TW201603058A - Dynamo-electric machine permanent magnet, method for manufacturing dynamo-electric machine permanent magnet, dynamo-electric machine, and method for manufacturing dynamo-electric machine - Google Patents

Abstract

Provided is a dynamo-electric machine permanent magnet with which it is possible to accurately and securely fix a permanent magnet to a rotor of a surface magnet dynamo-electric machine in a position designed in advance. Also provided are a method for manufacturing the dynamo-electric machine permanent magnet, a dynamo-electric machine in which the dynamo-electric machine permanent magnet is used, and a method for manufacturing a dynamo-electric machine. A compound (12) is created by crushing magnetic raw material into a magnetic powder and mixing the crushed magnetic powder and a binder. Also, a green sheet (14) is produced by molding the compound (12) that was created into a sheet-shape. Afterwards, a permanent magnet (1) is manufactured by molding a molded body (31) in which a to-be-engaged unit (4), which is to be engaged to an engaging unit (3) formed on a surface of a rotor (2), is formed from the molded green sheet (14) on a surface in contact with a surface of the rotor (2), and by sintering the molded body (31).

Description

Permanent magnet for rotating electric machine, method for manufacturing permanent magnet for rotating electric machine, manufacturing method for rotating electric machine and rotating electric machine

The present invention relates to a method for producing a permanent magnet for a rotating electrical machine and a permanent magnet for a rotating electrical machine, and a method for manufacturing a rotating electrical machine and a rotating electrical machine using a permanent magnet for a rotating electrical machine.

In recent years, a machine that converts mechanical motion energy transmitted from an engine or the like into electric energy or a motor (electric motor) that converts electrical energy into mechanical motion energy has been widely used in work machines, vehicles, aircrafts, wind power motives, and the like. Motor. Here, the surface magnet type rotating electric machine which is one of the rotating electric machines is a rotating electric machine to which a magnet is attached to the surface of the rotor, and it is possible to achieve high output and high efficiency with a relatively simple configuration.

For example, Japanese Laid-Open Patent Publication No. 2009-27846 discloses a surface magnet type motor in which a plurality of fan-shaped permanent magnets are disposed around a rotor.

[Previous Technical Literature] [Patent Literature]

[Patent Document 1] Japanese Patent Laid-Open Publication No. 2009-27846 (page 5, Fig. 1)

Here, as shown in FIG. 10, the prior surface magnet type rotating electrical machine is constructed by attaching a plurality of permanent magnets 102 of a fan shape to the surface of the rotor 101. Moreover, the rotating electric machine also seeks low torque ripple, so it is important to suppress the relative magnet 102 relative to each other. Positional deviation at the design location. For example, in order to set the torque ripple to 0.5% or less, it is necessary to suppress the positional deviation of the permanent magnet 102 with respect to the design position to 5 μm or less. However, the previous configuration of attaching a permanent magnet to the surface of the rotor makes it difficult to accurately position the permanent magnet for the rotor.

Further, in general, the rotor 101 and the permanent magnet 102 are fixed using an adhesive, but it is not easy to properly fix the permanent magnet 102 to the rotor 101 only by the adhesive. For example, if more adhesive is used, the spilled adhesive will adversely affect the motor. On the other hand, if the amount of the adhesive is small, there is a possibility that the permanent magnet 102 is detached from the rotor 101 which is rotated at a high speed, or the position of the permanent magnet 102 is displaced.

The present invention has been made to solve the above problems, and an object of the present invention is to provide a permanent magnet for a rotating electrical machine, a method for manufacturing a permanent magnet for a rotating electrical machine, and a method for manufacturing a rotating electrical machine and a rotating electrical machine using a permanent magnet for a rotating electrical machine. The rotor of the surface magnet type rotating electric machine can be accurately and firmly fixed to a pre-designed position, and can realize high output, high efficiency, and low torque pulse of the surface magnet type rotating electric machine.

A permanent magnet for a rotating electrical machine according to the present invention for achieving the above object is characterized in that it is disposed on a permanent magnet of a surface of a surface of a magnet-type rotating electrical machine, and is formed on the surface in contact with the surface of the rotor. The engaged portion of the engaging portion of the rotor surface is engaged with the engaging portion.

Further, the permanent magnet for a rotating electrical machine according to the present invention is characterized in that the magnet raw material is pulverized into a magnet powder; a mixture obtained by mixing the pulverized magnet powder and a binder is formed; and the mixture is formed into The molded body having the above-mentioned engaged portion; and sintering is performed by holding the molded body at a firing temperature in a state of being pressed in one axial direction.

Further, the permanent magnet for a rotating electrical machine of the present invention is characterized in that the above-mentioned forming In the step of sintering the body, the formed body is pressed in a direction in which it is placed in the same direction as the axial direction of the rotor when disposed on the surface of the rotor.

Further, in the permanent magnet for a rotating electrical machine according to the present invention, the binder comprises a thermoplastic resin, and the residue of the mixture produced by the step of molding the molded body is heated to reuse the residue. The above mixture for forming the above shaped body.

Further, the permanent magnet for a rotating electrical machine according to the present invention is characterized in that a plurality of the engaged portions are formed.

Further, the rotary electric machine according to the present invention is characterized in that a permanent magnet is disposed on a surface of the rotor; and the permanent magnet is formed on a surface in contact with the surface of the rotor, and is engaged with a engaging portion formed on a surface of the rotor. unit.

Moreover, the method for producing a permanent magnet for a rotating electrical machine according to the present invention is characterized in that it is a method for producing a permanent magnet disposed on a surface of a rotor of a surface magnet-type rotating electrical machine, and has the following steps: pulverizing a magnet raw material into a magnet powder; a mixture of the pulverized magnet powder and a binder; forming the mixture into a molded body; and sintering by maintaining the firing temperature in a state of being pressed in one axial direction; and The molded body has an engaged portion that engages with an engaging portion formed on the surface of the rotor on a surface in contact with the surface of the rotor.

Further, in the method of producing a permanent magnet for a rotating electrical machine according to the present invention, in the step of sintering the formed body, the forming is performed in the same direction as the axial direction of the rotor when disposed on the surface of the rotor. Sintering is performed in a state of body pressurization.

Moreover, the method of manufacturing a permanent magnet for a rotating electrical machine according to the present invention is characterized in that a plurality of the engaged portions are formed.

Moreover, the method for producing a permanent magnet for a rotating electrical machine according to the present invention is characterized in that the binder comprises a thermoplastic resin; and the residue of the mixture produced by the step of molding the molded body is heated to leave the residue. Reuse for forming The above mixture of the above shaped bodies.

Moreover, the manufacturing method of the rotary electric machine according to the present invention is characterized in that the permanent magnet is manufactured by the following steps: the magnet material is pulverized into a magnet by a permanent magnet disposed on the surface of the rotor. a powder; a mixture obtained by mixing the pulverized magnet powder and a binder; forming the mixture into a molded body; and maintaining the firing temperature in a state of being pressed in one axial direction Sintering; and the formed body is formed with an engaged portion that engages with an engaging portion formed on the surface of the rotor on a surface in contact with the surface of the rotor.

