Matsushita Electric Industrial Co., Ltd.

Panasonic Corporation

Nippon Steel Corporation

Fumitoshi Yamashita

Masami Wada

Yoshikazu Yamagata

Hiroshi Murakami

Kiyomi Kawamura

Takahiko Terada

Hiroshi Onishi

Yuichiro Sasaki

Yukihiro Okada

Hiroshi Ueda

Akihiko Watanabe

Seiji Kurozumi

Katsuhiro Murano

Sunao Hashimoto

Shuichi Kitayama

Hiroshi Ohnishi

Kazunori Hayashi

Masaki Nakano

Hirotoshi Fukunaga

Tomiaki Sakano

Hiroshi Dohi

Masaharu Miyagawa

Kanao Fukuda

Shinji Toda

Hiromichi Fujimoto

Takeichi Ota

Junko Kaneko

Masato Inayoshi

Eiji Uenishi

A process of manufacturing segments, an anisotropic direction of which is continuously changed in a plane vertically by a uniform magnetic field maintained in a constant direction and a process of arranging a plurality of segments on a circumference, extruding the segments in a ring shape by rheology based on the viscous deformation of the segments, from one thrust-direction end surface of the segments, and subsequently compressing the segments from both thrust-direction end surfaces of the segments are necessarily included. A ring magnet, anisotropy of which is controlled in a continuous direction, is provided, and a source for generating a static magnetic field has energy density (BH) max&#x2267;160 to 180 kJ/m.

Manufacturing method of rare earth-iron ring magnet with continuous orientation controlled anisotropy

To improve tranquility and controllability of an iron core-equipped permanent magnet motor with an improved maximum energy product (BH)by improving shape compatibility of a radial anisotropic magnet, there is provided a radial anisotropic magnet manufacturing method of fixing magnet powder in a net shape so as to maintain a magnetic anisotropic (C-axis) angle of a magnet with respect to a tangential line and for performing a deformation with a flow so as to have a predetermined circular arc shape or a predetermined annular shape. Particularly, by performing a deformation with a viscous flow or an extension flow, a deformability of the magnet is improved, and thus shape compatibility with respect to a thickness is. improved. A C-axis angle &#x3b8; with respect to a tangential direction is controlled at an arbitrary position and an arbitrary angle so as to reduce cogging torque without separating a magnetic pole into segments.

Radial anisotropic magnet manufacturing method, permanent magnet motor using radial anisotropic magnet, and iron core-equipped permanent magnet motor

To improve tranquility and controllability of an iron core-equipped permanent magnet motor with an improved maximum energy product (BH)by improving shape compatibility of a radial anisotropic magnet, there is provided a radial anisotropic magnet manufacturing method of fixing magnet powder in a net shape so as to maintain a magnetic anisotropic (C-axis) angle of a magnet with respect to a tangential line and for performing a deformation with a flow so as to have a predetermined circular arc shape or a predetermined annular shape. Particularly, by performing a deformation with a viscous flow or an extension flow, a deformability of the magnet is improved, and thus shape compatibility with respect to a thickness is improved. A C-axis angle &#x3b8; with respect to a tangential direction is controlled at an arbitrary position and an arbitrary angle so as to reduce cogging torque without separating a magnetic pole into segments.

In a radial-direction gap type magnet motor, when an energy density increases, a direction change M&#x3b8;/&#x3c6;p of a static magnetic field with respect to a mechanic angle between different poles increases in an exponential manner and thus to decrease a cogging torque of the motor is not compatible to increase a torque density. In order to solve the problem, assuming that &#x3c6;t denotes a mechanic angle of a stator iron core teeth, &#x3c6;p denotes a mechanical angle of a magnetic pole, and M&#x3b8; denotes an angle of a static magnetic field with respect to a circumferential tangential line of a radial magnetic pole center, a radial-direction type magnet motor in which &#x3c6;t&#x3c;&#x3c6;p, M&#x3b8; in a magnetic pole center region is 75 to 90&#xb0;, and M&#x3b8;/&#x3c6;p&#x2266;7 is satisfied in the magnetic pole end region of &#x3c6;p&#xd7;0.1&#xb0;, and further, a static magnetic field generating source is configured as a magnetic anisotropic magnetic pole having an energy density (BH) max&#x2267;150 kJ/mis provided.

Radial-direction gap type magnet motor

The present invention provides a method for manufacturing a self-organized rare earth-iron bonded magnet, including: a first step of covering a rare earth-iron magnet powder with oligomer or prepolymer in which one molecule includes at least two or more reactive ground substances to provide a surface-treated magnet powder; a second step of melting and kneading stretchable polymer and the surface-treated magnet powder to coarsely crush the resultant material to provide a granule; a third step of dry blending the granule with hardener to provide a compound; a fourth step of compressing the compound under temperature conditions by which the oligomer or prepolymer, the polymer, and the hardener are caused to melt and to flow to provide a green compact; a fifth step of causing the green compact to be a self-organized rare earth-iron bonded magnet by reacting the oligomer or prepolymer, and polymer with the hardener; and a sixth step of stretching the bonded magnet to transform the shape to any of a circular-shape or a circular arc-like shape.

