公开(公告)号：US20170178806A1

公开(公告)日：2017-06-22

申请号：US15118140

申请日：2014-02-12

Applicant: NITTO DENKO CORPORATION

Inventor： Keisuke TAIHAKU ,  Katsuya KUME ,  Toshiaki OKUNO ,  Izumi OZEKI ,  Tomohiro OMURE ,  Takashi OZAKI ,  Takashi YAMAMOTO

IPC: H01F41/02 ,  H02K1/27 ,  B22F3/10 ,  C22C38/00 ,  B22F9/04 ,  B22F3/16 ,  H02K15/03 ,  H01F7/02

CPC classification number: H01F41/0266 ,  B22F3/1017 ,  B22F3/1021 ,  B22F3/16 ,  B22F3/22 ,  B22F5/006 ,  B22F5/106 ,  B22F7/062 ,  B22F9/04 ,  B22F2009/041 ,  B22F2202/05 ,  B22F2301/355 ,  B22F2302/45 ,  B22F2303/40 ,  B22F2998/10 ,  B22F2999/00 ,  C22C33/0278 ,  C22C38/002 ,  C22C38/005 ,  C22C2202/02 ,  H01F1/0577 ,  H01F7/02 ,  H01F41/0273 ,  H02K1/27 ,  H02K15/03 ,  B22F2009/043 ,  B22F2009/044 ,  B22F2201/02 ,  B22F2201/11 ,  B22F2201/12 ,  B22F9/023 ,  B22F1/0074 ,  B22F3/105 ,  B22F2201/01

Abstract: Provided are: a permanent magnet wherein the magnetic field orientation process can be made simple and a degree of orientation thereof can be improved; a method for manufacturing a permanent magnet, an SPM motor using a permanent magnet, and a method for manufacturing an SPM motor. Raw material magnet is milled to magnet powder, and the magnet powder is mixed with a binder to form a compound. Then, the compound is molded by hot-melt molding to a green sheet in a shape of a sheet onto a supporting substrate. Thereafter, a magnetic field is applied to the green sheet thus molded to carry out magnetic field orientation. Further, with fixing plural green sheets after the magnetic field orientation by lamination under a deformed state thereof, the plural green sheets thus laminated are cut for shaping to a prescribed shape, which is followed by sintering to produce a permanent magnet.

公开(公告)号：US20170178773A1

公开(公告)日：2017-06-22

申请号：US15118116

申请日：2014-02-12

Applicant: NITTO DENKO CORPORATION

Inventor： Izumi OZEKI ,  Katsuya KUME ,  Toshiaki OKUNO ,  Takashi OZAKI ,  Tomohiro OMURE ,  Keisuke TAIHAKU ,  Takashi YAMAMOTO

IPC: H01F1/053 ,  B22F9/04 ,  C22C1/04

CPC classification number: H01F1/0536 ,  B22F3/1021 ,  B22F3/22 ,  B22F5/006 ,  B22F9/04 ,  B22F2009/041 ,  B22F2998/10 ,  B22F2999/00 ,  C22C1/0441 ,  C22C33/0278 ,  C22C38/002 ,  C22C38/005 ,  C22C2202/02 ,  H01F1/0577 ,  H01F41/0273 ,  B22F2009/043 ,  B22F2009/044 ,  B22F2201/01 ,  B22F2201/02 ,  B22F2201/11 ,  B22F2201/12 ,  B22F2202/05 ,  B22F9/023 ,  B22F1/0074 ,  B22F3/105

Abstract: Provided are a rare-earth permanent magnet whose magnet density after sintering is very high and a method for manufacturing a rare-earth permanent magnet. Thus, a magnet raw material is milled into magnet powder, and then, a compound 12 is formed by mixing the magnet powder thus milled with a binder. Next, the compound 12 thus formed is subjected to a hot-melt molding onto a supporting substrate 13 so as to form a green sheet 14 molded to a sheet-like shape. Thereafter, while the green sheet 14 thus molded is softened by heating, magnetic field orientation is carried out by applying a magnetic field to the green sheet 14 thus heated; and further, the green sheet 14 having been subjected to the magnetic field orientation is calcined by a vacuum sintering, which is further followed by a pressure sintering to produce a permanent magnet 1.

