Aichi Steel Corporation

Aichi Steel Works, Ltd.

Hiroshi Matsuoka

Yoshinobu Honkura

Hironari Mitarai

Masayuki Kato

Ikuzou Okumura

Daisuke Nagaya

Yoji Hashimoto

Masahiko Kato

Tadashi Fujimaki

Chisato Mishima

Satoru Kan

Kenji Noguchi

Yoshinobu Sugiura

Atsushi Kano

Yoshikazu Amahiro

A manufacturing method for obtaining an interior permanent magnet-type inner rotor without thermal demagnetization due to shrink fitting to a rotating shaft includes: a shrink fitting step of heating a rotor core having slots and inserting a rotating shaft into a shaft hole to shrinkfit the rotor core; and a filling step of filling the rotor core slots in a residual heat state after the shrink fitting step with a flowable mixture of a binder resin heated to a flowable state and anisotropic magnet particles, in oriented magnetic fields This allows, in similar manufacturing steps, an inner rotor of which the magnetic poles are anisotropic bond magnets formed by solidifying the flowable mixture in the slots and a conventional inner rotor of which the magnetic poles are sintered magnets. This allows both the inner rotors concurrently and in parallel (mixed flow production) in an already existing IPM motor manufacturing line.

Method and apparatus for manufacturing interior permanent magnet-type inner rotor

An apparatus for manufacturing an interior permanent magnet-type inner rotor and manufacturing method using the same. The apparatus including: a mold having a three-layer structure; the method including a shrink fitting step of heating a rotor core having slots; and a filling step of filling the rotor core slots in a residual heat state after the shrink fitting step with a flowable mixture of a binder resin heated to a flowable state and having anisotropic magnet particles, in oriented magnetic fields. This allows, in similar manufacturing steps, an inner rotor of which magnetic poles are anisotropic bond magnets formed by solidifying the flowable mixture in the slots and a conventional inner rotor of which the magnetic poles are sintered magnets. This allows both the inner rotors concurrently and in parallel (mixed flow production) in an already existing IPM motor manufacturing line.

Apparatus for manufacturing interior permanent magnet-type inner rotor and manufacturing method using same

A production method for an anisotropic bonded magnet includes: filling the annular cavity with a magnet raw material including one or more types of rare-earth anisotropic magnet powder and a binder resin; applying aligning magnetic fields to the magnet raw material being aligned in the softened or molten binder resin, the aligning magnetic fields are applied from an even number of aligning magnetic pole bodies arranged around outer periphery of the annular cavity such that directions of magnetic fields are alternated; subjecting the magnet raw material to a molding to form a compact; rotating the aligning magnetic pole bodies in circumferential direction for a predetermined angle; and applying demagnetization magnetic fields to the compact from the aligning magnetic pole bodies during the alignment step. The demagnetization magnetic fields are in directions for cancelling magnetization of the compact caused by the aligning magnetic fields.

Production method for anisotropic bonded magnet and production apparatus for same

A method for production of an anisotropic bonded magnet includes: aligning magnetic pole bodies which include an even number of permanent magnets arranged uniformly around an outer periphery of an annular cavity filled with magnetic raw material, aligning magnetic fields to cause rare-earth anisotropic magnet powder to be semi-radially aligned; compressively molding the semi-radially aligned magnet raw material to obtain an annular compact; discharging the compact from the annular cavity; demagnetizing causing the aligning magnetic pole bodies to relatively move only in circumferential direction with respect to the compact after the molding step thereby to apply demagnetization magnetic fields to the compact; The demagnetization magnetic fields are applied from the aligning magnetic pole bodies with opposite poles to those during the alignment step, and the demagnetization magnetic fields are in directions for cancelling the magnetization of the compact caused by the aligning magnetic fields.

