WO2012008416A1 - 処理装置 - Google Patents
処理装置 Download PDFInfo
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- WO2012008416A1 WO2012008416A1 PCT/JP2011/065804 JP2011065804W WO2012008416A1 WO 2012008416 A1 WO2012008416 A1 WO 2012008416A1 JP 2011065804 W JP2011065804 W JP 2011065804W WO 2012008416 A1 WO2012008416 A1 WO 2012008416A1
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- WIPO (PCT)
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- diffusion
- rtb
- sintered magnet
- based sintered
- magnet body
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
- H01F41/0293—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets diffusion of rare earth elements, e.g. Tb, Dy or Ho, into permanent magnets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/0006—Details, accessories not peculiar to any of the following furnaces
- C21D9/0018—Details, accessories not peculiar to any of the following furnaces for charging, discharging or manipulation of charge
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/0031—Rotary furnaces with horizontal or slightly inclined axis
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/0056—Furnaces through which the charge is moved in a horizontal straight path
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
- C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
- C23C10/28—Solid state diffusion of only metal elements or silicon into metallic material surfaces using solids, e.g. powders, pastes
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B7/00—Rotary-drum furnaces, i.e. horizontal or slightly inclined
- F27B7/02—Rotary-drum furnaces, i.e. horizontal or slightly inclined of multiple-chamber or multiple-drum type
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B7/00—Rotary-drum furnaces, i.e. horizontal or slightly inclined
- F27B7/14—Rotary-drum furnaces, i.e. horizontal or slightly inclined with means for agitating or moving the charge
- F27B7/16—Rotary-drum furnaces, i.e. horizontal or slightly inclined with means for agitating or moving the charge the means being fixed relatively to the drum, e.g. composite means
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B7/00—Rotary-drum furnaces, i.e. horizontal or slightly inclined
- F27B7/20—Details, accessories, or equipment peculiar to rotary-drum furnaces
- F27B7/22—Rotary drums; Supports therefor
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B7/00—Rotary-drum furnaces, i.e. horizontal or slightly inclined
- F27B7/20—Details, accessories, or equipment peculiar to rotary-drum furnaces
- F27B7/33—Arrangement of devices for discharging
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D2281/00—Making use of special physico-chemical means
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
- H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
- H01F1/0571—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes
- H01F1/0575—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together
- H01F1/0577—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together sintered
Definitions
- the present invention relates to a processing apparatus for diffusing a heavy rare earth element RH (consisting of at least one of Dy and Tb) into an RTB-based sintered magnet.
- RH heavy rare earth element
- An RTB-based sintered magnet mainly composed of an R 2 T 14 B-type compound is known as the most powerful magnet among permanent magnets, such as a voice coil motor (VCM) of a hard disk drive, It is used for various motors such as motors for hybrid vehicles and home appliances.
- VCM voice coil motor
- the RTB-based sintered magnet Since the RTB-based sintered magnet has a reduced coercive force at high temperatures, irreversible thermal demagnetization occurs. In order to avoid irreversible thermal demagnetization, when used for a motor or the like, it is required to maintain a high coercive force even in a high temperature range.
- replacing the light rare earth element RL (consisting of at least one of Nd and Pr) with the heavy rare earth element RH improves the coercive force while reducing the residual magnetic flux density. There is a problem of end. Further, since the heavy rare earth element RH is a rare resource, it is required to reduce the amount of use thereof.
- the present applicant has already supplied a heavy rare earth element RH such as Dy to the surface of the RTB-based sintered magnet body, and has converted the heavy rare earth element RH from the surface to the RTB-based sintered magnet.
- a method (vapor deposition diffusion) of diffusing inside the magnet body is disclosed.
- the RTB-based sintered magnet body and the RH bulk body are arranged to face each other with a predetermined interval inside a diffusion processing apparatus made of a refractory metal material.
- the diffusion processing apparatus includes a member that holds a plurality of RTB-based sintered magnet bodies and a member that holds an RH bulk body.
- Patent Document 2 discloses a heat-resistant sealed container containing Yb metal powder having a low boiling point and an RTB-based sintered magnet compact for the purpose of improving the magnetic properties of the RTB-based intermetallic compound magnetic material. It is disclosed that it is enclosed and heated. In the method of Patent Document 2, a Yb metal film is uniformly deposited on the surface of a sintered magnet compact, and a rare earth element is diffused from this film into the sintered magnet (Example 5 of Patent Document 2).
- the rare earth metal has a high saturated vapor pressure such as Yb, Eu, and Sm
- the formation of the coating on the sintered magnet body and the diffusion from the coating can be performed in the same temperature range (for example, 800 to 850 ° C.).
- the rare earth metal is selectively selected by induction heating using a high frequency heating coil. It is necessary to heat to a high temperature.
- the present invention has been made in view of the above circumstances, and an object of the present invention is to transfer the heavy rare earth element RH such as Dy and Tb from the surface of the RTB-based sintered magnet body without reducing the residual magnetic flux density.
- An object of the present invention is to provide a processing apparatus suitable for mass production for diffusing.
- the processing apparatus of the present invention includes an RH diffusion source made of a metal or an alloy of heavy rare earth element RH (made of at least one of Dy and Tb) and a diffusion processing section that rotates while heating an RTB-based sintered magnet body.
- RH diffusion source made of a metal or an alloy of heavy rare earth element RH (made of at least one of Dy and Tb)
- a diffusion processing section that rotates while heating an RTB-based sintered magnet body.
- a separation unit that is adjacent to the diffusion processing unit and rotates to selectively separate the RH diffusion source from the RH diffusion source and the RTB-based sintered magnet body delivered from the diffusion processing unit; And an inclination mechanism for inclining the diffusion processing part and the separation part.
- the separation part has a plurality of openings for discharging the RH diffusion source to the outside, and the size of the opening is smaller than that of the RTB-based sintered magnet body.
- the separation unit sends the RTB-based sintered magnet body to the diffusion processing unit while being rotated, and the diffusion processing unit has moved from the separation unit. -Perform heat treatment on the TB sintered magnet body.
- the diffusion processing section has a first outer wall section that houses a first inner wall section
- the separation section has a second outer wall section that houses a second inner wall section
- the inner wall portion has a cylindrical shape and is made of a metal or alloy made of at least one of Mo, W, Nb, and Ta.
- a sheet-like buffer member is disposed between the inner wall portion and the outer wall portion.
- a spiral baffle plate is provided on the inner wall portion of the diffusion processing unit, and the baffle plate of the diffusion processing unit rotates in the first direction when the RH in the diffusion processing unit.
- the diffusion source and the RTB-based sintered magnet body are sent to the separation unit and rotated in a second direction opposite to the first direction, the RH diffusion source in the diffusion processing unit and The RTB-based sintered magnet body is held in the diffusion processing section.
