公开(公告)号：US10475561B2

公开(公告)日：2019-11-12

申请号：US14777638

申请日：2014-03-13

Applicant: INTERMETALLICS CO., LTD. ,  DAIDO STEEL CO., LTD.

Inventor： Masato Sagawa ,  Shinobu Takagi ,  Hayato Hashino

IPC: H01F1/057 ,  B22F1/02 ,  H01F41/02 ,  B22F3/14 ,  C22C28/00

Abstract: A method for producing an RFeB system magnet with high coercivity by preventing a coating material from peeling off the surface of a base material during a grain boundary diffusion treatment is provided. A method for producing an RL2Fe14B system magnet which is a sintered magnet or a hot-deformed magnet containing, as the main rare-earth element, a light rare-earth element RL which is at least one of the two elements of Nd and Pr, the method including: applying, to a surface of a base material M of the RL2Fe14B system magnet, a coating material prepared by mixing a silicone grease and an RH-containing powder containing a heavy rare-earth element RH composed of at least one element selected from the group of Dy, Tb and Ho; and heating the base material together with the coating material. Improved coating and base materials adhesion facilitates transfer of RH into base material grain boundaries.

公开(公告)号：US09362035B2

公开(公告)日：2016-06-07

申请号：US14114656

申请日：2012-12-27

Applicant: INTERMETALLICS CO., LTD.

Inventor： Masato Sagawa ,  Tetsuhiko Mizoguchi

IPC: H01F1/055 ,  H01F41/02 ,  C22C38/00 ,  H01F1/053 ,  H01F7/02 ,  H01F1/057 ,  C22C33/02

Abstract: A NdFeB system sintered magnet according to the present invention is a NdFeB system sintered magnet having a base material produced by orienting powder of a NdFeB system alloy and sintering the powder, with Dy and/or Tb (the “Dy and/or Tb” is hereinafter called RH) attached to and diffused from a surface of the base material through the grain boundary inside the base material by a grain boundary diffusion treatment, wherein the number of grain-boundary triple points at which the difference Ct−Cw between the RH content Ct (wt %) at the grain-boundary triple point and the RH content Cw (wt %) at a two-grain boundary portion leading to that grain-boundary triple point is equal to or smaller than 4 wt % is equal to or larger than 60% of the total number of grain-boundary triple points.

公开(公告)号：US09449758B1

公开(公告)日：2016-09-20

申请号：US15168555

申请日：2016-05-31

Applicant: INTERMETALLICS CO., LTD. ,  DAIDO STEEL CO., LTD.

Inventor： Masato Sagawa ,  Osamu Itatani ,  Norio Yoshikawa

IPC: H01F41/02 ,  B65B1/04 ,  B65B1/16 ,  B22F3/00 ,  B30B15/30 ,  B65B7/28

CPC classification number: H01F41/0273 ,  B22F3/004 ,  B30B15/302 ,  B65B1/04 ,  B65B1/16 ,  B65B7/28 ,  H01F41/0266

Abstract: A powder-filling system capable of filling a container with powder at an approximately uniform filling density has: a hopper having an opening removably and hermetically closably attached to the container, the hopper communicating with the container at the opening for supplying powder to a container; a powder supplier for supplying powder to the hopper; a gas supplier for repeatedly supplying compressed gas in a pulsed form to the hopper, with the hopper hermetically closably attached to the container; and a sieve member provided at the opening and having a smaller openings in a region near a side wall of the hopper than in its central region. The smaller openings in the region near the side wall of the hopper where the powder more easily falls from the hopper into the container impedes the fall of the powder in that region and improves the overall uniformity in the filling density.

Abstract translation: 能够以大致均匀的填充密度填充粉末的容器的粉末填充系统具有：具有可拆卸地且气密地连接到容器的开口的料斗，料斗在开口处与容器连通以将粉末供应到容器; 用于向料斗供应粉末的粉末供应商; 用于将脉冲形式的压缩气体重复供应到料斗的气体供应器，料斗气密地附接到容器; 以及设置在所述开口处并且在所述料斗的侧壁附近的区域中比在其中心区域具有较小开口的筛子构件。 在料斗的侧壁附近的较小的开口，其中粉末更容易从料斗落入容器中，阻碍了该区域中的粉末的下降，并且提高了填充密度的整体均匀性。

公开(公告)号：US09028624B2

公开(公告)日：2015-05-12

申请号：US14113961

申请日：2012-12-27

Applicant: Intermetallics Co., Ltd.