According to the permanent magnet for a rotating electrical machine according to the present invention having the above configuration, since the engaged portion that engages with the engaging portion formed on the surface of the rotor is formed on the surface in contact with the surface of the rotor of the rotating electrical machine, the engaging portion is engaged. The portion is engaged with the engaged portion to accurately position the permanent magnet to the pre-designed position of the rotor. Moreover, since the contact area between the permanent magnet and the rotor can be increased, the permanent magnet can be firmly fixed to the rotor. As a result, even when the rotor is rotated at a high speed, the positional deviation of the permanent magnet with respect to the rotor can be prevented.

Further, according to the permanent magnet for a rotating electrical machine of the present invention, since the molded body is formed by mixing a mixture of the magnet powder and the binder by molding, the post-aligning magnet particles are used as compared with the case of using the previous powder molding or the like. It will not be rotated and the alignment will be improved. Further, when the magnetic field is aligned with the mixture of the magnet powder and the binder, since the number of current turns can be utilized, the magnetic field strength at the time of the magnetic field alignment can be ensured to be large, and the magnetic field can be applied for a long time in the static magnetic field. Therefore, a higher degree of alignment with less deviation can be achieved. Further, it is possible to achieve a high alignment with less variation and a reduction in shrinkage deviation due to sintering. That is, the uniformity of the shape of the product after sintering can be ensured. As a result, the burden on the outer shape processing after sintering can be alleviated. Moreover, the engaged portion can be easily formed as compared with the prior powder forming, and since the formed engaged portion does not occur in the subsequent manufacturing steps Since the deformation is largely performed, the engagement between the engaging portion and the engaged portion can be appropriately performed.

Further, since the permanent magnet for a rotating electrical machine according to the present invention is sintered in a state in which the molded body is pressed in the same direction as the axial direction of the rotor, the shrinkage due to sintering is uniform, thereby preventing generation of the permanent magnet. Deformation such as warpage or depression after sintering. As a result, even when the permanent magnet has a complicated shape in which the engaged portion is formed, the permanent magnet can be manufactured with high precision.

Further, according to the permanent magnet for a rotating electrical machine of the present invention, even when a mixture of a magnet powder and a binder is processed into a molded body having a complicated shape, a part of the residue generated by the processing can be regenerated into a part of the mixture. Therefore, the yield can be prevented from decreasing.

Further, according to the permanent magnet for a rotating electrical machine of the present invention, the permanent magnet can be firmly fixed to the rotor by providing a plurality of engaged portions. As a result, even when the rotor is rotated at a high speed, the positional deviation of the permanent magnet with respect to the rotor can be prevented.

Further, according to the rotary electric machine of the present invention, it is possible to achieve higher torque, smaller size, lower torque ripple, and higher efficiency of the rotary electric machine than before.

Further, according to the method of manufacturing a permanent magnet for a rotating electrical machine according to the present invention, since the engaged portion that engages with the engaging portion formed on the surface of the rotor is formed on the surface in contact with the surface of the rotor of the rotating electrical machine, the card is engaged. The engagement of the hinge with the engaged portion allows the permanent magnet to accurately position the rotor at a pre-designed position. Moreover, since the contact area between the permanent magnet and the rotor can be increased, the permanent magnet can be firmly fixed to the rotor. As a result, even when the rotor is rotated at a high speed, the positional deviation of the permanent magnet with respect to the rotor can be prevented.

Further, since the molded body is formed by mixing a mixture of the magnet powder and the binder by molding, the magnet particles after the alignment are not rotated and can be improved as compared with the case of using the previous powder molding or the like. Orientation. Further, when the magnetic field is aligned with the mixture of the magnet powder and the binder, since the number of current turns can be utilized, the magnetic field strength at the time of the magnetic field alignment can be ensured to be large, and the magnetic field can be applied for a long time in the static magnetic field. , Thereby, a higher degree of alignment with less deviation can be achieved. Further, it is possible to achieve a high alignment with less variation and a reduction in shrinkage deviation due to sintering. That is, the uniformity of the shape of the product after sintering can be ensured. As a result, the burden on the profile processing after sintering can be alleviated. Further, the engaged portion can be easily formed as compared with the prior art powder forming, and since the formed engaged portion does not undergo a large degree of deformation in the subsequent manufacturing step, the engagement can be appropriately performed. The part is engaged with the engaged part.

Further, according to the method for producing a permanent magnet for a rotating electrical machine according to the present invention, since the molded body is pressed in a direction in which the molded body is pressed in the same direction as the axial direction of the rotor, the shrinkage due to sintering becomes uniform. It can prevent deformation such as warpage or depression after sintering. As a result, even when the permanent magnet has a complicated shape in which the engaged portion is formed, the permanent magnet can be manufactured with high precision.

Further, according to the method of manufacturing a permanent magnet for a rotating electrical machine according to the present invention, the permanent magnet can be firmly fixed to the rotor by providing a plurality of engaged portions. As a result, even when the rotor is rotated at a high speed, the positional deviation of the permanent magnet with respect to the rotor can be prevented.

Further, according to the method for producing a permanent magnet for a rotating electrical machine according to the present invention, even when a mixture of a magnet powder and a binder is processed into a molded body having a complicated shape, the residue due to the processing can be partially regenerated into One part of the mixture prevents the yield from falling.

Further, according to the method for manufacturing a rotating electrical machine of the present invention, it is possible to achieve higher torque, smaller size, lower torque ripple, and higher efficiency of the manufactured rotating electrical machine than before.

1‧‧‧ permanent magnet

2‧‧‧Rotor

3‧‧‧Clock Department

4‧‧‧Be jammed

10‧‧‧Magnetic powder

11‧‧‧Bead mill

12‧‧‧ compounds

13‧‧‧Support substrate

14‧‧ ‧Mason

15‧‧‧Mold

22‧‧‧Applicator roller

25‧‧‧ Solenoid

26‧‧‧heating plate

27‧‧‧ arrow symbol

31‧‧‧Formed body

32‧‧‧Sintered body

42‧‧‧Axis

43‧‧‧ Stator

45‧‧‧SPM motor

101‧‧‧Rotor

102‧‧‧ permanent magnet

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a general view showing a permanent magnet of the present invention.

Fig. 2 is a view showing a state in which a permanent magnet is fixed to a rotor.

Fig. 3 is a view showing another shape of the engaged portion formed in the permanent magnet.

Fig. 4 is a view showing another shape of the engaged portion formed in the permanent magnet.

Fig. 5 is an explanatory view showing a manufacturing step of the permanent magnet of the present invention.

Fig. 6 is an explanatory view showing, in particular, a heating step and a magnetic field aligning step of the green sheet in the manufacturing process of the permanent magnet of the present invention.

Fig. 7 is a view for explaining a molding step of a molded body.

Fig. 8 is a view for explaining a heating state of a particularly baking step in the manufacturing process of the permanent magnet of the present invention.

Fig. 9 is an explanatory view showing a manufacturing procedure of the SPM motor of the present invention.

Fig. 10 is a diagram for explaining problems of the prior art.