- Another treatment apparatus of the present invention is a diffusion that rotates while heating an RH diffusion source and an RTB-based sintered magnet body made of a metal or alloy of heavy rare earth element RH (consisting of at least one of Dy and Tb).
- a separation section that is adjacent to the diffusion processing section and rotates to selectively separate the RH diffusion source from the RH diffusion source and the RTB-based sintered magnet body delivered from the diffusion processing section; And the RTB-based sintered magnet body in which the heavy rare earth element RH is diffused in the diffusion processing unit, adjacent to the separation unit, and rotated with the RH diffusion source removed.
- a heat treatment part that performs heat treatment while at least the tilting mechanism that inclines the diffusion treatment part, the separation part, and the heat treatment part.
- the separation unit moves the RH diffusion source to the outside while moving the RH diffusion source and the RTB-based sintered magnet body received from the diffusion processing unit to the heat treatment unit. It has a plurality of openings for discharging.
- the diffusion processing unit has a cylindrical first inner wall that accommodates the RH diffusion source and the RTB-based sintered magnet body, and is rotated by the driving unit,
- the RH diffusion source and the RTB system sintered magnet body are sent to the separation unit, and the separation unit accommodates the RH diffusion source and the RTB system sintered magnet body and has an opening.
- a cylindrical second inner wall provided with a portion, discharging the RH diffusion source from the opening to the outside while being rotated by the driving unit, and the RTB-based sintering
- the magnet body is sent to the heat treatment portion, and the heat treatment portion has a cylindrical third inner wall portion that accommodates the RTB-based sintered magnet body, and is rotated by the driving portion while being rotated by the drive portion.
- the RTB system sintered magnet body is delivered to the discharge port.
- a spiral baffle plate is provided on an inner wall portion of the diffusion treatment section and the heat treatment section, and the baffle plate of the diffusion treatment section has a spiral direction with respect to the baffle plate of the heat treatment section. It is held in the opposite direction.
- the diffusion processing section has a first outer wall section that houses the first inner wall section
- the separation section has a second outer wall section that houses the second inner wall section
- the heat treatment The portion has a third outer wall portion that accommodates the third inner wall portion, and at least the first inner wall portion and the third inner wall portion are cylindrical and are made of at least one of Mo, W, Nb, and Ta. Made of metal or alloy.
- a sheet-like buffer member is disposed between the inner wall portion and the outer wall portion.
- an RH diffusion source made of a metal or an alloy of heavy rare earth element RH (made of at least one of Dy and Tb) and a diffusion treatment part that rotates while heating an RTB-based sintered magnet body, Because it has a separation part that selectively separates the RH diffusion source, it can efficiently and smoothly produce a sintered magnet with improved coercive force without reducing the residual magnetic flux density from the RH diffusion treatment process to the heat treatment process. Can do.
- FIG. 5A is a perspective view showing a configuration example of a spiral baffle plate 70.
- FIG. 4B is a perspective view illustrating a configuration example of the baffle plate 80.
- (A) to (d) is a diagram showing the operation of the processing apparatus in the embodiment of FIG. 2 is a flowchart for explaining a method of manufacturing an RTB-based sintered magnet performed using the apparatus of FIG.
- (A) is a figure which shows the preferable form of a cross-sectional structure perpendicular
- (b) is sectional drawing which shows the preferable form of an inner wall part. It is a figure which shows the structure of another embodiment of the processing apparatus by this invention. It is a figure which shows typically the cross-sectional structure of the processing apparatus in embodiment of FIG. (A) to (d) is a diagram showing the operation of the processing apparatus in the embodiment of FIG. 8 is a flowchart for explaining a method of manufacturing an RTB-based sintered magnet performed using the apparatus of FIG.
- the processing apparatus of the present invention includes a diffusion processing section that can rotate to heat and stir the RH diffusion source and the RTB-based sintered magnet body.
- the RH diffusion source is made of a metal or alloy of heavy rare earth element RH (consisting of at least one of Dy and Tb). A preferred form of the RH diffusion source will be described later.
- heating is first performed in a state where a plurality of RH diffusion sources and a plurality of RTB-based sintered magnet bodies coexist, and the RTB-based sintered magnet body is transferred from the RH diffusion source.
- the RH diffusion source and the RTB-based sintered magnet body charged in the diffusion processing unit are not fixed by a holding member or the like and are relatively movable. Further, the RH diffusion source and the RTB-based sintered magnet body can move in the diffusion processing unit by the rotation of the diffusion processing unit, and can approach or come into contact with each other.
- the RH diffusion source and the RTB-based sintered magnet body are maintained in a temperature range of preferably 500 ° C. or more and 1000 ° C. or less by the heating means while being moved close to and away from each other by rotation of the diffusion processing unit.
- the diffusion processing section rotates, the RTB-based sintered magnet body and the RH diffusion source move continuously or intermittently within the diffusion processing section.
- the position of the contact portion between the body and the RH diffusion source changes, and the RTB-based sintered magnet body and the RH diffusion source repeat proximity and separation.
- the heavy rare earth element RH is supplied from the RH diffusion source to the RTB-based sintered magnet body and diffuses into the RTB-based sintered magnet body. (RH diffusion treatment process).
- the RH diffusion source that has moved from the diffusion processing section and the RH diffusion source among the RTB-based sintered magnet bodies are selectively selected from the RT A separation part for separating from the B-based sintered magnet body is provided.
- the above-described diffusion processing section can be used for heat treatment of only the RTB-based sintered magnet body after the RH diffusion source is separated.
- the treatment apparatus of the present invention is supplied with a heavy rare earth element RH in the diffusion treatment section, and performs a heat treatment section for performing additional heat treatment on the RTB-based sintered magnet body in which the heavy rare earth element RH is diffused. May be provided.
- the additional heat treatment performed in the heat treatment unit is a heat treatment performed in a state where the RH diffusion source is removed. In this heat treatment, the heavy rare earth element RH supplied from the RH diffusion source to the RTB-based sintered magnet body in the diffusion processing section is diffused deeper into the RTB-based sintered magnet body.
- the separation unit is an opening for selectively discharging the RH diffusion source to the outside while moving the RH diffusion source and the RTB-based sintered magnet body delivered from the diffusion processing unit to the heat treatment unit. Has a part. By discharging the RH diffusion source in the separation unit, it is possible to smoothly shift to the next heat treatment step.
- the diffusion treatment unit, separation unit, and heat treatment unit of the present invention can heat an object to be treated such as an RTB-based sintered magnet body and an RH diffusion source while rotating in an inclined state. .
- an object to be processed such as an RTB-based sintered magnet body and an RH diffusion source is sequentially moved from the diffusion processing section to the separation section and from the separation section to the heat treatment section without being exposed to the atmosphere. Can be made.
