Toyota Jidosha Kabushiki Kaisha

Nichia Corporation

Masaaki Ito

Noritsugu Sakuma

Tetsuya Shoji

Daisuke Ichigozaki

Masao Yano

Hidefumi Kishimoto

Hisashi Maehara

Motoki Hiraoka

Keiu Kanada

Akihito Kinoshita

Takuya Nomura

Kazuaki Haga

Akira Manabe

Michiya Kume

Kensuke Komori

Tatsuhiko Hirano

Reimi Tabuchi

Akira Kato

Shinya Sano

Toshimitsu Takahashi

Yasuhide Yagyu

Takeshi Tomonaga

Hisanori Koma

Mayumi Takazawa

Hiroaki Wakimoto

Reimi Sakaguchi

Kota Washio

Kyoko Nakamura

Shunji Suzuki

Kurima Kobayashi

Mitsutoshi Akita

Masanori Okanan

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

A Sm—Fe—N-based rare earth magnet more resistant to demagnetization than ever before, particularly at high temperatures, and a production method thereof are provided. The present disclosure presents a production method of a rare earth magnet, including mixing a SmFeN magnetic powder and a modifier powder to obtain a mixed powder, compression-molding the mixed powder in a magnetic field to obtain a magnetic-field molded body, pressure-sintering the magnetic-field molded body to obtain a sintered body, and heat-treating the sintered body, and a rare earth magnet obtained by the method. Dof the magnetic powder is 1.50 μm or more and 3.00 μm or less, the content ratio of the zinc component in the modifier powder is 6 mass % or more and 30 mass % or less, and the heat treatment temperature is 350° C. or more and 410° C. or less.

Rare earth magnet and production method thereof

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

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

A Sm—Fe—N-based rare earth magnet more resistant to demagnetization than ever before in an environment where an external magnetic field is applied, particularly at high temperatures, and a production method thereof are provided. The present disclosure presents a production method of a rare earth magnet, including preparing a coated magnetic powder, compression-molding the coated magnetic powder in a magnetic field to obtain a magnetic-field molded body, pressure-sintering the magnetic-field molded body to obtain a sintered body, and heat-treating the sintered body, and a rare earth magnet obtained by the method. Dof the magnetic powder in the coated magnetic powder is 1.50 μm or more and 3.00 μm or less, the content ratio of the zinc component in the coated magnetic powder is 3 mass % or more and 15 mass % or less, and the heat treatment temperature is 350° C. or more and 410° C. or less.

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

A method of producing a SmFeN-based rare earth magnet, the method including: dispersing a SmFeN-based anisotropic magnetic powder including Sm, Fe, La, W, R, and N, wherein R is at least one selected from the group consisting of Ti, Ba, and Sr, using a resin-coated metal media or a resin-coated ceramic media to obtain a dispersed SmFeN-based anisotropic magnetic powder; mixing the dispersed SmFeN-based anisotropic magnetic powder with a modifier powder to obtain a powder mixture; compacting the powder mixture in a magnetic field to obtain a magnetic field compact; pressure-sintering the magnetic field compact to obtain a sintered compact; and heat-treating the sintered compact.

Method of producing SmFeN-based rare earth magnet

A method of producing a SmFeN-based rare earth magnet, the method including: dispersing a SmFeN-based anisotropic magnetic powder comprising Sm, Fe, and N using a resin-coated metal media or a resin-coated ceramic media to obtain a dispersed SmFeN-based anisotropic magnetic powder; mixing the dispersed SmFeN-based anisotropic magnetic powder with a modifier powder to obtain a powder mixture; compacting the powder mixture in a magnetic field to obtain a magnetic field compact; pressure-sintering the magnetic field compact to obtain a sintered compact; and heat treating the sintered compact.

The present invention is a method for producing a rare earth magnet, including preparing a magnetic powder and a modifier powder, mixing them to obtain a mixed powder, compression-molding the mixed powder in a magnetic field to obtain a magnetic-field molded body, and pressure-sintering the magnetic-field molded body to obtain a sintered body, wherein the magnetic powder includes a first particle group and a second particle group, the Dvalues of the first particle group and the second particle group are denoted by dμm and dμm, respectively, dand dsatisfy the relationship of 0.350≤d/d≤0.500, and the ratio between the total volume of the first particle group and the total volume of the second particle group is from 9:1 to 4:1; and a rare earth magnet obtained by the production method.

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 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

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.

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.

Growing community of inventors

Susono, Japan

Masaaki Ito