JPWO2017033861A1 - 拡散処理装置およびそれを用いたr−t−b系焼結磁石の製造方法 - Google Patents
拡散処理装置およびそれを用いたr−t−b系焼結磁石の製造方法 Download PDFInfo
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Abstract
Description
R−T−B系焼結磁石片1は、以下の組成を有することが好ましい。
R量:29質量%以上40質量%以下
B(Bの一部はCで置換されていてもよい):0.85質量%以上1.2質量%以下
添加元素M(Al、Ti、V、Cr、Mn、Ni、Cu、Zn、Ga、Zr、Nb、Mo、Ag、In、Sn、Hf、Ta、W、Pb、およびBiからなる群から選択された少なくとも1種):0〜2質量%以下
T(Feを主とする遷移金属であって、Coを含んでいてもよい)および不可避不純物:残部
12 本体
14a 第1蓋
14b 第2蓋
24 処理空間
26a、26b 断熱室
30 搬送装置
40 回転装置
Claims (26)
- 複数のR−T−B系焼結磁石片と、拡散源とを受容する処理空間を有する円筒状の本体と、前記円筒状の本体の両端の第1開口および第2開口をそれぞれ気密シールする第1蓋および第2蓋とを有する処理容器と、
z軸方向を鉛直方向とする直交座標系xyzにおいて前記処理容器の長手方向をy軸方向に配置した状態で、前記処理容器をx軸方向に予め決められた距離だけ搬送する搬送装置と、
前記処理容器の下側に配置される下側加熱部と前記処理容器の上側に配置される上側加熱部とを有し、前記下側加熱部および前記上側加熱部の少なくとも1つはz軸方向に可動で、前記処理容器の少なくとも中央部分を包囲するように配置され得る、加熱装置と、
前記処理容器の長手方向をy軸方向に配置し、前記下側加熱部および前記上側加熱部によって包囲された状態で、前記処理容器をy軸を中心に回転させる第1回転装置とを有する、拡散処理装置。 - 前記下側加熱部および前記上側加熱部は、それぞれz軸方向に可動である、請求項1に記載の拡散処理装置。
- 前記処理容器は、長手方向の両端に第1フランジおよび第2フランジをさらに有し、前記第1蓋が前記第1フランジに固定され、前記第2蓋が前記第2フランジに固定されたときに、前記第1開口および前記第2開口はそれぞれ気密シールされる、請求項1または2に記載の拡散処理装置。
- 前記第1回転装置は、前記第1フランジおよび前記第1蓋の少なくとも一方に接触する第1車輪対と、前記第2フランジおよび前記第2蓋の少なくとも一方に接触する第2車輪対とを有し、
前記第1車輪対および前記第2車輪対は、それぞれがx軸方向に沿って配置されy軸を中心に回転可能な2つの車輪を有する、請求項3に記載の拡散処理装置。 - 前記第1車輪対と前記第2車輪対とで前記処理容器を支持しているとき、前記処理容器は、前記搬送装置から切り離されている、請求項4に記載の拡散処理装置。
- 前記第1車輪対および前記第2車輪対のそれぞれが有する2つの車輪は、回転速度が可変および/または逆回転も可能である、請求項4または5に記載の拡散処理装置。
- 前記第1蓋または前記第2蓋の一方に接続された接続部をさらに有する、請求項1から6のいずれかに記載の拡散処理装置。
- 前記第1蓋または前記第2蓋の他方に接続された安全弁をさらに有する、請求項7に記載の拡散処理装置。
- 前記処理容器のx軸方向への移動、前記下側加熱部および前記上側加熱部のz軸方向への移動、および前記第1回転装置の回転の少なくとも1つを制御する信号を出力する第1コントローラをさらに有する、請求項1から8のいずれかに記載の拡散処理装置。
- 前記加熱装置を制御する信号を出力する第2コントローラをさらに有する、請求項9に記載の拡散処理装置。
- 前記加熱装置の後段に配置された冷却装置をさらに有し、