- FIG. 1 is a schematic diagram showing a configuration of a processing apparatus in the present embodiment.
- the illustrated processing apparatus includes a diffusion processing unit 10 for performing RH diffusion processing and heat treatment as necessary, an RH diffusion source 2 and an RTB-based sintered magnet moved from the diffusion processing unit 10.
- a separation unit 20 that selectively separates the RH diffusion source 2 from the body 1 and sends out only the RTB-based sintered magnet body 1 after the RH diffusion treatment to the diffusion treatment unit 10 as necessary. Yes.
- the separation unit 20 is connected to the diffusion processing unit 10.
- the diffusion processing unit 10 and the separation unit 20 are connected by a stamping joint.
- the RTB-based sintered magnet body 1 is not exposed to the atmosphere while the RH diffusion treatment step, the RH diffusion source separation step, and the heat treatment step are sequentially performed. Further, in the RH diffusion source separation step performed between the RH diffusion treatment step and the heat treatment step, since the RH diffusion source is separated without manual intervention, the separation of the RH diffusion source 2 without reducing the processing temperature. It becomes possible to perform a process. As a result, productivity from the RH diffusion treatment process to the heat treatment process is improved.
- the diffusion processing unit 10 and the separation unit 20 are directly coupled in FIG. 1, they may be connected via a road pipe.
- the diffusion processing unit 10 is provided with an insertion port 15. From the insertion port 15, the RTB-based sintered magnet body 1 and the RH diffusion source 2 before the RH diffusion treatment are introduced into the diffusion processing unit 10. The RTB-based sintered magnet body 1 that has been subjected to the RH diffusion treatment step, the separation step, and the heat treatment step is taken out of the processing apparatus through the inlet 15.
- the diffusion processing unit 10 connected to the separation unit 20 is composed of a road pipe in FIG. 1 and is rotatably supported.
- At least one of the diffusion processing unit 10 and the separation unit 20 is provided with a tilt mechanism 50 that tilts the diffusion processing unit 10 and the separation unit 20. Due to the action of the tilting mechanism 50, the diffusion processing unit 10 and the separating unit 20 can take a horizontal or tilted state.
- the diffusion processing unit 10 and the separation unit 20 in the present embodiment can be inclined integrally as a whole.
- the diffusion processing unit 10 and the separation unit 20 can be rotated by a motor (not shown).
- the diffusion processing unit 10 and the separation unit 20 can rotate in both the horizontal state and the inclined state, and the direction and speed of rotation can be arbitrarily set.
- FIG. 2 is a diagram schematically showing a cross-sectional configuration of the processing apparatus of FIG.
- the diffusion processing unit 10 has a space for accommodating the RH diffusion source 2 and the RTB-based sintered magnet body 1 therein, and rotates with the separation unit 20 tilted downward. By doing so, the RH diffusion source 2 and the RTB-based sintered magnet body 1 can be sent to the separation unit 20. It is also possible to send the RTB-based sintered magnet body 1 from the separating unit 20 to the diffusion processing unit 10 by tilting in the opposite direction.
- the separation unit 20 also rotates in an inclined state, so that only the RH diffusion source 2 can be efficiently discharged out of the RH diffusion source 2 and the RTB-based sintered magnet body 1.
- the material of the diffusion processing part 10 has heat resistance that can withstand temperatures of about 500 to 1000 ° C., and at least the inner wall part is made of a material that does not easily react with the RTB-based sintered magnet body 1 and the RH diffusion source 2. Preferably it is formed.
- the inner wall portion of the diffusion processing unit 10 can be formed of, for example, Nb, Mo, W, Ta metal or an alloy containing at least one of them. Further, an Fe—Cr—Al alloy or an Fe—Cr—Co alloy may be used. The same applies to the separation unit 20 described later.
- FIG. 6A shows an example of a cross-sectional configuration perpendicular to the axial direction of the diffusion processing unit 10.
- the diffusion processing unit 10 in this example includes a cylindrical inner wall portion 14 made of the above metal or alloy, and an outer wall portion 12 that accommodates the inner wall portion 14.
- the outer wall part 12 is formed from stainless steel, for example.
- the inner wall part 14 of the diffusion processing unit 10 is set and connected so as to have the same diameter as the inner wall part 14 of the separation part 20 at least at a portion in contact with the inner wall part 14 of the separation part 20, diffusion is performed.
- the RTB-based sintered magnet body 1 and the RH diffusion source 2 can be smoothly moved between the processing unit 10 and the separation unit 20.
- the baffle plate is normally connected to the inner wall portion so as to follow the rotation of the diffusion processing portion. However, the baffle plate may be rotated independently without being connected to the inner wall portion.
- the outer wall portion 12 and the inner wall portion 14 are formed from materials having different thermal expansion coefficients, the outer wall portion If the 12 and the inner wall part 14 are fixed in close contact, the outer wall part 12 and the inner wall part 14 may be peeled off due to thermal expansion or contraction, or the inner wall part 14 may be torn.
- a gap is formed between the outer wall portion 12 and the inner wall portion 14 so that the outer wall portion 12 and the inner wall portion 14 do not collide. More preferably, it is provided and fixed with bolts.
- a sheet-like cushioning member is disposed between the outer wall portion 12 and the inner wall portion 14.
- This buffer member is preferably formed from a heat-resistant carbon material, a ceramic material, or a heat-resistant metal material, and may be formed from a non-woven fabric such as a heat-resistant felt.
- FIG. 6B is a diagram illustrating another configuration example of the inner wall portion 14.
- the inner wall portion 14 shown in FIG. 6B is designed such that one end 14a and the other end 14b overlap each other at room temperature by rounding a metal plate into a cylindrical shape.
- the one end 14a and the other end 14b of the metal plate constituting the inner wall portion 14 are not fixed, and the degree of overlap can be changed according to thermal expansion and thermal contraction. For this reason, even if a temperature change of about 900 ° C. occurs and the outer diameter of the inner wall portion 14 changes greatly, it is effectively prevented from colliding with the outer wall portion 12.
- the aforementioned buffer member may be further arranged.
- the cross-sectional shape perpendicular to the axial direction of the outer wall portion 12 and the inner wall portion 14 of the diffusion processing portion 10 is not necessarily limited to a circle, and may be an ellipse, a polygon, or other shapes. Further, in order to promote stirring of the RTB-based sintered magnet body 1 and the RH diffusion source 2 by the rotation of the diffusion processing unit 10, a protrusion may be provided on the inner wall portion 14 of the diffusion processing unit 10.
- a spiral first baffle plate 70 is provided inside the diffusion processing unit 10.
- the first baffle plate 70 has a configuration as shown in FIG.