公开(公告)号：US20160141100A1

公开(公告)日：2016-05-19

申请号：US15007318

申请日：2016-01-27

Applicant: NITTO DENKO CORPORATION

Inventor： Keisuke TAIHAKU ,  Katsuya Kume ,  Toshiaki Okuno ,  Izumi Ozeki ,  Tomohiro Omure ,  Takashi Ozaki

IPC: H01F41/02 ,  B22F1/02 ,  C22C38/00 ,  B22F5/00 ,  H01F1/053 ,  B22F1/00 ,  B22F3/10

CPC classification number: H01F1/0536 ,  B22F1/0062 ,  B22F1/02 ,  B22F3/02 ,  B22F3/1021 ,  B22F3/16 ,  B22F5/006 ,  B22F2001/0066 ,  B22F2003/248 ,  B22F2201/01 ,  B22F2301/45 ,  B22F2302/45 ,  B22F2998/10 ,  B22F2999/00 ,  C22C38/002 ,  C22C38/005 ,  C22C2202/02 ,  H01F1/06 ,  H01F1/42 ,  H01F41/0266 ,  B22F9/04 ,  B22F3/10

Abstract: There are provided a rare-earth permanent magnet and a manufacturing method thereof capable of preventing deterioration of magnet properties. In the method, magnet material is milled into magnet powder. Next, a mixture is prepared by mixing the magnet powder and a binder made of long-chain hydrocarbon and/or of a polymer or a copolymer consisting of monomers having no oxygen atoms. Next, the mixture is formed into a sheet-like shape so as to obtain a green sheet. After that, the green sheet is held for a predetermined length of time at binder decomposition temperature in a non-oxidizing atmosphere so as to remove the binder by causing depolymerization reaction or the like to the binder, which turns into monomer. The green sheet from which the binder has been removed is sintered by raising temperature up to sintering temperature. Thereby a permanent magnet 1 is obtained.

公开(公告)号：US20170170695A1

公开(公告)日：2017-06-15

申请号：US15118144

申请日：2014-02-12

Applicant: NITTO DENKO CORPORATION

Inventor： Takashi YAMAMOTO ,  Katsuya KUME ,  Toshiaki OKUNO ,  Izumi OZEKI ,  Tomohiro OMURE ,  Takashi OZAKI ,  Keisuke TAIHAKU

IPC: H02K1/27 ,  H01F1/08 ,  H01F41/02 ,  B22F3/14 ,  B22D7/00 ,  B22F9/04 ,  B22F3/16 ,  B22F5/00 ,  H02K15/03 ,  C22C38/00

CPC classification number: H02K1/2706 ,  B22D7/00 ,  B22F3/14 ,  B22F3/16 ,  B22F5/006 ,  B22F5/106 ,  B22F9/04 ,  B22F2009/044 ,  B22F2301/355 ,  B22F2998/10 ,  B22F2999/00 ,  C22C38/002 ,  C22C38/005 ,  C22C2202/02 ,  H01F1/086 ,  H01F41/0246 ,  H01F41/0273 ,  H02K1/2733 ,  H02K15/03 ,  B22F3/22 ,  B22F3/02 ,  B22F3/10 ,  B22F2202/05

Abstract: Provided are: a ring magnet for an SPM motor with which high output power, high efficiency, and low torque ripple of the SPM motor can be realized; a method for manufacturing a ring magnet for an SPM motor; an SPM motor using a ring magnet for an SPM motor; and a method for manufacturing an SPM motor. Raw material magnet is milled to magnet powder, and the magnet powder is molded to a shape of a sheet thereby forming a green sheet. Then, a magnetic field is applied to the green sheet to perform magnetic field orientation. Further, with fixing plural green sheets after the magnetic field orientation by lamination under deformed state thereof, the plural laminated green sheets are cut to a fan-like shape, which is then followed by connecting with each other to form a ring shape and further followed by sintering to produce a permanent magnet.