Process for producing self-assembled rare earth-iron bonded magnet and motor utilizing the same

An anisotropic permanent magnet motor includes a stator and a rotor opposed to teeth of the stator with a gap therebetween, and the rotor includes an anisotropic permanent magnet disposed on a surface of a rotor yoke. The anisotropic permanent magnet has an orientation direction set in a direction normal to the outer-peripheral surface in a range of both &#x3b8;r&#xb0;/2 from a magnetic pole center and continuously inclined toward a magnetic pole end with respect to a direction normal to the outer-peripheral surface.

Anisotropic permanent magnet motor

An anisotropic rare-earth bonded magnet having a network boundary phase is provided by imparting melt fluidity accompanied by a slip to a composite granule and compressing and molding the composite granule in a magnetic field together with extensible polymer molecules and a chemical contact. In the bonded magnet, the maximum energy product is 147 kJ/min the thickness of 1 mm, or 127 kJ/min the thickness of 300 &#x3bc;m. This bonded magnet contributes to increase in output and decrease in size and weight of a permanent-magnet motor.

Anisotropic rare earth bonded magnet having self-organized network boundary phase and permanent magnet motor utilizing the same

A motor generally has a contradictory relation between decrease of cogging torque and increase of torque density. To overcome this problem, continuous direction control is provided for anisotropy with modification of magnetic poles so that the average absolute value of differences between M&#x3b8; and 90&#xd7;sin [&#x3c6;{2&#x3c0;/(360/p)}] is set to be 3&#xb0; or less, where M&#x3b8; is a direction of anisotropy with respect to a radial tangent line of a magnetic pole plane, &#x3c6; is a mechanical angle, and p is the number of pole pairs.

Permanent magnet rotator and motor using the same

Methods for manufacturing a flexible bonded magnet, and a high-efficiency small motor using the magnet are disclosed. The flexible bonded magnet is manufactured through the processes of compressing a new compound consisting of flexible thermosetting resin composite and magnetic powder, which contains thermosetting resin, thermoplastic resin, etc.; heat-curing a green sheet derived from the above process; and rolling.

Manufacturing methods of flexible bonded magnet and motor using the same

A permanent magnet field small DC motor includes an arc-shaped rare earth magnet of maximum thickness 1 mm or less fabricated by compression molding from rare earth iron based melt-spun flakes and a binder. The magnet is provided with a certain specific portion at both ends in the circumferential direction, which has no back yoke when the magnet is press-fit in a soft-magnetic frame. The arc-shaped rare earth magnet fabricated by compression molding from a material containing more rare earth iron based melt-spun flakes exhibits simultaneous increase of both a remanence as a function of magnetizing field and a coercivity; and hence, exhibits a well-balanced demagnetization curve even in an unsaturated magnetized state.

Permanent magnet field small DC motor

A powder molded magnet manufactured by a method comprising the steps of: (1) forming a granular compound of diameter of not more than 250 &#x3bc;m with a rare earth-iron rapid-quenched flake, which has not more than 150 &#x3bc;m in diameter, being coarsely ground if necessary, and a binder, (2) dry-blending the granular compound with fatty acid metallic soap powder, (3) forming compressed powder from the granular compound dry-blended with the fatty acid metallic soap powder, by powder molding, and (4) heat-treating the compressed powder to a temperature higher than a thermally dissociating temperature of stabilized isocyanate.

Method of manufacturing rare earth-iron bond magnet

The method of manufacturing rare earth thick film magnet comprising a step of forming an alloy layer of 30-100 &#x3bc;m thick having a general formula RBTMon a substrate by a physical deposition process, and a step of heat-treating the alloy layer to form a thick film magnetic layer having RTMB phase as a main phase. In the general formula, R is at least one of rare earth elements, B is boron, TM is iron or its alloy partly substituted by cobalt. X is 0.1-0.2, Y is 0.05-0.2 and Z=1-X-Y. Further, the method of the present invention includes a step of laminating a plurality of alloy layers formed on a substrate together with the substrate. A motor comprising rare earth thick film magnet of the present invention is extremely small while obtaining high output.

Method of manufacturing a motor comprising a rare earth thick film magnet

A permanent magnet field-type compact DC motor having a high output and a low cogging torque is made by fixing a pair of rare earth magnets mainly composed of rare earth-iron-based rapidly quenched and solidified flakes to a soft magnetic frame so as to extend along an inner peripheral surface thereof, and by unsaturation-magnetizing the rare earth magnets so that demagnetization curves at circumferentially opposite end portions of the rare earth magnets are made smaller than a demagnetization curve at a central portion of a magnetic pole of each of the rare earth magnets.

Method of making a permanent magnet field-type compact DC motor

There is provided a process of producing a ring shaped resin bonded magnetic member by molding a feed mixture which contains a lubricant and a magnetic powder composite made of magnetic powder and a heat curable resin composition which is in a solid state at a room temperature. The process is characterized in that (1) heating an inner peripheral surface of the annular cavity so as to transfer heat to the feed mixture whereby heating the feed mixture to a temperature not lower than a softening temperature and below a curing temperature of the resin composition, and compressing the filled feed mixture after or during the heating; and (ii) cooling the inner peripheral surface so as to transfer heat from the heated and compressed feed mixture through the inner peripheral surface, whereby cooling the feed mixture to a temperature below the softening temperature of the resin composition so as to obtain a green compact having a ring shape.

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Nara, Japan

Fumitoshi Yamashita