JP2006261433A - Compound magnet, method for manufacturing the same and motor - Google Patents

Compound magnet, method for manufacturing the same and motor Download PDF

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JP2006261433A
JP2006261433A JP2005077585A JP2005077585A JP2006261433A JP 2006261433 A JP2006261433 A JP 2006261433A JP 2005077585 A JP2005077585 A JP 2005077585A JP 2005077585 A JP2005077585 A JP 2005077585A JP 2006261433 A JP2006261433 A JP 2006261433A
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magnet
composite
coercive force
magnetic flux
flux density
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JP4581770B2 (en
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Takasuke Kaneda
敬右 金田
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Toyota Motor Corp
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors
    • H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)
  • Hard Magnetic Materials (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)
  • Permanent Magnet Type Synchronous Machine (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a compound magnet which can have a necessary coersive force and magnetic flux density while reducing a manufacturing cost and can effectively reduce an eddy current generated in the magnet, a motor having the compound magnet, and also a method for manufacturing the compound magnet. <P>SOLUTION: A compound magnet 1 is made of an outer magnet 12 made of a material having relatively small magnetic flux density and relatively high coersive force performance, and an inner magnet 11 made of a material having relatively large magnetic flux and relatively low coersive force performance. A plurality of notches may be formed even at the side surface of the compound magnet 1 on the side of a stator. In this case, the periphery of the outer magnet 12 can also be covered with a resin material. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、保磁力性能や磁束密度の異なる磁石を組み合わせてなる複合磁石と該複合磁石を備えたモータ、および該複合磁石の製造方法に係り、特に、製造コストを低減しながら所要の保磁力および磁束密度を備えることができ、さらには磁石に生じ得る渦電流を効果的に低減することのできる複合磁石と該複合磁石を備えたモータ、および該複合磁石の製造方法に関するものである。   The present invention relates to a composite magnet formed by combining magnets having different coercive force performance and magnetic flux density, a motor including the composite magnet, and a method for manufacturing the composite magnet, and more particularly, a required coercive force while reducing manufacturing cost. Further, the present invention relates to a composite magnet that can be provided with a magnetic flux density and that can effectively reduce eddy currents that can be generated in the magnet, a motor including the composite magnet, and a method of manufacturing the composite magnet.

近時、排気ガスによる環境影響への問題やガソリン資源の将来的な限界への対策といった面から、電気自動車や、電気とガソリンとを適宜使い分けるハイブリット自動車が注目されており、その普及量は飛躍的に伸びている。かかる電気自動車やハイブリット自動車においては、最小限の消費電力で最大の駆動力を発揮し得る駆動用モータが極めて重要であり、自動車産業や電機産業においてはかかる駆動用モータの開発が鋭意進められているところである。尤も、かかる電機自動車やハイブリット自動車においては、燃料電池や駆動用モータが高価なものとなるため、それらの製造価格をいかに安価にできるかが、その普及量を大きく左右することとなる。   Recently, electric vehicles and hybrid vehicles that properly use electricity and gasoline are attracting attention from the viewpoints of environmental impacts caused by exhaust gas and measures for future limitations of gasoline resources. Is growing. In such electric vehicles and hybrid vehicles, a driving motor that can exert the maximum driving force with the minimum power consumption is extremely important, and the development of such a driving motor has been eagerly promoted in the automobile industry and the electrical industry. It is where you are. However, in such electric vehicles and hybrid vehicles, fuel cells and drive motors are expensive, and how much their manufacturing price can be reduced greatly affects the amount of their spread.

上記する駆動用モータの性能を向上させる、あるいはモータ製造価格を安価にするためのファクターは多様に存在するが、中でもモータのロータ内部に埋め込まれる、あるいはロータ表面に装着される磁石の改善が大きなものである。従来の磁石、例えば永久磁石においては、多少コストが高くても保磁力と磁束密度とがともに比較的高い高性能の単一材料からなる永久磁石が上記する自動車の駆動用モータに適用されており、磁石の性能とコストとの双方の最適値を求めるといった概念が存在しなかったといってもよい。尤も、性能の異なる材料からなる複合磁石を製造するよりも、単一材料からなる磁石を製造することの方が製造コストが安価となり易いという実態もある。   There are various factors to improve the performance of the driving motor described above or to reduce the motor manufacturing cost, but the improvement of the magnet embedded in the rotor of the motor or mounted on the rotor surface is significant. Is. In a conventional magnet, for example, a permanent magnet, a permanent magnet made of a high-performance single material having a relatively high coercive force and magnetic flux density is applied to the above-mentioned motor for driving an automobile, although the cost is somewhat high. It may be said that the concept of obtaining the optimum values of both the performance and cost of the magnet did not exist. However, there is an actual situation that it is easier to manufacture a magnet made of a single material than to manufacture a composite magnet made of materials having different performances.

しかし、電機自動車やハイブリット自動車が主流となる近い将来、高性能の永久磁石のみから磁石を製造することの方が製造コストが高価となることは十分に予想される。したがって、モータの駆動にかかせない磁石の複数の性能のうち、磁石のどの部位でそれぞれの性能が発揮されれば所要の性能を満足できるのかを精査し、各部位に要求される性能を備えた、異なる材料から構成される磁石とすることにより、その製造コストの低減が可能となる。   However, in the near future when electric vehicles and hybrid vehicles will become mainstream, it is fully expected that manufacturing costs will be higher if only magnets with high performance are manufactured. Therefore, of the multiple performances of magnets that are indispensable for driving the motor, we will investigate which parts of the magnets are capable of satisfying the required performance and provide the performance required for each part. In addition, by using a magnet made of different materials, the manufacturing cost can be reduced.

例えば特許文献１において、高価な２つの磁石材層の間に、体積百分率で２０％以下の軟磁性材層を挟み込んだ複合磁石とそれを利用したモータが開示されている。軟磁性材層が介在することにより、複合磁石を焼結成形する場合でも２つの磁石材層が熱収縮によって剥離することを防止することが可能となる。
特開２００１−１１０６１７号公報 For example, Patent Document 1 discloses a composite magnet in which a soft magnetic material layer having a volume percentage of 20% or less is sandwiched between two expensive magnet material layers and a motor using the same. By interposing the soft magnetic material layer, it is possible to prevent the two magnet material layers from being separated due to thermal contraction even when the composite magnet is sintered.
JP 2001-110617 A

特許文献１に開示の複合磁石によれば、磁石を焼結成形する際にも各磁石材層の剥離が防止でき、軟磁性材層の分だけ磁石のコストを低減することが可能となる。しかし、軟磁性材層は磁石全体に対して体積百分率で２０％以下であるため、コストの格段の低減を図ることができないことや、磁石全体の部位ごとに、保磁力性能の高い磁石や磁束密度の高い磁石を使い分けることによって性能とコストの双方の最適値を追求するといったものではないために、その構成には多分に改善の余地が残されている。   According to the composite magnet disclosed in Patent Document 1, peeling of each magnet material layer can be prevented even when the magnet is sintered and the cost of the magnet can be reduced by the amount of the soft magnetic material layer. However, since the soft magnetic material layer has a volume percentage of 20% or less with respect to the entire magnet, the cost cannot be remarkably reduced, and a magnet or magnetic flux with high coercive force performance is provided for each part of the entire magnet. Since the optimum value of both performance and cost is not pursued by properly using high-density magnets, there is still room for improvement in the configuration.

