JP3933040B2 - Rare earth bonded magnet manufacturing method and permanent magnet motor having the same - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to rare earth magnet powders, binders composed of thermosetting resin compositions, powder molding, and rolling and stamping, or rare earth bonded magnets ranging from a sheet whose flexibility is controlled by rolling or stamping to a film having a thickness of 200 μm or less. In addition, the present invention relates to an efficient method for manufacturing a permanent magnet motor using them.
[0002]
For example, the estimated number of small motors produced from 1992 to 2000 has already exceeded 2.4 to 4.7 billion. In particular, the production volume of DC motors, brushless motors, stepping motors, and ironless core motors has increased significantly, increasing by about 2.6 billion from 1992 to 2000. Moreover, we can estimate an average annual growth rate of 9% in the future.
[0003]
However, the production numbers of small induction motors and small synchronous motors are gradually decreasing. This trend suggests the development of efficient small motors with high performance magnets in the small motor industry and the high demand for high performance small motors in the field of electrical and electronic equipment. Approximately 70% of these small motors produced are DC motors, but Nd prepared by ferrite rubber magnets for general small DC motors and melt spinning for high-performance small DC motors. ₂ Fe ₁₄ At present, an annular magnet obtained by compression-molding a B-type flaky rare earth magnet powder with a hard thermosetting resin such as an epoxy resin is mainly used.
[0004]
On the other hand, according to statistics from the Ministry of Economy, Trade and Industry and the Agency for Natural Resources and Energy, the total electricity consumption in Japan was 2000 billion kWh in 2000. Based on the data, the power consumption by the motor is estimated to exceed 50% of the total domestic demand. The power consumption of the motor is not necessarily a large capacity power motor. For example, the power consumption of a 2.5 inch HDD spindle motor exceeds 50% of the power consumption of a PC in an idle state. (J. G. W. West, Power Engineering J., April 77, 1994).
[0005]
That is, for a small motor, the power consumption of the motor itself is a few tens of watts at most. However, considering the high demand for high-performance compact motors in the field of advanced devices such as electrical and electronic equipment, it is necessary from the viewpoint of environmental conservation and resource saving to provide and disseminate efficient compact motors. The present invention relates to an efficient small motor used in various advanced device devices mainly composed of the above-described efficient small motor, and a method for manufacturing a rare earth bonded magnet from a sheet to a film adapted thereto.
[0006]
[Prior art]
Small motors used in various advanced devices are required to be small, high output, or highly efficient as the motor size is further reduced as the equipment becomes smaller and lighter. Permanent magnet type motors have become popular since the 1960s because the application of magnets has led to a reduction in motor loss, which in turn was effective in the production of efficient small motors. In the development of such a small motor, in the case of a bonded magnet in which magnet powder is hardened with a binder, the magnet powder, the binder system, and the molding method are equally important as the three major element technologies.
[0007]
Regarding the above-mentioned bonded magnets widely used in small motors, “Recent Progress in Research and Development Related to Bonded Rare-Erth Permanent Magnets” by Hirosawa and Tomizawa et al., Vol. 21, no. 4-1, pp. 161-167 (1997) (Non-Patent Document 1) briefly explains. Therefore, using FIG. 1 based on the cited document, the three major element technologies in bond magnet production, that is, cooperation of magnet powder, binder, and molding method will be described.
[0008]
First, ferrite (1) -a, alnico (1) -b, rare earth (1) -c as magnet powder (1), and flexible (rubber, thermoplastic elastomer) as binder (2) ( 2) -a, hard thermoplastic resin (2) -b, hard thermosetting resin (2) -c, processing method (3) as calendering or extrusion molding (3) -a, injection molding (3)- b, compression molding (3) -c. These linkages are organized as shown by the solid line in the figure.
[0009]
For example, the rare earth magnet powder (1) -c is used as a binder (2) in a flexible system (rubber, thermoplastic elastomer) (2) -a, a hard thermoplastic resin (2) -b, a hard thermosetting resin (2). -C, and all of (2) and (3) as calendering or extrusion molding (3) -a, injection molding (3) -b, compression molding (3) -c as molding method (3) Is linked to the elements of
[0010]
However, in the cooperation of compression molding (3) -c and rare earth magnet powder (1) -c, the element of the binder (2) is composed of a hard thermosetting resin (2) -c such as an epoxy resin. The current situation is limited to relationships.
[0011]
As for the relationship between the above three major element technologies in bond magnet production, that is, the rare earth magnet powder (1) -c, the binder (2), and the molding method (3), and the high performance of the motor, for example, Yamashita, Y. et al. Sasaki, H .; Fukunaga, “Isotropic Nd-Fe-B Thin Arc-shaped Bonded Magnets for Small DC Motors Prepared by Powder Compacting Press Vital Japan Vita. 25, no. 4-2, pp. 683-686 (2001) (non-patent document 2), in the production of a thin arc magnet having a maximum thickness of 0.9 mm, rare earth magnet powder (1) -c and hard thermoplastic resin (2) -B and extrusion molding (3) -a are changed to cooperation between rare earth magnet powder (1) -c, hard thermosetting resin (2) -c, and compression molding (3) -c As a result, the maximum efficiency of the permanent magnet field type small DC motor having an output of 200 mW is improved by 8%. This is exactly the same for rare earth magnet powders. Time Even so, it suggests that an efficient small motor can be provided by recombination of cooperating elements. The above description is shown in FIG.
[0012]
By the way, as a magnet of a small motor with a machine output of 10 W or less, which is the subject of the present invention, the sheet magnets that have been studied in the past are arranged from the viewpoint of cooperation of the three major element technologies in the production of the bond magnet of FIG. Magnet system powder (1) -a or rare earth system magnet powder (1) -c, flexible system (rubber, thermoplastic elastomer) (2) -a, and calendering or extrusion molding (3) -a Can be expressed in cooperation. Many ideas have been made under this cooperation.
[0013]
For example, a sheet magnet composed of rare earth magnet powder (1) -c, flexible rubber, and thermoplastic elastomer (2) -a is cut into a strip shape, curled into a ring shape, and fixed to the inner surface of the peripheral wall of the frame. 2. Description of the Related Art A permanent magnet type motor having a configuration opposed to a salient pole surface of an iron core is known.
[0014]
As prior art of this magnet and motor, Japanese Patent No. 2766746 (Patent Document 1) describes (1) Nd—Fe—B, (Ce, La) —Fe—B rare earth magnet powder, and (2) natural rubber. , Isoprene rubber, butadiene rubber, styrene butadiene rubber, butyl rubber, ethylene propylene rubber, ethylene vinyl acetate rubber, nitrile rubber, acrylic rubber, urethane rubber, (3) chloroprene rubber, chlorosulfonated polyethylene, polyethylene chloride (1) to ( 3) 1 type or 2 types or more are selected from the group, (1) is 92 to 96 wt%, density is 4.9 to 5.8 Mg / m ^Three Sheet magnet.
[0015]
Japanese Patent No. 2528574 (Patent Document 2) includes (a) a step of kneading R-Fe-B (R is Nd / Pr) -based rare earth magnet powder and a resin such as rubber or thermoplastic elastomer; A method for producing a sheet magnet is disclosed which comprises the steps of: pulverizing the kneaded product and calendering the sheet, and (c) heat treating the sheet magnet at 125 to 180 ° C. for 60 to 180 mun.
[0016]
However, (1) the density of the sheet magnet is 4.9 to 5.8 Mg / m ^Three (2) Flexible thermoplastic elastomers and rubbers and rare earth magnet powders have poor adhesion, and rare earth magnet powders fall off due to the magnetic attraction force of the excited armature core. Problems with reliability such as causing rotational noise and rotation trouble during motor operation, (3) Brush commutator with vulcanization and residual sulfur gas caused by vulcanization There were also problems with reliability, such as corrosion and accelerated wear of electric sliding contacts.