- the magnetized body 1 can be sent to the separation unit 20, but when rotating in the second direction opposite to the first direction, the RH diffusion source 2 and the RTB-based sintered magnet body 1 Can be held in.
- the diameter of the first baffle plate may be smaller than the inner diameter of the inner wall portion 14. In this case, the clearance between the inner wall portion 14 and the first baffle plate 70 is set so that the RH diffusion source 2 and the RTB-based sintered magnet body 1 to be introduced do not leak.
- the first baffle plate 70 is provided in the diffusion processing unit 10, but the first baffle plate 70 may be disposed on the separation unit 20 side, You may arrange
- an RTB-based sintered magnet body to be diffused of heavy rare earth element RH is prepared.
- the RTB-based sintered magnet body prepared in the present invention has a known composition.
- This RTB-based sintered magnet body has, for example, the following composition.
- Rare earth element R 12 to 17 atomic%
- B part of B may be substituted with C: 5 to 8 atomic%
- additive element M Al, Ti, V, Cr, Mn, Ni, Cu , Zn, Ga, Zr, Nb, Mo, Ag, In, Sn, Hf, Ta, W, Pb, and Bi
- T mainly Fe And may contain Co
- inevitable impurities balance
- the rare earth element R is at least one element mainly selected from the light rare earth elements RL, but may contain a heavy rare earth element RH.
- the heavy rare earth element RH preferably contains at least one of Dy and Tb.
- the RTB-based sintered magnet body having the above composition is manufactured by a known manufacturing method.
- the RTB-based sintered magnet body 1 and the RH diffusion source 2 are placed in the RTB-based sintered magnet 10 inside the diffusion processing unit 10 shown in FIG.
- the magnetized body 1 and the RH diffusion source 2 are inserted so as to be relatively movable and close to or in contact with each other.
- the RTB-based sintered magnet body 1 and the RH diffusion source 2 are mixed in advance and filled with a feeder (not shown).
- the diffusion processing unit 10 and the separation unit 20 may have a horizontal inner wall or may be inclined.
- the RH diffusion source 2 is a heavy rare earth element RH composed of at least one of Dy and Tb or an alloy containing them.
- the RH diffusion source 2 is made of an alloy, it is preferably an alloy containing 30% by mass or more of the heavy rare earth element RH.
- the size of the RH diffusion source 2 is smaller than that of the RTB-based sintered magnet body 1.
- a stirring auxiliary member may be used for the purpose of promoting the contact between the RTB-based sintered magnet body 1 and the RH diffusion source 2.
- the stirring auxiliary member serves to bring the RH diffusion source into contact with the RTB system sintered magnet body more.
- the stirring auxiliary member is preferably a ceramic material made of zirconia, boron nitride, silicon nitride, silicon carbide, or a mixture thereof.
- a metal material made of a group element including Mo, W, Nb, Ta, Hf, and Zr, or a mixture thereof is also preferable.
- the stirring auxiliary member is preferably smaller than the RTB-based sintered magnet body and larger than the RH diffusion source.
- step S20 of FIG. 5 the RH diffusion process shown in step S20 of FIG. 5 is started.
- This RH diffusion process is performed by heating both the RTB-based sintered magnet body 1 and the RH diffusion source 2 while rotating the diffusion processing unit 10 in the state shown in FIG. At this time, it is preferable that the diffusion processing unit 10 rotates in a horizontal state. If the separation unit is in the downward direction, the rotation is performed in a direction that prevents the first baffle plate from moving to the separation unit 20.
- the shape of the RH diffusion source 2 is preferably a shape in which the contact point between the RTB-based sintered magnet body 1 and the RH diffusion source 2 moves quickly by the rotation of the diffusion processing unit 10. Specifically, it is preferable that a curved surface is formed on the surface of the RH diffusion source 2. Examples of a preferable shape of the RH diffusion source 2 are, for example, a spherical shape, an elliptical spherical shape, and a cylindrical shape.
- the inside of the diffusion processing unit 10 may be connected to an exhaust device such as a pump. By the action of the exhaust device, the inside of the diffusion processing unit 10 can be depressurized or pressurized while being shielded from the atmosphere (sealed state).
- An inert gas such as Ar can be introduced into the diffusion processing unit 10 from a gas cylinder (not shown).
- the diffusion processing unit 10 is heated by a heater (not shown).
- the RTB-based sintered magnet body 1 and the RH diffusion source 2 housed inside are heated by the heater.
- the diffusion processing unit 10 is supported so as to be rotatable around the central axis, but can be rotated by a motor during heating by the heater.
- the peripheral speed at the inner wall portion of the diffusion processing unit 10 is set to 0.01 m or more per second, for example. It is preferable to set it to 0.5 m or less per second so that the RTB-based sintered magnet bodies are vigorously brought into contact with each other by rotation and are not chipped.
- the inside of the diffusion treatment unit 10 during the RH diffusion treatment is in an inert atmosphere.
- the “inert atmosphere” in this specification includes a vacuum or an inert gas.
- the “inert gas” is a rare gas such as argon (Ar), for example, but chemically reacts with the RTB-based sintered magnet body 1 and the RH diffusion source 2 within the processing temperature range. Any gas that does not react with gas can be included in the “inert gas”.
- the atmospheric gas pressure inside the diffusion processing unit 10 is close to atmospheric pressure, for example, in the technique disclosed in Patent Document 1, the heavy rare earth element RH is transferred from the RH diffusion source 2 to the surface of the RTB-based sintered magnet body 1. It becomes difficult to be supplied to.
- the supply amount of the heavy rare earth element RH can be increased. For this reason, it is sufficient if the atmospheric gas pressure of the diffusion processing unit 10 is equal to or lower than the atmospheric pressure.
- the correlation between the degree of vacuum and the supply amount of heavy rare earth element RH is relatively small, and even if the degree of vacuum is further increased, the supply amount of heavy rare earth element RH is not greatly affected.
- the supply amount of the heavy rare earth element RH can be adjusted by controlling the temperature of the RTB-based sintered magnet body.
- the plurality of RTB-based sintered magnet bodies 1 and the RH diffusion source 2 charged into the diffusion processing unit 10 are heated to a temperature of 500 ° C. or more and 1000 ° C. or less, and for a predetermined time, Keep in the temperature range. At this time, in this embodiment, the diffusion processing unit 10 is rotated.
- the temperature range of 500 ° C. or more and 1000 ° C. or less is a temperature at which the diffusion of the rare earth element can proceed inside the RTB-based sintered magnet body 1, and the RH diffusion source 2 is subjected to RTB-based sintering.
- the heavy rare earth element RH diffuses into the RTB-based sintered magnet body 1 and increases its coercive force.
