Toyota Jidosha Kabushiki Kaisha

Tohoku University

Kazuaki Haga

Kensuke Komori

Noritsugu Sakuma

Keiu Kanada

Tetsuya Shoji

Shinya Sano

Mayumi Takazawa

Masaaki Ito

Takuya Nomura

Toshimitsu Takahashi

Fumitaka Yoshinaga

Yasuhide Yagyu

Takeshi Tomonaga

Hisanori Koma

Akira Yamashita

Motoki Hiraoka

Daisuke Ichigozaki

Daisuke Sakuma

Tatsuhiko Hirano

Tomonori Inuzuka

Hiroaki Wakimoto

Hisamitsu Toshida

Airi Kamimura

Noritaka Miyamoto

Shingo Fubuki

Tomonari Kogure

Noriyuki Ueno

Katsuhiko Tatebe

Akira Kano

Shinya Omura

Seishi Utsuno

Kyoko Nakamura

Satoshi Sugimoto

Daichi Maruyama

Yuya Ikeda

Hiroko Kurihara

Masashi Matsuura

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

In an axial gap motor, a rotor includes a plurality of rotor cores fixed in a circumferential direction of a rotor base, and a stator includes a plurality of stator cores fixed in a circumferential direction of a stator base, and coils wound around the stator cores. End faces of each of the rotor cores and end faces of the corresponding stator core are opposed to each other while being exposed to each other.

Axial gap motor with curved rotor and stator cores

A motor includes a rotor fixed to a rotary shaft, a stator arranged so as to surround the rotor with a gap from the rotor in a radial direction orthogonal to an axis direction of the rotary shaft, and a case accommodating the rotor and the stator. The rotor includes a plurality of rotor cores made from a soft magnetic material, and a rotor fixing member that fixes the rotor cores. The stator includes a plurality of stator cores made from a soft magnetic material, a stator fixing member that fixes the stator cores, and coils wound around the stator cores, respectively. The motor includes at least two sets of the rotor and the stator, and the sets are stacked in an axis direction of the rotary shaft.

Motor

An axial gap motor is configured such that: a rotor includes a plurality of rotor cores fixed along the circumferential direction of a rotor pedestal, and a plurality of magnets; and a stator includes a plurality of stator cores fixed along the circumferential direction of a stator pedestal, and coils wound around the stator cores. A first divided surface of each rotor core faces an N-pole of a corresponding magnet, and a second divided surface of the each rotor core faces an S-pole of a corresponding magnet. Respective divided surfaces of the rotor cores are placed to face respective divided surfaces of the stator cores across the magnets.

Axial gap motor

To provide a rare earth magnet having excellent coercive force and a production method thereof. A rare earth magnet, wherein the rare earth magnet comprises a magnetic phase containing Sm, Fe, and N, a Zn phase present around the magnetic phase, and an intermediate phase present between the magnetic phase and the Zn phase, wherein the intermediate phase contains Zn and the oxygen content of the intermediate phase is higher than the oxygen content of the Zn phase; and a method for producing a rare earth magnet, including mixing a magnetic raw material powder having an oxygen content of 1.0 mass % or less and an improving agent powder containing metallic Zn and/or a Zn alloy, and heat-treating the mixed powder.

Rare earth magnet and production method thereof

There is provided a method for manufacturing a soft magnetic member where a coating formed of an &#x3b1;-FeOsingle phase having a high electrical resistivity is formed on a soft magnetic alloy substrate. A soft magnetic alloy substrate is heated in an atmosphere containing water vapor and inert gas to form a coating on the soft magnetic alloy substrate. The atmosphere has an oxygen partial pressure in a range of 0 to 1.5 kPa. A soft magnetic member including the soft magnetic alloy substrate and the coating formed on its surface can be obtained.

Method for manufacturing soft magnetic member

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.

Rotating electrical machine

Provided is an IPM motor that is strong and has high output. An IPM motor has a rotor that includes a rotor core as a laminate of a plurality of metal foil pieces made of a soft magnetic material that are stacked in a direction of a rotation axis of the rotor. The rotor core has a plurality of through-holes that penetrates through the rotor core in the direction of the rotation axis, the plurality of through-holes including through-holes embedding magnets. The rotor core includes inner bridges and outer bridges. At least one of the inner bridges and the outer bridges of the rotor core is made of an amorphous soft magnetic material, and other parts are made of a nanocrystal soft magnetic material.

