公开(公告)号：US08545641B2

公开(公告)日：2013-10-01

申请号：US11630898

申请日：2005-06-30

申请人： Masato Sagawa ,  Hiroshi Nagata ,  Osamu Itatani

发明人： Masato Sagawa ,  Hiroshi Nagata ,  Osamu Itatani

IPC分类号： H01F1/057

CPC分类号： H01F41/0246 ,  B22F3/1021 ,  B22F2998/10 ,  C22C1/0433 ,  C22C33/0278 ,  C22C38/005 ,  C22C38/06 ,  C22C38/10 ,  C22C38/16 ,  H01F1/0557 ,  H01F1/0577 ,  H01F41/0273 ,  B22F2201/10 ,  B22F9/08 ,  B22F3/004 ,  B22F2202/01 ,  B22F3/005 ,  B22F2202/05 ,  B22F9/04

摘要： A method for manufacturing a sintered rare-earth magnet having a magnetic anisotropy, in which a very active powder having a small grain size can be safely used in a low-oxidized state. A fine powder as a material of the sintered rare-earth magnet having a magnetic anisotropy is loaded into a mold until its density reaches a predetermined level. Then, in a magnetic orientation section, the fine powder is oriented by a pulsed magnetic field. Subsequently, the fine powder is not compressed but immediately sintered in a sintering furnace. A multi-cavity mold for manufacturing a sintered rare-earth magnet having an industrially important shape, such as a plate magnet or an arched plate magnet, may be used.

摘要翻译： 一种制造具有磁各向异性的稀土类烧结磁体的方法，其中可以在低氧化态下安全地使用具有小粒径的非常活泼的粉末。 将作为具有磁各向异性的烧结稀土类磁铁的材料的细粉末装载到模具中，直到其密度达到预定水平。 然后，在磁性取向部分中，细粉末通过脉冲磁场取向。 随后，细粉末不被压缩，但在烧结炉中立即烧结。 可以使用用于制造具有工业上重要形状的稀土类烧结磁体的多空腔模具，例如板状磁体或拱形板状磁体。

公开(公告)号：US20120176212A1

公开(公告)日：2012-07-12

申请号：US13392311

申请日：2010-08-27

申请人： Masato Sagawa ,  Tetsuhiko Mizoguchi ,  Michiyasu Asazuma ,  Shinichi Hayashi

发明人： Masato Sagawa ,  Tetsuhiko Mizoguchi ,  Michiyasu Asazuma ,  Shinichi Hayashi

IPC分类号： H01F7/02 ,  B22F3/10 ,  B22F1/00

CPC分类号： C22C33/02 ,  B22F3/005 ,  B22F3/10 ,  B22F2998/00 ,  B22F2999/00 ,  C22C38/00 ,  C22C38/06 ,  C22C38/10 ,  C22C38/16 ,  H01F1/0577 ,  H01F41/0266 ,  H01F41/0273 ,  B22F3/004 ,  B22F3/02 ,  B22F2202/05

摘要： A method and system for producing a slim-shaped sintered NdFeB magnet having a high level of coercive force and high degree of orientation, as well as a sintered NdFeB magnet produced by the aforementioned method or system. A system for producing a slim-shaped sintered NdFeB magnet according to the present invention includes: a filling unit and filling alloy powder; an orienting unit; a sintering furnace; and a conveying unit. The orienting unit is provided with a heating and orienting coil for heating the alloy powder in the molds before and/or after the application of the magnetic field so as to decrease the coercive force of the individual particles of the alloy powder.

摘要翻译： 一种制造具有高矫顽力和高取向度的薄型烧结NdFeB磁体的方法和系统，以及通过上述方法或系统制造的烧结NdFeB磁体。 根据本发明的用于生产细长型烧结NdFeB磁体的系统包括：填充单元和填充合金粉末; 定向单元; 烧结炉; 和输送单元。 定向单元设置有用于在施加磁场之前和/或之后加热模具中的合金粉末的加热和定向线圈，从而降低合金粉末的各个颗粒的矫顽力。

公开(公告)号：US20110070118A1

公开(公告)日：2011-03-24

申请号：US12673937

申请日：2008-08-20

申请人： Masato Sagawa

发明人： Masato Sagawa

IPC分类号： B22F1/00

CPC分类号： H01F41/0273 ,  B22F3/087 ,  B22F2998/00 ,  B22F2998/10 ,  B22F2999/00 ,  C22C2202/02 ,  H01F1/0577 ,  H01F41/0266 ,  C22C33/02 ,  B22F3/004 ,  B22F3/10 ,  B22F3/02 ,  B22F2202/05 ,  B22F3/1216

摘要： A mold which is inexpensive and easy to process and does not embrittle. Also provided is a process by which a sintered. NdFeB magnet can be produced using the mold without suffering bending or deformation. At least part (e.g., a bottom plate) of the mold is made of a carbon material. Carbon materials have lower friction with a sinter during sintering than metals. The mold hence enables a sintered NdFeB magnet to be produced without suffering the bending or deformation caused by friction due to sintering shrinkage. Carbon materials are inexpensive and easy to process. The mold does not embrittle even when repeatedly used. Such effects can be significantly produced when a carbon material is used as the bottom plate, on which the load of the sinter is imposed during sintering.