[0017]
In JP-A-5-299221 (Patent Document 3), Sm-Fe-N rare earth magnet powder and acid-modified styrene elastomer are calendered (kneaded and rolled), and the cut strip is curled. 5.6Mg / m density for use in small motors ^Three Maximum energy product (BH) _max 35 kJ / m ^Three An annular magnet is disclosed. However, magnetically isotropic R-Fe-B (R is Nd or Pr) rare earth magnet powder and hard epoxy resin were compression molded (BH) _max ~ 80kJ / m ^Three Compared with magnets of this type, the magnetic performance does not reach and a strong static magnetic field cannot be obtained in the desired gap with the armature core.
[0018]
In addition, Sm-Fe-N magnet powder is Sm of several μm. ₂ Fe ₁₇ N _Three Because it is a fine powder consisting of a single magnetic phase, it is generally chemically active, rare earth-iron-nitrogen magnet powder is exposed to the atmosphere at the cut surface, and irreversible magnetic flux loss or thermoplastic elastomer based on permanent demagnetization due to oxidative corrosion There was also a serious problem that the magnet collapsed due to a decrease in adhesion between the magnet powder and the magnet powder, and the magnet powder fell off and scattered.
[0019]
On the other hand, film magnets having a thickness of 200 μm or less are used for millimeter-size high-performance motors, actuators, magnetic drive elements and the like that are used as drive sources in microrobots, medicine, space development, and the like. To tell Ma Rather, thin-film rare earth magnets are generally produced by sputtering.
[0020]
For example, Japanese Patent Laid-Open No. 05-21865 (Patent Document 4) discloses a method of forming a thin-film rare earth magnet on a substrate such as a glass substrate, a quartz substrate, or a silicon wafer by a sputtering method. A method of forming a metal layer with a thin film magnet is disclosed.
[0021]
In Japanese Patent Laid-Open No. 06-151226 (Patent Document 5), in a method of forming a thin-film rare earth magnet by sputtering, a metal layer having a film thickness of about 1 to 40 nm and an anisotropy in the film thickness direction is less than 5 μm. R ₂ Fe ₁₄ A method of forming a thin-film rare-earth magnet in which B (R is a rare-earth element including Y) alloy layers are alternately laminated, Japanese Patent Laid-Open No. 08-83713 (Patent Document 6) describes Nd ₂ Fe ₁₄ As the optimum production conditions in the sputtering method of a rare-earth magnet of a thin film containing B as the main phase, it is disclosed that the substrate temperature is 530 to 570 ° C., the deposition rate is 0.1 to 4 μm / hr, and the gas pressure is 0.05 to 4 Pa. ing.
[0022]
Furthermore, Japanese Patent Laid-Open No. 09-162034 (Patent Document 7) discloses that Nd on the substrate. ₂ Fe ₁₄ B, SmCo _Five , Sm (Co, Fe, Cu, Zr) ₇ , SmFe ₁₁ Ti, Sm ₂ Fe ₁₇ N ₂ In a film magnet having a multilayer alloy film in which hard magnetic layers made of so-called rare earth magnets and soft magnetic layers such as Fe, Fe—Ni, Fe—Co, Fe—Si, Fe—N, and Fe—B are alternately laminated. The hard magnetic layer having a thickness of 2 to 4 nm per layer on the substrate by sputtering at a substrate temperature of 450 to 800 ° C. and having anisotropy in the thickness direction, and a substrate temperature of 150 to 650 ° C. Also disclosed is a thin-film rare earth magnet having a multilayer structure in which the soft magnetic layers having a thickness of 6 to 12 nm per layer and magnetic anisotropy in the thickness direction are alternately laminated by the sputtering method of Yes.
[0023]
Also, JP 09-237714 A (Patent Document 8) and JP 11-214219 A (Patent Document 9) are adjacent to each other in the in-plane direction at a substrate temperature of 300 to 800 ° C., for example, by sputtering. A thin-film rare earth magnet having a multilayer structure of 0.01 to 300 μm in which the thicknesses of the soft magnetic layer and the hard magnetic layer are strictly controlled at the nm level is disclosed.
[0024]
However, in order to produce a thin-film rare earth magnet by sputtering, it is necessary to heat the substrate to 450 ° C. or higher, and the film formation rate is limited to 0.1 to 4 μm / hr. In particular, Nd ₂ Fe ₁₄ A thin-film rare-earth magnet having B as the main phase is limited to a film thickness of less than 5 μm in order to suppress a decrease in coercive force due to oxidation. In addition, in the thin-film rare earth magnet having a multilayer structure of 0.01 to 300 μm in which the thicknesses of the soft magnetic layer and the hard magnetic layer are strictly controlled at the nm level, the magnet production is further complicated and the economical consistency is poor. Become.
[0025]
Japanese Patent Application Laid-Open No. 11-288812 (Patent Document 10) discloses a thin-film R—Fe—B rare earth magnet formed by sputtering without heating the substrate and heat-treated after film formation. . However, this method also has a problem that the film formation rate is 4 μm / hr or less and a problem that the film thickness of the magnet is limited to tens of μm or less.
[0026]
There is a strong demand for downsizing motors and actuators. The key to miniaturization in motors and actuators is to reduce the number of components and simplify assembly. Therefore, the mover of a small motor or actuator is generally composed of rare earth sintered magnets by powder metallurgy technique or flaky magnet powders by melt span method, etc. is there. From the positional relationship between the magnet and the armature winding, an axial gap type in which the magnet and the armature winding have a gap in the axial direction, and a radial gap type in which the magnet and the armature winding have a gap in the radial direction, Has been proposed.
[0027]
However, for example, in the case of a millimeter-sized motor or actuator (in this case, an axial gap type) having a diameter of 5 mm and a height of 1 mm as shown in FIG. 2, the rare earth magnet constituting the mover is also a film magnet having a thickness of 300 μm or less. It is necessary to consist of. However, in FIG. 2, 11 is a film magnet, 12 is a rotating shaft, 13 is a bearing, and 14 is an armature winding.
[0028]
By the way, Nd ₂ Fe ₁₄ Rare earth sintered magnets with B as the main phase generally have a crystal grain size of 6-9 μm, and an R-rich phase exists at the crystal grain boundary, so the surface magnetic performance from the surface to several tens of μm deep during grinding. Causes processing deterioration. Further, since the material is brittle and difficult to process, the processing limit in consideration of the yield is estimated to be about 500 μm, making it difficult to cope with the application shown in FIG.
[0029]
Nd by melt span method ₂ Fe ₁₄ Rare earth bonded magnet with B as main phase is Nd of magnet ₂ Fe ₁₄ Although the B crystal grain size is relatively small as 20 to 100 nm, a decrease in magnetic performance due to a decrease in magnet density is inevitable, and the processing limit considering the maintenance of magnetic performance and the yield is still estimated to be about 500 μm.
[0030]
As described above, even in the case of millimeter-sized motors and actuators and magnetic drive elements, the conventional rare earth magnets can be used without modification using conventional rare earth sintered magnets by powder metallurgy, or bonded magnets that harden rare earth magnet powders with resin. It was not possible to fully draw out and use the magnetic performance as a motor or actuator.
[0031]
Further, in order to produce a thin-film rare earth magnet by sputtering, it is generally necessary to heat the substrate to 450 ° C. or higher, and the film formation rate is limited to 0.1 to 4 μm / hr. In particular, Nd ₂ Fe ₁₄ In a thin-film rare-earth magnet having B as the main phase, the film thickness is limited to less than 5 μm due to a decrease in coercive force due to oxidation during sputtering. In addition, in the thin-film rare-earth magnet having a multilayer structure of 0.01 to 300 μm in which the thicknesses of the soft magnetic layer and the hard magnetic layer are strictly controlled at the nm level, the magnet fabrication is particularly complicated and economically consistent. Has the disadvantage of becoming poor.
[0032]
When the motor or actuator is downsized, the electromagnetic force is “L” according to the scaling law. ^Three (L is the physique), for example, when the mover dimension (magnet) becomes 1/10, the electromagnetic force decreases to 1/1000. Therefore, if a thin film rare earth magnet having a film thickness of less than 5 μm is used as a mover, there is an essential problem that an output corresponding to a load in actual use cannot be obtained.
