JP2007305818A - Rare earth permanent magnet, its manufacturing method, and rotating machine - Google Patents
Rare earth permanent magnet, its manufacturing method, and rotating machine Download PDFInfo
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本発明は、高い磁気特性を有するＲ−Ｍ−Ｂ系希土類永久磁石に関し、特に高速回転を行う電気自動車用モータや発電機、ＦＡモータ等の永久磁石回転機に用いた際に発生する渦電流を低減した希土類永久磁石に関する。また、本発明はかかる永久磁石の製造方法及び該永久磁石を用いた回転機に関する。 The present invention relates to an R-MB-based rare earth permanent magnet having high magnetic characteristics, and in particular, an eddy current generated when used in a permanent magnet rotating machine such as an electric vehicle motor, a generator, or an FA motor that rotates at high speed. The present invention relates to a rare earth permanent magnet with reduced content. Moreover, this invention relates to the manufacturing method of this permanent magnet, and the rotary machine using this permanent magnet.
Ｎｄ−Ｆｅ−Ｂ系永久磁石は、その優れた磁気特性のために、ますます用途が広がってきている。近年、モータや発電機などの回転機の分野においても、機器の軽薄短小化、高性能化、省エネルギー化に伴い、Ｎｄ−Ｆｅ−Ｂ系永久磁石を利用した永久磁石回転機が開発されている。Ｎｄ−Ｆｅ−Ｂ系焼結磁石の電気抵抗は１００〜２００μΩ・ｃｍの導体であり、磁石に生じる渦電流に伴う発熱が、磁石の大きさの２乗で大きくなるために大容量回転機においては大きな問題となっている。渦電流低減のために有効な手段は、鉄心に使われる電磁鋼板のように薄板化して絶縁積層することであるが、細分化したセグメント磁石を接着固化して所要の大きさの磁石とする方法は、磁石の製造工程が増加し、製造コストの増加や磁石重量歩留まりの低下を招く。また、セグメント磁石を接着固化せず小磁石のまま用いることも考えられるが、磁石間の反発力に抗して小磁石をロータに組込み固着することは難しい。 Nd-Fe-B permanent magnets are increasingly used because of their excellent magnetic properties. In recent years, in the field of rotating machines such as motors and generators, permanent magnet rotating machines using Nd-Fe-B permanent magnets have been developed along with the reduction in the size, performance, and energy saving of equipment. . The Nd-Fe-B sintered magnet has a resistance of 100 to 200 μΩ · cm, and the heat generated by the eddy current generated in the magnet increases with the square of the size of the magnet. Has become a big problem. An effective means for reducing eddy currents is to thin and insulate and laminate like a magnetic steel sheet used for iron cores, but a method of bonding and solidifying segmented segment magnets into a magnet of the required size. Increases the manufacturing process of the magnet, leading to an increase in manufacturing cost and a decrease in magnet weight yield. Although it is conceivable to use the segment magnet as it is without bonding and solidifying the segment magnet, it is difficult to incorporate and fix the small magnet into the rotor against the repulsive force between the magnets.
積層磁石の製造工程を簡単にするものとして、特開２０００−２９５８０４号公報（特許文献１）の磁石表面に内周又は外周切断機やワイヤーソー等で加工して溝切りしてスリットを形成する方法がある。しかし、この方法でのスリット幅は外周切断で０．８ｍｍ程度であり、多くのスリットを入れると磁石体積が減少し、磁束量を得ることができない。１個の磁石に１０本以上のスリットを入れる場合、スリットにより失われる磁石体積がもとの体積の２０％になることもある。なお、ワイヤーソーならスリット幅を０．０５ｍｍ程度にできるが、加工速度が遅く、量産性に欠ける。 As a means for simplifying the manufacturing process of laminated magnets, slits are formed by machining grooves on the surface of a magnet disclosed in JP 2000-295804 A (Patent Document 1) using an inner or outer peripheral cutting machine or a wire saw. There is a way. However, the slit width in this method is about 0.8 mm when the outer periphery is cut, and if many slits are inserted, the magnet volume decreases and the amount of magnetic flux cannot be obtained. When ten or more slits are put in one magnet, the volume of the magnet lost by the slit may be 20% of the original volume. In the case of a wire saw, the slit width can be reduced to about 0.05 mm, but the processing speed is slow and the mass productivity is lacking.
また、特開２００５−１９８３６５号公報（特許文献２）には、矩形体の希土類永久磁石にその一側面から対向する側面側へ一定長さの複数のスリットを形成して分割部と前記スリット端で分割された磁石が保持される連通部とを設け、その後、スリット内に非導電性樹脂を充填し、更に分割部と連通部とを分離することで、複数の板状永久磁石を非導電性樹脂を介して積層配置された構成からなるモータ用希土類永久磁石が得られるとある。しかし、この方法でも、加工でスリットを入れるのでスリットの幅は０．５ｍｍ以上であり、多くのスリットを入れると磁石体積が減少し、磁束量を得ることができない。 Japanese Patent Laying-Open No. 2005-198365 (Patent Document 2) discloses that a rectangular rare earth permanent magnet is formed with a plurality of slits having a fixed length from one side surface to the opposite side surface side, and a divided portion and the slit end. A plurality of plate-like permanent magnets are made non-conductive by providing a non-conductive resin in the slit and then separating the divided portions and the communication portions. There is a case where a rare earth permanent magnet for a motor having a configuration in which layers are arranged via a conductive resin is obtained. However, even in this method, since slits are formed by processing, the width of the slits is 0.5 mm or more. If many slits are inserted, the magnet volume decreases, and the amount of magnetic flux cannot be obtained.