Inventor： Masato Sagawa ,  Tetsuhiko Mizoguchi

IPC: H01F7/02 ,  H01F1/057 ,  H01F41/02 ,  B22F1/00 ,  H01F1/055 ,  C22C33/02 ,  B22F9/02

CPC classification number: H01F7/02 ,  B22F1/0011 ,  B22F9/023 ,  C22C33/02 ,  H01F1/0557 ,  H01F1/057 ,  H01F1/0577 ,  H01F41/0266 ,  H01F41/0293

Abstract: Provided is a NdFeB sintered magnet which can be used in the grain boundary diffusion method as a base material in which RH can be easily diffused through the rare-earth rich phase and which itself has a high coercive force, a high maximum energy product and a high squareness ratio, as well as a method for producing such a magnet. A NdFeB system sintered has an average grain size of the main-phase grains magnet is equal to or smaller than 4.5 μm, the carbon content of the entire NdFeB system sintered magnet is equal to or lower than 1000 ppm, and the percentage of the total volume of a carbon rich phase in a rare-earth rich phase at a grain-boundary triple point in the NdFeB system sintered magnet to the total volume of the rare-earth rich phase is equal to or lower than 50%.

Abstract translation: 本发明提供一种NdFeB烧结磁体，其可以用作晶界扩散法中的基底材料，其中RH容易通过富稀土相扩散，本身具有高的矫顽力，高的最大能量积和 高矩形比，以及这种磁体的制造方法。 NdFeB系烧结后的主晶粒磁铁的平均粒径为4.5μm以下，NdFeB系烧结磁铁整体的碳含量为1000ppm以下， 在NdFeB系烧结磁体中的晶界三重点处的富稀相中的富碳相的体积相对于富稀土相的总体积为50％以下。

公开(公告)号：US20150125336A1

公开(公告)日：2015-05-07

申请号：US14397564

申请日：2013-06-27

Applicant: INTERMETALLICS CO., LTD.

Inventor： Masato Sagawa ,  Tetsuhiko Mizoguchi ,  Yasuhiro Une

IPC: H01F41/02 ,  H01F1/08 ,  B22F3/10 ,  H01F1/053

CPC classification number: H01F41/0266 ,  B22F3/10 ,  B22F3/16 ,  B22F2998/10 ,  C22C14/00 ,  C22C33/02 ,  C22C38/001 ,  C22C38/005 ,  C22C38/02 ,  C22C38/10 ,  C22C38/16 ,  C22C2202/02 ,  H01F1/0536 ,  H01F1/0573 ,  H01F1/0577 ,  H01F1/086 ,  H01F41/026 ,  B22F9/023 ,  B22F9/04

Abstract: A method for producing a NdFeB system sintered magnet. The method includes: a hydrogen pulverization process, in which coarse powder of a NdFeB system alloy is prepared by coarsely pulverizing a lump of NdFeB system alloy by making this lump occlude hydrogen; a fine pulverization process, in which fine powder is prepared by performing fine pulverization for further pulverizing the coarse powder; a filling process, in which the fine powder is put into a filling container; an orienting process, in which the fine powder in the filling container is oriented; and a sintering process, in which the fine powder after the orienting process is sintered as held in the filling container. The processes from hydrogen pulverization through orienting are performed with neither dehydrogenation heating nor evacuation each for desorbing hydrogen occluded in the hydrogen pulverization process. The processes from hydrogen pulverization through sintering are performed in an oxygen-free atmosphere.