摘要翻译： 一种廉价且易于加工并且不易碎的模具。 还提供了烧结的方法。 NdFeB磁体可以使用模具生产而不会产生弯曲或变形。 模具的至少一部分（例如，底板）由碳材料制成。 碳材料在烧结过程中与烧结体的摩擦比金属要低。 因此，该模具能够制造烧结NdFeB磁体，而不会由于烧结收缩而产生由摩擦引起的弯曲或变形。 碳材料便宜且易于加工。 即使重复使用，模具也不会脆化。 当使用碳材料作为烧结时施加烧结体的负载的底板时，可以显着地产生这种效果。

公开(公告)号：US20100119703A1

公开(公告)日：2010-05-13

申请号：US12595872

申请日：2008-04-21

申请人： Masato Sagawa

发明人： Masato Sagawa

IPC分类号： H01F41/02 ,  B05D5/00

CPC分类号： H01F41/005 ,  B22F2003/248 ,  B22F2998/10 ,  C22C33/0278 ,  C22C38/005 ,  C22C38/06 ,  C22C38/10 ,  C22C38/16 ,  C22C2202/02 ,  H01F1/0577 ,  H01F41/0293 ,  B22F3/02 ,  B22F3/10 ,  B22F3/20 ,  B22F3/24

摘要： The objective of the present invention is to provide a method for making a NdFeB sintered magnet, capable of enhancing the effect of increasing the coercive force and preventing the instability of the effects, and in addition, being inexpensive. The method for making a NdFeB sintered magnet according to the present invention has processes of coating a NdFeB sintered magnet with a powder containing Dy and/or Tb, then heating the NdFeB sintered magnet, and thereby diffusing Rh in the powder into the NdFeB sintered magnet through a grain boundary, and is characterized in that the powder contains 0.5 through 50 weight percent of Al in a metallic state; and the amount of oxygen contained in the NdFeB sintered magnet is equal to or less than 0.4 weight percent.

摘要翻译： 本发明的目的是提供一种制造NdFeB烧结磁体的方法，该方法能够提高矫顽力的提高效果，防止效果不稳定，另外，成本低廉。 根据本发明的制造NdFeB烧结磁体的方法具有用含有Dy和/或Tb的粉末涂覆NdFeB烧结磁体的方法，然后加热NdFeB烧结磁体，从而将粉末中的Rh扩散到NdFeB烧结磁体 通过晶界，其特征在于粉末含有0.5至50重量％的金属状态的Al; 并且NdFeB烧结磁体中所含的氧的量等于或小于0.4重量％。

公开(公告)号：US20090252865A1

公开(公告)日：2009-10-08

申请号：US12441124

申请日：2007-07-23

申请人： Masato Sagawa

发明人： Masato Sagawa

IPC分类号： B05D3/02 ,  B05D5/00 ,  B05D7/00

CPC分类号： H01F41/005 ,  B22F3/1039 ,  B22F7/06 ,  B22F2003/248 ,  B22F2999/00 ,  C22C38/005 ,  C22C38/06 ,  C22C38/08 ,  C22C38/10 ,  H01F1/0577 ,  H01F41/0293 ,  B22F2202/01 ,  B22F2201/20

摘要： The present invention provides a method for producing a sintered NdFeB magnet having high coercivity and capable of being brought into applications without lowering its residual magnetic flux density or maximum energy product and without reprocessing. The method for producing a sintered NdFeB magnet according to the present invention includes applying a substance containing dysprosium (Dy) and/or terbium (Tb) to the surface of the sintered NdFeB magnet forming a base body and then heating the magnet to diffuse Dy and/or Tb through the grain boundary and thereby increase the coercivity of the magnet. This method is characterized in that: (1) the substance containing Dy or Tb to be applied to the surface of the sintered NdFeB magnet is substantially a metal powder; (2) the metal powder is composed of a rare-earth element R and an iron-group transition element T, or composed of R, T and another element X, the element X capable of forming an alloy or intermetallic compound with R and/or T; and (3) the oxygen content of the sintered NdFeB magnet forming the base body is 5000 ppm or lower. The element T may contain nickel (Ni) or cobalt (Co) to produce an anticorrosion effect.