本発明は、上述した従来の問題点に鑑みなされたもので、Ｒ−Ｍ−Ｂ系焼結磁石（ＲはＹ及びＳｃを含む希土類元素から選ばれる１種又は２種以上、ＭはＦｅ、又はＦｅとＣｏを主体とする遷移金属）の磁石にスリットを入れた渦電流低減に有効な磁石において、スリット加工による磁石体積低減を少なくした希土類永久磁石、その製造方法、及び回転機を提供することを目的とするものである。 The present invention has been made in view of the above-described conventional problems. An R-MB-based sintered magnet (R is one or more selected from rare earth elements including Y and Sc, M is Fe, A rare earth permanent magnet with reduced volume reduction by slit machining, a manufacturing method thereof, and a rotating machine in a magnet effective for reducing eddy current by slitting a magnet of a transition metal mainly composed of Fe and Co) It is for the purpose.
本発明者らは、Ｎｄ−Ｆｅ−Ｂ系焼結磁石に代表されるＲ1−Ｍ−Ｂ系焼結磁石（Ｒ1はＹ及びＳｃを含む希土類元素から選ばれる１種又は２種以上、ＭはＦｅ、又はＦｅ及びＣｏを主体とする遷移金属）において、磁石体に複数のスリットを入れる工程を、焼結体に対し切断刃などを用いた加工で行うのではなく、焼結前の成型体に凹溝及び突条を設けて、突条面が重なるように成型体を複数個積み上げ、これを焼結する工程で得ること、更には、成型体の表面の凹溝にＲ3の酸化物（Ｒ3はＹ及びＳｃを含む希土類元素から選ばれる１種又は２種以上）を部分的に塗り、酸化物を塗った面に同様の成型体を複数個積み上げ、これを焼結する工程で得ることが有効で、ここで得られたスリットの空隙幅は０〜０．１ｍｍであり、しかも焼結後の加工を行うよりコストがかからない上、焼結工程でスリットを作製すると、スリットに面する焼結磁石体の表面はＹ及びＳｃを含む希土類元素から選ばれる１種又は２種以上の酸化物の層が形成され、この希土類元素の酸化物の電気抵抗は磁石体に比べ非常に大きいので、酸化物で実質的に絶縁している効果があることを知見し、本発明をなすに至った。 The inventors of the present invention are R 1 -MB sintered magnets represented by Nd-Fe-B sintered magnets (R 1 is one or more selected from rare earth elements including Y and Sc, M is a transition metal mainly composed of Fe or Fe and Co), and the step of making a plurality of slits in the magnet body is not performed by processing using a cutting blade or the like on the sintered body, but before the sintering. Providing concave grooves and ridges in the molded body, stacking a plurality of molded bodies so that the ridge surfaces overlap, and obtaining them by a process of sintering, and further, forming R 3 in the concave grooves on the surface of the molded body Oxide (R 3 is one or more selected from rare earth elements including Y and Sc) is partially coated, and a plurality of similar molded bodies are stacked on the surface coated with oxide, and this is sintered. It is effective to obtain in the process, the gap width of the slit obtained here is 0-0.1mm, and after sintering When the slit is produced in the sintering process, the surface of the sintered magnet body facing the slit is a layer of one or more oxides selected from rare earth elements including Y and Sc. Since the electric resistance of the rare earth element oxide is much larger than that of the magnet body, it was found that there is an effect of being substantially insulated by the oxide, and the present invention has been made.
即ち、本発明は、下記の回転機用として有効な希土類永久磁石及びその製造方法並びに回転機を提供する。
請求項１：
Ｒ1−Ｍ−Ｂ系組成（Ｒ1はＹ及びＳｃを含む希土類元素から選ばれる１種又は２種以上、ＭはＦｅ、又はＦｅ及びＣｏを主体とする遷移金属）からなる複数個の磁石単体が、一体に接合した焼結接合体からなり、該焼結接合体は一面から他面にかけて貫通するスリットを有しており、上記スリット面には、それぞれＲ2の酸化物層（Ｒ2はＹ及びＳｃを含む希土類元素から選ばれる１種又は２種以上）が形成されていることを特徴とする希土類永久磁石。
請求項２：
Ｒ1−Ｍ−Ｂ系組成（Ｒ1はＹ及びＳｃを含む希土類元素から選ばれる１種又は２種以上、ＭはＦｅ、又はＦｅ及びＣｏを主体とする遷移金属）からなる複数個の単体成型体の表面にそれぞれ凹溝を形成し、これによって突条部を形成すると共に、該突条部を介して上記複数個の単体成型体を積層し、次いで焼結して、上記突条部において上記単体成型体を互いに接合すると共に、上記各突条部の側方に一面から他面にかけて貫通し、表面に上記Ｒ1の酸化物層を有するスリットを上記凹溝によって形成した焼結接合体からなる希土類永久磁石を得ることを特徴とする希土類永久磁石の製造方法。
請求項３：
上記単体成型体の凹溝にＲ3の酸化物（Ｒ3はＹ及びＳｃを含む希土類元素から選ばれる１種又は２種以上）を塗布して該単体成型体を焼結することにより、スリット内にＲ3の酸化物層を形成した請求項２記載の希土類永久磁石の製造方法。
請求項４：
請求項１記載の希土類永久磁石を用いた回転機。
That is, the present invention provides a rare earth permanent magnet effective for the following rotating machines, a method for producing the same, and a rotating machine.