Abstract translation: NdFeB系烧结磁体的制造方法。 该方法包括：氢粉碎工艺，其中通过使该块堵塞氢来粗粉碎NdFeB系合金块，制备钕铁硼系合金粗粉末; 精细粉碎工序，其中通过进行细粉碎以进一步粉碎粗粉而制备细粉末; 填充过程，其中将细粉末放入填充容器中; 定向方法，其中填充容器中的细粉末定向; 以及将定向处理后的细粉末保持在填充容器中进行烧结的烧结工序。 通过定向氢氢粉碎的方法既进行脱氢加热也不进行排气，以解吸氢气粉碎过程中吸收的氢。 在无氧气氛中进行氢粉碎至烧结的工序。

公开(公告)号：US20140062632A1

公开(公告)日：2014-03-06

申请号：US14114657

申请日：2012-12-27

Applicant: INTERMETALLICS CO., LTD.

Inventor： Masato Sagawa ,  Tetsuhiko Mizoguchi

IPC: H01F1/057

CPC classification number: H01F1/0577 ,  C22C33/02 ,  C22C38/005 ,  C22C2202/02 ,  H01F41/0293

Abstract: A NdFeB system sintered magnet produced by the grain boundary diffusion method that has a high coercive force and squareness ratio with only a small decrease in the maximum energy product. The NdFeB system sintered magnet has a base material produced by orienting powder of a NdFeB system alloy and sintering the powder, with Dy and/or Tb (the “Dy and/or Tb” is hereinafter called RH) attached to and diffused from a surface of the base material through the grain boundary inside the base material by a grain boundary diffusion treatment, wherein the difference Cs-Cd3 between the RH content Cs (wt %) in the grain boundary reaching the surface to which RH is attached and the RH content Cd3 (wt %) in the grain boundary at a depth of 3 mm from the aforementioned attachment surface is equal to or smaller than 20 wt %.

Abstract translation: 通过晶界扩散法制造的具有高矫顽力和矩形比的NdFeB系烧结磁体，其最大能量乘积仅有小的减小。 NdFeB系烧结磁体具有通过使NdFeB系合金的粉末取向并烧结粉末而制成的基材，Dy和/或Tb（“Dy和/或Tb”以下称为RH）附着并从表面扩散 通过晶界扩散处理通过基材内部的晶界而使基体材料中的RH含量Cs（wt％）之间的差异Cs-Cd3与到达RH的表面的RH含量Cs（wt％）和RH含量 与上述附着面相距3mm的晶界的Cd3（wt％）为20重量％以下。

公开(公告)号：US10546673B2

公开(公告)日：2020-01-28

申请号：US14419350

申请日：2013-08-27

Applicant: INTERMETALLICS CO., LTD.

Inventor： Tetsuhiko Mizoguchi ,  Masato Sagawa

IPC: H01F1/053 ,  H01F1/057 ,  C22C38/00 ,  C22C38/06 ,  C22C38/10 ,  C22C38/16 ,  H01F1/08 ,  H01F41/02

Abstract: The present invention aims to provide a NdFeB system sintered magnet capable of improving the magnetization characteristic. The NdFeB system sintered magnet is a NdFeB system sintered magnet with the c axis oriented in one direction, characterized in that: the median of the grain size of the crystal grains at a section perpendicular to the c axis is 4.5 μm or less, and the area ratio of the crystal grains having grain sizes of 1.8 μm or smaller on the aforementioned section is 5% or lower. The median of the grain size is decreased (to 4.5 μm or less), whereby improve the coercive force is improved. Simultaneously, the area ratio of the crystal grains having grain sizes of 1.8 μm or smaller is decreased (to 5% or lower) to reduce the number of crystal grains having no magnetic wall formed, whereby the magnetization characteristic is improved.

公开(公告)号：US09738965B2

公开(公告)日：2017-08-22

申请号：US14777624

申请日：2014-03-13

Applicant: INTERMETALLICS CO., LTD. ,  DAIDO STEEL CO., LTD.