公开(公告)号：US20170169922A1

公开(公告)日：2017-06-15

申请号：US15118117

申请日：2014-02-12

Applicant: NITTO DENKO CORPORATION

Inventor： Takashi OZAKI ,  Katsuya KUME ,  Toshiaki OKUNO ,  Izumi OZEKI ,  Tomohiro OMURE ,  Keisuke TAIHAKU ,  Takashi YAMAMOTO

IPC: H01F1/053 ,  H01F41/02 ,  H01F7/02

CPC classification number: H01F1/0536 ,  B22F3/1021 ,  B22F3/22 ,  B22F5/006 ,  B22F2998/10 ,  B22F2999/00 ,  C22C33/0278 ,  C22C38/002 ,  C22C38/005 ,  C22C2202/02 ,  H01F1/0577 ,  H01F7/02 ,  H01F41/0253 ,  H01F41/0273 ,  B22F2009/043 ,  B22F2009/044 ,  B22F2202/05 ,  B22F2201/01 ,  B22F2201/10 ,  B22F9/04 ,  B22F2201/02 ,  B22F2201/11 ,  B22F2201/12 ,  B22F9/023 ,  B22F1/0074 ,  B22F3/105

Abstract: Provided are a rare earth permanent magnet whose permanent magnetic properties are improved by making density of the magnet very high and a method for manufacturing a rare earth permanent magnet. Thus, magnet raw material is milled into magnet powder, and then a compound is formed by mixing the magnet powder thus milled with a binder. Next, the compound thus formed is subjected to hot-melt molding onto a supporting substrate so as to form a green sheet molded to a sheet-like shape. Thereafter, while the green sheet thus molded is softened by heating, magnetic field orientation is carried out by applying a magnetic field to the green sheet thus heated; and further, the green sheet having been subjected to the magnetic field orientation is calcined in non-oxidizing atmosphere, and then, sintering thereof is carried out at a sintering temperature to produce a permanent magnet having density of 95% or more.

公开(公告)号：US20160196903A1

公开(公告)日：2016-07-07

申请号：US15071406

申请日：2016-03-16

Applicant: NITTO DENKO CORPORATION

Inventor： Keisuke TAIHAKU ,  Katsuya KUME ,  Toshiaki OKUNO ,  Izumi OZEKI ,  Tomohiro OMURE ,  Takashi OZAKI

IPC: H01F1/053 ,  H01F1/06 ,  B22F3/16 ,  H01F41/02 ,  B22F1/00

CPC classification number: H01F1/0536 ,  B22F1/0062 ,  B22F1/02 ,  B22F3/02 ,  B22F3/1021 ,  B22F3/16 ,  B22F5/006 ,  B22F2001/0066 ,  B22F2003/248 ,  B22F2201/01 ,  B22F2301/45 ,  B22F2302/45 ,  B22F2998/10 ,  B22F2999/00 ,  C22C38/002 ,  C22C38/005 ,  C22C2202/02 ,  H01F1/06 ,  H01F1/42 ,  H01F41/0266 ,  B22F9/04 ,  B22F3/10

Abstract: There are provided a rare-earth permanent magnet and a manufacturing method thereof capable of preventing deterioration of magnet properties. In the method, magnet material is milled into magnet powder. Next, a mixture is prepared by mixing the magnet powder and a binder made of long-chain hydrocarbon and/or of a polymer or a copolymer consisting of monomers having no oxygen atoms. Next, the mixture is formed into a sheet-like shape so as to obtain a green sheet. After that, the green sheet is held for a predetermined length of time at binder decomposition temperature in a non-oxidizing atmosphere so as to remove the binder by causing depolymerization reaction or the like to the binder, which turns into monomer. The green sheet from which the binder has been removed is sintered by raising temperature up to sintering temperature. Thereby a permanent magnet 1 is obtained.