Claim 1:
A plurality of magnets having an R 1 -MB system composition (R 1 is one or more selected from rare earth elements including Y and Sc, and M is a transition metal mainly composed of Fe or Fe and Co). The single body is composed of a sintered joined body integrally joined, and the sintered joined body has slits penetrating from one surface to the other surface, and each of the slit surfaces has an R 2 oxide layer (
Claim 2:
A plurality of simple substances having an R 1 -MB system composition (R 1 is one or more selected from rare earth elements including Y and Sc, M is a transition metal mainly composed of Fe or Fe and Co) A concave groove is formed on the surface of the molded body, thereby forming a ridge, and the plurality of unit molded bodies are laminated through the ridge, then sintered, and the ridge is formed. In addition, the single molded body is bonded to each other, and a sintered joint is formed by forming the slit having the R 1 oxide layer on the surface by the concave groove penetrating from one side to the other side of each protruding portion. A method for producing a rare earth permanent magnet comprising obtaining a rare earth permanent magnet comprising a body.
Claim 3:
Oxides of R 3 into the groove and the single molded body (R 3 is at least one element selected from rare earth elements inclusive of Y and Sc) by sintering said single body molded by applying a slit The method for producing a rare earth permanent magnet according to
Claim 4:
A rotating machine using the rare earth permanent magnet according to
本発明により、磁石にスリットを入れた渦電流低減に有効な希土類永久磁石において、スリット加工による方法より磁石体積低減を少なくした磁石を提供することができる。これにより大型・高回転モータなどの磁石に発生する渦電流問題を解決すると同時に、渦電流低減による磁束量の低下（トルク低下）がほとんど生じないので、産業上、その利用価値は極めて高い。 According to the present invention, in a rare earth permanent magnet effective for reducing eddy current by slitting a magnet, it is possible to provide a magnet with a reduced volume of magnet compared to a method by slit machining. This solves the problem of eddy currents generated in magnets such as large and high-rotation motors, and at the same time, almost no decrease in the amount of magnetic flux (torque reduction) due to eddy current reduction occurs.
本発明に係る希土類永久磁石は、Ｒ1−Ｍ−Ｂ系組成（Ｒ1はＹ及びＳｃを含む希土類元素から選ばれる１種又は２種以上、ＭはＦｅ、又はＦｅ及びＣｏを主体とする遷移金属）からなる複数個の焼結磁石単体が、一面から他面にかけて貫通するスリットを有して一体に接合してなり、上記スリット面には、それぞれＲ2の酸化物層（Ｒ2はＹ及びＳｃを含む希土類元素から選ばれる１種又は２種以上）が形成されているものである。 The rare earth permanent magnet according to the present invention has an R 1 -MB system composition (R 1 is one or more selected from rare earth elements including Y and Sc, M is mainly Fe, or Fe and Co). A plurality of sintered magnets made of transition metal are integrally joined with a slit penetrating from one surface to the other surface, and each of the R 2 oxide layers (R 2 is 1 type or 2 types or more selected from rare earth elements including Y and Sc) are formed.
なお、本発明において、Ｒ及びＲ1並びにＲ2はいずれもＹ及びＳｃを含む希土類元素から選ばれるものであるが、Ｒは主に得られた磁石体に関して使用し、Ｒ1は主に出発原料に関して用いる。更に、Ｒ2は主にスリットに形成された酸化物層である。
この場合、Ｒ2の酸化物層は、後述する本発明の製造方法によれば、Ｒ1−Ｍ−Ｂ系組成のＲ1の酸化により形成されるか、又はＲ3の酸化物の塗布に基づくものである。
In the present invention, R, R 1 and R 2 are all selected from rare earth elements including Y and Sc. R is mainly used for the obtained magnet body, and R 1 is mainly used as a starting material. Used for raw materials. Further, R 2 is an oxide layer mainly formed in the slit.
In this case, according to the manufacturing method of the present invention described later, the R 2 oxide layer is formed by the oxidation of R 1 having the R 1 -MB system composition, or the coating of the R 3 oxide. Is based.
磁石合金は、Ｒ1、Ｆｅ、Ｂを含有する。Ｒ1はＹ及びＳｃを含む希土類元素から選ばれる１種又は２種以上で、具体的にはＹ、Ｓｃ、Ｌａ、Ｃｅ、Ｐｒ、Ｎｄ、Ｓｍ、Ｅｕ、Ｇｄ、Ｔｂ、Ｄｙ、Ｈｏ、Ｅｒ、Ｙｂ及びＬｕが挙げられ、好ましくはＮｄ、Ｐｒ、Ｄｙを主体とする。これらＹ及びＳｃを含む希土類元素は合金全体の１０〜１５原子％、特に１２〜１５原子％であることが好ましく、更に好ましくはＲ1中にＮｄとＰｒあるいはそのいずれか１種を１０原子％以上、特に５０原子％以上含有することが好適である。Ｂは３〜１５原子％、特に４〜８原子％含有することが好ましい。その他、Ａｌ、Ｃｕ、Ｚｎ、Ｉｎ、Ｓｉ、Ｐ、Ｓ、Ｔｉ、Ｖ、Ｃｒ、Ｍｎ、Ｎｉ、Ｇａ、Ｇｅ、Ｚｒ、Ｎｂ、Ｍｏ、Ｐｄ、Ａｇ、Ｃｄ、Ｓｎ、Ｓｂ、Ｈｆ、Ｔａ、Ｗの中から選ばれる１種又は２種以上を０〜１１原子％、特に０．１〜５原子％含有してもよい。残部はＦｅ及びＣ、Ｎ、Ｏ等の不可避的な不純物であるが、Ｆｅは５０原子％以上、特に６５原子％以上含有することが好ましい。また、Ｆｅの一部、例えばＦｅの０〜４０原子％、特に０〜１５原子％をＣｏで置換しても差し支えない。 The magnet alloy contains R 1 , Fe, and B. R 1 is one or more selected from rare earth elements including Y and Sc, specifically, Y, Sc, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er , Yb, and Lu, preferably Nd, Pr, and Dy. These rare earth elements including Y and Sc are preferably 10 to 15 atomic%, particularly 12 to 15 atomic% of the whole alloy, more preferably 10% by atom of Nd and Pr or any one of them in R 1. As mentioned above, it is suitable to contain especially 50 atomic% or more. B is preferably contained in an amount of 3 to 15 atomic%, particularly 4 to 8 atomic%. In addition, Al, Cu, Zn, In, Si, P, S, Ti, V, Cr, Mn, Ni, Ga, Ge, Zr, Nb, Mo, Pd, Ag, Cd, Sn, Sb, Hf, Ta, One or two or more kinds selected from W may be contained in an amount of 0 to 11 atomic%, particularly 0.1 to 5 atomic%. The balance is inevitable impurities such as Fe and C, N, and O. Fe is preferably contained in an amount of 50 atomic% or more, particularly 65 atomic% or more. Further, a part of Fe, for example, 0 to 40 atomic%, particularly 0 to 15 atomic% of Fe may be substituted with Co.
