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    Rare-earth magnet and method of manufacturing the same
    1.
    发明授权
    Rare-earth magnet and method of manufacturing the same 有权

    公开(公告)号：US12217907B2

    公开(公告)日：2025-02-04

    申请号：US17539491

    申请日：2021-12-01

    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA ,  NICHIA CORPORATION

    Inventor： Masaaki Ito ,  Daisuke Ichigozaki ,  Noritsugu Sakuma ,  Akihito Kinoshita ,  Michiya Kume ,  Hisashi Maehara

    IPC: H01F41/02 ,  B22F3/16 ,  B22F3/24 ,  H01F1/059

    Abstract: A rare-earth magnet and a method of manufacturing the same are provided. The method includes: preparing Sm—Fe—N magnetic powder; preparing reforming material powder containing metallic zinc; mixing the magnetic powder and the reforming material powder to obtain mixed powder; subjecting the mixed powder to compression molding in a magnetic field to obtain a magnetic-field molded body; subjecting the magnetic-field molded body to pressure sintering to obtain a sintered body; and subjecting the sintered body to heat treatment. A content proportion of the metallic zinc in the reforming material powder is 10 to 30% by mass with respect to the mixed powder. When a temperature and time in conditions for the heat treatment are defined as x° C. and y hours, respectively, the formulas y≥−0.32x+136 and 350≤x≤410 are met.

    Magnetic material and manufacturing method thereof
    2.
    发明授权
    Magnetic material and manufacturing method thereof 有权

    公开(公告)号：US11996219B2

    公开(公告)日：2024-05-28

    申请号：US17478043

    申请日：2021-09-17

    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

    Inventor： Noritsugu Sakuma ,  Tetsuya Shoji ,  Akihito Kinoshita ,  Akira Kato

    IPC: H01F1/057 ,  H01F41/02

    CPC classification number: H01F1/057 ,  H01F41/0253

    Abstract: A magnetic material according to the present disclosure includes a main phase having an R2T14B type crystal structure (R is a rare earth element and T is a transition metal element). The main phase has a composition represented by ((Nd, Pr)(1-x-y)LaxR1y))2((Fe(1-z-w)(Co, Ni)zMw))14B (where, R1 is a rare earth element other than Nd, Pr, and La, M is an element other than Fe, Co, Ni, and a rare earth element, and the like, and 0.25≤x≤1.00, 0≤y≤0.10, 0.15≤z≤0.40, and 0≤w≤0.1 are satisfied). A manufacturing method of the magnetic material according to the present disclosure includes melting a raw material containing the elements constituting the main phase and solidifying the melted raw material.

    Rare earth magnet and producing method thereof
    4.
    发明授权
    Rare earth magnet and producing method thereof 有权

    公开(公告)号：US11869690B2

    公开(公告)日：2024-01-09

    申请号：US17578856

    申请日：2022-01-19

    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

    Inventor： Noritsugu Sakuma ,  Tetsuya Shoji ,  Akihito Kinoshita ,  Akira Kato

    IPC: H01F1/057 ,  H01F41/02 ,  B22F3/24 ,  C22C38/00 ,  C22C38/10

    CPC classification number: H01F1/0577 ,  C22C38/005 ,  C22C38/10 ,  H01F41/0293 ,  C22C2202/02 ,  H01F41/0266

    Abstract: A rare earth magnet in which the amount used of a heavy rare earth element is more reduced while maintaining enhancement of the coercive force, and a producing method thereof are provided. The rare earth magnet of the present disclosure has a main phase 10 and a grain boundary phase 20. The main phase 10 has a composition represented by R12T14B. The main phase 10 has a core part 12 and a shell part 14. Denoting the abundances of R2 and Ce (R2 is heavy rare earth element) occupying 4f site of the shell part 14 as R24f and Ce4f, respectively, and denoting the abundances of R2 and Ce occupying 4g site of the shell part 14 as R24g and Ce4g, respectively, the rare earth magnet satisfies 0.44≤R24g/(R24f+R24g)≤0.70 and 0.04≤(Ce4f+Ce4g)/(R24f+R24g). The rare earth magnet-producing method of the present disclosure uses a modifier containing at least R2 and Ce.

