In the case of the bonding method, the adhesive preferably has a low hardness such as an addition reaction type silicon adhesive in order to prevent cracking of the magnet due to a difference in thermal expansion between the shaft 21 and the ring magnet 1 during heating. . However, addition-reactive silicone adhesives contain platinum as a curing catalyst, so they may not cure on, for example, amine-containing paint surfaces (epoxy cation electrodeposition coating, etc.), and adhesion may be reduced depending on the environment. There is a case to do. On the other hand, the method of forming the resin spacer 22 by the injection molding can widen the selection range of the surface treatment, and is therefore a suitable method for configuring the rotor using the RTB sintered ring magnet of the present invention. It is.

(3) RTB sintered ring magnet The rotor 20 of the present invention is provided with the above-described multipolar anisotropic RTB sintered ring magnet 1 having a circular outer peripheral surface and a polygonal inner peripheral surface. use.

  A preferred embodiment of the R-T-B sintered ring magnet 1 includes a case where the number of poles on the outer peripheral surface is the same as the number of vertices of the polygonal section on the inner peripheral surface. However, when the RTB-based sintered ring magnet 1 having a large number of poles is used, the number of vertexes of the polygon increases and the cross-sectional shape of the inner peripheral surface becomes close to a circle. In some cases, the effect of detent between the binding ring magnet 1 and the shaft 21 may be reduced. In such a case, the cross-sectional shape of the inner peripheral surface is preferably a polygon having vertices that is half the number of poles, and when the number of poles increases, 1/3 of the number of poles, 1/4 ... and the number of vertices of the polygon may be reduced.

  For example, in the case of a polar anisotropic ring magnet with 14 poles on the outer peripheral surface, if the cross-sectional shape of the inner peripheral surface is a polygon with 14 vertices, the cross-sectional shape is close to a circle as shown in FIG. The anti-rotation effect is reduced. In this case, as shown in FIG. 12, by making the cross-sectional shape of the inner peripheral surface a polygon having seven vertices, although the efficiency of use of the magnet is slightly reduced, the rotation is reduced while minimizing the decrease in efficiency of use. The effect of stopping can be obtained.

  Normally, RTB sintered ring magnets are subjected to polishing of both end surfaces, polishing of the outer peripheral surface and polishing of the inner peripheral surface after sintering, but the present invention omits the polishing of the inner peripheral surface which is the most costly in the polishing process. This can greatly contribute to cost reduction. If the inner diameter of the R-T-B sintered ring magnet is not polished, the dimensional accuracy of the inner diameter surface is slightly worse than when the inner diameter is polished. Such a case can be dealt with by selecting a shaft that matches the shape of the inner diameter, or by setting the thickness of the adhesive when the shaft and the magnet are joined to each other. The shaft diameter may be smaller than the magnet inner diameter, and the resin spacer may be formed by injection molding. In the present invention, since the magnet and the shaft can be integrated by injection molding resin between the magnet and the shaft, polishing of the inner peripheral surface of the magnet can be omitted.

[3] Manufacturing Method The polar anisotropic sintered ring magnet of the present invention preferably consists essentially of RTB. Here, R is at least one of rare earth elements including Y, and preferably necessarily includes at least one of Nd, Dy, and Pr, and T is at least one of transition metal elements, preferably Fe. . B is boron. The RTB sintered ring magnet preferably has a composition of 24 to 34 mass% R, 0.6 to 1.8 mass% B, and the balance Fe. If the R amount is less than 24% by mass, the residual magnetic flux density Br coercivity iHc decreases. If the R content exceeds 34%, the region of the rare earth-rich phase inside the sintered body increases, so that the residual magnetic flux density Br decreases, and the microstructure also coarsens and the corrosion resistance decreases. When the amount of B is less than 0.6% by mass, B necessary for forming the main phase R ₂ Fe ₁₄ B phase is insufficient, and a R ₂ Fe ₁₇ phase having soft magnetic properties is generated, resulting in a decrease in coercive force. . On the other hand, when the amount of B exceeds 1.8% by mass, the phase rich in B which is a nonmagnetic phase increases and the residual magnetic flux density Br decreases. Fe may be partially substituted with Co, and may contain elements such as Al, Si, Cu, Ga, Nb, Mo, and W in an amount of about 3% by mass or less.