[0033]
[Patent Document 1]
Japanese Patent No. 2766746
[Patent Document 2]
Japanese Patent No. 2528574
[Patent Document 3]
JP-A-5-299221
[Patent Document 4]
JP 05-21865 A
[Patent Document 5]
Japanese Patent Laid-Open No. 06-151226
[Patent Document 6]
Japanese Patent Laid-Open No. 08-83713
[Patent Document 7]
Japanese Patent Laid-Open No. 09-162034
[Patent Document 8]
JP 09-237714 A
[Patent Document 9]
JP-A-11-214219
[Patent Document 10]
JP 11-288812 A
[Non-Patent Document 1]
Hirosawa, Tomizawa et al. “Recent Progress in Research and Development Related to Bonded Rare-Erth Permanent Magnets” Journal of Applied Magnetics Society of Japan, Vol. 21, no. 4-1, pp. 161-167 (1997)
[Non-Patent Document 2]
F. Yamashita, Y. et al. Sasaki, H .; Fukunaga, “Isotropic Nd-Fe-B Thin Arc-shaped Bonded Magnets for Small DC Motors Preparedby Powder Compacting Press Metal Metall. 25, no. 4-2, pp. 683-686 (2001)
[0034]
[Problems to be solved by the invention]
As described above, from the viewpoint of cooperation of the three major elemental technologies in the bond magnet production of FIG. 1, rare earth magnet powder (1) -c, flexible system (rubber, thermoplastic elastomer) (2) -a, Many devices have been made in the past under the cooperation of calendering or extrusion (3) -a.
[0035]
However, the magnets produced under this cooperation have many problems and are hardly used for permanent magnet type motors. Under this cooperation, the ferrite magnet powder (1) -a, the flexible system (rubber, thermoplastic elastomer) (2) -a, and the calendar ring or extrusion molding (3) -a A sheet magnet using the manufactured ferrite magnet powder is applied to a small motor. However, this magnet is (BH) _max ~ 12kJ / m at most ^Three Therefore, a strong static magnetic field cannot be obtained in the gap between the armature core and the field.
[0036]
Therefore, it is no exaggeration to say that it is a small motor that is not efficient for recent electrical and electronic equipment.
[0037]
Therefore, it will be described below how the magnets produced by the cooperation are mainly used for an efficient small motor with a machine output of 10 W or less.
[0038]
Japanese Patent Publication No. 6-87634 by the present inventors can be cited as one of typical proposals for an efficient small motor using rare earth bonded magnets. That is, magnetically isotropic R-Fe-B (R is Nd or Pr) rare earth magnet powder (1) -c and hard epoxy resin (2) in order to create a strong static magnetic field in the air gap facing the armature core. ) -C compression molded (3) -c, outer diameter 25 mm or less, density 5 Mg / m ^Three This is a permanent magnet type motor having a configuration in which the above-mentioned annular rare earth bonded magnet is magnetized in multiple poles. The magnetically anisotropic rare earth magnet powder (1) -c can be injection molded ((3) -b) with a hard thermoplastic resin ((2) -b) as a binder, or a hard thermosetting resin (( 2) -c) Regardless of the cooperation of compression molding ((3) -c), the radial anisotropic magnetic properties of radial anisotropy magnets decrease as the diameter decreases (downsizing). .
[0039]
Therefore, a motor using a radial anisotropic magnet cannot avoid a decrease in the mechanical output of the motor in conjunction with a decrease in the radial magnetic characteristics as the diameter of the annular magnet is reduced. That is, the radial anisotropic magnet has a drawback that it becomes an inefficient motor as the size is reduced (the diameter is reduced).
[0040]
However, if the magnetically isotropic rare earth magnet powder is used, for example, the magnetically isotropic Nd does not depend on the diameter of the annular magnet. ₂ Fe ₁₄ By compression molding B-type rare earth magnet powder (BH) _max 80 kJ / m ^Three To reach. This value is (BH) for ferrite-based sheet magnets. _max 12kJ / m ^Three Is approximately 6.7 times.
[0041]
As a result, this type of magnet was effective in increasing the output and current consumption of a small motor, and gained recognition as a so-called efficient small motor mainly in the field of electrical and electronic equipment. For example, manufactured in cooperation with ferrite magnet powder ((1) -a), flexible system (rubber, thermoplastic elastomer) ((2) -a), and calendering or extrusion molding ((3) -a) For a starting torque of 1.5 mN-m of a small motor, a sheet magnet having a thickness of 1.55 mm and a width of 7.2 mm was cut into a strip shape, curled and fixed to the inner surface of the peripheral wall of a rotor frame having an inner diameter of 22.5 mm , Magnetically isotropic rare earth magnet powder ((1) -c) and hard epoxy resin ((2) -c) compression molded ((3) -c), outer diameter 22.5 mm, thickness 1 .10 mm, height 9.4 mm, density 5.8 Mg / m ^Three The starting torque of the permanent magnet type motor using the magnet of 13 reaches 13 times 20 mN-m.
[0042]
As described above, typical magnets targeted in the present invention are ferrite magnet powder ((1) -a), flexible system (rubber, thermoplastic elastomer) ((2) -a), calendering or extrusion molding ( Magnets manufactured in conjunction with (3) -b), and magnetically isotropic rare earth magnet powders ((1) -c) and thermosetting resins such as hard epoxy resins ((2) -c ) And compression-molded ((3) -c) magnets. The present invention provides a more efficient motor and a method for manufacturing a rare-earth bonded magnet accompanying the present invention mainly for small DC motors that account for 70% of the number of small motors produced using them and annually about 3 billion units. Is the purpose.
[0043]
[Means for Solving the Problems]
In order to solve the above problems, the first invention according to the present application is as follows: (1) the magnet powder is a rare earth magnet powder, and (2) the binder is: Consists of an epoxy oligomer that is solid at least at room temperature and thermocompression-bonding polyamide and polyamideimide powder, or thermocompression-bonding polyamide or polyamideimide powder, and a powdery latent epoxy curing agent that is optionally added A thermosetting resin composition, wherein (3) a molding (molding) processing method is a method for producing a rare earth bonded magnet comprising warm compression molding, warm rolling and heat treatment; Said A powder compound comprising a thermosetting resin composition as a main component is prepared, a green sheet is prepared by warm compression molding the powder compound, and a binder component of the green sheet is thermoset to form a sheet magnet Is manufactured, and the sheet magnet is warm-rolled and then heat-treated to manufacture a rare-earth bonded magnet from a sheet having a thickness of 2.5 mm to 0.2 mm to a film.
[0044]
Moreover, 2nd invention which concerns on this application is (1) magnet powder is rare earth magnet powder, (2) binder is, Consists of an epoxy oligomer that is solid at least at room temperature and thermocompression-bonding polyamide and polyamideimide powder, or thermocompression-bonding polyamide or polyamideimide powder, and a powdery latent epoxy curing agent that is added as needed. A thermosetting resin composition, and (3) a rare earth magnet powder comprising: a rare earth magnet powder comprising: (3) a molding method comprising warm compression molding, warm stamping and heat treatment; Said A powdery compound comprising a thermosetting resin composition as a main component is prepared, a green sheet is prepared by warm compression molding the compound, and a binder component of the green sheet is thermoset to produce a sheet magnet. A method for producing a rare earth bonded magnet, comprising producing a rare earth bonded magnet from sheet to film having a thickness of 2.5 mm to 0.2 mm and then heat treating the sheet magnet after warm stamping.
[0045]
In addition, the 3 The present invention further relates to a method for producing a rare earth bonded magnet, wherein the difference between the average particle diameter of the rare earth magnet powder and the average particle diameter of the powdered compound is within 10 μm.
[0046]
In addition, the 4 According to the present invention, in the method for producing a rare earth bonded magnet, the apparent density of the powdered compound is 2.6 to 3.0 Mg / m. ^Three And the powder flow rate of the powdered compound is 40 sec / 50 g or less.
[0047]
In addition, the 5 According to the present invention, in the method for producing a rare earth bonded magnet, the powdered compound lubricant is calcium stearate powder, and the amount of the calcium stearate powder added to the powdered compound is 0.2 to 0.4 parts by weight. It is a manufacturing method of a certain rare earth bonded magnet.
