Toyota Jidosha Kabushiki Kaisha

Nichia Corporation

Aisin Aw Co., Ltd.

Daisuke Ichigozaki

Tetsuya Shoji

Masaaki Ito

Takeshi Yamamoto

Akira Kato

Noritaka Miyamoto

Noritsugu Sakuma

Akihito Kinoshita

Motoki Hiraoka

Kyoko Nakamura

Akira Yamashita

Akira Manabe

Keiu Kanada

Tatsuhiko Hirano

Mitsutoshi Akita

Reimi Sakaguchi

Osamu Yamashita

Kazuaki Haga

Akira Kano

Shinya Omura

Shinya Sano

Takuya Nomura

Daisuke Okamoto

Masaaki Tani

Hidefumi Kishimoto

Michiya Kume

Hisashi Maehara

Kensuke Komori

Shin Tajima

Shoichi Harakawa

Eisuke Hoshina

Tsuyoshi Miyaji

Mayumi Takazawa

Shinya Nagashima

Daichi Maruyama

Hisamitsu Toshida

Hiroaki Wakimoto

Yuya Ikeda

Naomi Inoue

Yuhei Asano

The present disclosure provides a rare earth magnet having a main phase and a grain boundary phase and a manufacturing method therefor. In the rare earth magnet of the present disclosure, the overall composition is represented by a formula (RLaCe)(FeCo)BM. (Ris a predetermined rare earth element, Mis a predetermined element, and the followings are satisfied, 0.05≤x≤0.25, 0.5≤y/(x+y)≤0.50, 13.5≤u≤20.0, 0≤z≤0.100, 5.0≤w≤10.0, and 0≤v≤2.00). The main phase has an RFeB-type crystal structure, and the average grain size and the volume fraction of the main phase are respectively 1.0 μm to 20.0 μm and 80.0% to 90.0%. The main phase and the grain boundary phase satisfy, (the existence proportion of La in the grain boundary phase)/(the existence proportion of La in the main phase)>1.30.

Rare earth magnet and manufacturing method therefor

Provided is a rare earth magnet that allows suppressing deterioration of magnetic properties and a method for manufacturing the same. The rare earth magnet of the present disclosure includes a magnet body containing a rare earth element R1, a transition metal element T, and boron B and includes a main phase. A region in the vicinity of a corner portion of the magnet body of a constituent surface constituting a surface of the magnet body is a processed surface on which a removal process has been performed, and a region closer to a center than the region in the vicinity of the corner portion of the constituent surface is a non-processed surface on which the removal process is not performed.

Rare earth magnet and method for manufacturing the same

The production method of a rare earth magnet of the present disclosure includes a coated magnetic powder preparation step, a mixed powder preparation step, and a pressure sintering step. In the coated magnetic preparation step, a zinc-containing coatingis formed on the particle surface of a samarium-iron-nitrogen-based magnetic powder to obtain a coated magnetic powder. In the mixed powder preparation step, a binder powderhaving a melting point not higher than the melting point of the coatingand the coated magnetic powderare mixed to obtain a mixed powder. In the pressure sintering step, denoting as T° C. the temperature at which the peak disappears in an X-ray diffraction pattern of the binder powderand as T° C. the temperature at which the magnetic phase in the samarium-iron-nitrogen-based magnetic powderdecomposes, the mixed powder is pressure-sintered at T° C. or more and (T−50° C.) or less.

Production method of rare earth magnet

Provided is a motor capable of increasing a torque while suppressing an increase in the physical size of the motor. A motor includes a rotor. The rotor includes pairs of magnet slots evenly spaced in a circumferential direction, each pair of magnet slots being arranged in a V-shape, pairs of main magnets housed in the pairs of magnet slots, and a plurality of auxiliary magnets including an outer magnet housed in an outer end in the circumferential direction in each of the pairs of magnet slots. The motor satisfies at least one of a first condition that the main magnets are sintered magnets and the auxiliary magnets are bonded magnets, or a second condition that magnetization directions of the main magnet and the outer magnet housed in the same magnet slot intersect outside in the radial direction so as to define an acute angle.