(1) Preparation of magnetic powder The pulverization of the magnetic powder is preferably carried out separately in coarse pulverization and fine pulverization. Roughly pulverizing the raw material alloy consisting essentially of R, T, B is preferably performed by a stamp mill, jaw crusher, brown mill, disk mill, hydrogen pulverization, etc., and fine pulverization is performed by a jet mill, a vibration mill, a ball mill, etc. It is preferable to carry out. In order to prevent oxidation, it is preferable to carry out in a non-oxidizing atmosphere using an organic solvent or an inert gas. The pulverized particle size is preferably 2 to 8 μm (FSSS). If it is less than 2 μm, the activity of the magnetic powder is high and oxidation occurs vigorously, so deformation during sintering is large and magnetic properties are also deteriorated. If it exceeds 8 μm, the crystal grain size after sintering becomes large and magnetization reversal occurs easily, leading to a decrease in coercive force.

(2) Molding
The RTB polar anisotropic sintered ring magnet is molded using a magnetic field molding apparatus 100 as shown in FIG. 13, for example. The magnetic field forming apparatus 100 includes a die 101 made of a magnetic material, and a core 102 made of a non-magnetic material having a polygonal cross section arranged concentrically in the annular space of the die. The die 101 is supported by support columns 111 and 112. The core 102 and the columns 111 and 112 are both supported by the lower frame 108. Similarly to the upper punch 104 made of a cylindrical nonmagnetic material, the lower punch 107 made of a cylindrical nonmagnetic material is inserted into the molding space 103 between the die 101 and the core 102, respectively. The upper punch 104 and the lower punch 107 are circular on the outer peripheral surface side, and the inner peripheral surface side is a polygon corresponding to the shape of the core 102. The lower punch 107 is fixed to the substrate 113, while the upper punch 104 is fixed to the upper frame 105. The upper frame 105 and the lower frame 108 are connected to the upper hydraulic cylinder 106 and the lower hydraulic cylinder 109, respectively.

  FIG. 14 shows an AA cross section of FIG. A plurality of grooves 117 are formed on the inner surface of the cylindrical die 101, and a magnetic field generating coil 115 is embedded in each groove 117. An annular non-magnetic annular sleeve 116 is provided on the inner surface of the die 101 so as to cover the groove. A space 103 between the annular sleeve 116 and the core 102 is formed. In FIG. 14, the magnetic field generating coils 115 in each groove 117 are arranged so that the current flows in a direction perpendicular to the paper surface, and are connected so that the current directions of the coils adjacent in the circumferential direction are alternately reversed. Has been.

  When a current is passed through the magnetic field generating coil 115, a flow of magnetic flux as shown by an arrow A is generated in the forming space 103, and S, N in order in the circumferential direction at points where the magnetic flux hits the annular sleeve (start point and end point of the arrow) , S, N... And magnetic poles whose polarities alternate (eight poles in the figure) are formed. At this time, the magnetic field generating coil 115 and the core 102 are arranged so that the position of the magnetic pole formed by the magnetic field generating coil 115 and the position of the polygonal apex of the core 102 on the inner diameter side substantially coincide with each other in the circumferential direction.

  R-T-B sintered magnets differ in the degree of shrinkage during sintering depending on the orientation direction of the magnetic particles. In the case of a polar anisotropic ring magnet, when a magnet is manufactured using a cavity having a circular inner diameter and an outer diameter, the positions of the poles become flat on the outer diameter side after sintering (the poles protrude relatively). A polygon having apexes between them), and the inner diameter side is a polygon corresponding to the deformation on the outer diameter side, or a circular shape having a depression in the protruding portion on the outer diameter side. Therefore, in the present invention, the polygonal vertex of the core 102 is arranged so as to coincide with the intermediate position between two adjacent magnetic poles.

The strength of the magnetic field applied to the forming space 103 to orient the magnetic powder is preferably 159 kA / m or more, more preferably 239 kA / m or more. When the strength of the orientation magnetic field is less than 159 kA / m, the orientation of the magnetic powder is insufficient and good magnetic properties cannot be obtained. The molding pressure is preferably 0.5 to 2 ton / cm ² . If it is less than 0.5 ton / cm ² , the strength of the compact tends to be weakened and broken. On the other hand, if it exceeds 2 ton / cm ² , the orientation of the magnetic powder is disturbed and the magnetic properties are deteriorated.