[0048]
In addition, the 6 According to the present invention, a sheet-shaped or film-shaped rare earth bonded magnet obtained by any one of the rare earth bonded magnet manufacturing methods of the present invention is used to constitute a rotor having the rare earth bonded magnet and a cylindrical frame. A bonded magnet is wound around the inner peripheral surface of the cylindrical frame, and the rare earth bonded magnet wound around the cylindrical frame is fixed to the cylindrical frame. It is a permanent magnet type motor comprising the annular magnet which is pole-magnetized to constitute an annular magnet and the permanent magnet field of the rotor is composed of the rare earth bonded magnet.
[0049]
In addition, the 7 According to the present invention, a sheet-shaped or film-shaped rare earth bonded magnet obtained by any one of the rare earth bonded magnet manufacturing methods of the present invention is used to constitute a rotor having the rare earth bonded magnet and a cylindrical frame. A bonded magnet is wound around the inner peripheral surface of the cylindrical frame, and the rare earth bonded magnet wound around the cylindrical frame is fixed to the cylindrical frame. This is a radial magnet type permanent magnet motor in which an annular magnet is formed by pole magnetization, the permanent magnet field of the rotor is composed of the rare earth bonded magnet, and a gap is provided in the radial direction of the rotor. .
[0050]
In addition, the 8 According to the present invention, a sheet-shaped or film-shaped rare earth bonded magnet obtained by any one of the rare earth bonded magnet manufacturing methods of the present invention is used to constitute a rotor having the rare earth bonded magnet and a cylindrical frame. The bonded magnet is wound around the outer peripheral surface of the cylindrical frame, the rare earth bonded magnet wound around the cylindrical frame is fixed to the cylindrical frame, and the rare earth bonded magnet fixed to the cylindrical frame is multipolar. It is a surface magnet type permanent magnet type motor that is magnetized to form an annular magnet, the permanent magnet field of the rotor is composed of the rare earth bonded magnet, and the annular magnet is provided on the surface of the rotor.
[0051]
In addition, the 9 According to the present invention, the shape of the sheet-like or film-like rare earth bonded magnet obtained by any one of the rare earth bonded magnet manufacturing methods of the present invention is an arc shape, and the arc-shaped rare earth bonded magnet is in the radial direction of the iron core of the rotor. It is a surface magnet type permanent magnet motor which is fixed to the surface, has a permanent magnet field of the rotor composed of a field of the rare earth bonded magnet, and has a permanent magnet field on the surface of the rotor.
[0052]
In addition, the 10 According to the present invention, the shape of the sheet-like or film-like rare earth bonded magnet obtained by any one of the rare earth bonded magnet manufacturing methods of the present invention is arcuate, and the arcuate rare earth bonded magnet is fixed inside the frame. The permanent magnet field motor of the frame frame includes a field magnet of the rare earth bonded magnet, and the frame frame is provided with a permanent magnet field.
[0053]
In addition, the 11 According to the present invention, a sheet-like or film-like rare earth bonded magnet obtained by any one of the methods for producing a rare earth bonded magnet according to the present invention has a hollow disk shape, and the rare earth bonded magnet having a hollow disk shape is multipolarly attached. This is an axial gap type permanent magnet motor which is provided with a gap in the axial direction of the rare earth bonded magnet which is magnetized and multipolarly magnetized.
[0054]
In addition, the 12 In the invention, a sheet or film-like rare earth bonded magnet obtained by any one of the rare earth bonded magnet manufacturing methods of the present invention is used, and a rotor is constituted by the rare earth bonded magnet and the rotor core, and the rotation The rotor is a rotor in which the rare earth bonded magnet is embedded in a part of a core of the core, and a permanent magnet motor having a magnet embedded rotor in which a rare earth bonded magnet is embedded in a part of the rotor core.
[0055]
In addition, the 13 In the invention, a sheet or film-like rare earth bonded magnet obtained by any one of the rare earth bonded magnet manufacturing methods of the present invention is used, and a rotor is constituted by the rare earth bonded magnet and the rotor core, and the rotation It is a rotor in which the rare earth bonded magnet is embedded in a part of a core of the rotor, and a permanent magnet motor having a magnet embedded rotor in which a rare earth bonded magnet is embedded in a part of the rotor core.
[0056]
In addition, the 14 In the permanent magnet type motor using the sheet-like or film-like rare earth bonded magnet obtained by any one of the rare earth bonded magnet manufacturing methods of the present invention,
A rotor core having a hole, a hole or a slot in the direction of the rotation axis of the rotor is prepared, and the intermediate process product or sheet magnet of a warm-rolled rare earth bonded magnet is the hole / hole of the rotor core. A rotor core in which a rare earth bond magnet is embedded is manufactured by heat-treating the intermediate magnet of the rare earth bond magnet or the sheet magnet together with the rotor core after being inserted into the portion or slot. This is a permanent magnet type motor in which the rotor core in which the rare earth bonded magnet is embedded is provided in the rotor.
[0057]
In addition, the 15 In the permanent magnet type motor using the sheet-like or film-like rare earth bonded magnet obtained by any one of the rare earth bonded magnet manufacturing methods of the present invention,
A rotor core having a hole, a hole, or a slot in the direction of the rotation axis of the rotor is prepared, and the intermediate process product or sheet magnet of the rare-earth bonded magnet that is warm stamped is the hole, hole, or hole of the rotor core. A rotor core in which a rare earth bond magnet is embedded is manufactured by heat-treating the intermediate magnet of the rare earth bond magnet or the sheet magnet together with the rotor core after being inserted into the portion or slot. This is a permanent magnet type motor in which the rotor core in which the rare earth bonded magnet is embedded is provided in the rotor.
[0058]
In addition, the 16 In the method for producing a rare earth bonded magnet according to any one of the present invention,
A method for producing a rare earth bonded magnet from a sheet to a film, characterized in that the heat treatment temperature is higher than the processing temperature of warm rolling.
[0059]
In addition, the 17 The present invention provides a method for producing a rare earth bonded magnet from a sheet to a film, characterized in that in the method for producing a rare earth bonded magnet of the present invention, the heat treatment temperature is higher than the processing temperature of warm stamping. is there.
[0060]
In addition, the 18 The method for producing a rare earth bonded magnet from a sheet to a film according to any one of the present invention, wherein the heat treatment temperature is higher than the endurance temperature of the permanent magnet type motor. It is.
[0061]
In addition, the 19 In the method for producing a rare earth bonded magnet according to any one of the present invention,
Part or all of the rare earth magnet powder is magnetically isotropic Nd prepared by spinning cup atomization. ₂ Fe ₁₄ It is a manufacturing method of the rare earth bond magnet from the sheet | seat to a film characterized by being B type spherical powder.
[0062]
In addition, the 20 According to the present invention, in any of the rare earth bonded magnet manufacturing methods of the present invention, part or all of the rare earth magnet powder is magnetically anisotropic Nd prepared by HDDR treatment (hydrogen decomposition / recombination). ₂ Fe ₁₄ It is a manufacturing method of the rare earth bond magnet from the sheet | seat to a film characterized by being a B type powder.
[0063]
In addition, the 21 According to the present invention, in any of the rare earth bonded magnet manufacturing methods of the present invention, part or all of the rare earth magnet powder is magnetically anisotropic Nd prepared by HDDR treatment (hydrogen decomposition / recombination). ₂ Fe ₁₄ A method for producing a rare earth bonded magnet from a sheet to a film, wherein the surface of the B-based powder is previously inactivated.
[0064]
In addition, the 22 According to the present invention, in any of the rare earth bonded magnet manufacturing methods of the present invention, a part or all of the rare earth magnet powder is magnetically anisotropic RD-Sm prepared by RD (oxidation reduction) treatment. ₂ Fe ₁₇ N _Three A method for producing a rare earth bonded magnet from a sheet to a film, wherein the surface of the system fine powder has been previously inactivated.