Motor

A rare-earth magnet and a method of manufacturing the same are provided. The method includes: preparing Sm—Fe—N magnetic powder; preparing reforming material powder containing metallic zinc; mixing the magnetic powder and the reforming material powder to obtain mixed powder; subjecting the mixed powder to compression molding in a magnetic field to obtain a magnetic-field molded body; subjecting the magnetic-field molded body to pressure sintering to obtain a sintered body; and subjecting the sintered body to heat treatment. A content proportion of the metallic zinc in the reforming material powder is 10 to 30% by mass with respect to the mixed powder. When a temperature and time in conditions for the heat treatment are defined as x° C. and y hours, respectively, the formulas y≥−0.32x+136 and 350≤x≤410 are met.

Rare-earth magnet and method of manufacturing the same

An Sm—Fe—N-based magnetic material according to the present disclosure includes a main phase having a predetermined crystal structure. The main phase has a composition represented by (SmLaCeR)(FeCoNiM)N(where, Ris predetermined rare earth elements and the like, M is predetermined elements and the like, and 0.04≤x+y≤0.50, 0≤z≤0.10, 0≤p+q≤0.10, 0≤s≤0.10, and 2.9≤h≤3.1 are satisfied). A crystal volume of the main phase is 0.833 nmto 0.840 nm. A manufacturing method of the Sm—Fe—N-based magnetic material according to the present disclosure includes nitriding a magnetic material precursor including a crystal phase having a composition represented by (SmLaCeR)(FeCoNiM).

Sm—Fe—N-based magnetic material and manufacturing method thereof

An Sm—Fe—N-based magnetic material according to the present disclosure includes a main phase having a predetermined crystal structure. The main phase has a composition represented by a molar ratio formula (SmLaCeR)(FeCoNiM)N(where, Ris a predetermined rare earth element, M is a predetermined element, and 0≤x+y<0.04, 0≤z≤0.10, 0<p+q≤0.10, 0≤s≤0.10, and 2.9≤h≤3.1 are satisfied). A lattice volume of the main phase is 0.830 nmto 0.840 nm, and a density of the main phase is 7.70 g/cmto 8.00 g/cm.

The method for manufacturing the Halbach magnet array comprises a) magnetizing at least one first magnetic material piece and at least one second magnetic material piece in a direction parallel to a first direction, and b) magnetizing a third magnetic material piece in a direction parallel to a second direction perpendicular to the first direction, in this order. The first magnetic material piece and the second magnetic material piece are alternately arranged in the second direction with the third magnetic material piece interposed therebetween. The first magnetic material piece adheres to the adjacent third magnetic material piece via a non-magnetic layer with a thickness t, the second magnetic material piece adhere to the adjacent third magnetic material piece via a non-magnetic layer with a thickness t, and tand tsatisfy a formula t<t

Method for manufacturing Halbach magnet array and Halbach magnet array

The method for manufacturing the Halbach magnet array includes the steps of: (a) magnetizing at least two first magnetic material pieces in a direction parallel to a first direction, and (b) magnetizing at least one second magnetic material piece in a direction parallel to a second direction perpendicular to the first direction, in this order. In the step (a), the first magnetic material pieces and the second magnetic material piece are alternately arranged in the second direction with the first magnetic material pieces being each adhered to the adjacent second magnetic material piece, and the magnetization is performed under a condition in which a residual magnetization ratio rof the first magnetic material pieces is higher than a residual magnetization ratio rof the second magnetic material piece.