Inventor： Masato Sagawa ,  Shinobu Takagi

IPC: H01F1/057 ,  C23C10/30 ,  C22C38/00 ,  B22F1/00 ,  H01F41/02 ,  C22C28/00 ,  C22C38/02 ,  C22C38/10 ,  C22C38/16 ,  B22F3/16 ,  B22F3/24 ,  C22C38/06

Abstract: Producing an RFeB system sintered magnet with high corrosion resistance and low loss of energy in an RFeB system sintered magnet with high magnetic properties produced by a grain boundary diffusion process. A paste prepared by mixing an organic matter having a molecular structure including an oxygen atom and a metallic powder containing a heavy rare-earth element which is at least one element selected from the group of Dy, Ho and Tb, is applied to the surface of an RFeB system sintered compact composed of crystal grains whose main phase is R2Fe14B containing, as a main rare-earth element, a light rare-earth element which is at least one element selected from the group of Nd and Pr. A heating process for a grain boundary diffusion treatment is performed. As a result, a protective layer containing an oxide of the light rare-earth element is formed on the surface.

公开(公告)号：US09412505B2

公开(公告)日：2016-08-09

申请号：US14114653

申请日：2012-12-27

Applicant: INTERMETALLICS CO., LTD.

Inventor： Masato Sagawa ,  Tetsuhiko Mizoguchi

IPC: H01F1/055 ,  H01F41/02 ,  C22C38/00 ,  H01F1/057 ,  C22C33/02

CPC classification number: H01F1/0577 ,  C22C33/0278 ,  C22C38/00 ,  C22C38/005 ,  C22C38/06 ,  C22C38/10 ,  C22C38/16 ,  C22C2202/02 ,  H01F1/057 ,  H01F41/0293

Abstract: A NdFeB system sintered magnet produced by the grain boundary diffusion method and has a high coercive force and squareness ratio with only a small decrease in the maximum energy product. A NdFeB system sintered magnet having a base material produced by orienting powder of a NdFeB system alloy and sintering the powder, with Dy and/or Tb (the “Dy and/or Tb” is hereinafter called RH) attached to and diffused from a surface of the base material through the grain boundary inside the base material by a grain boundary diffusion treatment, wherein the difference Cgx-Cx between the RH content Cgx (wt %) in the grain boundary and the RH content Cx (wt %) in main-phase grains which are grains constituting the base material at the same depth within a range from the surface to which RH is attached to a depth of 3 mm is equal to or larger than 3 wt %.

Abstract translation: 由晶界扩散法生产的NdFeB系烧结磁体，具有高的矫顽力和矩形比，其最大能量积只有很小的降低。 一种NdFeB系烧结磁体，其具有通过使NdFeB系合金的粉末取向并烧结粉末而制造的基体，Dy和/或Tb（“Dy和/或Tb”在下文中称为RH）附着并从表面扩散 通过晶界扩散处理通过基材内部的晶界而使晶粒边界的RH含量Cgx（wt％）与主晶相中的RH含量Cx（wt％）之间的差Cgx-Cx， 在从RH附着的表面到3mm的深度的范围内，构成基材的颗粒的相位晶粒等于或大于3重量％。

公开(公告)号：US09384890B2

公开(公告)日：2016-07-05

申请号：US14765130

申请日：2014-02-03

Applicant: INTERMETALLICS CO., LTD. ,  DAIDO STEEL CO., LTD.

Inventor： Masato Sagawa ,  Osamu Itatani ,  Norio Yoshikawa

IPC: H01F41/02 ,  B65B1/04 ,  B65B1/16 ,  B22F3/00 ,  B30B15/30 ,  B65B7/28

CPC classification number: H01F41/0273 ,  B22F3/004 ,  B30B15/302 ,  B65B1/04 ,  B65B1/16 ,  B65B7/28 ,  H01F41/0266

Abstract: A powder-filling system capable of filling a container with powder at an approximately uniform filling density has: a hopper having an opening removably and hermetically closably attached to the container, the hopper communicating with the container at the opening for supplying powder to a container; a powder supplier for supplying powder to the hopper; a gas supplier for repeatedly supplying compressed gas in a pulsed form to the hopper, with the hopper hermetically closably attached to the container; and a sieve member provided at the opening and having a smaller openings in a region near a side wall of the hopper than in its central region. The smaller openings in the region near the side wall of the hopper where the powder more easily falls from the hopper into the container impedes the fall of the powder in that region and improves the overall uniformity in the filling density.