本発明は、上記する問題に鑑みてなされたものであり、磁石の部位ごとに要求される保磁力や磁束密度を確保しながら各部位ごとに磁石の材料を変更することにより、その製造コストの低減と性能確保の双方を満足することのできる複合磁石と該複合磁石を備えたモータ、および該複合磁石の製造方法を提供することを目的とする。また、磁石に生じ得る渦電流を効果的に低減することのできる複合磁石と該複合磁石を備えたモータ、および該複合磁石の製造方法を提供することを目的とする。   The present invention has been made in view of the problems described above, and by changing the material of the magnet for each part while ensuring the coercive force and magnetic flux density required for each part of the magnet, the production cost can be reduced. It is an object of the present invention to provide a composite magnet capable of satisfying both reduction and performance securing, a motor including the composite magnet, and a method of manufacturing the composite magnet. It is another object of the present invention to provide a composite magnet capable of effectively reducing eddy currents that can be generated in the magnet, a motor including the composite magnet, and a method for manufacturing the composite magnet.

前記目的を達成すべく、本発明による複合磁石は、第一の磁石と、第一の磁石を囲繞する第二の磁石とからなり、第一の磁石は、磁束密度が相対的に高く、保磁力が相対的に低い材料から構成されており、第二の磁石は、磁束密度が相対的に低く、保磁力が相対的に高い材料から構成されていることを特徴とする。   In order to achieve the above object, a composite magnet according to the present invention comprises a first magnet and a second magnet surrounding the first magnet, and the first magnet has a relatively high magnetic flux density and is maintained. The second magnet is made of a material having a relatively low magnetic force, and the second magnet is made of a material having a relatively low magnetic flux density and a relatively high coercive force.

例えば、内磁型の磁石（ロータ内部に磁石が埋め込まれている）において、磁石の側面付近（ステータ側の側面や、該ステータ側の側面に直交する短辺側の側面）には、ステータ側から入ってくる外部磁界が磁石の内部に比して相対的に強いため、磁力を保持するために高い保磁力が要求される。一方、磁石の内部においては、外部磁界が相対的に弱いことからその側面付近ほどの保磁力は必要なく、その一方でモータのトルク性能に寄与する高い磁束密度が要求される。この保磁力と磁束密度に関しては、いずれの磁石材料を取ってみても、一方が強ければ他方が相対的に弱くなるといった傾向があり、双方の性能をともに適度に満足しうる磁石（保磁力と磁束密度との積からなる最大エネルギー積の高い磁石）、例えばネオジム系磁石はコストが高価となる。なお、ネオジム系の磁石といっても、その保磁力性能によってそのコストは多様である。   For example, in an inner magnet type magnet (the magnet is embedded in the rotor), the side of the magnet (the side on the stator side or the side on the short side perpendicular to the side on the stator side) Since the external magnetic field entering from the inside is relatively stronger than the inside of the magnet, a high coercive force is required to maintain the magnetic force. On the other hand, since the external magnetic field is relatively weak inside the magnet, a coercive force as close to the side surface is not necessary, and on the other hand, a high magnetic flux density contributing to the torque performance of the motor is required. Regarding this coercive force and magnetic flux density, no matter which magnet material is taken, there is a tendency that if one is strong, the other is relatively weak, and a magnet (coercive force and A magnet having a high maximum energy product consisting of a product of magnetic flux density), for example, a neodymium magnet, is expensive. Even if it is a neodymium magnet, its cost varies depending on its coercive force performance.

本発明においては、第一の磁石と第二の磁石という２つの磁石を組み合わせ、第二の磁石が第一の磁石の外側を囲繞するように構成されている。そして、上記する磁石の有する保磁力と磁束密度といった性能を勘案して、外部磁界の影響が強く高い保磁力が要求される複合磁石の外側部分（第二の磁石）には、複合磁石の内側の部分（第一の磁石）に対して相対的に保磁力が高く、相対的に磁束密度の低い磁石材料を使用し、外部磁界の影響をそれ程受けない磁石内部には、磁石の外側に対して相対的に保磁力が低く、相対的に磁束密度の高い磁石材料を使用するものである。このように、磁石の部位ごとに要求される性能に応じて材質の異なる材料から磁石を形成することにより、磁石の要求性能を満たしながら製造コストを低減することが可能となる。これは、高い保磁力と磁束密度が要求される、例えばハイブリット車用のモータに使用される磁石に好適であり、その製造数が増加するにつれて、高価な単一材料から磁石を製造する場合に比して製造コストが低減できるものである。   In the present invention, two magnets of a first magnet and a second magnet are combined, and the second magnet surrounds the outside of the first magnet. In consideration of the coercive force and magnetic flux density of the magnet, the outer part of the composite magnet (second magnet), which is strongly influenced by the external magnetic field and requires a high coercive force, A magnet material with a relatively high coercive force and a relatively low magnetic flux density with respect to the part of the magnet (first magnet) is used. Therefore, a magnet material having a relatively low coercive force and a relatively high magnetic flux density is used. In this way, by forming the magnet from different materials according to the performance required for each part of the magnet, it is possible to reduce the manufacturing cost while satisfying the required performance of the magnet. This is suitable for magnets that require high coercive force and magnetic flux density, for example, used in motors for hybrid vehicles. When the number of manufactured magnets increases, magnets are manufactured from expensive single materials. In comparison, the manufacturing cost can be reduced.

なお、使用される磁石材料は特に限定するものではないが、既述するようなネオジム系磁石や、サマリウム系磁石、セリウム系磁石、アルニコ、フェライトなどがあり、それぞれの材料においても、成分組成の相違により、保磁力性能や磁束密度が多様に相違する。   In addition, although the magnet material to be used is not particularly limited, there are neodymium magnets as described above, samarium magnets, cerium magnets, alnicos, ferrites, etc., and each material also has a component composition. Due to the difference, coercive force performance and magnetic flux density are variously different.