Method for manufacturing Halbach magnet array

A rotating electrical machine capable of obtaining a higher torque while minimizing the amount of permanent magnets used. A rotor core includes a plurality of first insertion holes each having an auxiliary magnet embedded therein, the auxiliary magnet being embedded so as to surround a rotation axis of a rotor in a cross-section orthogonal to the rotation axis. The rotor core includes a plurality of second insertion holes each having a main magnet embedded therein, the main magnet being embedded so as to extend from the auxiliary magnet toward an outer circumferential direction of the rotor. The rotor includes a plurality of magnetic poles formed around the rotation axis, the magnetic poles each having the auxiliary magnet and the plurality of main magnets. The auxiliary magnet is arranged disproportionately on one side of the first insertion hole in the circumferential direction of the rotor so as to form a clearance on the other side of the first insertion hole.

Rotating electrical machine

Provided is a motor capable of suppressing reduction of the torque of the motor even if the amount of use of the permanent magnets embedded in the rotor core is reduced. A motor includes a rotor with permanent magnets embedded in a rotor core, and a stator positioned on an outer circumference of the rotor. The rotor includes magnetic poles formed around a rotation axis of the rotor, the magnetic poles having the permanent magnets arranged therein. The permanent magnets in adjacent magnetic poles are arranged such that positions of a north pole and a south pole of the permanent magnet in one magnetic pole are inverted from those of the permanent magnet in a magnetic pole adjacent to the one magnetic pole. The permanent magnets each have a residual magnetization that decreases as it moves from the north pole toward the south pole.

A plurality of auxiliary magnets is embedded in a rotor core so as to surround the rotation axis of the rotating electrical machine in the cross-section orthogonal to the rotation axis. A plurality of main magnets is embedded in the rotor core so as to extend from the auxiliary magnet in the outer circumferential direction of the rotor. A plurality of magnetic poles of the rotor is formed around the rotation axis, the magnetic poles each having the auxiliary magnet and the plurality of main magnets arranged at a distance from each other in the circumferential direction of the rotor, and the plurality of main magnets of each magnetic pole is arranged asymmetrically about a virtual line passing the rotation axis and axisymmetrically dividing the auxiliary magnet of each magnetic pole.

A rotating electrical machine capable of obtaining a higher torque while limiting the amount of permanent magnets used. A magnetic pole of a rotor includes an auxiliary magnet embedded in a rotor core and at least one main magnet arranged on an outer circumferential side than the auxiliary magnet of the rotor. In each magnetic pole, the distance from an end of the main magnet, the end facing the auxiliary magnet, to the auxiliary magnet facing the main magnet is shorter than the length of the main magnet in the radial direction. In a cross-section orthogonal to the rotation axis of the rotating electrical machine, the main magnets of each magnetic pole are arranged so as to be asymmetrical about a virtual line passing the rotation axis and axisymmetrically dividing the auxiliary magnet.

A manufacturing method of a core for a rotary electric machine, the method includes inserting a permanent magnet that is not yet magnetized in a magnet insertion hole that is formed in a rotor core; injecting a magnet fixing material in the magnet insertion hole; curing the magnet fixing material by heating the rotor core and the permanent magnet; and magnetizing the permanent magnet before a temperature of the rotor core and the permanent magnet decreases to a normal temperature, after the curing of the magnet fixing material.

Manufacturing method of rotor for rotary electric machine

Provided is a method for producing a rare-earth magnet that can resolve a problem of deterioration of the residual magnetization and coercive force of the rare-earth magnet due to spring-back in producing the rare-earth magnet through performing hot deformation processing of upsetting on a sintered body. The method includes a first step of producing the sintered body through press-forming of magnetic powder for a rare-earth magnet, and a second step of producing a rare-earth magnet precursor through hot deformation processing of upsetting in which the sintered body is placed within a plastic processing mold and is pressurized in a predetermined direction so as to impart magnetic anisotropy to the sintered body, and performing cooling of the rare-earth magnet precursor while a predetermined pressure is kept being applied thereto in the predetermined direction, so that the rare-earth magnet is produced.

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Toyota, Japan

Daisuke Ichigozaki