- the reason why diffusion occurs in such a temperature range is considered to be that the RH diffusion source and the RTB-based sintered magnet body are close to or in contact with each other, and the distance between the two becomes sufficiently small.
- the temperature and holding time of the RH diffusion treatment are the ratio of the amounts of the RTB-based sintered magnet body 1 and the RH diffusion source 2 charged during the RH diffusion treatment step, the RTB-based sintered magnet body. 1, composition of the RH diffusion source 2, shape, amount of heavy rare earth element RH (diffusion amount) supplied to the RTB-based sintered magnet body 1 by the RH diffusion treatment, and whether or not a stirring auxiliary member is input Determined in consideration of
- the RTB system is used in order to rotate the diffusion processing unit in a state in which the RTB system sintered magnet body 1 and the RH diffusion source 2 are relatively movable and close to or in contact with each other.
- the sintered magnet body 1 and the RH diffusion source 2 move continuously or intermittently.
- the intended RH diffusion can be realized. That is, the RTB-based sintered magnet body 1 and the RH diffusion source 2 are not fixed in contact with each other for a long time by being fixed at a fixed position, but are continuously or intermittently connected to the RH diffusion source 2.
- the contact portion with the RTB-based sintered magnet body 1 moves or separates.
- the heavy rare earth element RH can be supplied from the RH diffusion source 2 to the RTB-based sintered magnet body 1.
- the heavy rare earth element RH is obtained from the RH diffusion source 2. While being supplied to the surface of the RTB-based sintered magnet body 1, it can be diffused into the RTB-based sintered magnet body 1.
- “loading the RTB-based sintered magnet body and the RH diffusion source so as to be relatively movable and close to or in contact with each other” means, as described above, the RH diffusion treatment step after the charging step.
- the RTB-based sintered magnet body 1 and the RH diffusion source 2 move continuously or intermittently in the diffusion processing section, so that the RH diffusion source 2 and the RTB-based sintered magnet body 1 Means to be fixed at a certain place so as not to be constrained by contact or proximity for a long time (for example, at 1000 ° C. for 2 minutes or more). Therefore, in the present invention, as described in Patent Document 1, it is not necessary to arrange the RTB-based sintered magnet body 1 and the RH diffusion source 2 at predetermined positions.
- step S30 in FIG. 5 is executed. Specifically, as shown in FIG. 4B, the RTB-based sintering in the diffusion processing unit 10 is performed by rotating the diffusion processing unit 10 with the separation unit 20 inclined downward. The magnet body 1 and the RH diffusion source 2 are moved to the separation unit 20. At this time, the first baffle plate 70 conveys the RH diffusion source 2 and the RTB-based sintered magnet body 1 to the separation unit 20, so that the inner wall of the diffusion processing unit 10 as shown in FIG. It connects to a part by welding etc., and follows the rotation of the diffusion process part 10.
- FIG. 4B the RTB-based sintering in the diffusion processing unit 10 is performed by rotating the diffusion processing unit 10 with the separation unit 20 inclined downward. The magnet body 1 and the RH diffusion source 2 are moved to the separation unit 20. At this time, the first baffle plate 70 conveys the RH diffusion source 2 and the RTB-based sintered magnet body 1 to the separation unit 20, so that the inner wall of the diffusion processing unit 10 as shown in FIG. It connects
- the baffle plate may be connected to a shaft extending from the insertion port or the like and rotated independently.
- the rotation direction of the diffusion processing unit 10 is selected so that the RTB-based sintered magnet body 1 and the RH diffusion source 2 are moved to the separation unit 20 as the diffusion processing unit 10 rotates.
- the separation unit 20 has a configuration capable of selectively discharging the RH diffusion source 2.
- an opening is provided in the inner wall of the separation part 20, and the opening is formed larger than the RH diffusion source 2 and smaller than the RTB-based sintered magnet body 1.
- the inner wall of the separation part may be, for example, a net made of a heat-resistant material or a metal plate provided with a plurality of openings.
- the RH diffusion source 2 falls to the outside of the separation unit from the opening provided on the inner wall of the separation unit 20 as shown in FIG. 4C (step S40 in FIG. 5). .
- the separation unit 20 rotates even after the RH diffusion source 2 falls. Since the size of the opening is set so that only the RTB-based sintered magnet body 1 remains on the inner wall portion of the separation unit 20, the RH diffusion source 2 of the separation unit 20 is rotated by the rotation of the separation unit 20. It is discharged from the inner wall portion to the outside of the separation portion 20.
- the dropped RH diffusion source 2 is collected in a container through a valve (not shown).
- the separation unit 20 is further returned to the horizontal position, and the bottom of the separation unit is vibrated to remove the RH diffusion source 2 remaining in the separation unit 20. You may make it fall to the outer side of the separation part 20 from an inner wall.
- a net is installed as a separation unit on the end face of the diffusion processing unit 10, and only the RH diffusion source is accommodated in the separation unit. Good.
- the size of the opening of the net is set so that the RTB-based sintered magnet body 1 remains, and when the diffusion treatment unit 10 is inclined to the side in contact with the separation unit, the opening of the net is RH.
- the diffusion source 2 moves to the separation unit, and the RTB-based sintered magnet body 1 remains in the diffusion processing unit 10.
- the RTB-based sintered magnet body 1 is additionally subjected to heat treatment for the purpose of more uniformly diffusing the diffused heavy rare earth element RH. For this reason, first, the RTB-based sintered magnet body 1 is returned from the separation unit 20 to the diffusion processing unit 10 again. Specifically, as shown in FIG. 4 (d), the first baffle plate 70 is moved in accordance with the rotation of the diffusion processing unit 10 while the separation unit 20 and the diffusion processing unit 10 are inclined downward. The rotation direction of the diffusion processing unit 10 is selected so that the TB sintered magnet body 1 is moved from the separation unit 20 to the diffusion processing unit 10. Thus, as shown in FIG. 4D, the RTB-based sintered magnet body 1 is moved to the diffusion processing unit 10 (step S50 in FIG. 5).
- the RTB-based sintered magnet body 1 is not moved to the separation unit 20, so that the R- There is no need to return the TB sintered magnet body 1 from the separation unit 20 to the diffusion processing unit 10 again.
- heat treatment is performed while rotating the diffusion processing section.
- the heat treatment is performed at a temperature of, for example, 500 ° C. to 1000 ° C. (step S60 in FIG. 5).
- This heat treatment does not cause further supply of the heavy rare earth element RH to the surface of the RTB-based sintered magnet body 1, but the heavy rare-earth element is present inside the RTB-based sintered magnet body 1.
- RH diffusion occurs.
- the heat treatment time is, for example, 10 minutes to 72 hours. Preferably it is 1 to 6 hours.
- the RTB-based sintered magnet body 1 that has been subjected to the above heat treatment is slowly cooled to lower the temperature inside the furnace to room temperature, and then discharged from the inlet 15.