[0065]
In addition, the 23 According to the present invention, in the method for producing a rare earth bonded magnet according to any one of the present invention, the rare earth magnet powder is anisotropic HDDR-Nd. ₂ Fe ₁₄ B-based magnet powder and anisotropic RD-Sm ₂ Fe ₁₇ N _Three Fine powder or anisotropic HDDR-Nd ₂ Fe ₁₄ B magnet powder or anisotropic RD-Sm ₂ Fe ₁₇ N _Three System fine powder,
Magnetically isotropic Nd prepared by spinning cup atomization ₂ Fe ₁₄ It is a manufacturing method of the rare earth bonded magnet from the sheet | seat to a film characterized by being a mixed system with B type spherical powder.
[0066]
In addition, the 24 According to the present invention, in any of the rare earth bonded magnet manufacturing methods of the present invention, the maximum energy product (BH) at room temperature magnetized with a pulse magnetic field of 4 MA / m. _max 80kJ / m ^Three It is the manufacturing method of the rare earth bonded magnet from the sheet | seat to a film characterized by being adjusted above.
[0067]
In addition, the 25 The present invention provides a method for producing a rare earth bonded magnet from a sheet to a film, wherein the rare earth magnet powder content is in the range of 92 wt% to 98 wt% in the method for producing a rare earth bonded magnet of the present invention. It is.
[0068]
In addition, the 26 According to the present invention, in the method for producing a rare earth bonded magnet according to any one of the present inventions, the material of the rare earth bonded magnet is exposed on the surface without forming a surface layer made of a nonmagnetic dissimilar material. It is a manufacturing method of the rare earth bonded magnet from a film to a film.
[0069]
In addition, the 27 The present invention provides a method for producing a rare earth bonded magnet from a sheet to a film, wherein the thickness of the rare earth bonded magnet is 1 mm to 0.2 mm in the method for producing a rare earth bonded magnet of the present invention. .
[0070]
In addition, the 28 The present invention is a permanent magnet motor having a rare-earth bonded magnet manufactured by any one of the rare-earth bonded magnet manufacturing methods of the present invention.
[0071]
In addition, the 29 The present invention is a mobile communication portable device having any one of the permanent magnet motors of the present invention.
[0072]
In addition, the 30 The present invention is an information device having any one of the permanent magnet motors of the present invention.
[0073]
In addition, the 31 The present invention is a home electric appliance having any one of the permanent magnet motors of the present invention.
[0074]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described.
[0075]
A thick solid line arrow in FIG. 1 is a new cooperation of magnet manufacturing elements according to the present invention. As shown in FIG. 1, in the binder (2), which is one of the three major element technologies in the manufacture of bonded magnets, as shown in FIG. 1, a flexible thermosetting resin composition ((2) -d) is introduced to form a rare earth. Magnet powder ((1) -c), compression molding, rolling or stamping ((3) -d), new rare earth bonded magnet from sheet to film, and new high performance and small size An object of the present invention is to provide a permanent magnet type motor (4). In particular, the present invention relates to the improvement and reliability improvement of the invention previously filed by the present inventors.
[0076]
For example, the present invention provides a spherical Nd with high performance magnetically isotropic spinning cup gas atomization. ₂ Fe ₁₄ Based on B-based rare earth magnet powder, anisotropic HDDR-Nd ₂ Fe ₁₄ B-based rare earth magnet powder and RD-Sm ₂ Fe ₁₇ N _Three Rare earth magnet powder or anisotropic HDDR-Nd ₂ Fe ₁₄ B-based rare earth magnet powder or RD-Sm ₂ Fe ₁₇ N _Three A high-filled high-density green sheet in a magnetic field in the presence of anisotropic rare earth magnet powder, and heat-curing and rolling After stamping, rolling, or stamping, heat treatment is performed to form a ring or arc. Then, compression molding ((3)-) with conventional magnetically isotropic rare earth magnet powder ((1) -c) and thermosetting resin ((2) -c) such as hard epoxy resin d) (BH) of magnet _max 80 kJ / m ^Three Can be provided without being affected by the diameter.
[0077]
Spherical Nd by magnetically isotropic spinning cup gas atomization ₂ Fe ₁₄ Based on B-based rare earth magnet powder (BH) _max 40 kJ / m ^Three It is also possible to produce a magnet with a degree of economic consistency, which is effective in improving the efficiency of an inefficient small motor using a ferrite rubber magnet. Therefore, it is possible to provide a more efficient small motor (4) using a magnet prepared from a new form.
[0078]
The operation of the present invention will be described below.
[0079]
In the present invention, a rare earth magnet powder ((1) -c), warm compression molding and warm rolling with a flexible thermosetting resin binder ((2) -d) as shown by a thick solid arrow in FIG. And warm stamping, or warm rolling or warm stamping ((3) -d), and by applying an optimal heat treatment to the magnet, various materials ranging from sheet to film having high performance and reliability Another object of the present invention is to provide a rare earth bonded magnet having a different form and a high performance permanent magnet type motor (4) having high reliability using the same.
[0080]
More specifically, regarding the binder ((2) -d) in FIG. 1, a powdery resin component having at least a thermocompression function and a thermosetting functional group is essential as a binder. The compound is to integrate the rare earth magnet powder by the adhesive force of the binder component, and to give a role to prevent mechanical separation of the binder and the rare earth magnet powder before compression molding. As a specific means for that purpose, the binder is at least a solid epoxy oligomer at room temperature and a thermo-compressible polyamide and polyamide-imide powder imparted with tack at room temperature, or a thermo-compressible polyamide or polyamide-imide powder, and as required It is preferably composed of a powdery latent epoxy curing agent to be added.
[0081]
In the present invention, the tackiness and thermocompression bonding property of polyamide and polyamideimide powder, or polyamide or polyamideimide powder is determined by adding a tackifier or the like, and first combining with rare earth magnet powder in a compound state before compression molding. The agent is fixed by its adhesive force.
[0082]
Next, when forming a green sheet by warm compression of the compound using a die of 50 ° C. or higher, promotion of plastic deformation by thermal softening of polyamide and polyamideimide powder, or polyamide or polyamideimide powder, By improving wettability, the thermocompression bonding property of polyamide and polyamideimide powder, or polyamide or polyamideimide powder, or epoxy oligomer is enhanced.
[0083]
The rare earth magnet powder is previously coated with a solid epoxy oligomer at room temperature in order to strengthen the binding force with the binder. As a method for coating the rare earth magnet powder with the epoxy oligomer, first, the epoxy oligomer is dissolved in an organic solvent, then wet mixed with the rare earth magnet powder, and the massive mixture from which the solvent has been removed is crushed. In order to increase the crosslinking density of the epoxy oligomer, a novolak type epoxy having an epoxy group in the molecular chain is desirable.
[0084]
Examples of the powder epoxy curing agent that crosslinks with the epoxy oligomer include one or more selected from the group of dicyandiamide and derivatives thereof, carboxylic acid dihydrazide, diaminomaleonitrile and hydrazides of derivatives thereof, and the like. These are generally high melting point compounds that are hardly soluble in organic solvents, but those having a particle size adjusted to several to several tens of μm are preferred.
[0085]
Examples of the dicyandiamide derivatives include o-tolylbiguanide, α-2 · 5-dimethylbiguanide, α-ω-diphenylbiguanide, 5-hydroxybutyl-1-biguanide, phenylbiguanide, α-, ω-dimethylbiquine. There are anides. Furthermore, examples of the carboxylic acid dihydrazide include succinic acid hydrazide, adipic acid hydrazide, isophthalic acid hydrazide, and p-axylbenzoic acid hydrazide.
[0086]
These curing agents are preferably added to the compound by dry mixing. In order to prevent the compound from being transferred to the mold, 0.2 or more of one or more selected from higher fatty acids, higher fatty acid amides and higher fatty acid metal soaps having a melting point higher than the set temperature of the mold is 0.2. It is desirable to dry-mix the compound to about ~ 0.4 wt%.
[0087]
The content of the rare earth magnet powder of the compound is 92 wt% to 98 wt%, and it is desirable that the compounding is in a powder form with an average particle diameter of the rare earth magnet powder and the compound substantially equal to or less than 10 μm by a mixer. The apparent density of the compound is 2.6 to 3.0 Mg / m. ^Three The powder fluidity is desirably adjusted to 40 sec / 50 g or less.