(3) Sintering Sintering is preferably performed at 1000 to 1150 ° C. in a vacuum or argon atmosphere. If it is less than 1000 ° C., the required density cannot be obtained due to insufficient sintering, and the magnetic properties deteriorate. Above 1150 ℃, oversintering causes deformation and deterioration of magnetic properties.

  Sintering is performed by placing a Mo plate in a heat-resistant container using Mo and placing a compact on it. In order to prevent the sintered body from sticking to the Mo plate, it is desirable to increase the surface roughness of the Mo plate by machining or the like and reduce the contact area with the formed body. When the Mo plate is a rolled material and the surface roughness is low, seizure between the sintered body and the Mo plate is likely to occur, and the sintered magnet may be deformed in the process of shrinkage accompanying the sintering. Blasting is preferred as the machining. The surface roughness (JISR6001-1983) of the Mo plate after blasting is preferably 5 μm to 100 μm, more preferably 7 μm to 50 μm, and even more preferably 10 μm to 30 μm in terms of Rmax. If it is less than 5 μm, seizure between the sintered body and the Mo plate is likely to occur, and the magnet after sintering is deformed. If it exceeds 100 μm, the sintered body gets caught in the Mo plate during the shrinkage process, causing deformation. By applying neodymium oxide or the like to the Mo plate, it is possible to prevent seizure of the sintered body and the Mo plate during sintering.

(4) Other steps After the sintering, the sintered body is preferably subjected to a heat treatment. The heat treatment may be performed before or after processing described later.

  The obtained sintered body processes the outer peripheral surface, the inner peripheral surface, and the end surface to the required dimensions as required. For processing, existing equipment such as an outer diameter polishing machine, an inner diameter polishing machine, a flat surface polishing machine, or a shape processing machine can be used as appropriate. Surface treatments such as plating, painting, vacuum deposition of aluminum, and chemical conversion treatment after processing can be performed as necessary.

  The present invention will be described in more detail with reference to examples, but the present invention is not limited thereto.

Example 1
According to the manufacturing method, using the magnetic field molding apparatus shown in FIG. 13 and FIG. 14, 23.5 mass% Nd, 2.2 mass% Dy, 6.5 mass% Pr, 1.0 mass% B, the balance Fe and inevitable Ten polar anisotropic ring magnet sintered bodies having a composition composed of Al, Nb and Ga as impurities and a small amount of additive elements and having 8 poles on the outer peripheral surface were produced. Furthermore, except for changing the configuration of the molding apparatus in the magnetic field according to the number of poles, the pole poles of 4, 6, 10, 12, and 14 poles are different in the same manner as the 8-pole anisotropic ring magnet sintered body. Ten isotropic ring magnet sintered bodies were produced for each. A magnetic field forming apparatus for manufacturing a polar anisotropic ring magnet having each number of poles includes a magnetic field generation device corresponding to the number of poles of the ring magnet, and a regular polymorph having the same number of vertices as the number of poles of the ring magnet. A core having a square cross-sectional shape arranged such that the vertex position of the regular polygon coincides with the intermediate position between two adjacent magnetic poles was used.

  The sintered ring magnet was polished with an outer diameter of 0.5 mm, and then both end surfaces were polished. The inner surface is not polished. Table 3 shows the inner / outer diameter ratio of each ring magnet.

  When the presence or absence of cracks in the ring magnet after outer diameter polishing was confirmed, no cracks were generated in all the magnets.

Comparative Example 1
4 poles, 6 poles, 8 poles, 10 poles in the same manner as in Example 1 except that the outside diameter of the core of the forming apparatus in the magnetic field was changed and the inside / outside diameter ratio of the obtained ring magnet was changed as shown in Table 4. Polar anisotropic ring magnet sintered bodies with poles, 12 poles and 14 poles were prepared.

  When the presence or absence of cracks in the ring magnet after outer diameter polishing was confirmed, cracks occurred in 1 to 7 of 10 magnets under all conditions.