- the RTB system sintered magnet body 1 and the RH diffusion source 2 are repeatedly brought close to and separated from each other, and the heavy rare earth element RH is supplied from the surface of the RTB system sintered magnet body 1. Since the separation unit for selectively separating the RH diffusion source 2 is provided after the RH diffusion treatment, the process from the RH diffusion treatment step to the heat treatment step can be performed efficiently and smoothly without reducing the residual magnetic flux density. The productivity of the RTB-based sintered magnet with improved coercive force is greatly improved.
- a heavy rare earth substitution layer is formed in the main phase outer shell portion, so that the outer shell of the main phase crystal grains of the RTB-based sintered magnet can be obtained.
- the heavy rare earth substitution layer is disposed not only in the region close to the surface of the RTB-based sintered magnet body 1 but also in the region deep from the surface of the RTB-based sintered magnet body 1. Since it can be formed in the shell, the coercive force H cJ can be improved.
- the heavy rare earth substitution layer is sufficiently thin and the heavy rare earth element RH is hardly diffused inside the main phase. The density Br is hardly lowered.
- FIG. 7 is a schematic diagram showing another configuration of the processing apparatus in the present embodiment.
- the processing apparatus of FIG. 7 selectively selects the RH diffusion source from the diffusion processing unit 10 for performing the RH diffusion processing, the RH diffusion source moved from the diffusion processing unit 10 and the RTB-based sintered magnet body.
- the separation unit 20 also has a function of sending only the RTB-based sintered magnet body after the RH diffusion treatment to the heat treatment unit 30.
- the entire diffusion processing unit 10, separation unit 20, and heat treatment unit 30 can be integrally inclined.
- the separation unit 20 is located between the diffusion processing unit 10 and the heat treatment unit 30, and connects the diffusion processing unit 10 and the heat treatment unit 30. Therefore, the RTB-based sintered magnet body is not exposed to the atmosphere until a series of steps of the RH diffusion treatment process, the RH diffusion source separation process, and the heat treatment process is completed. Further, in the RH diffusion source separation step performed between the RH diffusion treatment step and the heat treatment step, since the RH diffusion source is separated without human intervention, the separation step of the RH diffusion source can be performed without lowering the temperature. It becomes possible to do. As a result, productivity from the RH diffusion treatment process to the heat treatment process is improved.
- the diffusion processing unit 10 is provided with an insertion port 15. From the inlet 15, the RTB-based sintered magnet body and the RH diffusion source before the RH diffusion treatment are introduced into the diffusion processing unit 10.
- the heat treatment section 30 is provided with a discharge port 35, and the RTB-based sintered magnet body that has been subjected to the RH diffusion treatment and the heat treatment is taken out from the treatment device.
- the diffusion processing unit 10 and the heat treatment unit 30 connected by the separation unit 20 are each constituted by a path pipe and are rotatably supported around a central axis (not shown).
- a tilting mechanism 50 that tilts the diffusion processing unit 10, the separation unit 20, and the heat treatment unit 30 is provided, and the diffusion processing unit 10, the separation unit 20, and the heat treatment unit 30 are operated by the tilting mechanism 50.
- the diffusion processing unit 10, the separation unit 20, and the heat treatment unit 30 can be rotated around the central axis by a motor (not shown).
- the diffusion processing unit 10, the separation unit 20, and the heat treatment unit 30 can rotate in any of the horizontal state and the inclined state, and the direction and speed of rotation can be arbitrarily set.
- tilt mechanism 50 has been described, the same effect can be obtained even if the entire diffusion processing unit 10, separation unit 20, and heat treatment unit 30 are tilted at a predetermined angle.
- FIG. 8 is a diagram schematically showing a cross-sectional configuration of the processing apparatus of FIG.
- the diffusion processing unit 10 has a space in which the RH diffusion source 2 and the RTB-based sintered magnet body 1 are housed, and rotates in an inclined state, thereby RH diffusion.
- the source 2 and the RTB-based sintered magnet body 1 can be sent to the separation unit 20.
- the heat treatment section 30 has a space for accommodating the RTB-based sintered magnet body 1, and also rotates in an inclined state so that the RTB-based sintered magnet body 1 is removed from the discharge port 35. Can be sent to.
- the separation unit 20 also rotates in an inclined state, so that only the RH diffusion source 2 can be efficiently discharged out of the RH diffusion source 2 and the RTB-based sintered magnet body 1.
- the material of the diffusion processing part 10 has heat resistance that can withstand temperatures of about 500 to 1000 ° C., and at least the inner wall part is made of a material that does not easily react with the RTB-based sintered magnet body 1 and the RH diffusion source 2. Preferably it is formed.
- the inner wall portion of the diffusion processing unit 10 can be formed of, for example, Nb, Mo, W, Ta metal or an alloy containing at least one of them. Further, an Fe—Cr—Al alloy or an Fe—Cr—Co alloy may be used for the inner wall portion of the diffusion treatment part 10. The same applies to the separation unit 20 and the heat treatment unit 30.
- a spiral first baffle plate 70 is provided inside the diffusion processing unit 10.
- the first baffle plate 70 can send the internal RH diffusion source 2 and the RTB-based sintered magnet body 1 to the separation unit 20 when the diffusion processing unit 10 rotates in the first direction.
- the RH diffusion source 2 and the RTB-based sintered magnet body 1 can be held inside the diffusion processing unit 10.
- a spiral second baffle plate 80 shown in FIG. 3B is provided inside the heat treatment section 30. The second baffle plate 80 is disposed so that the helical twist direction is opposite to the first baffle plate 70.
- the second baffle plate 80 holds the RTB-based sintered magnet body 1 in the separation part 20 in the separation part 20 when the heat treatment part 30 rotates in the first direction.
- the RTB-based sintered magnet body 1 in the separation unit 20 can be delivered into the heat treatment unit 30.
- the first baffle plate 70 and the second baffle plate 80 are usually fixed to the inner wall portion.
- the distance between the inner wall portion 14 and the first baffle plate 70 and the second baffle plate 80 is set so that the RH diffusion source and the RTB-based sintered magnet body to be introduced do not leak.
- FIGS. 7 and 8 Next, the operation of another processing apparatus shown in FIGS. 7 and 8 will be described in detail with reference to FIGS. 9 (a) to (d) and FIG.
- step S110 of FIG. 10 the RTB-based sintered magnet body 1 and the RH diffusion source 2 are loaded into the diffusion processing unit 10 shown in FIG. 9A. At this time, the RTB-based sintered magnet body 1 and the RH diffusion source 2 are mixed in advance and filled in a feeder (not shown). Here, the size of the RH diffusion source 2 is adjusted to be smaller than that of the RTB-based sintered magnet body 1.