また、本発明による複合磁石の他の実施形態において、前記第一の磁石は保磁力が１０〜２０ｋＯｅのネオジムからなり、前記第二の磁石は保磁力が２０ｋＯｅよりも大きなネオジムに、ジスプロシウムを含む重希土類元素が添加された材料からなることを特徴とする。   In another embodiment of the composite magnet according to the present invention, the first magnet is made of neodymium having a coercive force of 10 to 20 kOe, and the second magnet contains dysprosium in neodymium having a coercive force larger than 20 kOe. It is characterized by comprising a material to which a heavy rare earth element is added.

既述するように、複合磁石の外側を構成する第二の磁石には、少なくとも第一の磁石に比して高い保磁力を備えた材料を使用する。本発明において使用する磁石材料は、ネオジムであるが、第一の磁石と第二の磁石で、それぞれ保磁力の相違する２種類のネオジムを使用するものである。なお、保磁力が高くなるに従いその材料コストも高くなることを付言しておく。また、既述するように、保磁力の増加に伴って磁束密度は低減するものである。   As described above, a material having a coercive force higher than that of the first magnet is used for the second magnet that forms the outside of the composite magnet. The magnet material used in the present invention is neodymium, but the first magnet and the second magnet use two types of neodymium having different coercive forces. Note that the material cost increases as the coercive force increases. In addition, as described above, the magnetic flux density decreases as the coercive force increases.

ネオジムの保磁力性能は、少なくとも１０ｋＯｅ以上であるが、現在その測定可能な最大値は４０〜５０ｋＯｅである。そこで、相対的に高い保磁力が要求される第二の磁石には、保磁力が２０ｋＯｅよりも大きなネオジムを使用する。一方、第一の磁石には、保磁力が１０〜２０ｋＯｅのネオジムを使用することで、複合磁石全体の材料コストを低減できる。また、保磁力の性能の相違に伴い、第一の磁石の磁束密度は、第二の磁石の磁束密度に対して相対的に高いものとなる。   The coercive force performance of neodymium is at least 10 kOe or more, but the maximum value currently measurable is 40 to 50 kOe. Therefore, neodymium having a coercive force larger than 20 kOe is used for the second magnet that requires a relatively high coercive force. On the other hand, the material cost of the entire composite magnet can be reduced by using neodymium having a coercive force of 10 to 20 kOe for the first magnet. Further, with the difference in coercive force performance, the magnetic flux density of the first magnet is relatively higher than the magnetic flux density of the second magnet.

また、第二の磁石には、保磁力が２０ｋＯｅよりも大きなネオジムにジスプロシウムやテルビウムなどの重希土類元素が添加されている。ジスプロシウムやテルビウムを添加することにより、磁石の耐熱性を向上させることができる。磁石は高温雰囲気下においてその保磁力や磁束密度の双方が低下するため、特に、モータの温度上昇が激しいハイブリット車用のモータには、本発明の複合磁石は好適である。   The second magnet is added with a rare earth element such as dysprosium or terbium in neodymium having a coercive force larger than 20 kOe. By adding dysprosium or terbium, the heat resistance of the magnet can be improved. Since both the coercive force and the magnetic flux density of a magnet decrease in a high temperature atmosphere, the composite magnet of the present invention is suitable for a motor for a hybrid vehicle, in which the temperature of the motor is extremely high.

また、本発明による複合磁石の他の実施形態において、前記第一の磁石はアルニコからなり、前記第二の磁石は保磁力が２０ｋＯｅよりも大きなネオジムに、ジスプロシウムを含む重希土類元素が添加された材料からなることを特徴とする。   In another embodiment of the composite magnet according to the present invention, the first magnet is made of alnico, and the second magnet is made of neodymium having a coercive force larger than 20 kOe and a heavy rare earth element containing dysprosium added thereto. It is made of a material.

本発明においては、高い保磁力が要求されない第一の磁石において保持力性能が低いアルニコを使用するものであり、複合磁石の製造コストを格段に低減することが可能となる。   In the present invention, alnico having a low coercive force performance is used in the first magnet that does not require a high coercive force, and the manufacturing cost of the composite magnet can be significantly reduced.

なお、他の実施形態としては、アルニコのほかに、さらに低価格なフェライトを使用することもできる。   As another embodiment, in addition to alnico, it is also possible to use a lower-cost ferrite.

また、本発明による複合磁石の他の実施形態は、前記複合磁石において、第二の磁石の側面には、その軸心方向に伸びる切り欠きが所定の間隔を置いて複数設けられていることを特徴とする。   In another embodiment of the composite magnet according to the present invention, in the composite magnet, a plurality of notches extending in the axial direction are provided on a side surface of the second magnet at a predetermined interval. Features.

ロータ内部に磁石が埋め込まれてなる磁石埋込み型ロータであっても、ロータ表面に磁石が接着されてなる表面型ロータであっても、該ロータの回転に伴って磁石に入ってくる磁束が変化することからその表面（ステータ側の側面）には渦電流が生じ易い。渦電流によって生じる発熱により、モータのトルク性能が阻害されることから、モータのトルク性能を確保するためには磁石表面に生じ得る渦電流を可及的に低減することが望まれる。なお、渦電流は、磁束密度や、部材の厚み、部材の幅などに比例して大きくなる傾向がある。   Whether the rotor is a magnet-embedded rotor with a magnet embedded in the rotor or a surface-type rotor with a magnet bonded to the rotor surface, the magnetic flux entering the magnet changes as the rotor rotates. Therefore, eddy currents are likely to occur on the surface (side surface on the stator side). Since the torque performance of the motor is hindered by the heat generated by the eddy current, it is desirable to reduce the eddy current that can be generated on the magnet surface as much as possible in order to ensure the torque performance of the motor. The eddy current tends to increase in proportion to the magnetic flux density, the thickness of the member, the width of the member, and the like.

そこで、本発明では、複合磁石の外側部分である第二の磁石の側面に、その軸心方向に伸びる切り欠きを間隔を置いて複数設けることにより、複合磁石のステータ側側面を複数に縁切りして渦電流を低減するものである。なお、切り欠きの幅を大きくしすぎると、磁石に入る外部磁束量が低減し、結果としてモータのトルク性能を低減してしまうため、切り欠きの幅は可及的に狭い方が望ましい。   Therefore, in the present invention, the side surface of the second magnet, which is the outer portion of the composite magnet, is provided with a plurality of notches extending in the axial direction at intervals, so that the stator side surface of the composite magnet is divided into a plurality of edges. This reduces eddy currents. If the width of the notch is too large, the amount of external magnetic flux entering the magnet is reduced, resulting in a reduction in the torque performance of the motor. Therefore, it is desirable that the width of the notch is as narrow as possible.