本発明の希土類永久磁石を製造する場合は、常法に従い、磁石合金を粗粉砕、微粉砕、成形、焼結させることにより得ることができる。この場合、磁石合金は、原料金属あるいは合金を真空あるいは不活性ガス、好ましくはＡｒ雰囲気中で溶解した後、平型に鋳込む、あるいはストリップキャストにより鋳造することで得られる。上記合金は、通常０．０５〜３ｍｍに粗粉砕される。粗粉砕工程にはブラウンミルあるいは水素粉砕が用いられる。粗粉は、例えば高圧窒素を用いたジェットミルにより通常０．２〜３０μｍに微粉砕される。
微粉末は磁界中、圧縮成型機に挿入され、成型機中のパンチにより微粉末を成型することができる。
When the rare earth permanent magnet of the present invention is produced, it can be obtained by roughly pulverizing, finely pulverizing, forming and sintering the magnet alloy according to a conventional method. In this case, the magnet alloy can be obtained by melting the raw metal or alloy in a vacuum or an inert gas, preferably in an Ar atmosphere, and then casting it into a flat mold or casting it by strip casting. The alloy is usually coarsely pulverized to 0.05 to 3 mm. Brown mill or hydrogen pulverization is used for the coarse pulverization process. The coarse powder is usually finely pulverized to 0.2 to 30 μm by, for example, a jet mill using high-pressure nitrogen.
The fine powder is inserted into a compression molding machine in a magnetic field, and the fine powder can be molded by a punch in the molding machine.
ここで、本発明の希土類永久磁石を得るには、
第一の方法として、上記のようにして複数個の単体成型体を作製し、これら単体成型体の表面に凹溝を形成すると共に、これによって突条部を形成し、このように形成された突条部を介して上記複数個の単体成型体を積層し、次いで焼結して、上記凹溝において一面から他面にかけて貫通し、スリットが形成された状態で上記突条部において上記単体成型体が焼結することによってＲ2の酸化物層が形成された焼結磁石単体が接合することで希土類永久磁石を得る方法、更には、
第二の方法として、上記のように複数個の単体成型体を作製後、これらの単体成型体の表面の凹溝にＲ3の酸化物層を部分的に形成し、このＲ3の酸化物層が互いに重なり合うように上記複数個の単体成型体を積層し、次いで焼結して上記Ｒ3の酸化物層非形成部分において上記単体成型体が焼結することによって形成された焼結磁石単体が接合することで希土類永久磁石を得る方法
が好適に採用される。
Here, in order to obtain the rare earth permanent magnet of the present invention,
As a first method, a plurality of unit molded bodies were produced as described above, and a concave groove was formed on the surface of these unit molded bodies, thereby forming a protrusion, and thus formed. The plurality of single-piece molded bodies are laminated through the ridge, then sintered, penetrated from one surface to the other in the concave groove, and the single-piece molding is performed in the ridge with the slit formed. A method of obtaining a rare earth permanent magnet by bonding a sintered magnet alone in which an R 2 oxide layer is formed by sintering the body,
As a second method, after producing a plurality of unit molded bodies as described above, an R 3 oxide layer is partially formed in the concave grooves on the surfaces of these unit molded bodies, and this R 3 oxide is formed. A sintered magnet unit formed by laminating the plurality of unit molded bodies so that the layers overlap each other, then sintering and sintering the unit molded body in the R 3 oxide layer non-forming portion A method of obtaining a rare earth permanent magnet by joining is suitably employed.