    R-T-B-BASED RARE EARTH MAGNET AND PRODUCTION METHOD THEREOF
    5.
    发明公开
    R-T-B-BASED RARE EARTH MAGNET AND PRODUCTION METHOD THEREOF 审中-公开

    公开(公告)号：US20240186036A1

    公开(公告)日：2024-06-06

    申请号：US18488076

    申请日：2023-10-17

    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

    Inventor： Noritsugu Sakuma ,  Tetsuya Shoji ,  Akihito Kinoshita

    IPC: H01F1/057

    CPC classification number: H01F1/057

    Abstract: The R-T-B-based rare earth magnet 100 of the present disclosure includes a main phase 10 having an R2T14B-type crystal structure and a grain boundary phase 20. The average grain size of the main phase 10 is from 1.0 to 10,0 μm. The main phase 10 has a core portion 12 and a shell portion 14. The total content ratio of cerium, lanthanum, yttrium and scandium is higher in the core portion 12 than in the shell portion 14. The total content ratio of neodymium, praseodymium, gadolinium, terbium, dysprosium and holmium is higher in the shell portion 14 than in the core portion 12. The R-T-B-based rare earth magnet 100 contains from 0.05 to 0.50 at % of carbon. The content ratio of the carbon is higher in the grain boundary phase 20 than in the main phase 10.

    Rare earth magnet and manufacturing method therefor
    6.
    发明授权
    Rare earth magnet and manufacturing method therefor 有权

    公开(公告)号：US11664140B2

    公开(公告)日：2023-05-30

    申请号：US17182993

    申请日：2021-02-23

    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

    Inventor： Noritsugu Sakuma ,  Tetsuya Shoji ,  Akihito Kinoshita

    IPC: H01F1/057 ,  H01F41/02 ,  C22C38/00 ,  H01F1/058

    CPC classification number: H01F1/0577 ,  C22C38/005 ,  H01F1/058 ,  H01F41/0266 ,  H01F41/0293

    Abstract: A rare earth magnet includes a main phase and a particle boundary phase and in which an overall composition is represented by a formula, (R2(1-x)R1x)yFe(100-y-w-z-v)CowBzM1v.(R3(1-p)M2p)q.(R4(1-s)M3s)t, where R1 is a light rare earth element, R2 and R3 are a medium rare earth element, R4 is a heavy rare earth element, M1, M2, M3 are a predetermined metal element. The main phase includes a core portion, a first shell portion, and a second shell portion. The content proportion of medium rare earth element is higher in the first shell portion than in the core portion, the content proportion of medium rare earth element is lower in the second shell portion than in the first shell portion. The second shell portion contains heavy rare earth elements.

    Method of producing motor core
    7.
    发明授权
    Method of producing motor core 有权

    公开(公告)号：US11522420B2

    公开(公告)日：2022-12-06

    申请号：US16811811

    申请日：2020-03-06

    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

    Inventor： Akihito Kinoshita ,  Noritsugu Sakuma ,  Tetsuya Shoji ,  Kosuke Yonekawa

    IPC: H01F1/057 ,  H01F1/147 ,  H02K15/03 ,  C22C38/00 ,  H02K1/02 ,  H05B6/80

    Abstract: A method of producing a motor core includes preparing a soft magnetic plate containing a transition metal element, preparing a modifying member containing an alloy having a melting point lower than a melting point of the soft magnetic plate, bringing the modifying member into contact with a part of a plate surface of the soft magnetic plate, causing the modifying member to diffuse and penetrate into the soft magnetic plate from a contact surface between the soft magnetic plate and the modifying member and forming a hard magnetic phase-containing part in a part of the soft magnetic plate, and laminating a plurality of soft magnetic plates on each other after the modifying member is brought into contact with the part of the plate surface of the soft magnetic plate.

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