Interior permanent-magnet motor and method for manufacturing the same

Provided is a laminate of soft magnetic ribbons having a simple structure and capable of avoiding a damage of the soft magnetic ribbons and improving the occupancy of the soft magnetic ribbons. The laminate of soft magnetic ribbons includes: a laminated part of first soft magnetic ribbons stacked; and a reinforcing part disposed at both ends of the laminated part in the stacking direction of the first soft magnetic ribbons. The reinforcing part includes second soft magnetic ribbons stacked in the stacking direction of the first soft magnetic ribbons and hardening resin that covers the second soft magnetic ribbons as a whole and is impregnated into areas between the neighboring second soft magnetic ribbons.

Laminate of soft magnetic ribbons

The present disclosure provides a method for producing a magnetic component that enables efficient processing of an amorphous soft magnetic material or a nanocrystalline soft magnetic material. The method for producing a magnetic component comprising an amorphous soft magnetic material or nanocrystalline soft magnetic material comprises: a step of preparing a stacked body comprising a plurality of plate-shaped amorphous soft magnetic materials or nanocrystalline soft magnetic materials; a step of heating at least a portion of shearing in the stacked body to a temperature equal to or higher than the crystallization temperature of the soft magnetic materials; and a step of shearing the stacked body at the portion of shearing after the step of heating.

Method for producing magnetic component using amorphous or nanocrystalline soft magnetic material

Provided is a stator for rotating electrical machine that can avoid the sagging of teeth stacked at the distal ends under the self-weight. A stator core is a laminate of metal foil members stacked in a direction of a rotation axis of the rotating electrical machine. Each tooth has a pair of side walls facing the neighboring teeth in the circumferential direction. The stator includes a pair of insulating reinforcing members so as to become a bridge between the corresponding tooth and a part of the yoke and sandwich the corresponding tooth from both sides in the direction of the rotation axis while exposing the pair of side walls; insulating fixing members, each fixing member fixing the corresponding pair of reinforcing members to the corresponding tooth while wrapping around the pair of reinforcing members and tooth; and coils formed as distributed windings at the teeth fixed with the fixing members.

Stator for rotating electrical machine having components for reinforcing laminations

A method includes: manufacturing a sintered compact represented by (Rl)(Rh)TBMand has a grain boundary phase; manufacturing a rare earth magnet precursor from the sintered compact; and performing a heat treatment on the rare earth magnet precursor at 450&#xb0; C. to 700&#xb0; C. to diffuse and to infiltrate a melt of a modified alloy containing a light rare earth element and either a transition metal element, Al, In, Zn, or Ga into the grain boundary phase. Rl represents a light rare earth element. Rh represents Dy or Tb. T represents a transition metal containing at least one of Fe, Ni, and Co. B represents boron. M represents at Ga, Al, or Cu. x, y, z, s, and t represent mass % of Rl, Rh, T, B, and M. Following expressions are established: 27&#x2264;x&#x2264;44, 0&#x2264;y&#x2264;10, z=100&#x2212;x&#x2212;y&#x2212;s&#x2212;t, 0.75&#x2264;s&#x2264;3.4, 0&#x2264;t&#x2264;3. An infiltration amount of the modified alloy is 0 mass % to 5 mass %.

Method of manufacturing rare earth magnet

A manufacturing method includes: manufacturing a sintered compact having a composition of (Rl)(Rh)TBM; manufacturing a precursor by performing hot deformation processing on the sintered compact; and manufacturing a rare earth magnet by performing an aging treatment on the precursor in a temperature range of 450&#xb0; C. to 700&#xb0; C. In this method, a main phase thereof is formed of a (RlRh)TB phase. A content of a (RlRh)TBphase in a grain boundary phase thereof is more than 0 mass % and 50 mass % or less. Rl represents a light rare earth element. Rh represents a heavy rare earth element. T represents a transition metal. M represents at least one of Ga, Al, Cu, and Co. x, y, z, s, and t are percentages by mass of Rl, Rh, T, B, and M. x, y, z, s, and t are expressed by the following expressions: 27&#x2264;x&#x2264;44, 0&#x2264;y&#x2264;10, z=100&#x2212;x&#x2212;y&#x2212;s&#x2212;t, 0.75&#x2264;s&#x2264;3.4, 0&#x2264;t&#x2264;3.

A manufacturing method of a rare-earth magnet includes: manufacturing a first sealing body by filling a graphite container with a magnetic powder to be a rare-earth magnet material and by sealing the graphite container; manufacturing a sintered body by sintering the first sealing body to manufacture a second sealing body in which the sintered body is accommodated; and manufacturing a rare-earth magnet by performing hot plastic working on the second sealing body to give magnetic anisotropy to the sintered body.

Growing community of inventors

Toyota, Japan

Kazuaki Haga