また、本発明による複合磁石の他の実施形態において、第二の磁石の端辺付近における切り欠きと切り欠きの間隔は、第二の磁石の中央付近における切り欠きと切り欠きの間隔に対して相対的に狭くなっていることを特徴とする。   Further, in another embodiment of the composite magnet according to the present invention, the interval between the notch and the notch in the vicinity of the end of the second magnet is relative to the interval between the notch and the notch in the vicinity of the center of the second magnet. It is characterized by being relatively narrow.

ステータ側から入ってくる外部磁界は、磁石の側面、特に磁石の短辺を構成する端部付近に卓越する傾向があるため、切り欠き同士の間隔を、磁石側面の中央付近よりも端部付近において狭くすることにより、渦電流を効果的に低減することができる。   The external magnetic field that enters from the stator side tends to dominate the sides of the magnet, especially near the ends that make up the short side of the magnet, so the distance between the notches is closer to the ends than near the center of the magnet side. By narrowing at, eddy current can be effectively reduced.

また、本発明による複合磁石の他の実施形態は、前記複合磁石において、第二の磁石の側面には、その軸心方向に直交する方向に伸びる切り欠きが所定の間隔を置いて複数設けられていることを特徴とする。   In another embodiment of the composite magnet according to the present invention, in the composite magnet, a plurality of notches extending in a direction perpendicular to the axial direction are provided on a side surface of the second magnet at predetermined intervals. It is characterized by.

第二の磁石の側面には、既述するような磁石の軸心方向に伸びる切り欠きのほかに、本発明のように磁石の軸心方向に直交する方向に伸びる切り欠きであっても同様の渦電流低減効果が得られる。   On the side surface of the second magnet, in addition to the notch extending in the axial direction of the magnet as described above, the same applies to the notch extending in the direction perpendicular to the axial direction of the magnet as in the present invention. Eddy current reduction effect can be obtained.

また、本発明による複合磁石の他の実施形態は、前記複合磁石において、第二の磁石のまわりには樹脂の被膜が形成されており、切り欠きには該樹脂が満たされていることを特徴とする。   Another embodiment of the composite magnet according to the present invention is characterized in that in the composite magnet, a resin film is formed around the second magnet, and the notch is filled with the resin. And

第二の磁石の側面に複数の切り欠きを設けることにより、複合磁石の耐食性と剛性が低減する可能性がある。そこで、本発明においては、第二の磁石のまわりに樹脂の被膜を形成することにより、切り欠き部分に樹脂が満たされた状態で樹脂が硬化し、したがって複合磁石全体の耐食性の低減や剛性の低減を防止することができる。なお、かかる樹脂は特に限定するものではないが、例えばフェノール樹脂などを使用することができる。   By providing a plurality of notches on the side surface of the second magnet, the corrosion resistance and rigidity of the composite magnet may be reduced. Therefore, in the present invention, by forming a resin film around the second magnet, the resin is cured in a state where the resin is filled in the notch portion, and therefore the overall corrosion resistance of the composite magnet is reduced and the rigidity is reduced. Reduction can be prevented. In addition, although this resin is not specifically limited, For example, a phenol resin etc. can be used.

また、本発明によるモータは、前記複合磁石がロータの内部に埋め込まれていることを特徴とする。   The motor according to the present invention is characterized in that the composite magnet is embedded in a rotor.

既述するように経済的で、かつ高い保磁力と磁束密度を有し、さらには渦電流を効果的に低減できる複合磁石をロータ内部に埋め込むことにより、経済的で高性能のモータを製作することが可能となり、かかるモータは、特に、今後、大幅な需要が期待されるハイブリット自動車や電気自動車に好適である。   As described above, an economical and high-performance motor is manufactured by embedding a composite magnet inside the rotor that is economical and has high coercive force and magnetic flux density and can effectively reduce eddy currents. Such a motor is particularly suitable for a hybrid vehicle and an electric vehicle that are expected to have a great demand in the future.

また、本発明による複合磁石の製造方法は、第一の磁石と、第一の磁石を囲繞する第二の磁石とからなり、第一の磁石は、磁束密度が相対的に高く、保磁力が相対的に低い材料から構成されており、第二の磁石は、磁束密度が相対的に低く、保磁力が相対的に高い材料から構成されている複合磁石の製造方法であって、第一の磁石と型との間に第二の磁石の厚みを確保した姿勢で第一の磁石の圧粉体を型内に配設し、型と第一の磁石の圧粉体との間に第二の磁石を構成する粉体を充填し、型にその外側から圧力を加えて第一の磁石の圧粉体と第二の磁石の圧粉体を成形し、該第一の磁石の圧粉体と第二の磁石の圧粉体を焼結させることを特徴とする。   The method of manufacturing a composite magnet according to the present invention includes a first magnet and a second magnet surrounding the first magnet. The first magnet has a relatively high magnetic flux density and a coercive force. The second magnet is a method of manufacturing a composite magnet made of a material having a relatively low magnetic flux density and a relatively high coercive force. The green compact of the first magnet is disposed in the mold in a posture in which the thickness of the second magnet is ensured between the magnet and the mold, and the second compact is placed between the mold and the green compact of the first magnet. The first magnet compact and the second magnet compact are formed by filling the mold with the powder constituting the magnet and applying pressure from the outside to the mold to form the first magnet compact and the second magnet compact. And the green compact of the second magnet is sintered.

本発明は既述する複合磁石の製造方法に関するものであり、例えば、公知の圧粉成形および焼結によって複合磁石を製造することができる。   The present invention relates to a method for manufacturing a composite magnet as described above. For example, a composite magnet can be manufactured by known compacting and sintering.

また、本発明による複合磁石の製造方法の他の実施形態において、前記第一の磁石は保磁力が１０〜２０ｋＯｅのネオジムからなり、前記第二の磁石は保磁力が２０ｋＯｅよりも大きなネオジムに、ジスプロシウムを含む重希土類元素が添加された材料からなることを特徴とする。   In another embodiment of the method for producing a composite magnet according to the present invention, the first magnet is made of neodymium having a coercive force of 10 to 20 kOe, and the second magnet is made of neodymium having a coercive force larger than 20 kOe. It consists of the material to which the heavy rare earth element containing dysprosium was added.