上記第一の方法について更に詳述すると、単体成型体に凹溝及びこれにより突条を形成する方法としては、図８に示すように磁石合金の微粉末をパンチにより圧縮成型する場合、パンチの先端面に突条及び凹溝を形成し、このパンチによって圧縮成型する際に圧縮成型体（単体成型体）の成形と同時に凹溝及び突条を形成する方法が挙げられる。図３は、このような凹溝及び突条が形成された単体成型体の一例を示すもので、１０が単体成型体、１１が凹溝、１２が突条であり、本発明においては凹溝１１の一側部は側壁がなく、一側方に開放された状態を含む。なお、この例においては、凹溝１１、突条１２の長さ方向が磁化方向と一致する。また、パンチ材料は特に限定されるものではなく、磁場中成形できるものであればよく、上述したように予めパンチに所望の形状になるように凹凸が設けられている。突条の高さＨは０．１ｍｍ以下であり、より好ましくは１〜１００μｍ、特に２０〜８０μｍであることが好ましい。図３は突条の数が３個であるが、３個に限定されない。また、突条の幅の合計（Ｗ１＋Ｗ２＋Ｗ３）は磁石幅Ｗの１０〜５０％、特に２０〜４０％の割合で選ばれる。この比率が１０％未満では接合面積が小さく、磁石体の強度が弱くなってしまい、５０％を超えると、スリットによる渦電流低減効果が少なくなってしまう場合がある。
The above-mentioned first method will be described in more detail. As a method of forming the concave grooves and the protrusions in the single molded body, as shown in FIG. There is a method of forming a ridge and a groove on the front end surface and forming the groove and ridge simultaneously with the molding of the compression molded body (single molded body) when compression molding with this punch. FIG. 3 shows an example of a single molded body in which such concave grooves and ridges are formed. 10 is a single molded body, 11 is a concave groove, and 12 is a ridge. 11 includes a state in which one side portion has no side wall and is open to one side. In this example, the length direction of the
これらの成型体を複数個積み上げ、焼結炉に投入するが、この場合、本発明においては上記突条部を介して（即ち、一の単体成型体の表面に形成された突条面が他の単体成型体面と当接した状態で）単体成型体を積層する。焼結は真空あるいは不活性ガス雰囲気中、通常９００〜１，２００℃で行われる。この焼結により、上記各単体成型体は焼結されて、焼結磁石単体がそれぞれ形成されると共に、この際、上記突条部において一の単体成型体（焼結磁石単体）と他の単体成型体（焼結磁石単体）とが接合、一体化される一方、上記凹溝部分が磁石体の一面から他面（対向面）にかけて貫通するスリットとなる図１に示すような磁石体（希土類永久磁石）１が焼結接合体として得られる。なお、２は焼結磁石単体、３は上記突条部に由来する焼結磁石単体相互の接合連結部、４は上記凹溝に由来するスリットである。ここで、各スリットは、そのスリット面に上記焼結時に形成された上記Ｒ1の酸化に基づくＲ2の酸化物層５が形成される。このＲ2の酸化物層５は、焼結時に磁石合金のＲ1が焼結雰囲気中の微量の酸素により酸化されて形成されるもので、この第一の方法においてＲ2≒Ｒ1である。なお、この酸化物層は、ＥＰＭＡ（電子線マイクロプローグ分析装置）やＸＰＳ（Ｘ線電子分光分析装置）等で酸化物の層であることを確認できる。酸化物の層厚は通常５０μｍ以下、特に０．５〜５０μｍが好ましい。また、上記スリットの空隙幅ＳＷは１００μｍ以下、より好ましくは１〜１００μｍ、特に２０〜８０μｍが好ましい。
A plurality of these molded bodies are stacked and put into a sintering furnace. In this case, in the present invention, the ridge surface formed on the surface of one single molded body is the other through the above-mentioned ridge portion. The single molded body is laminated (in a state where it is in contact with the single molded body surface). Sintering is usually performed at 900 to 1,200 ° C. in a vacuum or an inert gas atmosphere. By this sintering, each of the single molded bodies is sintered to form a sintered magnet single body. At this time, one single molded body (sintered magnet single body) and another single body are formed at the protruding portion. The molded body (sintered magnet alone) is joined and integrated, while the concave groove portion is a slit that penetrates from one surface of the magnet body to the other surface (opposed surface) (magnet body as shown in FIG. 1 (rare earth). Permanent magnet) 1 is obtained as a sintered joined body. In addition, 2 is a sintered magnet simple substance, 3 is a joining connection part of the sintered magnet simple substance originating in the said protrusion part, 4 is a slit originating in the said concave groove. Here, in each slit, an
次に、第二の方法について説明すると、この方法は、上記した方法で得られた単体成型体の凹溝にＲ3の酸化物層を必要により部分的に形成する。図４はこれを示すもので、１０は単体成型体、１１は凹溝、１２は突条部、１３はＲ3の酸化物層である。なお、この第二の方法において、Ｒ3はＲ1と同じ元素であってもよく、異なる元素であってもよい。上記Ｒ3の酸化物層を形成する方法としては、Ｒ3の酸化物粉末をそのまま又はそのスラリーを単体成型体の凹溝表面に必要により部分的に塗布し、乾燥する方法が好適である。なお、Ｒ3は、上述したようにＹ及びＳｃを含む希土類元素から選ばれ、具体的にはＹ、Ｓｃ、Ｌａ、Ｃｅ、Ｐｒ、Ｎｄ、Ｓｍ、Ｅｕ、Ｇｄ、Ｔｂ、Ｄｙ、Ｈｏ、Ｅｒ、Ｙｂ及びＬｕが挙げられ、好ましくはＹを主体（５０質量％以上）とする。酸化物粉末の平均粒子径は１００μｍ以下、好ましくは１０μｍ以下が望ましい。その下限は特に制限されないが、１ｎｍ以上が好ましい。酸化物粉末を成型体に塗布する方法として、粉末の状態でつける方法と有機溶剤や水に分散させ、このスラリー状のものを刷毛塗りやスプレイ塗布した後に風や真空により乾燥させる、あるいは自然乾燥させる方法が挙げられる。この場合、Ｒ3の酸化物層１３の厚さは、上記突条部１２の高さと一致するか又はこれより低いことが必要で、塗布の厚さは好ましくは０．０５ｍｍ以下、より好ましくは０．０１〜０．０５ｍｍである。なお、図４は塗布部の数が４個であるが、４個に限定されなく、所望の形状になるように塗布すればよい。また、突条の幅の合計（Ｗ１＋Ｗ２＋Ｗ３）は磁石幅Ｗの１０〜５０％、特に２０〜４０％の割合で選ばれる。この比率が１０％未満では、接合面積が小さく磁石体の強度が弱くなってしまい、５０％を超えると、スリットによる渦電流低減効果が少なくなってしまう場合がある。なお、この例では上記Ｒ3の酸化物層１３の長さ方向は、磁化方向と一致している。