In the following, an embodiment of the permanent magnet for a rotating electrical machine and a permanent magnet for a rotating electrical machine according to the present invention will be described in detail below with reference to the drawings.

[Composition of permanent magnets]

First, the configuration of the permanent magnet 1 corresponding to the permanent magnet for a rotating electrical machine according to the present invention will be described. Figure 1 is a general view showing a permanent magnet 1 of the present invention. Further, as shown in Fig. 1, the permanent magnet 1 of the present invention has a segment-shaped permanent magnet. Further, as shown in FIG. 2, a plurality of surfaces of the rotor 2 of a surface magnet type rotary electric machine (motor or generator) are arranged to form a surface magnet type rotary electric machine. 2 is a view showing the rotor 2 of the SPM motor in which the permanent magnet 1 is disposed. In the following embodiments, an example in which the permanent magnet 1 is a fan-shaped permanent magnet will be described. However, the shape of the permanent magnet 1 can be appropriately determined according to the shape or arrangement number of the rotor 2 to be placed. change. For example, it may be a fan shape, a ring shape, a bow shape, or a square shape.

Further, the permanent magnet 1 of the present invention contains a Nd-Fe-B based magnet. Further, the content of each component is: Nd: 27 to 40% by weight, B: 0.8 to 2% by weight, and Fe (electrolytic iron): 60 to 70% by weight. Moreover, in order to improve magnetic properties, a small amount of Dy, Tb, Co, Cu, or Other elements such as Al, Si, Ga, Nb, V, Pr, Mo, Zr, Ta, Ti, W, Ag, Bi, Zn, Mg, and the like.

Further, the number of the permanent magnets 1 relative to the rotor 2 is equal to the number of poles formed around the rotor 2, for example, when the number of poles is set to 8 poles, as shown in FIG. 2, 8 permanent The magnets 1 are arranged at equal intervals with respect to the rotor 2. Further, on the surface of the permanent magnet 1 that is in contact with the surface of the rotor 2, the engaged portion 4 that engages with the engaging portion 3 formed on the surface of the rotor 2 is formed.

Here, in the example shown in FIG. 1 and FIG. 2, the engaged portion 4 formed in the permanent magnet 1 is a convex-shaped leg member formed at both end portions of the rotor 2 in the circumferential direction, and The engaging portion 3 formed in the rotor 2 is an insertion hole into which the leg member is inserted. Further, in a state in which the engaged portion 4 of the permanent magnet 1 is engaged with the engaging portion 3 of the rotor 2, the permanent magnet 1 is configured to be positioned at a predetermined design position with respect to the rotor 2. In other words, as shown in FIG. 2, eight permanent magnets 1 are placed so that the engaging portion 3 and the engaged portion 4 are engaged with each other, and the permanent magnet 1 and the rotor 2 are fixed by an adhesive or the like, whereby the permanent magnet 1 can be permanently fixed. The magnet 1 is accurately positioned at the design position and fixed to the rotor 2. Further, since the area where the permanent magnet 1 abuts against the rotor 2 is increased by forming the engaging portion 3 and the engaged portion 4, the permanent magnet 1 can be made to the rotor 2 when the adhesive is fixed. Securely fixed.

Further, in the example shown in FIG. 2, the engaged portion 4 formed in the permanent magnet 1 is formed in two places for one permanent magnet 1, but the engaged portion 4 may be set only It is formed in one place or formed in three or more places. Further, it is also possible to form a configuration in which only the permanent magnet 1 is formed by forming the engaged portion 4 for all of the permanent magnets 1 disposed in the rotor 2. Moreover, in the example shown in FIG. 2, the engaging portion 3 is formed in a concave shape, and the engaged portion 4 is formed in a convex shape. However, the engaging portion 3 may be formed in a convex shape and the engaged portion may be engaged. 4 is set to a concave shape.

Moreover, the size or shape of the engaging portion 3 and the engaged portion 4 can be appropriately changed.

For example, as shown in FIG. 3, the shape of the engaging portion 3 and the engaged portion 4 may be a concavo-convex shape continuously formed on the abutting surface. Further, it may be a wedge shape as shown in FIG. again If the wedge shape is as shown in FIG. 4, the permanent magnet 1 and the rotor 2 can be fixed without using an adhesive. Further, as described below, when the permanent magnet 1 is formed using the blank molded body, it can be easily formed into a complicated shape as shown in Fig. 3 or Fig. 4 . Further, when sintering is performed by pressure sintering, the shrinkage of the molded body due to sintering becomes uniform. Therefore, the permanent magnet after sintering does not undergo warpage or deformation such as depression, and the dimensional accuracy of the permanent magnet after sintering is improved. Therefore, the shape correcting process of the permanent magnet after sintering is not required, and the engaging portion 3 and the engaged portion 4 can be appropriately engaged.

Further, the permanent magnet 1 is formed by sintering a molded body (embryo molded body) obtained by molding a mixture of a magnet powder and a binder as follows. Further, it is also possible to adopt a configuration in which the mixture is not directly molded into a final product shape (for example, a fan shape as shown in FIG. 1), and is temporarily formed into a shape other than the final product shape (for example, a sheet shape, a block shape, etc.). Then, punching, cutting, deformation processing, and the like are performed to form a final product shape. Further, in particular, when the mixture is temporarily formed into a sheet shape and processed into a final product shape, the production is carried out in a continuous step, so that productivity can be improved and the molding precision can be improved. In the case where the mixture is in the form of a sheet, for example, a film member having a film thickness of 0.05 mm to 10 mm (for example, 1 mm) is used. Further, even in the case of a sheet shape, a large permanent magnet 1 can be produced by laminating a plurality of sheets.

On the other hand, in the present invention, particularly in the case of producing the permanent magnet 1, the binder mixed in the magnet powder is a resin, a long-chain hydrocarbon, a fatty acid ester or the like, or the like.

Further, in the case where a resin is used for the binder, it is preferred to use a plasma which does not contain oxygen atoms in the structure and which has depolymerization property. Further, as described below, in order to reuse the residue of the mixture generated when the mixture of the magnet powder and the binder is formed into a desired shape (for example, a fan shape), and to soften the mixture in order to heat the mixture, The magnetic field is aligned and a thermoplastic resin is used. Specifically, a polymer selected from the following formula (1) One or more of the polymers or polymers containing the copolymers are eligible.

(wherein R1 and R2 represent a hydrogen atom, a lower alkyl group, a phenyl group or a vinyl group)

As the polymer satisfying the above conditions, for example, a polymer of isobutylene, that is, polyisobutylene (PIB); a polymer of isoprene, that is, polyisoprene (isoprene rubber, IR); 1, 3 - a polymer of butadiene, ie polybutadiene (butadiene rubber, BR); a polymer of styrene, ie polystyrene; a copolymer of styrene and isoprene, ie styrene-isoprene Diene block copolymer (SIS); copolymer of isobutylene and isoprene, ie butyl rubber (IIR); copolymer of styrene and butadiene, ie styrene-butadiene block copolymer ( SBS); a polymer of 2-methyl-1-pentene, ie a polymer of 2-methyl-1-pentene; a polymer of 2-methyl-1-butene, ie 2-methyl-1- Butylene polymer resin; a polymer of α-methyl styrene, that is, an α-methyl styrene polymer resin or the like. Further, in order to impart flexibility, it is preferred to add a low molecular weight polyisobutylene to the α-methylstyrene polymer resin. Further, the resin used as the binder may be a polymer or copolymer containing a small amount of a monomer having an oxygen atom (for example, polybutyl methacrylate or polymethyl methacrylate ( Composition of Polymethyl methacrylate). Further, a monomer which does not satisfy the above formula (1) may be partially copolymerized. That is, in the case of this situation, the object of the present invention can also be achieved.