摘要翻译： 本发明提供一种制造具有高矫顽力的NdFeB烧结磁体的方法，能够在不降低其剩余磁通密度或最大能量产物的情况下进行应用，而不需要后处理。 根据本发明的NdFeB烧结磁体的制造方法包括将镝（Dy）和/或铽（Tb）的物质施加到形成基体的NdFeB烧结磁体的表面，然后加热磁体以扩散Dy和 /或Tb通过晶界，从而提高磁体的矫顽力。 该方法的特征在于：（1）应用于烧结NdFeB磁体表面的含有Dy或Tb的物质基本上是金属粉末; （2）金属粉末由稀土元素R和铁基过渡元素T构成，或由R，T和另一元素X构成，能够与R和/ 或T; 和（3）形成基体的烧结NdFeB磁体的氧含量为5000ppm以下。 元素T可以含有镍（Ni）或钴（Co）以产生抗腐蚀效果。

公开(公告)号：US20070245851A1

公开(公告)日：2007-10-25

申请号：US11630898

申请日：2005-06-30

申请人： Masato Sagawa ,  Hiroshi Nagata ,  Osamu Itatani

发明人： Masato Sagawa ,  Hiroshi Nagata ,  Osamu Itatani

IPC分类号： B22F3/10 ,  B22F7/00

CPC分类号： H01F41/0246 ,  B22F3/1021 ,  B22F2998/10 ,  C22C1/0433 ,  C22C33/0278 ,  C22C38/005 ,  C22C38/06 ,  C22C38/10 ,  C22C38/16 ,  H01F1/0557 ,  H01F1/0577 ,  H01F41/0273 ,  B22F2201/10 ,  B22F9/08 ,  B22F3/004 ,  B22F2202/01 ,  B22F3/005 ,  B22F2202/05 ,  B22F9/04

摘要： To improve the performance of a rare-earth magnet, it is effective to use a low-oxidized powder having a small grain size. One objective of the present invention is to provide a method for manufacturing a sintered rare-earth magnet having a magnetic anisotropy, in which a very active powder having a small grain size can be safely used in a low-oxidized state. Another objective is to provide a method capable of efficiently manufacturing products having various shapes. In a weighing and loading section 41 and a high-density loading section 42, a fine powder as a material of the sintered rare-earth magnet having a magnetic anisotropy is loaded into a mold until its density reaches a predetermined level. Then, in a magnetic orientation section 43, the fine powder is oriented by a pulsed magnetic field. Subsequently, the fine powder is not compressed but immediately sintered in a sintering furnace 44. The present method enables the mass-producing machine to be simple in its operation and its housing to be accordingly smaller, so that it will be possible to eliminate the danger of oxidization or burning of the powder, which has been a serious problem for a conventional method that uses a large-scale die-pressing machine. Furthermore, the manufacturing efficiency can be improved by using a multi-cavity mold for manufacturing a sintered rare-earth magnet having an industrially important shape, such as a plate magnet or an arched plate magnet.

摘要翻译： 为了提高稀土类磁铁的性能，使用粒径小的低氧化物粉末是有效的。 本发明的一个目的是提供一种制造具有磁各向异性的稀土类烧结磁体的方法，其中可以在低氧化态下安全地使用具有小晶粒尺寸的非常活泼的粉末。 另一个目标是提供能够有效地制造具有各种形状的产品的方法。 在称重装载部41和高密度装载部42中，将作为具有磁各向异性的稀土类烧结磁体的材料的细粉末装载到模具中，直到其密度达到预定水平。 然后，在磁取向部43中，细粉末通过脉冲磁场取向。 随后，细粉末不被压缩，但在烧结炉44中立即烧结。 本发明的方法使得批量生产机器的操作简单，并且壳体相应地更小，从而可以消除粉末的氧化或燃烧的危险，这对于常规的这是一个严重的问题 使用大型压模机的方法。 此外，通过使用多腔模具来制造具有工业上重要的形状的稀土类稀土磁体，例如板状磁铁或拱形磁体磁铁，可以提高制造效率。

公开(公告)号：US06814928B2

公开(公告)日：2004-11-09

申请号：US10137393

申请日：2002-05-03

申请人： Masato Sagawa ,  Tochihiro Watanabe ,  Hiroshi Nagata

发明人： Masato Sagawa ,  Tochihiro Watanabe ,  Hiroshi Nagata

IPC分类号： B22F312

CPC分类号： B30B15/302 ,  B30B11/00

摘要： A powder compaction method in which a powder p is filled by air tapping or other suitable method into a mold 1, then while the mold 1 being filled with the powder, the powder particles are bound with each other without application of force from outside the mold to form a compact C, and then the compact C is taken out from the mold 1. This method produces a variety of shapes of the compact far greater than in conventional methods, and net shape manufacturing of products with complex shapes is made possible by this method. Because this method uses far less binder compared to MIM and PIM that are expected as methods for producing products with complicated shapes, the time needed for elimination of the binder is much shorter than in MIM and PIM.