- the RTB-based sintered magnet body 1 and the RH diffusion source 2 are added to the diffusion processing unit 10 while the diffusion processing unit 10, the separation unit 20, and the heat treatment unit 30 remain horizontal. May be charged using a screw conveyor.
- step S120 of FIG. 10 the RH diffusion process shown in step S120 of FIG. 10 is started.
- both the RTB-based sintered magnet body 1 and the RH diffusion source 2 are stirred by rotating the diffusion processing unit 10 in the state shown in FIG. 9A.
- RH diffusion treatment is performed while heating.
- step S130 of FIG. 10 is executed. Specifically, as shown in FIG. 9B, the diffusion processing unit 10 is rotated in an inclined state, whereby the RTB-based sintered magnet body 1 and the RH diffusion source 2 are separated by the separation unit 20. Move to.
- the first baffle plate 70 is rotated by the RTB-based sintered magnet as the diffusion processing unit 10 rotates.
- the body 1 and the RH diffusion source 2 can be moved to the separation unit 20.
- An opening is provided in the inner wall portion of the separation unit 20, and as shown in FIG. 9C, the RH diffusion source 2 falls from the opening provided in the inner wall portion of the separation unit 20 to the outside of the separation unit ( In step S140 in FIG. 10, the RH diffusion source 2 can be selectively discharged outside the separation unit.
- the size of the openings is set to be larger than the size of the RH diffusion source 2 and smaller than the size of the RTB-based sintered magnet body 1.
- the diffusion processing unit 10 is rotated in an inclined state, whereby the RTB-based sintered magnet body 1 and the RH diffusion source 2 are moved to the separation unit 20, and the separation unit 20 performs R ⁇
- the TB sintered magnet body 1 and the RH diffusion source 2 are separated, and only the RH diffusion source 2 is discharged to the outside of the separation portion.
- the inner wall portion may have a mesh shape or a structure in which a plurality of openings are provided in a metal plate.
- the stirring assisting member is discharged from the separation part together with the RH diffusion source to the outside of the RTB-based sintered magnet body and the separation part, or together with the RH diffusion source, the separation part. Whether it is not discharged to the outside is arbitrarily determined according to the shape, weight, etc. of the RTB-based sintered magnet body.
- the separation unit 20 is returned to the horizontal position, and the separation unit 20 is vibrated to screen out the RH diffusion source 2.
- a mechanism may be further provided.
- the RTB-based sintered magnet body 1 is heat-treated for the purpose of more uniformly diffusing the diffused heavy rare earth element RH. For this reason, first, the RTB-based sintered magnet body 1 is moved from the separation unit 20 to the heat treatment unit 30. Specifically, as shown in FIG. 9D, the heat treatment unit 30 is rotated in an appropriate direction while the separation unit 20 and the heat treatment unit 30 are inclined. At this time, the second baffle plate 80 is installed so as to move the RTB-based sintered magnet body 1 to the heat treatment unit 30 as the heat treatment unit 30 rotates (step S150 in FIG. 10). In this way, the RTB-based sintered magnet body 1 is moved to the heat treatment section 30 as shown in FIG.
- the heat treatment is performed at a temperature of, for example, 500 ° C. to 1000 ° C. (step S160 in FIG. 10).
- This heat treatment does not cause further supply of the heavy rare earth element RH to the surface of the RTB-based sintered magnet body 1, but the heavy rare-earth element is present inside the RTB-based sintered magnet body 1.
- RH diffusion occurs.
- the heat treatment time is 10 minutes to 72 hours. Preferably it is 1 to 6 hours.
- the RTB-based sintered magnet body 1 that has been heat-treated is slowly cooled to lower the temperature inside the furnace to room temperature, and then discharged from the discharge port 35.
- the separation part for selectively separating the RH diffusion source is provided, the process from the RH diffusion treatment process to the heat treatment process can be performed efficiently and smoothly, and the coercive force is improved without reducing the residual magnetic flux density. The productivity of the RTB-based sintered magnet is greatly improved.
- the first baffle plate 70 is provided in the diffusion processing unit 10, but the first baffle plate 70 may be disposed on the separation unit 20 side, You may arrange
- the second baffle plate 80 may be disposed on the separation unit 20 side, or may be disposed across both the separation unit 20 and the heat treatment unit 30.
- first baffle plate 70 and the second baffle plate 80 are arranged so that the twist directions are opposite to each other, when the state changes from the state of FIG. 9B to the state of FIG. 9C, R ⁇ It is possible to prevent the TB-based sintered magnet body 1 from moving to the heat treatment section 30. If the second baffle plate 80 is arranged to move the first baffle plate 70 in parallel, the RTB-based sintered magnet body 1 passes through the separation portion and reaches the heat treatment portion 30. Will reach.
- this embodiment also eliminates the time for placing the RTB-based sintered magnet body 1 and the RH diffusion source 2 in a predetermined position in the RH diffusion processing apparatus.
- the present invention can be applied to the production of an RTB-based sintered magnet having a high residual magnetic flux density and a high coercive force.
- a magnet is suitable for various motors such as a motor for mounting on a hybrid vehicle exposed to high temperatures, home appliances, and the like.