さらに、本発明による複合磁石の製造方法の他の実施形態において、前記第一の磁石はアルニコからなり、前記第二の磁石は保磁力が２０ｋＯｅよりも大きなネオジムに、ジスプロシウムを含む重希土類元素が添加された材料からなることを特徴とする。   Furthermore, in another embodiment of the method of manufacturing a composite magnet according to the present invention, the first magnet is made of alnico, and the second magnet is made of neodymium having a coercive force larger than 20 kOe and a heavy rare earth element containing dysprosium. It consists of the added material.

また、本発明による複合磁石の製造方法の他の実施形態は、焼結された複合磁石の第二の磁石の側面に、その軸心方向に伸びる切り欠き、またはその軸心方向に直交する方向に伸びる切り欠きを所定の間隔を置いて複数設けることを特徴とする。   In another embodiment of the method of manufacturing a composite magnet according to the present invention, a side surface of the second magnet of the sintered composite magnet has a notch extending in the axial direction or a direction orthogonal to the axial direction. A plurality of notches extending at a predetermined interval are provided.

本発明は、複合磁石が焼結された後で、例えば切断刃を使用して所望の切り欠きを穿設する方法である。なお、他の実施形態としては、予め型の内壁面に縦方向または横方向に伸びる切り欠き用の板材（板材の型内壁面からの突出長は、第二の磁石の厚み程度）を所望数だけ取り付けておき、型と第一の磁石の圧粉体との間に第二の磁石を構成する粉体を充填加圧して焼結する方法であってもよい。   The present invention is a method of drilling a desired notch using, for example, a cutting blade after a composite magnet is sintered. In another embodiment, a desired number of notch plates (the length of protrusion of the plate material from the inner wall surface of the plate is about the thickness of the second magnet) that extends in the vertical direction or the horizontal direction on the inner wall surface of the mold in advance. Alternatively, a method may be used in which the powder constituting the second magnet is filled and pressed between the mold and the green compact of the first magnet and sintered.

以上の説明から理解できるように、本発明の複合磁石およびその製造方法によれば、磁石の部位ごとに要求される保磁力と磁束密度に応じて磁石材料を相違させることで、磁石の製造コストを低減しながら所要の磁石性能（保磁力や磁束密度）を確保することができる。さらに、本発明の複合磁石およびその製造方法によれば、複合磁石の側面に複数の切り欠きを設けることにより、側面で卓越する渦電流を可及的に低減することができる。また、本発明のモータによれば、上記する複合磁石がロータ内部に埋め込まれているため、高い信頼性とトルク性能を確保しながらもその製造コストの低減を図ることができる。   As can be understood from the above description, according to the composite magnet of the present invention and the manufacturing method thereof, the magnet manufacturing cost can be reduced by making the magnet material different according to the coercive force and the magnetic flux density required for each part of the magnet. The required magnet performance (coercive force and magnetic flux density) can be ensured while reducing. Furthermore, according to the composite magnet of the present invention and the method of manufacturing the same, by providing a plurality of notches on the side surface of the composite magnet, the eddy current that is dominant on the side surface can be reduced as much as possible. Further, according to the motor of the present invention, since the composite magnet described above is embedded in the rotor, the manufacturing cost can be reduced while ensuring high reliability and torque performance.

以下、図面を参照して本発明の実施の形態を説明する。図１は、本発明のモータの一実施形態の平面図を、図２は、図１のＩＩ部分の拡大平面図を、図３は、図２のＸラインおよびＹラインにおける外部磁界を模式的に示したグラフを、図４は、２種類の磁石の材質を、保持力特性と磁束密度の関係で示したグラフをそれぞれ示している。図５〜図８はそれぞれ、本発明の複合磁石の実施形態を示した斜視図である。   Embodiments of the present invention will be described below with reference to the drawings. 1 is a plan view of an embodiment of the motor of the present invention, FIG. 2 is an enlarged plan view of a portion II in FIG. 1, and FIG. 3 is a schematic view of external magnetic fields in the X and Y lines in FIG. FIG. 4 is a graph showing the materials of two types of magnets in relation to the holding force characteristics and the magnetic flux density. 5 to 8 are perspective views showing embodiments of the composite magnet of the present invention.

図１は、内磁型のリラクタンスモータ１０を示したものである。モータ１０は、駆動用シャフトと一体化してその内部に複数の複合磁石１，１，…が埋め込まれてなるロータ２と、ロータ２の外周に配設されるステータ３とから大略構成されており、ステータのティースのまわりに装着された図示しないコイルに逐次電流を流すことによって磁界（矢印Ｘ）を形成し、かかる磁界（外部磁界）が複合磁石１，１，…に吸引力を作用させることにより、ロータ２は矢印Ｙ方向に回転することができる。   FIG. 1 shows an inner magnet type reluctance motor 10. The motor 10 is generally composed of a rotor 2 that is integrated with a drive shaft and has a plurality of composite magnets 1, 1,... Embedded therein, and a stator 3 that is disposed on the outer periphery of the rotor 2. A magnetic field (arrow X) is formed by sequentially passing current through a coil (not shown) mounted around the teeth of the stator, and this magnetic field (external magnetic field) causes an attractive force to act on the composite magnets 1, 1,. Thus, the rotor 2 can rotate in the arrow Y direction.

図１のＩＩ部分の拡大図が図２に示されている。複合磁石１は、内部磁石１１（第一の磁石）と外部磁石１２（第二の磁石）とから構成されている。ここで、内部磁石１１および外部磁石１２は、それぞれが有する保磁力性能と磁束密度が異なる材料から成形されている（かかる材料は後述する）。図２からも明らかなように、外部磁石１２のステータ側の側面には、ステータ側から外部磁界が直接入ってくるため、かかる側面には少なくとも高い保磁力性能が要求される。   An enlarged view of part II in FIG. 1 is shown in FIG. The composite magnet 1 includes an internal magnet 11 (first magnet) and an external magnet 12 (second magnet). Here, the inner magnet 11 and the outer magnet 12 are formed from materials having different coercive force performance and magnetic flux density (the materials will be described later). As apparent from FIG. 2, an external magnetic field directly enters the side surface of the external magnet 12 on the stator side from the stator side. Therefore, at least high coercive force performance is required for the side surface.