摘要翻译： 粉末压制方法，其中粉末p通过空气攻丝或其它合适的方法填充到模具1中，然后当模具1填充粉末时，粉末颗粒彼此结合，而不受模具外部的力 以形成紧凑的C，然后将紧凑的C从模具1中取出。该方法产生远远大于常规方法的多种形状的紧凑形状，并且通过这种方式可以实现具有复杂形状的产品的净形状制造 方法。 由于与MIM和PIM相比，该方法使用的粘合剂远远少于生产具有复杂形状的产品的方法，所以消除粘合剂所需的时间比MIM和PIM短得多。

公开(公告)号：US6113979A

公开(公告)日：2000-09-05

申请号：US143250

申请日：1998-08-28

申请人： Masato Sagawa ,  Osamu Itatani ,  Akira Fujiwara

发明人： Masato Sagawa ,  Osamu Itatani ,  Akira Fujiwara

IPC分类号： B05D1/06 ,  B05D7/00 ,  B05D7/24 ,  C09D5/03 ,  B05D1/36

CPC分类号： B05D7/54

摘要： The powder coating of the present invention was used for a method for forming coatings comprising the steps of making the powder coating adhere to an adhesive layer previously formed on the surface of a material to be coated, and then heating it, thereby forming a coating, comprising a resin particle containing a thermosetting resin, and a particle containing a curing agent.

摘要翻译： 将本发明的粉末涂料用于形成涂层的方法，包括以下步骤：使粉末涂料粘附到预先形成在待涂覆材料的表面上的粘合剂层上，然后加热，从而形成涂层， 包含含有热固性树脂的树脂颗粒和含有固化剂的颗粒。

公开(公告)号：US5449481A

公开(公告)日：1995-09-12

申请号：US155229

申请日：1993-11-22

申请人： Masato Sagawa ,  Hiroshi Nagata ,  Osamu Itatani

发明人： Masato Sagawa ,  Hiroshi Nagata ,  Osamu Itatani

IPC分类号： B22F3/02 ,  B22F3/12 ,  B30B11/00 ,  B30B11/02 ,  B30B11/08 ,  B30B15/02 ,  H01F41/02 ,  B29C43/02

CPC分类号： B30B11/02 ,  B22F3/1233 ,  B30B11/008 ,  B30B15/024 ,  H01F41/0266

摘要： Methods and apparatuses for producing a powder compacts are disclosed. A powder compaction apparatus includes a recess formed by die and a lower punch inserted into the die. The recess is loaded with rubber mold provided with a cavity shaped according to the desired configuration of the compact. Subsequently, the powder is packed in the cavity of the rubber mold, and an upper punch is placed on die to press the rubber mold with powder in the space formed by the die, the lower punch and the upper punch, thereby producing a powder compact.

摘要翻译： 公开了制造粉末压块的方法和装置。 粉末压实装置包括由模具形成的凹部和插入模具中的下冲头。 凹部装有橡胶模具，该橡胶模具具有根据压块的所需构造形成的空腔。 随后，将粉末填充在橡胶模具的空腔中，并且将上冲头放置在模具上以将粉末挤压在由模具，下冲头和上冲头形成的空间中，从而产生粉末压块 。

公开(公告)号：US5273782A

公开(公告)日：1993-12-28

申请号：US926433

申请日：1992-08-10

申请人： Masato Sagawa ,  Hiroshi Watanabe ,  Hiroo Shirai

发明人： Masato Sagawa ,  Hiroshi Watanabe ,  Hiroo Shirai

IPC分类号： C23C24/04 ,  B05D3/12 ,  B05D3/02

CPC分类号： C23C24/045

摘要： Powder-content of a powder-coating is enhauced. Powder material forms a skeleton structure. The clearances are filled with resin. The coating comprises a resin layer which bonds the power-compacted layer to the parts or any underlying powder-compacted layer. The work pieces on which a resin film may be preliminarily formed, is subjected to vibration or stirring together with the powder material and means for mediating the formation of the coating, which eans is of substantially smaller size than said work pieces and greater size than said powder material, as well as with or without the resin, to vibration or stirring in a container.