前記冷却装置は、前記処理容器の下側に配置される下側冷却部と前記処理容器の上側に配置される上側冷却部とを有し、前記下側冷却部および前記上側冷却部の少なくとも1つはz軸方向に可動で、前記処理容器の少なくとも中央部分を包囲するように配置され得る、請求項1から10のいずれかに記載の拡散処理装置。 - 前記下側冷却部および前記上側冷却部は、それぞれz軸方向に可動である、請求項11に記載の拡散処理装置。
- 前記処理容器の長手方向をy軸方向に配置し、前記下側冷却部および前記上側冷却部によって包囲された状態で、前記処理容器をy軸を中心に回転させる第2回転装置をさらに有する、請求項11または12に記載の拡散処理装置。
- 前記下側冷却部および前記上側冷却部の少なくとも1つは、エアー導入口および水用のスプレイノズルの少なくとも1つを有する、請求項11から13のいずれかに記載の拡散処理装置。
- 前記処理容器のx軸方向への移動、前記下側冷却部および前記上側冷却部のz軸方向への移動、前記第2回転装置の回転の少なくとも1つを制御する信号を出力する第3コントローラをさらに有する、請求項11から14のいずれかに記載の拡散処理装置。
- 前記冷却装置を制御する信号を出力する第4コントローラをさらに有する、請求項15に記載の拡散処理装置。
- 前記加熱装置の前段に配置された予備加熱装置をさらに有し、
前記予備加熱装置は、前記処理容器の下側に配置される下側予備加熱部と前記処理容器の上側に配置される上側予備加熱部とを有し、前記下側予備加熱部および前記上側予備加熱部の少なくとも1つはz軸方向に可動で、前記処理容器の少なくとも中央部分を包囲するように配置され得る、請求項1から16のいずれかに記載の拡散処理装置。 - 前記下側予備加熱部および前記上側予備加熱部は、それぞれz軸方向に可動である、請求項17に記載の拡散処理装置。
- 前記加熱装置の前段に配置されたワーク投入装置をさらに有し、
前記投入装置は、前記処理容器の長手方向をy軸方向に配置した状態で、前記処理容器をyz面内で傾斜させることができる、請求項1から18のいずれかに記載の拡散処理装置。 - 前記拡散処理装置全体の水平を調整する支持構造をさらに有している、請求項1から19のいずれかに記載の拡散処理装置。
- 前記処理容器は、前記処理空間の前記第1開口側に配置された第1断熱室と、前記第2開口側に配置された第2断熱室とを有する、請求項1から20のいずれかに記載の拡散処理装置。
- 前記第1断熱室および前記第2断熱室は、断熱繊維を有している、請求項21に記載の拡散処理装置。
- 希土類元素の含有量によって定義されるR量が29質量%以上40質量%以下であるR−T−B系焼結磁石片を準備する工程(a)と、
拡散源を準備する工程(b)と、
請求項1から22のいずれかに記載の拡散処理装置の前記処理空間に、少なくとも前記焼結磁石片と前記拡散源とを投入する工程(c)と、
前記処理空間内を真空排気しながら約200℃以上約600℃以下の温度で予備加熱する工程(d)と、
前記予備加熱工程の後で、減圧状態または不活性ガスを含む状態で気密シールする工程(e)と、
前記工程(e)の後で前記処理容器を約450℃以上約1000℃以下の処理温度に加熱する拡散工程(f)と、
を包含する、R−T−B系焼結磁石の製造方法。 - 前記拡散源は、Dy及びTbの少なくとも一方を含有するRH拡散源である、請求項23に記載のR−T−B系焼結磁石の製造方法。
- 前記拡散源は、Dy及びTbの少なくとも一方を含有するRH拡散源であり、且つ、大きさが90μm以下の粒子を主に含む粉末である、請求項23に記載のR−T−B系焼結磁石の製造方法。
- 前記RH拡散源は、重希土類元素RH(DyおよびTbの少なくとも一方)および30質量%以上80質量%以下のFeを含有する、請求項23から25のいずれかに記載のR−T−B系焼結磁石の製造方法。
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