[0088]
The powder fluidity is preferably adjusted by adding calcium stearate powder, for example, by adjusting the powder flow rate to 0.2 to 0.4 parts by weight with respect to 100 parts by weight of the compound. Further, when the warm compression molding pressure is 0.4 GPa or more, a high density green sheet is obtained. When the magnet obtained by curing the green sheet is warm-rolled at a rolling rate of 2% or more, a rare-earth bonded magnet from a sheet having a good winding property to a film can be obtained. However, it is necessary to heat-treat the magnet after rolling for dimensional stability under high temperature exposure of the magnet. However, the heat treatment temperature needs to be set higher than the rolling temperature and the motor operating temperature.
[0089]
On the other hand, a rare earth bonded magnet according to the present invention in the form of an arc or a hollow disk from a sheet to a film when heated by stamping a strip-shaped green sheet into a mold having, for example, an arc-shaped cavity, and then heat-treating. Ready. Also in this case, like the heat treatment after warm rolling, the heat treatment temperature needs to be set higher than the rolling temperature and the motor operating temperature in order to ensure high dimensional accuracy in high temperature exposure.
[0090]
However, in the case of a magnet-embedded rotor or the like, after warm rolling and warm stamping, or after warm rolling or warm stamping, the magnet is inserted into a magnet slot of the rotor core, for example. Thereafter, a final heat treatment may be performed. Then, the inserted magnet expands substantially isotropically in the magnet slot by the heat treatment, and the gap between the magnet and the iron core can be eliminated. Since the volume expansion at the time of heat treatment is irreversible, even if it is cooled after the heat treatment, no gap is generated between the magnet and the iron core. Of course, the subsequent volume expansion of the magnet will be reversible if it is below the heat treatment temperature.
[0091]
Stamping is generally a method of heating, softening, and press-molding a thermoplastic sheet, and is also called stampable sheet molding because it is molded by the same system as a sheet metal press. (Supervised by Shinroku Saito, New Material Molding Dictionary, p775, Industrial Information Society Material Information Center, 1988). The binder according to the present invention contains a thermosetting epoxy resin as a component, but from the viewpoint of the molding process, the stamping cited is considered to be the most similar method, and is therefore stamping.
[0092]
Next, as a magnetically isotropic rare earth magnet powder, Nd-Fe-B spherical powder prepared by spinning cup atomization (BH Rabin, BM Ma, “Recent Developments in NdFeB Powder”). "120th Topical Symposium of the Magnetic Society of Japan 23, 2001).
[0093]
Magnetically anisotropic rare earth magnet powders are magnetically anisotropic Nd prepared by HDDR treatment (hydrogen decomposition / recombination). ₂ Fe ₁₄ B-based rare earth magnet powder, ie, Nd-Fe (Co) -B-based alloy Nd ₂ (Fe, Co) ₁₄ B phase hydrogenation ( H hydrogenation, Nd ₂ [Fe, Co] ₁₄ BHx), phase decomposition at 650-1000 ° C. ( D ecocomposition, NdH ₂ + Fe + Fe ₂ B), dehydrogenation ( D esorpsion), recombination ( R ecobind) HDDR Treatment (T. Takeshita and R. Nakayama: Proc. Of the 10 ^th RE Magnets and Ther Applications, Kyoto, Vol. 1, 551 1989), which is a magnetically anisotropic rare earth magnet powder. (above Double Abbreviated HDDR with the underlined initials).
[0094]
Inactive powder such as Zn whose surface has been photolyzed in advance (for example, K. Macida, K. Noguchi, M. Nashimura, Y. Hamaguchi, G. Adachi, Proc. 9th Int. Workshop Rare-Earth) Magnets and Ttheir Applications, Sendai, Japan, II, 845 2000, or K. Macida, Y. Hamaguchi, K. Noguchi, G. Adachi, Digests of the 25. ^th Annual conference on Magnetcs in Japan, 28aC-6 2001) can also be used.
[0095]
The coercive force at 20 ° C. after 4 MA / m pulse magnetization of these magnet powders is preferably 1.1 MA / m or more. Further, as magnetically anisotropic rare earth magnet powder, magnetically anisotropic Sm prepared by RD (oxidation reduction) treatment is used. ₂ Fe ₁₇ N _Three Rare earth magnet powder. Alternatively, a powder obtained by previously deactivating the surface of the powder can be mentioned, and the coercive force at 20 ° C. after the 4 MA / m pulse magnetization of the powder is desirably 0.6 MA / m or more.
[0096]
The rare earth magnet powder may be used alone or in combination of two or more.
[0097]
A permanent magnet type DC motor in which a flexible magnet as described above is wound around the inner peripheral surface of a cylindrical frame, and a fixed and multipolar magnetized annular magnet is used as a permanent magnet field. A permanent magnet type motor having an annular magnet on the inner peripheral surface of a cylindrical frame and having a radial gap rotor. Examples include a permanent magnet type motor having a surface magnet type rotor provided with an annular magnet on the outer peripheral surface of a cylindrical frame.
[0098]
【Example】
Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to the examples. Other embodiments corresponding to this embodiment can also be conceived from this embodiment.
[0099]
(material)
The materials will be described below.
[0100]
In this example, four types of rare earth magnet powders having different forms were used. That is, Nd prepared by magnetically isotropic spinning cup gas atomization ₂ Fe ₁₄ B series spherical magnet powder (Nd _13.3 Fe _62.5 B _6.8 Ga _0.3 Zr _0.1 ) Powder A (Powder-A), magnetically anisotropic HDDR-Nd prepared by HDDR treatment (hydrogenolysis / recombination) ₂ Fe ₁₄ B magnet powder (Nd _12.3 Dy _0.3 Fe _64.7 Co _12.3 B _6.0 Ga _0.6 Zr _0.1 ) Powder B (Powder-B) and RD (Redox) RD-Sm ₂ Fe ₁₇ N _Three Fine powder Powder C (Powder-C), and Nd prepared by melt spinning as a comparative example ₂ Fe ₁₄ B-type flaky magnet powder (Nd ₁₂ Fe ₇₇ Co _Five B ₆ ) Powder D (Powder-D). The form of these magnet powders is shown in FIG. In addition, the average particle diameters of powder A (Powder-A), -B, -C, and -D used here were 50, 80, 2-5, and 75 μm, respectively.
[0101]
The binder system is composed of a novolak epoxy oligomer that is solid at room temperature, a powdery latent epoxy curing agent having a particle size of 15 μm or less, a polyamide powder that is frozen and ground to 100 μm or less in advance, and a particle size of 10 μm. The following lubricants were used in this example. The chemical structure of the novolac type epoxy oligomer (Chemical Formula 1) and the powdery latent epoxy curing agent (Chemical Formula 2) is as follows.
[0102]
[Chemical 1]
[0103]
(NH ₂ NHCOCH ₂ CH ₂ ) ₂ N (CH ₂ ) 11CONHNH2 (Chemical formula 2)
(Outline of manufacturing process)
The outline of the manufacturing process will be described below.
[0104]
The present invention relates to Nd prepared by magnetically isotropic spinning cup gas atomization. ₂ Fe ₁₄ B series spherical magnet powder (Nd _13.3 Fe _62.5 B _6.8 Ga _0.3 Zr _0.1 ) Based on Powder A (Powder-A), magnetically anisotropic HDDR-Nd according to the required magnetic properties ₂ Fe ₁₄ B system magnet powder B (Powder-B) and RD-Sm ₂ Fe ₁₇ N _Three It was made to provide various types of rare earth bonded magnets ranging from one or more kinds of rare earth magnet powders such as fine powder C (Powder-C) to films, and to provide an efficient small motor. It was. In particular, the rare-earth bonded magnet from the sheet to the film according to the present invention including anisotropic magnet powder B (Powder-B) and powder C (Powder-C) winds the magnet around a frame or mandrel before and after magnetization. This overcomes the difficulty of lowering the degree of orientation accompanying the small diameter of the radial magnetic field orientation, that is, lowering the magnetic properties.
