JPWO2007018123A1 - 希土類合金系バインダレス磁石およびその製造方法 - Google Patents
希土類合金系バインダレス磁石およびその製造方法 Download PDFInfo
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Abstract
Description
4 ダイ
6 下パンチ
8 上パンチ
10 成形体(圧縮成形体)
14 固定ダイプレート
16 下部ラム
18 上部ラム
28 上パンチ外径補強ガイド
30a リニアガイドレール
30b リニアガイドレール
32 フィーダカップ
42a 下パンチ
42b 下パンチ
44a 上パンチ
44b 上パンチ
以下、本発明による希土類合金系バインダレス磁石の製造方法の好ましい実施形態を説明する。
以下、本発明による希土類合金系バインダレス磁石と、無樹脂圧粉磁心とが一体的に成形された磁気回路部品の実施形態を説明する。軟磁性材料粉末の無樹脂圧粉磁心は、ヨークやシャフト等の軟磁性部材して機能し得るため、この磁気回路部品は、モータ回転子などのコア材として好適に用いられる。
SPRAX−XDの磁石粉末を用意した後、98wt%の磁石粉末と2wt%のエポキシ樹脂とに対してニーダー処理(攪拌処理)を施すことにより、磁石粉末とエポキシ樹脂との混合物を得た。この混合物に対し、0.5outwt%のステアリン酸カルシウムを添加した後、900MPaの圧力で圧縮成形を行うことにより、成形体を作製した。
比較例1では、98wt%の磁石粉末と2wt%のエポキシ樹脂とを混合したが、比較例2では、97wt%の磁石粉末と3wt%のエポキシ樹脂とを混合した。これ以外の点では、比較例1と比較例2との間に作製方法の差異はない。
SPRAX−XDの磁石粉末を用意した後、90wt%の磁石粉末と10wt%のPPS(ポリフェニレンサルファイド:Polyphenylene Sulfide)とを二軸押し出し機にて押し出した。この後、適切な長さにカットすることにより、φ3mm×4mmのペレット原料を作製した。このペレットを用いて、樹脂温度340℃、金型温度180℃、射出圧220MPaの条件で射出成形を行い、比較例3の成形体(ボンド磁石)を作製した。
SPRAX−XBの磁石粉末を用意した後、95wt%の磁石粉末と5wt%のポリアミド(PA12)とを二軸押し出し機にて押し出した。この後、適切な長さにカットすることにより、φ3mm×4mmのペレット原料を作製した。このペレットを用いて、樹脂温度290℃、金型温度120℃、射出圧210MPaの条件で射出成形を行い、比較例4の成形体(ボンド磁石)を作製した。
表1のN2の合金組成を有する急冷合金鋳片(平均厚さ:25μm)から作製した磁石粉末を用意し、実施例1、4〜7と同一装置および方法で圧縮成形体を作製した(実施例8)。圧縮成形体の寸法は内径7.7mm、外径12.8mm、高さ4.8mmであった。以下の表6は、実施例8および実施例6について、急冷合金平均鋳片厚、粉砕後の平均粉末粒径、成形条件、および圧縮成形体に熱処理を行った後のバインダレス磁石の密度を示している。
Claims (20)
- 希土類系急冷合金磁石粉末の粒子が樹脂バインダを介さずに結合した磁石であって、
全体に占める前記希土類系急冷合金磁石粉末の体積比率が70%以上95%以下である、希土類合金系バインダレス磁石。 - 前記急冷合金磁石粉末の粒子は、前記急冷合金磁石粉末粒子からの析出物によって結合している、請求項1に記載の希土類合金系バインダレス磁石。
- 前記急冷合金磁石粉末の粒子は、ホウ素を含有する鉄基希土類合金から形成されており、前記析出物は、鉄、希土類、およびホウ素からなる群から選択された少なくとも1種類の元素から構成されている、請求項2に記載の希土類合金系バインダレス磁石。
- 前記急冷合金磁石粉末の粒子にはクラックが形成されており、前記析出部の少なくとも一部は前記クラック内に存在している、請求項2または3に記載の希土類合金系バインダレス磁石。
- 全体に占める前記希土類系急冷合金磁石粉末の体積比率が70%超92%未満である、請求項1に記載の希土類合金系バインダレス磁石。
- 前記希土類系急冷合金磁石粉末の粒子は固相焼結によって相互に結合している、請求項1に記載の希土類合金系バインダレス磁石。
- 前記希土類系急冷合金磁石粉末の粒子は、1種以上の強磁性結晶相を含有し、その平均結晶粒径が10nm以上300nm以下の範囲にある、請求項1に記載の希土類合金系バインダレス磁石。
- 前記希土類系急冷合金磁石粉末の粒子は、硬磁性相および軟磁性相を含有するナノコンポジット磁石組織を有している、請求項1に記載の希土類合金系バインダレス磁石。
- 密度が5.5g/cm3〜7.0g/cm3である請求項1に記載の希土類合金系バインダレス磁石。
- 組成式T100-x-y-zQxRyMz(TはFe、または、CoおよびNiからなる群から選択された1種以上の元素とFeとを含む遷移金属元素、QはBおよびCからなる群から選択された少なくとも1種の元素、RはLaおよびCeを実質的に含まない少なくとも1種の希土類元素、Mは、Ti、Al、Si、V、Cr、Mn、Cu、Zn、Ga、Zr、Nb、Mo、Ag、Hf、Ta、W、Pt、Au、およびPbからなる群から選択された少なくとも1種の金属元素)で表現され、組成比率x、y、およびzが、それぞれ、
10<x≦35原子%、
2≦y≦10原子%、および
0≦z≦10原子%
を満足する組成を有している、請求項1に記載の希土類合金系バインダレス磁石。 - 組成式T100-x-y-zQxRyMz(TはFe、または、CoおよびNiからなる群から選択された1種以上の元素とFeとを含む遷移金属元素、QはBおよびCからなる群から選択された少なくとも1種の元素、RはLaおよびCeを実質的に含まない少なくとも1種の希土類元素、Mは、Ti、Al、Si、V、Cr、Mn、Cu、Zn、Ga、Zr、Nb、Mo、Ag、Hf、Ta、W、Pt、Au、およびPbからなる群から選択された少なくとも1種の金属元素)で表現され、組成比率x、y、およびzが、それぞれ、
4<x≦10原子%、
6≦y<12原子%、および
0≦z≦10原子%
を満足する組成を有している、請求項1に記載の希土類合金系バインダレス磁石。 - 希土類系急冷合金磁石粉末を用意する工程(A)と、