Further, the resin used as the binder is preferably a thermoplastic resin which is softened at 250 ° C or lower for the purpose of appropriately performing magnetic field alignment. More specifically, it is preferred to use a glass transition point or a flow initiation temperature of 250. A thermoplastic resin below °C.

On the other hand, in the case of using long-chain hydrocarbons for the binder, it is preferably used in the chamber. A long-chain saturated hydrocarbon (long-chain alkane) which is solid at room temperature and above a room temperature. Specifically, it is preferred to use a long-chain saturated hydrocarbon having a carbon number of 18 or more. Further, as described below, when the mixture of the magnet powder and the binder is subjected to magnetic field alignment, the mixture is subjected to magnetic field alignment in a state where the mixture is heated and softened by a glass transition point or a flow initiation temperature of the long-chain hydrocarbon.

Further, in the case where a fatty acid ester is used for the binder, it is preferably used as a solid at room temperature and liquid at room temperature or higher (Stearic Acid Methyl Ester), or methyl behenate. (Docosanoic Acid Methyl Ester). Further, as described below, when the mixture of the magnet powder and the binder is subjected to magnetic field alignment, the mixture is subjected to magnetic field alignment while heating and softening the mixture at a temperature above the flow initiation temperature of the fatty acid methyl ester.

By using a binder satisfying the above conditions as a binder mixed in the magnet powder, the amount of carbon and the amount of oxygen contained in the magnet can be reduced. Specifically, the amount of carbon remaining in the magnet after sintering is 2,000 ppm or less, more preferably 1,000 ppm or less. Moreover, the amount of oxygen remaining in the magnet after sintering is 5,000 ppm or less, more preferably 2,000 ppm or less.

Further, in order to increase the thickness precision of the molded body when molding the slurry or heating the molten compound, the amount of the binder added is an amount that appropriately fills the gap between the magnet particles. For example, the ratio of the binder to the total amount of the magnet powder and the binder is from 1 wt% to 40 wt%, more preferably from 2 wt% to 30 wt%, still more preferably from 3 wt% to 20 wt%.

[Method of manufacturing permanent magnet]

Next, a method of manufacturing the permanent magnet 1 of the present invention will be described with reference to Fig. 5 . Fig. 5 is an explanatory view showing a manufacturing procedure of the permanent magnet 1 of the embodiment.

First, an ingot containing a specific fraction of Nd-Fe-B (for example, Nd: 32.7 wt%; Fe (electrolytic iron): 65.96 wt%; B: 1.34 wt%) is produced. Thereafter, the ingot is coarsely pulverized to a size of about 200 μm by a masher, a crusher or the like. Alternatively, the ingot is melted, and a flake is produced by a strip casting method, and the powder is pulverized by hydrogen pulverization. Chemical. Thereby, the coarsely pulverized magnet powder 10 can be obtained.

Next, the coarsely pulverized magnet powder 10 is micronized by a wet method using a bead mill 11 or a dry method using a jet mill. For example, in the fine pulverization using the wet method using the bead mill 11, the coarsely pulverized magnet powder 10 is finely pulverized into a specific range of particle diameter (for example, 0.1 μm to 5.0 μm) in a solvent, and the magnet powder is dispersed. In the solvent. Thereafter, the magnet powder contained in the solvent after the wet pulverization is dried by vacuum drying or the like, and the dried magnet powder is taken out. Further, the type of the solvent to be used for the pulverization is not particularly limited, and examples thereof include alcohols such as isopropyl alcohol, ethanol, and methanol, esters such as ethyl acetate, and lower hydrocarbons such as pentane and hexane, and benzene, toluene, and An aromatic compound such as toluene, a ketone, or a mixture thereof or the like. Further, it is preferred to use a solvent which does not contain an oxygen atom in the solvent.

On the other hand, in the fine pulverization using a dry method using a jet mill, (a) an atmosphere containing an inert gas such as nitrogen gas, argon gas (Ar) or helium gas (He) having an oxygen content of substantially 0%. Or, in (b) an atmosphere containing an inert gas such as nitrogen gas, argon gas (Ar) or helium gas (He) having an oxygen content of 0.0001 to 0.5%, the coarsely pulverized magnet powder is micro-pulverized by a jet mill. The pulverization is carried out to obtain a fine powder having an average particle diameter of a specific range of particle diameters (for example, 0.7 μm to 5.0 μm). In addition, the fact that the oxygen concentration is substantially 0% means that the oxygen concentration is not limited to 0%, and oxygen may be contained in an amount such that an oxide film is formed on the surface of the fine powder in a very small amount.

Next, the magnet powder finely pulverized by the bead mill 11 or the like is molded into a desired shape. Further, the formation of the magnet powder is carried out by forming a mixture of the magnet powder and the binder. In the following embodiments, the magnetic field is aligned by applying a magnetic field in a state in which the mixture is temporarily molded into a shape other than the shape of the product, and thereafter, punching, cutting, deformation processing, or the like is performed, thereby forming a product shape ( For example, the fan type shown in Fig. 1). In particular, in the following examples, the mixture was temporarily formed into a sheet-shaped embryo molded body (hereinafter referred to as a green sheet), and then formed into a product shape. Further, in the case where the mixture is particularly formed into a sheet shape, there is a forming by, for example, hot-melt coating or slurry coating, and hot-melt coating Applying a compound obtained by mixing a heated magnet powder and a binder to form a sheet shape, and applying the slurry to a substrate by applying a slurry containing a magnet powder, a binder, and an organic solvent. Formed into a sheet.

Hereinafter, the formation of the green sheet using hot melt coating will be specifically described.

First, a clay-like mixture (compound) 12 containing a magnet powder and a binder is produced by mixing a binder with a magnet powder finely pulverized by a bead mill 11 or the like. Here, as the binder, as described above, a resin, a long-chain hydrocarbon, a fatty acid ester or a mixture thereof or the like is used. For example, in the case of using a resin, it is preferred to use a thermoplastic resin which does not contain oxygen atoms in the structure and which contains a polymer having depolymerization property, and on the other hand, in the case of using a long-chain hydrocarbon, it is preferably used in the case of using a resin. A long-chain saturated hydrocarbon (long-chain alkane) which is solid at room temperature and liquid above room temperature. Further, in the case of using a fatty acid ester, methyl stearate or methyl behenate or the like is preferably used. Further, the amount of the binder added is as described above, and the ratio of the binder in the compound 12 after the addition to the total amount of the magnet powder and the binder is from 1% by weight to 40% by weight, more preferably from 2% by weight to 30% by weight. %, further preferably from 3 wt% to 20 wt%.