[0105]
FIG. 4A shows the preparation of a flexible bonded magnet from powder A (Powder-A), -B, -C and a solid epoxy oligomer, and a powdery latent epoxy curing agent and polyamide powder containing an adhesive. It is a block diagram which shows the process for doing. FIG. 4B shows compression molding ((1) -c) together with a thermosetting resin ((2) -c) such as a hard epoxy resin ((2) -c). It is a block diagram which shows the process for preparing the magnet which 3) -d). FIG. 4B shows, for example, F.A. Yamashita, Y. et al. Sasaki, H .; Fukunaga, “Isotropic Nd-Fe-B Thin Arc-shaped Bonded Magnets for Small DC Motors Prepared by Powder Compacting Press with Metal Ion. Magn. Soc. Japan, Vol. 25, no. 4, pp. 683-686 (2001). As is apparent from FIGS. 4A and 4B, the compound of the present invention can be prepared by mixing rare earth magnet powder and a binder component. Further, the compression molding and curing of the compound are the same as in the conventional example, but in the present invention, it is desirable to perform the compression molding warmly. Furthermore, in the present invention, warm rolling and warm stamping, or warm rolling or warm stamping and heat treatment for making a sheet-like magnet into a final form are essential steps.
[0106]
(Compound adjustment)
The compound adjustment will be described below. First, the adjustment of the compound will be described in accordance with the manufacturing process of the example of the present invention shown in FIG. 5 kg of a predetermined amount of rare earth magnet powder A (Powder-A) is put in a Henschel mixer heated to 60 ° C., and the powder is stirred at 480 r / min, and a 50% acetone solution of a solid epoxy oligomer at room temperature 50 g was added dropwise. When stirring was continued, a rare earth magnet powder coated with an epoxy oligomer dried in about 5 minutes was obtained. Subsequently, 3-7 wt% of a 20% adhesive containing polyamide particles, a powdery latent epoxy curing agent, and a lubricant (calcium stearate having a particle diameter of 10 μm or less) are added to the rare earth magnet powder whose surface is coated with the epoxy oligomer. And it was set as the powdery compound.
[0107]
As a result, Nd prepared by spinning cup gas atomization ₂ Fe ₁₄ Powdered compound prepared from B-type spherical magnet powder A (Powder-A) (FIG. 5) Square Mark) Particle size distribution of magnet powder (Fig. 5) triangle ), An intermediate (FIG. 5) with magnet powder coated with an epoxy oligomer Circle It is shown in FIG. As shown in the figure, the average particle diameter was 50 to 55 μm, and the difference in the average particle diameter was 10 μm or less. When a magnetic field is applied to an anisotropic rare earth magnet powder having a particle size range similar to that of Powder A (Powder-A) in a cavity, each powder particle can rotate freely independently. Therefore, when the anisotropic magnet powder is used in combination, the degree of orientation is high, which means that the original magnetic properties of the magnet powder can be extracted as the magnet performance.
[0108]
(Optimization of lubricant addition amount)
Hereinafter, optimization of the lubricant addition amount will be described.
[0109]
The powder fluidity of the compound in which 0.2 to 0.4% of calcium stearate is mixed as a lubricant is 30 sec / 50 g (JIS Z-2511), and the apparent density is 2.7 to 2.9 Mg / m. ^Three (JIS Z-2511). The latter apparent density level is Nd by melt spinning. ₂ Fe ₁₄ It is equivalent to a granular compound of B-type flaky magnet powder and epoxy resin. On the other hand, the powder flowability of the former is greatly improved from 40 to 50 sec / 50 g. This means that, for example, the filling property into a thin slit-shaped mold cavity or the like is improved as compared with a granular compound of flaky rare earth magnet powder, and a thin sheet magnet can be produced.
[0110]
FIG. 6 is a characteristic diagram showing the relationship between the amount of compound filling into four slit cavities having a width of 1.25 mm and a length of 65 mm with respect to the amount of lubricant (calcium stearate) added to the compound. As is apparent from the figure, the filling property into the slit-like cavity is improved with the addition amount of the lubricant, and the maximum is shown at 0.4 part by weight. For this reason, the amount of lubricant added to the compound according to the present invention is preferably less than 0.4. Moreover, even if it replaces Powder B (Powder-B) and C as rare earth magnet powder of the powdery compound concerning the said invention, the powder fluidity | liquidity provided to a powder compression molding machine with a lubricant can be adjusted.
[0111]
Next, the powdery compound was put into the feeder cup of the powder compression molding machine, and the powdery compound was filled into the mold cavity. However, only the upper and lower punches of the mold and the periphery of the cavity are heated to 50 to 80 ° C. The compound containing magnetically anisotropic rare earth magnet powder filled in the cavity was compressed by an upper and lower punch in an axial magnetic field of 1.4 MA / m and demagnetized to obtain a green compact. This green sheet had sufficient handling
FIG. 7 shows that Powder A (Powder-A) having a width of 6.1, a length of 65 mm, and a thickness of 1.25 mm is 96 wt. FIG. 5 is a characteristic diagram showing the weight fluctuation of the green sheet with respect to the number of moldings when a green sheet consisting of% is repeatedly molded by a powder molding machine. However, the compression pressure is 0.4 GPa, and the cavity has a slit shape with a width of 1.25 mm and a length of 65 mm.
[0112]
The weight standard deviation of the green sheet formed with the four slit-like cavities was 0.029, and the weight standard deviation of the green sheet formed with the one cavity was 0.017. From both standard deviation values, industrial production with four cavities is possible. Further, the compression pressure of the compound according to the present invention is 0.4 to 0.5 GPa. ₂ Fe ₁₄ Since it is less than half of the general compression pressure of 0.8 to 10 GPa of the granular compound of the B-type flaky magnet powder and the epoxy resin, the productivity is doubled with a molding machine having the same compression capacity.
[0115]
(Control of dimensional stability of magnet after rolling)
The dimensional stability control of the magnet after rolling will be described below.
[0113]
Next, a green sheet composed of 96 wt% of the above powder A (Powder-A) was heated at 180 ° C. for 20 minutes to obtain a heat-cured hard magnet sheet. FIG. 8 shows a spinning cup gas atomization Nd with a thickness of 1.27 mm. ₂ Fe ₁₄ It is the characteristic view which plotted the shrinkage | contraction rate by the thermosetting of the thickness direction of the sheet magnet which B system spherical magnet powder powder A (Powder-A) consists of 96 wt% with respect to the lubricant addition amount. As shown in the figure, when the amount of lubricant added is about 0.2 parts by weight, it becomes almost no contraction. When the amount added is smaller than that, the contraction occurs.
[0114]
FIG. 9 shows the sheet magnet and the thickness change rate of the sheet magnet when the magnet is warm-rolled at 70 ° C. (average rolling ratio of 10.1%) and then exposed to high temperature (15 hours at 100 ° C.). FIG. As shown in the figure, the sheet magnet without rolling contracts by about 0.5% when exposed to high temperature, and the value does not depend on the amount of lubricant added. On the other hand, the rolled sheet magnet expands when exposed to high temperatures. The degree of expansion is large when the amount of lubricant is small, and shows a tendency to become constant as the amount of lubricant added increases. The thickness direction of the sheet magnet is generally the magnetization direction, which means that in the permanent magnet motor, the gap distance from the armature core changes, and the thickness of the rolled sheet magnet (magnetization direction) due to high temperature exposure. ) Controlling change is important.
[0115]
FIG. 10 is a characteristic diagram showing a change in thickness of the sheet magnet rolled at 70 ° C. (average rolling ratio: 10.1%) with respect to the heat treatment temperature. However, the heat treatment time is standardized for 5 minutes, and the heat treatment temperature is normalized using the exposure temperature (100 ° C.) as a reference temperature. The plot of 1 in the figure is a change in thickness after heat treatment, showing a tendency to increase rapidly above the rolling temperature and saturate above the reference temperature + 40 ° C. (140 ° C.). The plot 2 in the figure shows the thickness change after the heat-treated sheet magnet is exposed to high temperature (15 hours at 100 ° C.) with respect to the original normalized heat treatment temperature. As is apparent from the figure, the thickness of the sheet magnet heat-treated below the exposure temperature continues to increase, but no change in the thickness of the magnet heat-treated above the exposure temperature is observed.