図２のＸラインおよびＹラインにおける外部磁界（Ｈ）を、複合磁石１のＰ点付近からＱ点付近までの間で模式的にグラフ化すると図３のようになる。Ｐ点、Ｑ点付近では、平面視で磁石の長手方向に直交する方向から入ってくる外部磁界に加えて、湾曲軌跡で入ってくる、いわゆる無効磁束の存在により、トータルの外部磁界強度が大きくなる。したがって、保磁力性能の高い外部磁石１２は、ステータ側に対向する側面〜磁石の短辺部分にわたって必要とされるため、本発明においては、外部磁石１２を中空の矩形柱体に成形し、その内部に矩形柱体の内部磁石１１を配設して複合磁石１を構成させている。   When the external magnetic field (H) in the X line and the Y line in FIG. 2 is schematically graphed from the vicinity of the P point to the vicinity of the Q point of the composite magnet 1, it is as shown in FIG. In the vicinity of the points P and Q, the total external magnetic field strength is large due to the presence of so-called reactive magnetic flux that enters the curved path in addition to the external magnetic field that enters from the direction orthogonal to the longitudinal direction of the magnet in plan view. Become. Therefore, since the external magnet 12 having high coercive force performance is required from the side facing the stator side to the short side of the magnet, in the present invention, the external magnet 12 is formed into a hollow rectangular column, A composite magnet 1 is configured by disposing an internal magnet 11 of a rectangular column.

既述するように、磁石の有する保磁力性能と磁束密度の関係は、一方が高くなると他方が低下するといった関係にあり、かかる関係を図４のグラフに示している。図４には、相対的に保磁力性能に優れた磁石（グラフＹ）と、相対的に高い磁束密度を有する磁石（グラフＸ）を模式的に示している。磁束密度の大小はモータのトルク性能に寄与するものであり、保磁力の大小は減磁し易いか否かのファクターとなる。また、保磁力性能の優れた磁石は一般に高価となる。   As described above, the relationship between the coercive force performance of the magnet and the magnetic flux density is such that when one increases, the other decreases, and this relationship is shown in the graph of FIG. FIG. 4 schematically shows a magnet (graph Y) having relatively high coercive force performance and a magnet (graph X) having a relatively high magnetic flux density. The magnitude of the magnetic flux density contributes to the torque performance of the motor, and the magnitude of the coercive force is a factor of whether or not it is easy to demagnetize. Further, a magnet having excellent coercive force performance is generally expensive.

そこで、本発明における複合磁石１は、保磁力性能に優れた磁石（図４のグラフＹ）を外部磁石として使用し、磁束密度の高い磁石（図４のグラフＸ）を内部磁石として使用することにより、複合磁石の製造コストを極力低減しながら、保磁力性能と磁束密度といった双方の性能を可及的に満足させ得る複合磁石とするものである。   Therefore, in the composite magnet 1 of the present invention, a magnet having excellent coercive force performance (graph Y in FIG. 4) is used as an external magnet, and a magnet having a high magnetic flux density (graph X in FIG. 4) is used as an internal magnet. Thus, a composite magnet that can satisfy both the coercive force performance and the magnetic flux density as much as possible while reducing the production cost of the composite magnet as much as possible.

例えば、内部磁石１１を保磁力が１０〜２０ｋＯｅのネオジムから成形し、外部磁石１２を保磁力が２０ｋＯｅのネオジムから成形することができる。ここで、外部磁石１２には、保磁力が２０ｋＯｅのネオジムにジスプロシウムやテルビウムなどの重希土類元素を添加することにより、複合磁石１の耐熱性を向上させ、モータ駆動時の発熱によって複合磁石の保磁力と磁束密度の双方の低減を防止することができる。   For example, the inner magnet 11 can be formed from neodymium having a coercive force of 10 to 20 kOe, and the outer magnet 12 can be formed from neodymium having a coercive force of 20 kOe. Here, by adding a heavy rare earth element such as dysprosium or terbium to neodymium having a coercive force of 20 kOe, the external magnet 12 improves the heat resistance of the composite magnet 1 and retains the composite magnet by heat generation when the motor is driven. Reduction of both magnetic force and magnetic flux density can be prevented.

なお、複合磁石の製造コストをさらに低減するために、内部磁石は、ネオジムに代えて、アルニコやフェライト系磁石を使用することもできる。   In addition, in order to further reduce the manufacturing cost of the composite magnet, the inner magnet may be an alnico or a ferrite magnet instead of neodymium.

複合磁石１の製造方法は、例えば、内部磁石の圧粉体を型内に配設し、型と内部磁石の圧粉体との間に外部磁石を構成する粉体を充填し、型にその外側から圧力を加えて内部磁石の圧粉体と外部磁石の圧粉体を成形し、これらを焼結させることによって製造することができる。   The method of manufacturing the composite magnet 1 includes, for example, arranging a green compact of an internal magnet in a mold, filling a powder constituting the external magnet between the mold and the green compact of the internal magnet, It can be manufactured by applying pressure from the outside to form a green compact of an internal magnet and a green compact of an external magnet and sintering them.

図５は、複合磁石の他の実施形態を示したものであり、この複合磁石１ａでは、外部磁石１２のステータ側の側面に、磁石の長手方向に沿った複数の切り欠き１２ａ，１２ａ，…が穿設されている。これは、ロータの回転に伴って複合磁石に入ってくる外部磁界の大きさが変化することにより、複合磁石の側面に生じる渦電流を効果的に低減するために設けられたものである。磁石はバルク材であることから渦電流が生じ易いため、複合磁石の側面を複数に縁切りすることで該渦電流を低減することが可能となる。なお、渦電流は、部材の厚みに比例して大きくなるものである。   FIG. 5 shows another embodiment of the composite magnet. In this composite magnet 1a, a plurality of notches 12a, 12a,... Along the longitudinal direction of the magnet are formed on the side surface of the external magnet 12 on the stator side. Is drilled. This is provided in order to effectively reduce the eddy current generated on the side surface of the composite magnet by changing the magnitude of the external magnetic field entering the composite magnet as the rotor rotates. Since the magnet is a bulk material, an eddy current is likely to be generated. Therefore, the eddy current can be reduced by cutting the side surface of the composite magnet into a plurality of edges. Note that the eddy current increases in proportion to the thickness of the member.

一方、図６に示す複合磁石１ｂは、そのステータ側の側面に穿設された切り欠き１２ａ，１２ａ，…の間隔を変化させたものである。これは、図３でも説明したように、複合磁石の側面に作用する外部磁界が磁石の端部付近で大きくなることから、磁石側面の中央から端部付近にいくにしたがって切り欠き１２ａ，１２ａ間の間隔を狭めることにより、渦電流の発生をさらに効果的に抑制することができる。   On the other hand, the composite magnet 1b shown in FIG. 6 is obtained by changing the intervals between the notches 12a, 12a,. As described with reference to FIG. 3, the external magnetic field acting on the side surface of the composite magnet increases near the end of the magnet, so that the distance between the notches 12a and 12a increases from the center of the magnet side to the end. By narrowing the interval, generation of eddy current can be more effectively suppressed.