Further, in order to increase the degree of alignment in the magnetic field alignment step to be performed later, an additive which contributes to alignment may be added to the above compound 12. As the additive which contributes to the alignment, for example, a hydrocarbon-based additive is used, and it is particularly preferable to use an additive having a polarity (specifically, an acid dissociation constant pKa of less than 41). Further, the amount of the additive to be added depends on the particle diameter of the magnet powder, and the smaller the particle diameter of the magnet powder, the more the amount of addition is required. The specific addition amount is 0.1 parts to 10 parts, more preferably 1 part to 8 parts, per part of the magnet powder. Further, the additive added to the magnet powder adheres to the surface of the magnet particles, and has an effect of assisting the rotation of the magnet particles in the magnetic field alignment treatment described below. As a result, the alignment can be easily performed when a magnetic field is applied, and the easy magnetization axes of the magnet particles can be unified in the same direction (that is, the alignment degree is improved). In particular, when a binder is added to the magnet powder, since the binder is present on the surface of the particle, the frictional force at the time of alignment increases, and the orientation of the particles decreases. Therefore, the effect of adding an additive becomes larger.

Further, the addition of the binder is carried out in an atmosphere containing an inert gas such as nitrogen, Ar gas or He gas. Further, the mixing of the magnet powder and the binder is carried out by, for example, feeding the magnet powder and the binder to a stirrer and stirring it with a stirrer. Further, in order to promote kneading, heating and stirring may be performed. Further, the mixing of the magnet powder and the binder is preferably carried out in an atmosphere containing an inert gas such as nitrogen gas, Ar gas or He gas. Further, in particular, when the magnet powder is pulverized by a wet method, the magnet powder may be taken out from the solvent used for the pulverization, and the binder may be added to the solvent and kneaded. Thereafter, The solvent was volatilized to obtain the following compound 12.

Then, the embryonic sheet was prepared by forming the compound 12 into a sheet shape. In particular, in the hot melt coating, the compound 12 is melted by heating the compound 12 to form a liquid, and then applied to a support substrate 13 such as a separator. Thereafter, heat is radiated to solidify, whereby a long sheet-like lamella 14 is formed on the support substrate 13. Further, the temperature at which the compound 12 is heated and melted differs depending on the type or amount of the binder to be used, but is set to 50 to 300 °C. However, it must be set to a temperature higher than the flow initiation temperature of the binder used. Further, in the case of coating with a slurry, the magnet powder and the binder (which may further contain an additive which contributes to alignment) are dispersed in a large amount of solvent, and the slurry is applied to a support base such as a spacer. On the material 13. Thereafter, drying is carried out to volatilize the solvent, whereby a long sheet-like green sheet 14 is formed on the support substrate 13.

Here, the method of applying the molten compound 12 is preferably a method in which thickness controllability such as a slit die method or a calender roll method is excellent. In particular, in order to achieve high thickness precision, it is particularly preferable to use a stamper method or a doctor blade method which is excellent in thickness controllability (that is, a layer which can apply a layer of high precision to the surface of the substrate). For example, in the slit die method, the compound 12 heated to be fluid is extruded by a gear pump and inserted into a mold to perform coating. Further, in the calender roll method, a fixed amount of the compound 12 is fed into the gap between the two heated rolls, and the roll is rotated while supporting the substrate 13 The compound 12 which is melted by the heat of the roll is applied. Further, as the support substrate 13, for example, a polyester film is treated with polyfluorene. Further, it is preferred to use an antifoaming agent or to perform defoaming treatment by heating vacuum defoaming or the like so as not to leave air bubbles in the developed layer. Further, the compound 12 may be formed into a sheet shape by extrusion molding or injection molding without applying the compound 12 to the support substrate 13, and extruded to the support substrate 13 . Thereby, the green sheet 14 is formed on the support substrate 13.

Further, in the step of forming the green sheet 14 by the slit mold method, it is preferable to actually measure the sheet thickness of the coated green sheet, and feedback the gap between the mold 15 and the support substrate 13 based on the measured value. control. Further, it is preferable to reduce the fluctuation of the amount of the liquid compound 12 supplied to the mold 15 as much as possible (for example, to suppress the variation of ±0.1% or less), and to suppress the fluctuation of the coating speed as much as possible (for example, the suppression is ±0.1). % change below). Thereby, the thickness precision of the green sheet 14 can be further improved. Further, the thickness accuracy of the green sheet 14 to be formed is set to within ±10% with respect to the design value (for example, 1 mm), more preferably within ±3%, and even more preferably within ±1%. Further, in another calender roll method, the film thickness of the transfer compound 12 to the support substrate 13 can be controlled by controlling the calendering conditions based on the measured values as well.

Further, it is preferable to set the thickness of the green sheet 14 to a thickness of 0.05 mm to 20 mm. If the thickness is made thinner than 0.05 mm, it is necessary to carry out multilayer lamination, which leads to a decrease in productivity.

Next, the magnetic field alignment of the green sheets 14 formed on the support substrate 13 by the above-described hot melt coating is performed. Specifically, first, the green sheet 14 is softened by heating the green sheet 14 which is continuously conveyed together with the support substrate 13. Specifically, the viscosity of the green sheet 14 to the green sheet 14 is 1 to 1500 Pa‧s, more preferably 1 to 500 Pa‧s. Thereby, the magnetic field alignment can be appropriately performed.

Further, the temperature and time when the green sheet 14 is heated differ depending on the type or amount of the binder to be used, but it is, for example, 100 to 250 ° C and 0.1 to 60 minutes. However, in order to soften the green sheet 14, it must be set to the glass transition point or flow initiation temperature of the adhesive used. The temperature above. Further, as a heating method for heating the green sheet 14, there is, for example, a heating method using a hot plate or a heating method using a heat medium (polyoxygenated oil) as a heat source. Next, magnetic field alignment is performed by applying a magnetic field to the in-plane direction and the longitudinal direction of the green sheet 14 softened by heating. The intensity of the applied magnetic field is set to 5000 [Oe] to 15000 [Oe], preferably 10000 [Oe] to 120,000 [Oe]. As a result, the C-axis (easy magnetization axis) of the magnet crystals included in the green sheet 14 is aligned in one direction. Further, as a direction in which the magnetic field is applied, a magnetic field may be applied to the in-plane direction and the width direction of the green sheet 14. Further, it is also possible to adopt a configuration in which a magnetic field is simultaneously applied to the plurality of green sheets 14.

Further, a configuration may be adopted in which a magnetic field is applied to the green sheet 14 and a step of applying a magnetic field simultaneously with the heating step, or a step of applying a magnetic field may be performed after the heating step and before the green sheet is solidified. Further, it is also possible to adopt a configuration in which magnetic field alignment is performed before the coated green sheet 14 is solidified by hot melt coating. In this case, no heating step is required.