樹脂バインダを用いずに前記希土類系急冷合金磁石粉末を冷間にて圧縮して成形することにより、全体に占める前記希土類系急冷合金磁石粉末の体積比率が70%以上95%以下の圧縮成形体を形成する工程(B)と、
前記工程(B)の後に350℃以上800℃以下の温度で前記圧縮成形体に対して熱処理を施す工程(C)と、
を含む希土類合金系バインダレス磁石の製造方法。 - 前記工程(B)では、500MPa以上2500MPa以下の圧力で前記希土類系急冷磁石用急冷合金磁石粉末を圧縮する、請求項12に記載の希土類合金系バインダレス磁石の製造方法。
- 前記工程(C)の熱処理は、圧力が1×10-2Pa以下の不活性ガス雰囲気中で実行する請求項13に記載の希土類合金系バインダレス磁石の製造方法。
- 前記工程(C)の熱処理は、露点が−40℃以下の不活性ガス雰囲気中で実行する請求項13または14に記載の希土類合金系バインダレス磁石の製造方法。
- 請求項1に記載の希土類合金系バインダレス磁石と、
軟磁性材料粉末が樹脂バインダを介さずに結合した無樹脂圧粉磁心と、を備え、
前記バインダレス磁石と前記無樹脂圧粉磁心とが一体化された磁気回路部品。 - 前記無樹脂圧粉磁心における軟磁性粉末の粒子は焼結によって相互に結合している、請求項16に記載の磁気回路部品。
- 前記バインダレス磁石と前記無樹脂圧粉磁心とは、焼結によって相互に結合している請求項16または17に記載の磁気回路部品。
- 請求項16に記載の磁気回路部品の製造方法であって、
希土類系急冷合金粉末および軟磁性材料粉末を用意する工程(A)と、
前記希土類系急冷合金粉末および前記軟磁性材料粉末を冷間にて500MPa以上2500MPa以下の圧力で圧縮して一体化する工程(B)と、
前記一体化圧縮成形体に対して350℃以上800℃以下の温度で熱処理を施す工程(C)と、
を含む、磁気回路部品の製造方法。 - 前記工程(A)は、前記希土類系急冷合金粉末および前記軟磁性材料粉末の少なくとも一方の仮成形体を形成する工程を含み、
前記工程(B)では、前記仮成形体を少なくとも一部に含む前記希土類系急冷合金粉末および前記軟磁性材料粉末を圧縮する、請求項19に記載の磁気回路部品の製造方法。
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JP2007529533A JP4732459B2 (ja) | 2005-08-08 | 2006-08-03 | 希土類合金系バインダレス磁石およびその製造方法 |
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PCT/JP2006/315409 WO2007018123A1 (ja) | 2005-08-08 | 2006-08-03 | 希土類合金系バインダレス磁石およびその製造方法 |
JP2007529533A JP4732459B2 (ja) | 2005-08-08 | 2006-08-03 | 希土類合金系バインダレス磁石およびその製造方法 |
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EP (1) | EP1947657A1 (ja) |
JP (1) | JP4732459B2 (ja) |
KR (1) | KR101247796B1 (ja) |
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JP5057111B2 (ja) | 2009-07-01 | 2012-10-24 | 信越化学工業株式会社 | 希土類磁石の製造方法 |
JP5093215B2 (ja) * | 2009-11-26 | 2012-12-12 | トヨタ自動車株式会社 | 焼結希土類磁石の製造方法 |
US9666361B2 (en) | 2011-03-02 | 2017-05-30 | Hitachi Metals, Ltd. | Rare-earth bond magnet manufacturing method |
MY165562A (en) | 2011-05-02 | 2018-04-05 | Shinetsu Chemical Co | Rare earth permanent magnets and their preparation |
WO2013103132A1 (ja) * | 2012-01-04 | 2013-07-11 | トヨタ自動車株式会社 | 希土類ナノコンポジット磁石 |
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JP6500470B2 (ja) * | 2015-02-06 | 2019-04-17 | Tdk株式会社 | 窒化鉄系磁石 |
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- 2006-08-03 US US12/063,150 patent/US7938915B2/en active Active
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- 2006-08-03 EP EP06782269A patent/EP1947657A1/en not_active Withdrawn
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Also Published As
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US20090127494A1 (en) | 2009-05-21 |
CN101238530A (zh) | 2008-08-06 |
US7938915B2 (en) | 2011-05-10 |
WO2007018123A1 (ja) | 2007-02-15 |
KR101247796B1 (ko) | 2013-03-26 |
EP1947657A1 (en) | 2008-07-23 |
CN101238530B (zh) | 2011-12-07 |
JP4732459B2 (ja) | 2011-07-27 |
KR20080034918A (ko) | 2008-04-22 |
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