JPWO2016151622A1 - 永久磁石、モータ、および発電機 - Google Patents
永久磁石、モータ、および発電機 Download PDFInfo
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Abstract
Description
本実施形態の永久磁石およびその製造方法例について以下に説明する。
(BH)max(理論値)=Mr 2/4μ0・・・(1)
角型比は、測定で得られる(BH)maxと(BH)max(理論値)の比により評価され、下記式(2)により求められる。
(BH)max(実測値)/(BH)max(理論値)×100・・・(2)
第1の実施形態の永久磁石は、各種モータや発電機に使用することができる。また、可変磁束モータや可変磁束発電機の固定磁石や可変磁石として使用することも可能である。第1の実施形態の永久磁石を用いることによって、各種のモータや発電機が構成される。第1の実施形態の永久磁石を可変磁束モータに適用する場合、可変磁束モータの構成やドライブシステムには、例えば特開2008−29148号公報や特開2008−43172号公報に開示されている技術を適用することができる。
永久磁石に用いられる各原料を所定の比率で秤量して混合した後、Arガス雰囲気でアーク溶解して合金インゴットを作製した。合金インゴットに対して粗粉砕とジェットミルによる粉砕とを実施し、磁石の原料粉末としての合金粉末を調製した。得られた合金粉末を磁界中でプレス成形して圧縮成形体を作製した。
圧縮成形体の総重量を表1に示すように2000g(2kg)として実施例1と同様の方法により磁石を得た。溶体化処理における1145℃(TST)から945℃(TST−200℃)までの冷却速度は5℃/sであった。また、他の実施例と同様に保磁力を算出した。
焼成炉を従来の冷却機構を搭載した実験炉を用いて実施例1と同様の方法により磁石を得た。溶体化処理における1145℃(TST)から945℃(TST−200℃)までの冷却速度は4℃/sと3℃/sであった。また、他の実施例と同様に保磁力を算出した。
実施形態の冷却部材を用いずに実施例1と同様の方法により磁石を得た。溶体化処理における1145℃(TST)から945℃(TST−200℃)までの冷却速度は1℃/sであった。また、他の実施例と同様に保磁力を算出した。
表1に示すように圧縮成形体の総重量を100gとし、焼成炉として従来の冷却機構を搭載した実験炉を用いて実施例1と同様の方法により磁石を得た。溶体化処理における1145℃(TST)から945℃(TST−200℃)までの冷却速度は20℃/sであった。また、他の実施例と同様に保磁力を算出した。
Claims (8)
- 合金粉末を磁場中で加圧成形して圧縮成形体を作製する工程と、前記圧縮成形体を焼結して焼結体を形成する工程と、前記焼結体に対して溶体化処理を行う工程と、前記溶体化処理後の焼結体に対して時効処理を行う工程と、を少なくとも行うことにより永久磁石を製造する永久磁石の製造方法であって、
前記溶体化処理は、
加熱体を有する加熱室の内部において、1100℃以上1200℃以下の温度TSTで前記焼結体を有する被処理体の熱処理を行う工程と、
前記熱処理の後に、第1の熱放射率を有する第1の層と、前記第1の層上に設けられ、前記第1の熱放射率よりも低い第2の熱放射率を有する第2の層と、を有する冷却部材を前記加熱室の内部に搬入し、前記被処理体側に前記第1の層が位置するように前記冷却部材を前記加熱体と前記被処理体との間に配置する工程と、
前記冷却部材とともに前記被処理体を前記加熱室の外部に搬出し、前記被処理体の温度が温度TST−200℃よりも低い温度になるまで前記被処理体を冷却する工程と、を備え、
前記被処理体を冷却する工程において、前記被処理体の温度が温度TST−200℃になるまでの冷却速度は5℃/s以上である、永久磁石の製造方法。 - 前記永久磁石は、
組成式:RpFeqMrCusCo100−p−q−r−t
(式中、Rは希土類元素から選ばれる少なくとも1つの元素、MはZr、Ti、およびHfからなる群より選ばれる少なくとも1つの元素、pは10.5≦p≦12.5原子%を満足する数、qは27≦q≦40原子%を満足する数、rは0.88≦r≦4.5原子%を満足する数、tは4.5≦t≦10.7原子%を満足する数である)
で表される組成を備える、請求項1に記載の永久磁石の製造方法。 - 前記組成式における元素Rの50原子%以上がSmであり、
前記組成式における元素Mの50原子%以上がZrである、請求項2に記載の永久磁石。 - Th2Zn17型結晶相を有する主相と、前記主相を構成する結晶粒の間に設けられた粒界相を含む金属組織と、をさらに具備し、
前記主相は、Th2Zn17型結晶相を有するセル相と、CaCu5型結晶相を有するCuリッチ相と、を有する、請求項2に記載の永久磁石の製造方法。 - 前記金属組織の90体積%以上が前記Th2Zn17型結晶相および前記CaCu5型結晶相であり、
前記永久磁石に存在する結晶粒のうち、300nm以上の径を有するTh2Zn17型結晶相からなる結晶粒で構成される領域が5体積%未満である、請求項4に記載の永久磁石の製造方法。 - 前記第1の層は、炭素、金属炭化物、金属酸化物、または耐火レンガを有し、
前記第2の層は、銅、モリブデン、タングステン、チタン、またはステンレス鋼を有する、請求項1に記載の永久磁石の製造方法。 - 前記圧縮成形体の総重量が200g以上2000g以下である、請求項1に記載の永久磁石の製造方法。
- 加熱体を有する加熱室と、
第1の熱放射率を有する第1の層と、前記第1の層上に設けられ、前記第1の熱放射率よりも低い第2の熱放射率を有する第2の層とを有する冷却部材と、
前記加熱室の内部と外部との間において、磁場中で加圧成形された合金粉末の焼結体を有する被処理体と前記冷却部材とを搬送する搬送機構と、
前記搬送機構により前記被処理体を前記加熱室の内部に搬入する動作と、前記搬送機構により前記加熱室の内部に前記冷却部材を搬入し、前記被処理体側に前記第1の層が位置するように前記冷却部材を前記加熱体と前記被処理体との間に配置する動作と、前記搬送機構により前記加熱室の内部にある前記被処理体を前記冷却部材とともに前記加熱室の外部に搬出する動作と、の実行を制御する制御機構と、を具備する、永久磁石の製造装置。
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