Next, the heating step and the magnetic field alignment step of the green sheet 14 will be described in more detail with reference to FIG. Fig. 6 is a schematic view showing a heating step and a magnetic field alignment step of the green sheet 14. Further, in the example shown in Fig. 6, an example in which the magnetic field alignment step is performed simultaneously with the heating step will be described.

As shown in Fig. 6, the heating and the magnetic field alignment of the green sheet 14 applied by the slit die method are performed on the long sheet-shaped green sheets 14 in a state in which the rolls are continuously conveyed. That is, the apparatus for performing heating and magnetic field alignment is disposed on the downstream side of the coating apparatus (mold or the like), and is carried out by a step that is continuous with the coating step.

Specifically, on the downstream side of the mold 15 or the application roller 22, the solenoid 25 is placed such that the supported support substrate 13 and the green sheet 14 pass through a solenoid 25. Further, the heating plate 26 is disposed in the solenoid 25 with respect to the green sheet 14 in a pair. Then, the green sheet 14 is heated by the pair of upper and lower heating plates 26, and an electric current flows through the solenoid 25, thereby being in the in-plane direction of the elongated sheet-like green sheet 14 (i.e., parallel to the green sheet). The direction of the one-sided plane of 14) and the magnetic field is generated in the longitudinal direction. Thereby, the continuously transported embryo is heated by heating The softening 14 applies a magnetic field to the in-plane direction and the longitudinal direction of the softened green sheet 14 (the direction of the arrow 27 in Fig. 6), so that proper and uniform magnetic field alignment of the green sheet 14 can be achieved. In particular, the surface of the green sheet 14 can be prevented from fluffing by setting the direction in which the magnetic field is applied to the in-plane direction.

Further, heat dissipation and solidification of the green sheet 14 after the magnetic field alignment is preferably performed in a conveyed state. Thereby, the production steps can be made more efficient.

Further, when the magnetic field is aligned in the in-plane direction and the width direction of the green sheet 14, a pair of magnetic field coils are disposed on the right and left sides of the transferred green sheet 14 instead of the solenoid 25. Further, by causing a current to flow through the respective field coils, a magnetic field can be generated in the in-plane direction and the width direction of the elongated sheet-like green sheet 14.

Further, the magnetic field alignment may be set to be perpendicular to the surface of the green sheet 14. When the magnetic field alignment is performed in the vertical direction with respect to the surface of the green sheet 14, it is performed by, for example, a magnetic field applying device using a magnetic pole piece. In the case where the direction in which the magnetic field is aligned is perpendicular to the surface of the green sheet 14, it is preferable to laminate the film on the surface opposite to the side of the support substrate 13 with respect to the green sheet 14. Thereby, the surface of the green sheet 14 can be prevented from fluffing.

Further, instead of using the heating method of the heating plate 26, a heating method using a heat medium (polyoxygenated oil) as a heat source may be used.

Here, in the case where the green sheet is formed by a liquid material having a high fluidity such as a slurry, a general-purpose slit mold method or a doctor blade method is not used, and a magnetic field gradient is generated. When the green sheet 14 is carried, the magnet powder contained in the green sheet 14 is attracted to the stronger magnetic field side, and the liquid phase which causes the slurry forming the green sheet 14 is generated, that is, the thickness deviation of the green sheet 14 is generated. On the other hand, when the compound 12 is formed into the green sheet 14 by hot melt forming as in the present invention, the viscosity at room temperature reaches tens of thousands to hundreds of thousands of Pa‧ s, and no magnetic field gradient is passed. The offset of the magnetic powder. Further, it is conveyed to a uniform magnetic field, and the viscosity of the adhesive is lowered by heating, and the same C-axis alignment can be realized only by the rotational torque in the uniform magnetic field.

Moreover, instead of using hot melt forming, a general slit die method or a scraper is used. When a liquid material having a high fluidity such as a slurry containing an organic solvent is molded into the green sheet 14 or the like, if a film having a thickness of more than 1 mm is to be formed, the organic solvent contained in the slurry or the like during drying is required. The bubbles generated by the gasification become a problem. Further, if the drying time is prolonged in order to suppress the bubbles, sedimentation of the magnet powder occurs, and a variation in density distribution of the magnet powder with respect to the direction of gravity occurs, which causes warpage after firing. Therefore, since the upper limit of the thickness is substantially limited in the molding from the slurry, the green sheet 14 must be formed to a thickness of 1 mm or less, and then laminated. However, in this case, the adhesion of the adhesives to each other is insufficient, resulting in interlayer peeling in the subsequent debonding step (baking treatment), which results in a decrease in the alignment of the C-axis (easy magnetization axis), that is, the residual magnetic flux density. (Br) Reason for the decrease. On the other hand, when the compound 12 is formed into the green sheet 14 by hot melt forming as in the present invention, since the organic solvent is not contained, even if a sheet having a thickness of more than 1 mm is formed, the foaming as described above is eliminated. Worry. Moreover, since the adhesive is in a state of being sufficiently bonded, there is no fear that interlayer glass is generated in the debonding step.

In the case where a plurality of magnetic sheets are simultaneously applied to the plurality of pieces, the plurality of sheets (for example, six pieces) of the green sheets 14 are continuously conveyed, and the laminated green sheets 14 are passed through the solenoids 25, for example. Composition. Thereby, productivity can be improved.

Then, after the magnetic field alignment of the green sheet 14 is performed by the method shown in Fig. 6, the green sheet 14 is perforated or deformed, whereby the molded body 31 having a desired shape is formed. Further, the magnetic field alignment may be configured not for the green sheet 14, but also for the molded body 31 after punching or deformation. Further, the magnetic field alignment or formation of the shaped body 31 is such that the direction of the easy axis of magnetization required for the final article (e.g., radial alignment, polar anisotropic alignment, etc.) is achieved.

Further, when the molded body 31 is molded, the engaged portion 4 that engages with the engaging portion 3 formed on the surface of the rotor 2 is formed on the surface that is placed in contact with the surface of the rotor 2 when placed on the rotary electric machine. The engaged portion 4 is, for example, a convex leg-shaped member that is formed at both end portions of the rotor 2 in the circumferential direction. Further, the engaged portion 4 may be integrally formed with the molded body 31, or only the portion to be engaged by the engaging portion 4 may be separately formed. Furthermore, in the case of separate forming, as shown in FIG. The formed engaged portion 4 and the molded body 31 are joined to each other by an adhesive, a plasticizer, thermocompression bonding or the like to form a molded body having a final product shape. Further, since the production method of the present invention is used for forming an embryo body in which a binder is added to a magnet powder, it is possible to appropriately bond the molded bodies to each other as compared with the case of using a general powder molding.

Further, the residue portion of the green sheet 14 which is produced by the step of molding the molded body 31 can be reused as the compound 12 which is melted by heating to a flow initiation temperature of the adhesive or more. As a result, the residue portion to be reused is partially reproduced as one of the green sheets 14. Therefore, even when formed into a complicated shape, the yield is not lowered.