Comparative Example 2
4 poles, 6 poles, 8 poles, 10 poles in the same manner as in Example 1 except that the outer diameter of the core of the molding apparatus in the magnetic field was changed and the inner and outer diameter ratios of the obtained ring magnets were changed as shown in Table 5. Polar anisotropic ring magnet sintered bodies with poles, 12 poles and 14 poles were prepared.

  When the presence or absence of cracks in the ring magnet after outer diameter polishing was confirmed, no cracks were generated in all the magnets. However, since this magnet has a small inner / outer diameter ratio and a heavy weight, it is not suitable for a rotor of a rotating machine that requires a small inertia force.

Explanation of symbols 1 ... RTB polar anisotropy ring magnet
1a ・ ・ ・ Outer surface
1b ・ ・ ・ Inner peripheral surface
2a ~ 2h ・ ・ ・ Pole
3a ~ 3h ・ ・ ・ Vertex
11 ... Polar anisotropic ring magnet
11a ・ ・ ・ Outer peripheral surface
11b ・ ・ ・ Inner peripheral surface
12a ~ 12h ・ ・ ・ Pole
13a ~ 13c ・ ・ ・ Vertex
21 ... Shaft
21a ・ ・ ・ Polygonal column
21b ・ ・ ・ Cylindrical part
100 ... Molding device in magnetic field
101 ・ ・ ・ Dice
102 ... Core
103 ・ ・ ・ Forming space
104 ... Upper punch
105 ... Upper frame
106 ... Upper hydraulic cylinder
107 ... Bottom punch
108 ... lower frame
109 ... Lower hydraulic cylinder
111,112 ・ ・ ・ support
113 ... Board
115 ... Magnetic field generating coil
116 ... annular sleeve
117 ・ ・ ・ Groove
200 ・ ・ ・ Intermediate position

Claims (8)

A polar anisotropy RTB having a circular outer peripheral surface and a polygonal inner peripheral surface, and the outer peripheral surface has a number of poles of 6, 6, 8, 10, 12, or 14 poles A sintered ring magnet,
The number of poles is an integer multiple of the number of vertices of the polygon;
When the number of poles is P, the ratio between the inner diameter (D1: diameter of the circle circumscribing the polygon) and the outer diameter (D2) is the formula:
D1 / D2 = 1-K (π / P)
[However,
When P = 4, the value of K is 0.51 to 0.70,
When P = 6, the value of K is 0.57 ~ 0.86,
When P = 8, the value of K is 0.59-0.97,
When P = 10, the value of K is 0.59 ~ 1.07,
When P = 12, the value of K is 0.61 to 1.18, and
When P = 14, the value of K is 0.62 to 1.29. ]
And at least one of the intermediate positions of two adjacent poles on the outer peripheral surface and at least one vertex of a polygonal cross section constituting the inner peripheral surface coincide with each other in the circumferential direction. RTB sintered ring magnet.   The R-T-B system sintered ring magnet according to claim 1, wherein the inner peripheral surface of the polygonal cross section is unprocessed.   The R-T-B system sintered ring magnet according to claim 1 or 2, wherein the number of poles is the same as the number of vertices of the polygon.   The R-T-B system sintered ring magnet according to claim 1 or 2, wherein the number of poles is twice the number of vertices of the polygon. In RTB system sintered ring magnet in any one of Claims 1-4,
When P = 4, the value of K is 0.51 ~ 0.64,
When P = 6, the value of K is 0.57 ~ 0.76,
When P = 8, the value of K is 0.59 ~ 0.84,
When P = 10, the value of K is 0.59 to 0.91,
When P = 12, the value of K is 0.61 to 0.99, and
When P = 14, the value of K is 0.62 to 1.07
An RTB sintered ring magnet characterized by   An RTB sintered ring magnet according to any one of claims 1 to 5, a columnar shaft inserted in an axial center of the RTB sintered ring magnet, the shaft and the RTB sintered ring magnet It consists of a resin spacer for filling the space and fixing the shaft to the RTB sintered ring magnet, and the shaft extends in the axial center of the polygonal column and the axial ends of the polygonal column. And the resin spacer is disposed so as to fill a space between the outer peripheral surface of the polygonal column portion and the inner peripheral surface of the RTB sintered ring magnet. Child.   The rotor according to claim 6, wherein the resin spacer is made of a thermoplastic resin.   The rotor according to claim 7, wherein the resin spacer is injection-molded.

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