図７では、切り欠き１２ａ，１２ａ、…を側面に水平方向に穿設してなる複合磁石１ｃが示されており、このように切り欠き１２ａ，１２ａ，…を設けることによっても、磁石尺の側面を複数に縁切りできることから渦電流の低減を図ることができる。   FIG. 7 shows a composite magnet 1c having notches 12a, 12a,... Horizontally drilled on the side surfaces, and by providing the notches 12a, 12a,. Since the side surface can be divided into a plurality of edges, the eddy current can be reduced.

最後の実施形態として、図５に示す複合磁石のまわりをフェノール樹脂などの樹脂材１３にて被覆してなる複合磁石１ｄが図８に示されている。これは、磁石側面に複数の切り欠き１２ａ，１２ａ，…を設けることにより、複合磁石全体の剛性低下や耐食性低下の防止を図ることができる。なお、図６，７に示す複合磁石１ｂ、１ｃのまわりに樹脂材を被覆してなる実施形態であってもよい。   As a final embodiment, FIG. 8 shows a composite magnet 1d formed by covering the composite magnet shown in FIG. 5 with a resin material 13 such as phenol resin. By providing a plurality of notches 12a, 12a,... On the side surface of the magnet, it is possible to prevent the rigidity of the composite magnet from being lowered and the corrosion resistance from being lowered. 6 and 7 may be an embodiment in which a resin material is coated around the composite magnets 1b and 1c.

なお、切り欠き１２ａ，１２ａ、…は、切断刃を使用しながら、所定の間隔および所定の切り欠き幅にて焼結後の複合磁石の側面に設けることができる。   The notches 12a, 12a,... Can be provided on the side surface of the composite magnet after sintering at a predetermined interval and a predetermined notch width while using a cutting blade.

発明者等は、従来の単一材料からなる磁石をロータに備えたモータと、本発明の複合磁石をロータに備えたモータとで、高負荷時の耐久時間と最大トルク、および材料コストの比較をおこなった。この解析結果とコスト比較結果を表１に示す。   The inventors compared a conventional motor having a rotor made of a single material magnet and a motor having the rotor of a composite magnet of the present invention, and compared the durability time, maximum torque, and material cost under high load. I did it. Table 1 shows the analysis results and the cost comparison results.

Figure 2006261433
Figure 2006261433

ここで、Ｘ材料とは、保磁力が１０〜２０ｋＯｅのネオジムにジスプロシウムやテルビウムなどの重希土類元素が添加された材料であり、Ｙ材料とは、保磁力が２０ｋＯｅよりも大きなネオジムにＸ材料と同様の重希土類元素が添加された材料である。また、本発明とは、内部磁石としてＸ材料を使用し、外部磁石としてＹ材料を使用したものであり、Ｘ材料からなる従来磁石に対する比率で表している。さらに、本発明においては、内部磁石と外部磁石の平面視における面積比を１：１としている。   Here, the X material is a material in which a heavy rare earth element such as dysprosium or terbium is added to neodymium having a coercive force of 10 to 20 kOe. The Y material is a neodymium having a coercive force greater than 20 kOe and an X material It is a material to which the same heavy rare earth element is added. Further, the present invention uses an X material as an internal magnet and a Y material as an external magnet, and is expressed as a ratio to a conventional magnet made of the X material. Furthermore, in the present invention, the area ratio of the inner magnet and the outer magnet in a plan view is 1: 1.

原材料比と最大トルク、および耐久時間のすべてのファクターを総合的に勘案した場合には、本発明の複合磁石が最も優れていることが理解できる。   It can be understood that the composite magnet of the present invention is most excellent when all the factors of the raw material ratio, the maximum torque, and the durability time are taken into consideration.

以上、本発明の実施の形態を図面を用いて詳述してきたが、具体的な構成はこの実施形態に限定されるものではなく、本発明の要旨を逸脱しない範囲における設計変更等があっても、それらは本発明に含まれるものである。例えば、複合磁石は、２つの性能の異なる磁石の組み合わせのほかに、３つ以上の性能の異なる磁石の組み合わせであってもよい。   The embodiment of the present invention has been described in detail with reference to the drawings. However, the specific configuration is not limited to this embodiment, and there are design changes and the like without departing from the gist of the present invention. They are also included in the present invention. For example, the composite magnet may be a combination of three or more different performance magnets in addition to a combination of two different performance magnets.

この場合であっても、複合磁石の外側を構成する磁石には保磁力が相対的に高い材質の磁石を使用し、複合磁石の内部にいくにしたがって保磁力が相対的に低くなる一方で磁束密度が相対的に高くなるような構成であることが望ましい。さらには、単一材料の磁石を使用しながらも、外側は保持力が高くなり（そこでは磁束密度が相対的に低い）、内部にいくにしたがって磁束密度が高くなるように（そこでは保磁力が相対的に低い）、材質を連続的に変化させる製造工程を経た磁石を使用することによって本発明の目的を達成することもできる。   Even in this case, a magnet made of a material having a relatively high coercive force is used as the magnet constituting the outside of the composite magnet, and the magnetic force decreases while the coercive force becomes relatively low as it goes into the composite magnet. It is desirable that the density be relatively high. Furthermore, while using a single-material magnet, the outer side has a higher coercive force (where the magnetic flux density is relatively low), and the magnetic flux density increases toward the inside (where the coercive force is). The object of the present invention can also be achieved by using a magnet that has undergone a manufacturing process in which the material is continuously changed.

本発明のモータの一実施形態の平面図。The top view of one Embodiment of the motor of this invention. 図１のＩＩ部分の拡大平面図。The enlarged plan view of the II part of FIG. 図２のＸラインおよびＹラインにおける外部磁界を模式的に示したグラフ。The graph which showed typically the external magnetic field in the X line and Y line of FIG. ２種類の磁石の材質を、保持力特性と磁束密度の関係で示したグラフ。The graph which showed the material of two types of magnets by the relationship between coercive force characteristic and magnetic flux density. 本発明の複合磁石の一実施形態を示した斜視図。The perspective view which showed one Embodiment of the composite magnet of this invention. 本発明の複合磁石の他の実施形態を示した斜視図。The perspective view which showed other embodiment of the composite magnet of this invention. 本発明の複合磁石の他の実施形態を示した斜視図。The perspective view which showed other embodiment of the composite magnet of this invention. 本発明の複合磁石の他の実施形態を示した斜視図。The perspective view which showed other embodiment of the composite magnet of this invention.