A production method for a case-integrated bonded magnet includes: filling a tubular cavity with a magnet raw material that includes a rare-earth magnet powder and a thermosetting resin binder; heating the magnet raw material to cause the thermosetting resin softened or melted while compressively molding the magnet raw material to obtain a tubular compact; discharging the tubular compact from the tubular cavity while press-fitting the tubular compact into a metal tubular case having an inner peripheral surface coaxial with the tubular cavity; and heat-curing the tubular compact with the tubular case to cure the thermosetting resin. The tubular compact press-fitted into the tubular case is thermally cured thereby causing the tubular compact to transform to a tubular bonded magnet, which expands unexpectedly due to heat.

Case-integrated bonded magnet and production method for same

To improve resistance of a motor device against an organic solvent and to suppress degradation in performance of the motor device with time. In a motor device, an excitation magnet is formed using a hollow-cylinder shaped anisotropic bonded magnet. This bonded magnetis press-fitted in a housingand is held. The bonded magnetis formed of a hollow-cylinder shaped anisotropic rare earth bonded magnet which is obtained by compounding an anisotropic rare earth magnet powder with a phenol-novolac type epoxy resin, followed by molding. The anisotropic rare earth bonded magnetis press-fitted along an inner peripheral portion of the housing, and on an exposed surface layer of the anisotropic rare earth bonded magnet press-fitted in the housing, a coating layer is formed by an infiltration treatment using a polyamide-imide-based resin.

Permanent magnet for motor, motor housing, and motor device

A hollow cylindrically shaped anisotropic bonded magnet for use in a 4-pole motor, is formed by molding anisotropic rare-earth magnet powder with resin. The alignment distribution of the anisotropic rare-earth magnet powder in a cross section perpendicular to the axis of the anisotropic bonded magnet is in the normalized direction of the cylindrical side of the hollow cylindrical shape in the main region of a polar period, and in a transition region in which the direction of the magnetic pole changes, steadily points towards a direction tangential to the periphery of the cylindrical side at points closer to the neutral point of the magnetic pole, and becomes a direction tangential to the periphery of the cylindrical side at that neutral point, and steadily points toward the normalized direction of the cylindrical side at points farther away from the neutral point.

Anisotropic bonded magnet for use in a 4-pole motor, a motor employing that magnet, and an alignment process apparatus for the anisotropic bonded magnet for use in a 4-pole motor

To realize an anisotropic bonded magnet that reduces cogging torque without lowering output torque. The present invention provides a hollow cylindrically shaped anisotropic bonded magnet for use in a 4-pole motor, formed by molding anisotropic rare-earth magnet powder with resin. The alignment distribution of the anisotropic rare-earth magnet powder in a cross section perpendicular to the axis of the anisotropic bonded magnet is in the normalized direction of the cylindrical side of the hollow cylindrical shape in the main region of a polar period, and in a transition region in which the direction of the magnetic pole changes, steadily points towards a direction tangential to the periphery of the cylindrical side at points closer to the neutral point of the magnetic pole, and becomes a direction tangential to the periphery of the cylindrical side at that neutral point, and steadily points toward the normalized direction of the cylindrical side at points farther away from the neutral point.

Anisotropic bond magnet for four-magnetic-pole motor, motor using the same, device for orientation processing of anisotropic bond magnet for four-magnetic-pole motor

The present invention provides miniaturization of brushless motors and brush motors used in electric devices, a ring magnet which simultaneously achieves both high torque and a reduction in cogging torque, a ring magnet with yoke, and a brushless motor. The thin hybrid magnetized ring magnet of the present invention is structured of, in a ring magnet comprised of a plurality of magnetic poles, a radially magnetized main pole and an interface for which the interface of the adjoining main pole is polar anisotropic. When the thin hybrid magnetized ring magnet structured in this manner is applied to a brushless motor, in the case of radial magnetizing, the abrupt change in magnetic flux of the interface between the magnetic poles becomes smooth and cogging torque is greatly reduced due to polar anisotropic magnetization of the interface. At the same time, by polar anisotropically magnetizing the interface between the magnetic poles, magnetic flux is concentrated on the radially magnetized main pole, and in comparison to only radial magnetization, maximum surface magnetic flux improves and it is possible to attain high torque.

Growing community of inventors

Aichi-ken, Japan

Hiroshi Matsuoka