Next, the second method will be described. In this method, an R 3 oxide layer is partially formed as necessary in the concave groove of the unit molded body obtained by the above method. FIG. 4 shows this, wherein 10 is a single molded body, 11 is a groove, 12 is a protrusion, and 13 is an R 3 oxide layer. In this second method, R 3 may be the same element as R 1 or a different element. As a method for forming the R 3 oxide layer, a method in which the R 3 oxide powder is applied as it is or a slurry thereof is partially applied to the concave groove surface of the single molded body and dried is preferable. R 3 is selected from rare earth elements including Y and Sc as described above, and specifically, Y, Sc, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er , Yb, and Lu, and preferably Y is the main component (50% by mass or more). The average particle diameter of the oxide powder is 100 μm or less, preferably 10 μm or less. The lower limit is not particularly limited, but is preferably 1 nm or more. As a method of applying the oxide powder to the molded body, it is applied in a powder state and dispersed in an organic solvent or water, and the slurry is applied by brushing or spraying and then dried by wind or vacuum, or naturally dried. The method of letting it be mentioned. In this case, the thickness of the
これらのＲ3の酸化物層が凹溝に帯状に必要により部分的に形成された成型体を複数個積み上げ、焼結炉に投入する。焼結は真空あるいは不活性ガス雰囲気中、通常９００〜１，２００℃で行われる。この焼結により上記各単体成型体は焼結されて、焼結磁石単体がそれぞれ形成されると共に、この際突条部において一の単体成型体（焼結磁石単体）と他の単体成型体（焼結磁石単体）とが接合、一体化される一方、上記Ｒ3の酸化物形成部分がそのまま磁石体の一面から他面（対向面）にかけて帯状に残る図２に示すような磁石体（希土類永久磁石）１が焼結接合体として得られる。なお、２は焼結磁石単体、６は突条部に由来する焼結磁石単体相互の接合連結部である。この場合、図２の焼結接合体においては、凹溝内に突条部と同一高さになるようにＲ3の酸化物層を形成したため、スリット内がＲ3の酸化物層で充満されているが、これに限られるものではなく、Ｒ3の酸化物層を突条部より低く形成して、スリット内に空隙を与えるようにしてもよい。 A plurality of molded bodies in which these R 3 oxide layers are partially formed in a groove shape if necessary in a groove shape are stacked and put into a sintering furnace. Sintering is usually performed at 900 to 1,200 ° C. in a vacuum or an inert gas atmosphere. By this sintering, each of the single molded bodies is sintered to form a single sintered magnet, and at this time, one single molded body (sintered magnet single body) and another single molded body ( A sintered magnet (single magnet) is joined and integrated, while the R 3 oxide forming portion remains in a belt shape from one surface of the magnet body to the other surface (opposite surface) as shown in FIG. Permanent magnet) 1 is obtained as a sintered joined body. In addition, 2 is a sintered magnet single-piece | unit, 6 is a joining connection part of the sintered magnet single-piece | unit derived from a protrusion part. In this case, in the sintered joined body of FIG. 2, since the R 3 oxide layer is formed in the groove so as to be the same height as the protrusion, the slit is filled with the R 3 oxide layer. However, the present invention is not limited to this, and the oxide layer of R 3 may be formed lower than the protruding portion to give a gap in the slit.
本発明によれば、上述した従来の問題点を解決することができ、Ｒ−Ｍ−Ｂ系焼結磁石にスリットを入れた渦電流低減に有効な磁石において、スリット加工による磁石体積低減を少なくした磁石を提供することができる。本発明の希土類永久磁石は、Ｒ1−Ｍ−Ｂ系組成からなる焼結前の成型体に突条を設けてこの面が重なるように複数個積み上げ、これを焼結するものと、成型体の凹溝にＲ3の酸化物を必要により部分的に塗り、同様に成型体を突条を介して複数個積み上げて焼結する工程で得るといったものがあるが、上記した本発明の第一及び第二の方法で得られた希土類永久磁石におけるスリットの空隙幅あるいは希土類酸化物の厚みは０．１ｍｍ以下であり、スリットによる磁石体積の減少は、従来の加工でスリットを付けるものの１／１０程度になる。しかも加工を行うよりコストがかからない。 According to the present invention, the above-mentioned conventional problems can be solved, and in the magnet effective for reducing the eddy current obtained by slitting the R-MB-based sintered magnet, the volume reduction of the magnet due to the slit processing is reduced. Magnets can be provided. The rare earth permanent magnet of the present invention includes a sintered body formed of an R 1 -MB system composition, provided with protrusions, stacked so that the surfaces overlap, and sintered. In some cases, R 3 oxide is partially applied to the concave grooves of the substrate, and a plurality of molded bodies are similarly stacked and sintered through protrusions. In the rare earth permanent magnet obtained by the second method, the gap width of the slit or the thickness of the rare earth oxide is 0.1 mm or less, and the reduction of the magnet volume due to the slit is 1/10 of that in which the slit is formed by the conventional processing. It will be about. Moreover, it is less expensive than processing.