符号の説明Explanation of symbols

１，１ａ，１ｂ，１ｃ，１ｄ…複合磁石、１１…内部磁石（第一の磁石）、１２…外部磁石（第二の磁石）、１２ａ…切り欠き、１３、樹脂被膜、２…ロータ、３…ステータ、１０…モータ   DESCRIPTION OF SYMBOLS 1, 1a, 1b, 1c, 1d ... Composite magnet, 11 ... Internal magnet (1st magnet), 12 ... External magnet (2nd magnet), 12a ... Notch, 13, Resin coating, 2 ... Rotor, 3 ... Stator, 10 ... Motor

Claims (12)

第一の磁石と、第一の磁石を囲繞する第二の磁石とからなり、第一の磁石は、磁束密度が相対的に高く、保磁力が相対的に低い材料から構成されており、第二の磁石は、磁束密度が相対的に低く、保磁力が相対的に高い材料から構成されていることを特徴とする複合磁石。   A first magnet and a second magnet surrounding the first magnet. The first magnet is made of a material having a relatively high magnetic flux density and a relatively low coercive force. The second magnet is composed of a material having a relatively low magnetic flux density and a relatively high coercive force. 前記第一の磁石は保磁力が１０〜２０ｋＯｅのネオジムからなり、前記第二の磁石は保磁力が２０ｋＯｅよりも大きなネオジムに、ジスプロシウムを含む重希土類元素が添加された材料からなることを特徴とする請求項１に記載の複合磁石。   The first magnet is made of neodymium having a coercive force of 10 to 20 kOe, and the second magnet is made of a material in which a heavy rare earth element containing dysprosium is added to neodymium having a coercive force larger than 20 kOe. The composite magnet according to claim 1. 前記第一の磁石はアルニコからなり、前記第二の磁石は保磁力が２０ｋＯｅよりも大きなネオジムに、ジスプロシウムを含む重希土類元素が添加された材料からなることを特徴とする請求項１に記載の複合磁石。   The first magnet is made of alnico, and the second magnet is made of a material obtained by adding a heavy rare earth element containing dysprosium to neodymium having a coercive force larger than 20 kOe. Composite magnet. 請求項１〜３のいずれかに記載の複合磁石において、
第二の磁石の側面には、その軸心方向に伸びる切り欠きが所定の間隔を置いて複数設けられていることを特徴とする複合磁石。 In the composite magnet according to any one of claims 1 to 3,
A composite magnet comprising a plurality of notches extending in the axial direction on the side surface of the second magnet at predetermined intervals. 第二の磁石の端辺付近における切り欠きと切り欠きの間隔は、第二の磁石の中央付近における切り欠きと切り欠きの間隔に対して相対的に狭くなっていることを特徴とする請求項４に記載の複合磁石。   The notch and the notch interval near the end of the second magnet are relatively narrow with respect to the notch and notch interval near the center of the second magnet. 4. The composite magnet according to 4. 請求項１〜３のいずれかに記載の複合磁石において、
第二の磁石の側面には、その軸心方向に直交する方向に伸びる切り欠きが所定の間隔を置いて複数設けられていることを特徴とする複合磁石。 In the composite magnet according to any one of claims 1 to 3,
A composite magnet, wherein a plurality of notches extending in a direction orthogonal to the axial direction of the second magnet are provided at predetermined intervals on a side surface of the second magnet. 請求項４〜６のいずれかに記載の複合磁石において、
第二の磁石のまわりには樹脂の被膜が形成されており、切り欠きには該樹脂が満たされていることを特徴とする複合磁石。 In the composite magnet according to any one of claims 4 to 6,
A composite magnet characterized in that a resin film is formed around the second magnet, and the notch is filled with the resin. 請求項１〜７のいずれかに記載の複合磁石がロータの内部に埋め込まれていることを特徴とするモータ。   A motor comprising the composite magnet according to claim 1 embedded in a rotor. 第一の磁石と、第一の磁石を囲繞する第二の磁石とからなり、第一の磁石は、磁束密度が相対的に高く、保磁力が相対的に低い材料から構成されており、第二の磁石は、磁束密度が相対的に低く、保磁力が相対的に高い材料から構成されている複合磁石の製造方法であって、
第一の磁石と型との間に第二の磁石の厚みを確保した姿勢で第一の磁石の圧粉体を型内に配設し、型と第一の磁石の圧粉体との間に第二の磁石を構成する粉体を充填し、型にその外側から圧力を加えて第一の磁石の圧粉体と第二の磁石の圧粉体を成形し、該第一の磁石の圧粉体と第二の磁石の圧粉体を焼結させることを特徴とする複合磁石の製造方法。 A first magnet and a second magnet surrounding the first magnet. The first magnet is made of a material having a relatively high magnetic flux density and a relatively low coercive force. The second magnet is a method of manufacturing a composite magnet made of a material having a relatively low magnetic flux density and a relatively high coercive force,
The green compact of the first magnet is disposed in the mold in a posture in which the thickness of the second magnet is ensured between the first magnet and the mold, and between the mold and the green compact of the first magnet. Is filled with the powder constituting the second magnet, and pressure is applied to the mold from the outside to form the green compact of the first magnet and the green compact of the second magnet. A method of manufacturing a composite magnet, comprising sintering a green compact and a green compact of a second magnet. 前記第一の磁石は保磁力が１０〜２０ｋＯｅのネオジムからなり、前記第二の磁石は保磁力が２０ｋＯｅよりも大きなネオジムに、ジスプロシウムを含む重希土類元素が添加された材料からなることを特徴とする請求項９に記載の複合磁石の製造方法。   The first magnet is made of neodymium having a coercive force of 10 to 20 kOe, and the second magnet is made of a material in which a heavy rare earth element containing dysprosium is added to neodymium having a coercive force larger than 20 kOe. The manufacturing method of the composite magnet of Claim 9. 前記第一の磁石はアルニコからなり、前記第二の磁石は保磁力が２０ｋＯｅよりも大きなネオジムに、ジスプロシウムを含む重希土類元素が添加された材料からなることを特徴とする請求項９に記載の複合磁石の製造方法。   The first magnet is made of alnico, and the second magnet is made of a material obtained by adding a heavy rare earth element containing dysprosium to neodymium having a coercive force larger than 20 kOe. A method for producing a composite magnet. 焼結された複合磁石の第二の磁石の側面に、その軸心方向に伸びる切り欠き、またはその軸心方向に直交する方向に伸びる切り欠きを所定の間隔を置いて複数設けることを特徴とする請求項９〜１１のいずれかに記載の複合磁石の製造方法。   The side surface of the second magnet of the sintered composite magnet is provided with a plurality of notches extending in the axial direction or extending in a direction perpendicular to the axial direction at predetermined intervals. The manufacturing method of the composite magnet in any one of Claims 9-11.
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