Then, the shaped body 31 is pressurized to atmospheric pressure, or pressurized to a high pressure or low pressure (for example, 1.0 Pa or 1.0 MPa) in a non-oxidizing atmosphere (especially in the present invention, hydrogen atmosphere or hydrogen and inertness). In the mixed gas atmosphere of the gas, the baking treatment is carried out at a binder decomposition temperature for several hours to several tens of hours (for example, five hours). In the case of performing under a hydrogen atmosphere, for example, the supply amount of hydrogen in the baking is set to 5 L/min. By performing the calcination treatment, an organic compound such as a binder can be decomposed into a monomer by a depolymerization reaction or the like and dispersed. That is, so-called decarburization which reduces the amount of carbon in the molded body 31 can be performed. In addition, the calcination treatment is carried out under the conditions that the amount of carbon in the molded body 31 is 2,000 ppm or less, more preferably 1,000 ppm or less. Thereby, the entire molded body 31 can be densely sintered in the subsequent sintering treatment, thereby suppressing a decrease in residual magnetic flux density or coercive force. Moreover, when the pressurization condition at the time of performing the said sintering process is carried out by the pressure of the atmospheric pressure, it is preferable to set it as 15 MPa or less. In addition, when the pressure condition is set to a pressure higher than atmospheric pressure, more specifically, 0.2 MPa or more, the effect of lowering the carbon amount can be expected.

Further, the binder decomposition temperature is determined based on the analysis results of the binder decomposition product and the decomposition residue. Specifically, the decomposition product of the binder is collected, and the decomposition product other than the monomer is selected, and the temperature of the product due to the side reaction of the remaining binder component is not detected in the analysis of the residue. range. Depending on the type of adhesive The difference is, but it is set to 200 ° C ~ 900 ° C, more preferably 400 ° C ~ 600 ° C (for example, 450 ° C).

Further, it is preferable that the calcination treatment lowers the temperature increase rate as compared with the case where the general magnet is sintered. Specifically, the temperature increase rate is set to 2 ° C / min or less (for example, 1.5 ° C / min). Therefore, when the baking treatment is performed, the temperature is raised at a specific temperature increase rate of 2 ° C/min or less as shown in FIG. 8 , and after reaching a predetermined set temperature (adhesive decomposition temperature), the set temperature is maintained for several hours to several tens of times. In this case, the baking treatment is performed. As described above, by lowering the temperature increase rate in the calcination process, the carbon in the formed body 31 is not removed violently, but is removed stepwise, so that the density of the permanent magnet after sintering can be increased (i.e., the permanent magnet is reduced). The gap). In addition, when the temperature increase rate is 2 ° C / min or less, the density of the permanent magnet after sintering can be made 95% or more, and high magnet characteristics can be expected.

Further, the molded body 31 calcined by the calcination treatment may be further subjected to a dehydrogenation treatment by being maintained in a vacuum atmosphere. In the dehydrogenation treatment, NdH ₃ (large activity) in the molded body 31 produced by the calcination treatment is gradually changed from NdH ₃ (large activity) to HdH ₂ (small activity), and the calcination is lowered. The activity of the activated molded body 31 is treated. Thereby, even when the molded body 31 fired by the baking process is moved to the atmosphere thereafter, the bonding of Nd and oxygen can be prevented, and the reduction of the residual magnetic flux density or the coercive force can be suppressed. Further, an effect of restoring the structure of the magnet crystal from NdH ₂ or the like to the Nd ₂ Fe ₁₄ B structure can be expected.

Then, a sintering treatment for sintering the molded body 31 fired by the baking treatment is performed. In addition, as a sintering method of the molded body 31, there is a uniaxial pressure sintering in which vacuum is sintered in a state of being pressed in a uniaxial direction, and sintering is performed in a state of being pressed in a biaxial direction. Biaxial pressure sintering, isotropic pressure sintering in which the sintering is performed in an isotropic state, and the like. For example, when the molded body 31 is placed on the surface of the rotor 2, uniaxial pressure sintering is performed in a state of being pressed in a direction in which the axial direction of the rotor 2 is in the same direction. Further, as the pressure sintering, there are, for example, hot press sintering and hot pressure pressurization (HIP) burning. Knot, ultra-high pressure synthetic sintering, gas pressure sintering, discharge plasma (SPS) sintering, and the like. However, it is preferred to use SPS sintering which can be pressed in a single axial direction and sintered by electric conduction sintering. Further, in the case of sintering by SPS sintering, it is preferred to set the heating value to, for example, 0.01 MPa to 100 MPa, and to increase the temperature to 10 ° C/min to 940 ° C in a vacuum atmosphere of several Pa or less, and thereafter to maintain 5 minute. Thereafter, cooling was performed, and heat treatment was again performed at 300 ° C to 1000 ° C for 2 hours. Thus, as a result of the sintering, the sintered body 32 can be produced.

Thereafter, the sintered body 32 is magnetized along the C axis. As a result, the permanent magnet 1 can be manufactured. Further, for the magnetization of the permanent magnet 1, for example, a magnetizing coil, a magnetizing yoke, a capacitor type magnetizing power supply device, or the like is used. Further, the magnetization of the permanent magnet 1 may be configured as follows after being disposed in the rotor 2 of the rotating electrical machine.

Next, a method of manufacturing an SPM motor in which the permanent magnet 1 manufactured by the above-described manufacturing method is disposed on the surface of the rotor will be described.

First, as shown in FIG. 9, a plurality of permanent magnets 1 are disposed on the surface of the rotor 2. Further, when the permanent magnet 1 is placed on the rotor 2, the engaging portion 3 formed in the rotor 2 is engaged with the engaged portion 4 formed in the permanent magnet 1. Thereby, the permanent magnet 1 can be accurately positioned for the rotor 2 at the design position. Thereafter, the rotor 2 and the permanent magnet 1 disposed on the surface are fixed to each other by an adhesive or the like.

Thereafter, members other than the rotor 2 such as the shaft 42 or the stator 43 are assembled. Thereby, the SPM motor 45 can be manufactured.

As described above, in the manufacturing method of the permanent magnet 1 and the permanent magnet 1 of the present embodiment, the magnet raw material is pulverized into a magnet powder, and the pulverized magnet powder and the binder are mixed to form the slurry 12. Then, the produced slurry 12 is formed into a sheet shape to produce a green sheet 14. Thereafter, the formed body 31 is molded from the formed green sheet 14, and the formed body 31 is sintered, whereby the permanent magnet 1 is formed, and the formed body 31 is formed on the surface in contact with the surface of the rotor 2 and formed on the surface of the rotor 2. The engaged portion 3 is engaged with the engaged portion 4. As a result, the permanent magnet 1 can be accurately positioned with respect to the rotor 2 by engaging the engaging portion 3 with the engaged portion 4. In a pre-designed location. Further, since the contact area between the permanent magnet 1 and the rotor 2 can be increased, the permanent magnet 1 can be firmly fixed to the rotor 2. As a result, even when the rotor 2 is rotated at a high speed, the positional deviation of the permanent magnet 1 with respect to the rotor 2 can be prevented.