また、焼結工程でスリットを作製すると、スリットに面する焼結磁石体の表面は希土類元素の酸化物が形成されており、希土類元素の酸化物の電気抵抗は磁石体に比べ非常に大きいので、スリット面で酸化物層が接触していて空隙がなくても実質的に絶縁している効果がある。
なお、本発明で得られた希土類永久磁石におけるスリットは、磁石表面に形成される溝、磁石内部に形成される空隙をも含むものである。
このようにして得られた絶縁効果のある磁石は、着磁され、回転機等に用いることができる。
In addition, when a slit is produced in the sintering process, rare earth element oxide is formed on the surface of the sintered magnet body facing the slit, and the electric resistance of the rare earth element oxide is much larger than that of the magnet body. Even if the oxide layer is in contact with the slit surface and there is no gap, there is an effect of substantially insulating.
In addition, the slit in the rare earth permanent magnet obtained by the present invention includes a groove formed on the magnet surface and a void formed inside the magnet.
The magnet having an insulating effect thus obtained is magnetized and can be used for a rotating machine or the like.
以下、実施例及び比較例を示し、本発明を具体的に説明するが、本発明は下記の実施例に制限されるものではない。 EXAMPLES Hereinafter, although an Example and a comparative example are shown and this invention is demonstrated concretely, this invention is not restrict | limited to the following Example.
［実施例１−１〜３、比較例１，２］
Ｎｄ−Ｆｅ−Ｂ系焼結磁石（信越化学工業（株）製／Ｎ４２ＳＨ）において、単体成型体寸法が１０ｍｍ×６０ｍｍ×１４．５ｍｍの６０ｍｍ×１４．５ｍｍの面にパンチにより０．１ｍｍの突条部を形成した。得られた突条部を有する単体成型体６枚を重ねて、不活性ガス雰囲気中、１，０５０℃で焼結した。これにより、密度が上がって、５０ｍｍ×５０ｍｍ×１０ｍｍの焼結体が得られた。磁化方向は１０ｍｍ方向である。突条の位置は次の３種類で、突条の幅の合計は磁石幅の４０％にあわせている。実施例１−１は図５のようにスリットがほぼ等しい間隔になるよう３箇所で接合されている。実施例１−２は図６のように両端と中央の３箇所で接合されている。実施例１−３は図７のように中央の１箇所で接合されている。実施例１−１、実施例１−２、実施例１−３ではスリットの幅は０．０８ｍｍであった。焼結工程で磁石体の表面には合金に含有される希土類元素の酸化物が形成されるので、スリットに面する焼結磁石体の表面にも希土類酸化物層が形成されている。本実施例では厚さ約１５μｍのＮｄの酸化物が形成される（ＥＰＭＡ）。酸化物の電気抵抗は合金に比べて大きいので、スリット面の酸化物層が接触し、隙間がゼロの状態でも渦電流は流れ難い。
[Examples 1-1 to 3, Comparative Examples 1 and 2]
In a Nd-Fe-B sintered magnet (manufactured by Shin-Etsu Chemical Co., Ltd./N42SH), a single molded body size of 10 mm × 60 mm × 14.5 mm, 60 mm × 14.5 mm surface is punched by 0.1 mm A streak was formed. Six obtained single molded bodies having the protrusions were stacked and sintered at 1,050 ° C. in an inert gas atmosphere. Thereby, the density increased and a sintered body of 50 mm × 50 mm × 10 mm was obtained. The magnetization direction is 10 mm. The positions of the ridges are the following three types, and the total width of the ridges is adjusted to 40% of the magnet width. In Example 1-1, as shown in FIG. 5, the slits are joined at three locations so that the slits are at substantially equal intervals. Example 1-2 is joined at three places at both ends and the center as shown in FIG. Example 1-3 is joined at one central position as shown in FIG. In Example 1-1, Example 1-2, and Example 1-3, the width of the slit was 0.08 mm. Since the rare earth element oxide contained in the alloy is formed on the surface of the magnet body in the sintering process, a rare earth oxide layer is also formed on the surface of the sintered magnet body facing the slit. In this embodiment, an oxide of Nd having a thickness of about 15 μm is formed (EPMA). Since the electrical resistance of the oxide is larger than that of the alloy, the eddy current hardly flows even when the oxide layer on the slit surface is in contact and the gap is zero.
この磁石に磁場強度±０．０１５テスラ、周波数２，０００Ｈｚの交番磁場を印加し、発生する渦電流損失を測定した。なお、比較例１としてスリットを設けていない５０ｍｍ×５０ｍｍ×１０ｍｍ（信越化学工業（株）製／Ｎ４２ＳＨ）の焼結体、比較例２として加工にてスリットを実施例１−３と同様に施した焼結体を用意した。なお、加工は切断刃によるものでスリット幅は０．８ｍｍであった。結果を表１にまとめた。比較例１の渦電流損失を基準値としたものも示した。 An alternating magnetic field having a magnetic field strength of ± 0.015 Tesla and a frequency of 2,000 Hz was applied to the magnet, and the generated eddy current loss was measured. As Comparative Example 1, a sintered body of 50 mm × 50 mm × 10 mm (manufactured by Shin-Etsu Chemical Co., Ltd./N42SH) without slits, and as Comparative Example 2, slits were applied in the same manner as in Example 1-3. A sintered body was prepared. The processing was performed with a cutting blade, and the slit width was 0.8 mm. The results are summarized in Table 1. Also shown is the reference value of the eddy current loss of Comparative Example 1.