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Abstract
Description
以下、図面を参照しながら、本発明の処理装置の好ましい実施形態を説明する。本発明は、この実施形態に限定されるものではない。
まず、図5のステップS10に示すように、R-T-B系焼結磁石体1およびRH拡散源2を図4(a)に示す拡散処理部10の内部にR-T-B系焼結磁石体1とRH拡散源2とを相対的に移動可能かつ近接または接触可能に装入する。このとき、R-T-B系焼結磁石体1とRH拡散源2とはあらかじめ混合されて不図示の供給機により充填されている。拡散処理部10および分離部20は図4(a)に示すように内壁部を水平にしてもよいし、傾斜していてもよい。
次に、図5のステップS30を実行する。具体的には、図4(b)に示すように、分離部20を下方に傾斜させた状態で拡散処理部10を回転させることにより、拡散処理部10内のR-T-B系焼結磁石体1およびRH拡散源2を分離部20に移動させる。このとき、第1邪魔板70は、RH拡散源2およびR-T-B系焼結磁石体1を分離部20へ搬送するため、図3(a)に示すように拡散処理部10の内壁部に溶接等により接続し、拡散処理部10の回転に追随するようにする。また、邪魔板が内壁部と接続していなくとも、邪魔板は投入口等から延ばしたシャフトに接続し独自に回転するようにしてもよい。拡散処理部10の回転に伴ってR-T-B系焼結磁石体1およびRH拡散源2を分離部20に移動させるよう拡散処理部10の回転方向を選択する。
RH拡散処理工程および分離工程後に、拡散された重希土類元素RHをより均一に拡散する目的で、R-T-B系焼結磁石体1に対する熱処理を追加的に行う。このため、まず、R-T-B系焼結磁石体1を分離部20から再び拡散処理部10に戻す。具体的には、図4(d)に示すように、分離部20および拡散処理部10を下方に傾斜させた状態で、第1邪魔板70は、拡散処理部10の回転に伴ってR-T-B系焼結磁石体1を分離部20から拡散処理部10に移動させるよう拡散処理部10の回転方向を選択する。こうして、図4(d)に示すようにR-T-B系焼結磁石体1を拡散処理部10に移動させる(図5のステップS50)。
まず、図10のステップS110に示すように、R-T-B系焼結磁石体1およびRH拡散源2を図9(a)に示す拡散処理部10の内部に装入する。このとき、R-T-B系焼結磁石体1とRH拡散源2とはあらかじめ混合し不図示の供給機に充填している。ここで、RH拡散源2の大きさは、R-T-B系焼結磁石体1よりも小さくなるよう調整する。
次に、図10のステップS130を実行する。具体的には、図9(b)に示すように、拡散処理部10を傾斜させた状態で回転させ、それによってR-T-B系焼結磁石体1およびRH拡散源2を分離部20に移動させる。
RH拡散処理工程後に、拡散された重希土類元素RHをより均一に拡散する目的で、R-T-B系焼結磁石体1に対する熱処理を行う。このため、まず、R-T-B系焼結磁石体1を分離部20から熱処理部30に移動させる。具体的には、図9(d)に示すように、分離部20および熱処理部30を傾斜させた状態で、熱処理部30を適切な方向に回転させる。このとき、第2邪魔板80は、熱処理部30の回転に伴ってR-T-B系焼結磁石体1を熱処理部30に移動させるように設置する(図10のステップS150)。こうして、図9(d)に示すようにR-T-B系焼結磁石体1を熱処理部30に移動させる。
2 RH拡散源
10 拡散処理部
14 内壁部
15 投入口
20 分離部
30 熱処理部
35 排出口
50 傾斜機構
70 第1邪魔板
80 第2邪魔板
Claims (12)
- 重希土類元素RH(DyおよびTbの少なくとも一方からなる)の金属または合金からなるRH拡散源およびR-T-B系焼結磁石体を加熱しながら回転する拡散処理部と、
前記拡散処理部に隣接し、前記拡散処理部から送出した前記RH拡散源および前記R-T-B系焼結磁石体から前記RH拡散源を選択的に分離するために回転する分離部と、
前記拡散処理部および前記分離部を傾ける傾斜機構と、
を備える処理装置。 - 前記分離部は、前記RH拡散源を分離部外側に排出する複数の開口部を有しており、前記開口部の大きさは、R-T-B系焼結磁石体よりも小さい請求項1に記載の処理装置。
- 前記分離部は、回転させられながら、前記R-T-B系焼結磁石体を前記拡散処理部に送出し、
前記拡散処理部は、前記分離部から移動してきた前記R-T-B系焼結磁石体に対する熱処理を行う請求項1または2に記載の処理装置。 - 前記拡散処理部は、第1内壁部を収容する第1外壁部を有し、
前記分離部は、第2内壁部を収容する第2外壁部を有し、
少なくとも前記第1内壁部は、円筒形で、Mo、W、Nb、Taの少なくとも1種からなる金属または合金からなる請求項1から3のいずれかに記載の処理装置。 - 前記第1内壁部と前記第1外壁部との間または前記第2内壁部と前記第2外壁部との間にはシート状の緩衝部材が配置されている、請求項4に記載の処理装置。
- 前記拡散処理部の内壁部には、螺旋状の邪魔板が設けられており、
前記拡散処理部の邪魔板は、第1方向に回転するとき、前記拡散処理部内の前記RH拡散源および前記R-T-B系焼結磁石体を前記分離部に送出し、かつ、前記第1方向とは反対の第2方向に回転するとき、前記拡散処理部内の前記RH拡散源および前記R-T-B系焼結磁石体を前記拡散処理部内に保持する、請求項1から4のいずれかに記載の処理装置。 - 重希土類元素RH(DyおよびTbの少なくとも一方からなる)の金属または合金からなるRH拡散源およびR-T-B系焼結磁石体を加熱しながら回転する拡散処理部と、
前記拡散処理部に隣接し、前記拡散処理部から送出した前記RH拡散源および前記R-T-B系焼結磁石体から前記RH拡散源を選択的に分離するため回転する分離部と、
前記分離部に隣接し、前記拡散処理部で重希土類元素RHが拡散された前記R-T-B系焼結磁石体に対して、前記RH拡散源が取り除かれた状態で回転しながら熱処理を行う熱処理部と、
少なくとも前記拡散処理部、前記分離部および前記熱処理部を傾ける傾斜機構と、
を備える処理装置。 - 前記分離部は、前記拡散処理部から送出された前記RH拡散源および前記R-T-B系焼結磁石体を、前記熱処理部に移動させながら、前記RH拡散源を分離部外側に排出する複数の開口部を有している、請求項7に記載の処理装置。
- 前記拡散処理部は、前記RH拡散源および前記R-T-B系焼結磁石体を収容する円筒形状の第1内壁部を有し、回転させられながら、前記RH拡散源および前記R-T-B系焼結磁石体を前記分離部に送出し、
前記分離部は、前記RH拡散源および前記R-T-B系焼結磁石体を収容し、開口部が設けられた円筒形状の第2内壁部を有し、回転させられながら、前記RH拡散源を前記開口部から外部に排出し、かつ、前記R-T-B系焼結磁石体を前記熱処理部に送出し、
前記熱処理部は、前記R-T-B系焼結磁石体を収容する円筒形状の第3内壁部を有し、前記駆動部によって回転させられながら、前記R-T-B系焼結磁石体を排出口に送出する請求項7または8に記載の処理装置。 - 前記拡散処理部および前記熱処理部の内壁部には、螺旋状の邪魔板が設けられており、
前記拡散処理部の邪魔板は、前記熱処理部の邪魔板とは螺旋方向が反対向きとなるように保持されている、請求項7から9のいずれかに記載の処理装置。 - 前記拡散処理部は、前記第1内壁部を収容する第1外壁部を有し、
前記分離部は、前記第2内壁部を収容する第2外壁部を有し、
前記熱処理部は、前記第3内壁部を収容する第3外壁部を有し、
少なくとも前記第1内壁部および前記第3内壁部は、円筒形で、Mo、W、Nb、Taの少なくとも1種からなる金属または合金からなる請求項7から10のいずれかに記載の処理装置。 - 前記内壁部と前記外壁部との間にはシート状の緩衝部材が配置されている、請求項7から11のいずれかに記載の処理装置。
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