Further, since the molded body is formed by mixing a mixture of the magnet powder and the binder by molding, the magnet particles after the alignment are not rotated and can be improved as compared with the case of using the previous powder molding or the like. Orientation. Further, when the magnetic field is aligned with the mixture of the magnet powder and the binder, since the current is used, the magnetic field strength during the magnetic field alignment can be ensured to be large, and since the magnetic field is applied for a long time by the static magnetic field, Achieve a higher degree of alignment with less deviation. Further, it is possible to achieve a higher degree of alignment with less variation and a decrease in deviation due to shrinkage due to sintering. That is, the uniformity of the shape of the product after sintering can be ensured. As a result, the burden on the profile processing after sintering can be alleviated. Moreover, the engaged portion 4 can be easily formed as compared with the prior art powder forming, and the formed engaged portion 4 does not undergo a large degree of deformation in the subsequent manufacturing steps, so that it can be appropriately performed. The engaging portion 3 is engaged with the engaged portion 4.

In addition, since the sintered body is pressed in a state in which the molded body 31 is pressed in the same direction as the axial direction of the rotor 2, the shrinkage due to sintering is uniform, thereby preventing warpage or depression after sintering. Deformation. As a result, even when the permanent magnet 1 has a complicated shape in which the engaged portion 4 is formed, the permanent magnet 1 can be manufactured with high precision.

Further, even when the mixture of the magnet powder and the binder is processed into the molded article 31 having a complicated shape, since the residue due to the processing can be partially regenerated into a part of the mixture, the decrease in the yield can be prevented.

Further, by providing a plurality of engaged portions 4 for the permanent magnet 1, the permanent magnet 1 can be firmly fixed to the rotor 2. As a result, even when the rotor 2 is rotated at a high speed, the positional displacement of the permanent magnet 1 with respect to the rotor 2 can be prevented.

Further, in the present embodiment, the rotating magnet and the previous phase in which the permanent magnet 1 is disposed on the surface In comparison, high torque, miniaturization, low torque ripple, and high efficiency can be achieved.

It is a matter of course that the present invention is not limited to the above-described embodiments, and various modifications and changes can be made without departing from the spirit and scope of the invention.

For example, the pulverization conditions, the kneading conditions, the molding conditions, the magnetic field alignment step, the baking conditions, the sintering conditions, and the like of the magnet powder are not limited to the conditions described in the above examples. For example, in the above embodiment, the magnet raw material is pulverized by wet pulverization using a bead mill, but it may be pulverized by dry pulverization using a jet mill. Further, the atmosphere at the time of baking may be carried out in an atmosphere other than a hydrogen atmosphere (for example, a nitrogen atmosphere, a He atmosphere, or an Ar atmosphere) as long as it is a non-oxidizing atmosphere. Further, the baking treatment may be omitted. In this case, decarburization is carried out during the sintering process.

Further, in the above embodiment, after the magnet powder is molded, it is calcined in a hydrogen gas atmosphere or a mixed gas atmosphere of hydrogen gas and an inert gas, but the magnet powder before molding may be calcined to form a calcined body, that is, a magnet. The powder is shaped into a shaped body, which is then sintered, thereby producing a permanent magnet. According to this configuration, since the powdery magnet particles are fired, the surface area of the magnet to be fired can be increased as compared with the case where the magnet particles after molding are fired. That is, the amount of carbon in the calcined body can be more reliably reduced. However, in order to thermally decompose the binder during the baking treatment, it is preferred to carry out the calcination treatment after the molding.

Further, the permanent magnet of the present invention can be applied to various rotating electrical machines such as a generator or a magnetic reducer in addition to the motor. Further, when the rotary electric machine of the present invention is applied to a magnetic reducer, it is a dual-rotor type having two rotors, and a stator core or a winding may be replaced by a specific number of magnetic pole pieces including a magnetic material. The stator 43 is constructed.

Further, in the present invention, an Nd-Fe-B-based magnet has been described as an example, but other magnets (for example, lanthanum-cobalt magnet, alnico magnet, ferrite magnet, or the like) may be used. Further, in the present invention, the alloy composition of the magnet is such that the Nd component is larger than the metering composition, but may be a metering composition.

1‧‧‧ permanent magnet

2‧‧‧Rotor

3‧‧‧Clock Department

4‧‧‧Be jammed

Claims (11)

A permanent magnet for a rotating electrical machine, characterized in that it is disposed on a permanent magnet of a surface of a surface of a magnet-type rotating electrical machine, and is formed with a card portion formed on the surface of the rotor on a surface in contact with the surface of the rotor. The joint is closed. The permanent magnet for a rotating electrical machine according to claim 1, which is produced by pulverizing a magnet raw material into a magnet powder; and forming a mixture obtained by mixing the pulverized magnet powder and a binder; and forming the mixture into The molded body of the engaged portion is sintered by holding the molded body at a firing temperature in a state of being pressed in one axial direction. The permanent magnet for a rotating electrical machine according to claim 2, wherein in the step of sintering the formed body, the formed body is pressed in a direction in which the molded body is pressed in the same direction as the axial direction of the rotor. . The permanent magnet for a rotating electrical machine according to claim 2, wherein the binder comprises a thermoplastic resin; and the residue is reused by heating the residue of the mixture produced by the step of forming the shaped body. The above mixture of the above shaped bodies is formed. A permanent magnet for a rotating electrical machine according to claim 1, wherein a plurality of the above-mentioned engaged portions are formed. A rotary electric machine is characterized in that a permanent magnet is disposed on a surface of the rotor; and the permanent magnet is formed on an surface in contact with the surface of the rotor, and an engaged portion that engages with an engaging portion formed on a surface of the rotor is formed. A method for producing a permanent magnet for a rotating electrical machine, characterized in that it is a method for producing a permanent magnet disposed on a surface of a rotor of a surface magnet-type rotating electrical machine, and has the following steps: pulverizing a magnet raw material into a magnet powder; a mixture of the following magnet powder and a binder; forming the mixture into a shaped body; and sintering by maintaining the forming body at a firing temperature in a state of being pressed in an axial direction; The body forms an engaged portion that engages with an engaging portion formed on the surface of the rotor on a surface in contact with the surface of the rotor. The method of manufacturing a permanent magnet for a rotating electrical machine according to claim 7, wherein in the step of sintering the formed body, the formed body is pressurized in a direction which is the same direction as an axial direction of the rotor when disposed on the surface of the rotor. The state is sintered. A method of manufacturing a permanent magnet for a rotating electrical machine according to claim 7, wherein a plurality of said engaged portions are formed. The method of producing a permanent magnet for a rotating electrical machine according to claim 7, wherein the binder comprises a thermoplastic resin; and the residue is heated by heating the residue of the mixture produced by the step of forming the shaped body The above mixture is used for forming the above shaped body. A method of manufacturing a rotating electrical machine, characterized in that it is a method of manufacturing a rotating electrical machine manufactured by disposing a permanent magnet on a surface of a rotor, and the permanent magnet is manufactured by pulverizing a magnet raw material into a magnet powder; a mixture of the pulverized magnet powder and a binder; forming the mixture into a shaped body; Sintering is performed by holding the molded body at a firing temperature in a state of being pressed in one axial direction; and forming a contact portion formed on the surface of the rotor with respect to the molded body on a surface in contact with the surface of the rotor The engaged portion of the snap fit.