実施例のようにスリットを入れることで、比較例１のスリットのないものより３３〜７４％の損失にできた。スリットの入れ方によって損失の低減度合いが変化する。実施例１−３と比較例２は同形状のスリットであるので渦電流低減は同じであった。但し、スリット幅を比較すると本発明は比較例２の１／１０であり、磁石体積が減らないので比較例２より大きな磁束を得ることができる。 By inserting a slit as in the example, a loss of 33 to 74% was achieved compared to the comparative example 1 without a slit. The degree of loss reduction varies depending on how the slits are inserted. Since Example 1-3 and Comparative Example 2 are slits having the same shape, eddy current reduction was the same. However, when the slit width is compared, the present invention is 1/10 of Comparative Example 2, and the magnet volume is not reduced, so that a larger magnetic flux than Comparative Example 2 can be obtained.
［実施例２］
実施例１−１の磁石成形体の凹溝に平均粒子径１０μｍのＹ（イットリウム）酸化物微粉末を有機溶剤に分散させ、このスラリー状のものを刷毛塗りした後に自然乾燥させた。塗布の厚さは０．０３ｍｍである。塗布された成形体６枚を重ねて不活性ガス雰囲気中、１，０５０℃で焼結すると、密度が上がって５０ｍｍ×５０ｍｍ×１０ｍｍの焼結体が得られた。磁化方向は１０ｍｍ方向である。酸化物が塗布されていない突条部分は焼結過程で接合した。スリット面に酸化イットリウム（ＥＰＭＡ）が形成されていた。接合部の位置と面積が実施例１−１と同じになるような試料を作製し、実施例１と同様に交番磁場中の渦電流損失を測定した。結果は１７Ｗであった。
[Example 2]
Y (yttrium) oxide fine powder having an average particle diameter of 10 μm was dispersed in an organic solvent in the concave groove of the magnet molded body of Example 1-1, and this slurry was brush-coated and then naturally dried. The coating thickness is 0.03 mm. When six coated compacts were stacked and sintered at 1,050 ° C. in an inert gas atmosphere, the density increased and a sintered body of 50 mm × 50 mm × 10 mm was obtained. The magnetization direction is 10 mm. The protrusions not coated with oxide were joined during the sintering process. Yttrium oxide (EPMA) was formed on the slit surface. A sample was prepared so that the position and area of the joint were the same as in Example 1-1, and eddy current loss in an alternating magnetic field was measured in the same manner as in Example 1. The result was 17W.
１ 磁石体
２ 焼結磁石単体
３ 接合連結部
４ スリット
５ Ｒ2の酸化物層
６ 接合連結部
１０ 単体成型体
１１ 凹溝
１２ 突条
１３ Ｒ3の酸化物層
Ｈ 突条の高さ
ＳＷ スリットの空隙幅
Ｗ 磁石幅
Ｗ１，Ｗ２，Ｗ３ 突条の幅
1 height SW slit oxide layer H projection of the
Claims (4)
A rotating machine using the rare earth permanent magnet according to claim 1.
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| WO2009116540A1 (en) * | 2008-03-18 | 2009-09-24 | 日東電工株式会社 | Permanent magnet for motor, and method for manufacturing the permanent magnet for motor |
| JP2012050329A (en) * | 2011-11-24 | 2012-03-08 | Nitto Denko Corp | Permanent magnet for motor and manufacturing method of permanent magnet for motor |
| JP5690141B2 (en) * | 2008-11-06 | 2015-03-25 | インターメタリックス株式会社 | Rare earth sintered magnet manufacturing method and powder filled container for manufacturing rare earth sintered magnet |
| JP2017022977A (en) * | 2015-07-14 | 2017-01-26 | 株式会社東芝 | Rotary electric machine and vehicle |
| US10017871B2 (en) | 2014-02-19 | 2018-07-10 | Shin-Etsu Chemical Co., Ltd. | Electrodepositing apparatus and preparation of rare earth permanent magnet |
| US10138564B2 (en) | 2012-08-31 | 2018-11-27 | Shin-Etsu Chemical Co., Ltd. | Production method for rare earth permanent magnet |
| US10181377B2 (en) | 2012-08-31 | 2019-01-15 | Shin-Etsu Chemical Co., Ltd. | Production method for rare earth permanent magnet |
| US10179955B2 (en) | 2012-08-31 | 2019-01-15 | Shin-Etsu Chemical Co., Ltd. | Production method for rare earth permanent magnet |
| US10526715B2 (en) | 2014-02-19 | 2020-01-07 | Shin-Etsu Chemical Co., Ltd. | Preparation of rare earth permanent magnet |
| CN114400126A (en) * | 2022-01-26 | 2022-04-26 | 上海盘毂动力科技股份有限公司 | Magnetic element and manufacturing method |
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| US10138564B2 (en) | 2012-08-31 | 2018-11-27 | Shin-Etsu Chemical Co., Ltd. | Production method for rare earth permanent magnet |
| US10181377B2 (en) | 2012-08-31 | 2019-01-15 | Shin-Etsu Chemical Co., Ltd. | Production method for rare earth permanent magnet |
| US10179955B2 (en) | 2012-08-31 | 2019-01-15 | Shin-Etsu Chemical Co., Ltd. | Production method for rare earth permanent magnet |
| US10017871B2 (en) | 2014-02-19 | 2018-07-10 | Shin-Etsu Chemical Co., Ltd. | Electrodepositing apparatus and preparation of rare earth permanent magnet |
| US10526715B2 (en) | 2014-02-19 | 2020-01-07 | Shin-Etsu Chemical Co., Ltd. | Preparation of rare earth permanent magnet |
| JP2017022977A (en) * | 2015-07-14 | 2017-01-26 | 株式会社東芝 | Rotary electric machine and vehicle |
| CN114400126A (en) * | 2022-01-26 | 2022-04-26 | 上海盘毂动力科技股份有限公司 | Magnetic element and manufacturing method |
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