[0116]
FIG. 11 is a characteristic diagram showing the dimensional stability after heat treatment with respect to the rolling rate of the sheet magnet rolled at 70 ° C. and after high temperature exposure. In the figure, 1T and 1L are the thickness and length of the sheet magnet after rolling and before heat treatment, 2T and 2L broken lines are after heat treatment (120 ° C., 5 min), 2T and 2L solid lines are after high temperature exposure (at 100 ° C. for 120 hours) ) Shows the thickness and length of the sheet magnet. The thickness and length of the sheet magnet are in a trade-off relationship with the rolling rate. It can also be seen that the dimensional change rate before and after the heat treatment is increased according to the rolling rate.
[0117]
However, once heat-treated, the thickness and length of the sheet magnet after high temperature exposure hardly change. Even when the heat treatment was set to 100 ° C., the same result as the 120 ° C. shown here was obtained. Therefore, it is desirable that the heat treatment temperature is selected to be at least equal to or higher than the rising temperature of the field magnet in consideration of the temperature rise during operation of the permanent magnet type motor targeted by the present invention.
[0118]
FIG. 12 (a) shows Nd by spinning cup gas atomization according to the present invention after the heat treatment. ₂ Fe ₁₄ B spherical rare earth magnet powder N (dowed by melt spinning) instead of sheet magnet containing 96% of powder A (Powder-A) ₂ Fe ₁₄ A sheet magnet containing 96% B-flake rare earth magnet powder powder D (Powder-D) was prepared, and the rate of change in thickness, length, and width after high-temperature long-time exposure (1000 h at 100 ° C.) was compared. It is a characteristic view which shows a result. FIG. 12B is a perspective view showing a permanent magnet field type small DC motor to which the sheet magnet is typically applied and a field magnet corresponding to the sheet magnet. As is clear from the figure, the direction of dimensional change due to long-term high-temperature exposure of the sheet magnet heat-treated after rolling using Powder A (Powder-A) according to the present invention is the direction of narrowing the gap with the armature core, that is, There is no increase in length or thickness. On the other hand, the dimensional change of the sheet magnet heat-treated after rolling using Powder D (Powder-D) during long-term high-temperature exposure increases the length and thickness, narrows the gap with the armature core, and forms a ring. There is a risk that the magnet will overhang the inner periphery of the iron frame and will have a significant impact on the function maintenance of the permanent magnet motor.
[0119]
FIG. 13 is a characteristic diagram showing the thickness change after the heat treatment with respect to the compression direction and the rolling rate when the green sheet is compression-molded. As is apparent from the figure, the directionality of the dimensional change of the sheet magnet after long-time high temperature exposure is not affected by the pressure application direction when the green sheet is compression-molded. Therefore, it can be said that the directionality of the dimensional change of the sheet magnet due to the high temperature exposure for a long time as shown in FIG. 12 is caused by the form of the rare earth magnet powder (spherical or flake). Therefore, since the magnetically anisotropic rare earth magnet powder powder B (Powder-B) and -C referred to in the present invention are not in the form of flakes like Powder D (Powder-D), it is called Powder A (Powder-A). It can be said that the direction of the same dimensional change is exhibited.
[0120]
FIG. 14 is a characteristic diagram showing the mechanical properties of the sheet magnet after heat treatment (120 ° C., 5 min) with respect to the rolling rate. It is a characteristic view which shows the magnetic flux change with respect to a rolling rate. However, both rare earth magnet powder powder A (Powder-A) is contained 96 wt%. The tension and the elongation ratio show a trade-off relationship depending on the rolling rate, but any rolling rate of about 2% or more can be wound around an iron frame to form an annular permanent magnet field.
[0121]
(Other reliability)
Other reliability items other than the reliability items described above will be described.
[0122]
FIG. 15 shows Nd by spinning cup gas atomization according to the present invention after heat treatment. ₂ Fe ₁₄ B spherical rare earth magnet powder N (dowed by melt spinning) instead of sheet magnet containing 96% of powder A (Powder-A) ₂ Fe ₁₄ It is a characteristic view which shows the result of having produced the sheet magnet which contains 96% of B flakes rare earth magnet powder powder D (Powder-D), and comparing the weight change rate after high-temperature long-time exposure (1000 hrs at 100 degreeC). . As is apparent from the figure, Nd by spinning cup gas atomization according to the present invention. ₂ Fe ₁₄ The sheet magnet containing 96% of B-spherical rare earth magnet powder A (Powder-A) is stable with less weight increase at high temperature exposure than the sheet magnet containing 96% of Powder D (Powder-D).
[0123]
FIG. 16 is a characteristic diagram comparing the irreversible magnetic flux loss when the above-mentioned two kinds of sheet magnets are magnetized with 4 MA / m pulses and exposed to a high temperature for a long time (100 ° C., 1000 hrs). Nd by heat-treated spinning cup gas atomization according to the present invention ₂ Fe ₁₄ B Spherical rare earth magnet powder A (Powder-A) 96% sheet magnets with initial irreversible magnetic flux loss regardless of coercive force 648 kA / m and powder D (Powder-D) 748 kA / m It is understood that long-term irreversible magnetic flux loss is also small. This can be said to be advantageous in improving the reliability of the permanent magnet type motor in connection with the fact that the weight change under long-term high-temperature exposure under the same conditions in FIG. 15 is extremely small.
[0124]
On the other hand, FIG. 17 is a characteristic diagram showing a change in weight when the two types of sheet magnets are exposed to a humid atmosphere of 40 ° C. and 97% RH for a long time (1000 hrs). Nd by heat-treated spinning cup gas atomization according to the present invention ₂ Fe ₁₄ As with the result of weight change at high temperature, the sheet magnet containing 96% of B spherical rare earth magnet powder powder A (Powder-A) has very little weight change compared to the magnet using powder D (Powder-D). In the surface of the sheet magnet after 1000 hrs, red rust was uniformly observed on the surface of the magnet using Powder D (Powder-D), but Nd by heat-treated spinning cup gas atomization according to the present invention was used. ₂ Fe ₁₄ The surface of the sheet magnet containing 96% of the B spherical rare earth magnet powder A (Powder-A) was not rusted with the naked eye. The surface of the sheet magnet containing 96% of the heat-treated powder B (Powder-B) and -C according to the present invention was not rusted with the naked eye. That is, it is understood that the present invention greatly contributes to improving the reliability of the permanent magnet type motor targeted by the present invention, such as rust resistance, in addition to the directionality of dimensional change at high temperatures.
[0125]
As described above, the magnet temperature during operation of the permanent magnet type motor targeted in the present invention is 100 ° C. or less. Therefore, the sheet-like rare earth bonded magnet containing Powder A (Powder-A), -B, and C heat-treated after rolling according to the present invention is obtained by Nd by melt spinning. ₂ Fe ₁₄ Compared to a bonded magnet using a B-based rare earth magnet powder, it is possible to improve reliability such as stability and rust resistance in the operating temperature range of a permanent magnet type motor.
[0126]
(Production of film magnet)
The production of a film magnet will be described below.
[0127]
Next, Nd by spinning cup gas atomization according to the present invention after heat treatment ₂ Fe ₁₄ An example of a magnet from a sheet containing 96% B spherical rare earth magnet powder powder A (Powder-A) to a film will be described. FIG. 18 is a characteristic diagram showing the relationship between the thickness of the magnet from the sheet to the film and the magnetic flux after 4 MA / m pulse magnetization. In the figure, 1 is a magnet heat-treated after rolling containing 96% of powder A (Powder-A) according to the present invention, and 3 and 4 are magnetically anisotropic powder B (Powder-B) and powder according to the present invention, respectively. A magnet heat treated after rolling containing 96% C (Powder-C). 2 is Nd by melt spinning shown as a comparative example ₂ Fe ₁₄ It is a hard plate-like magnet formed by compression molding a granular compound with an epoxy resin containing 97% of B-type flaky rare earth magnet powder.
[0128]
In Comparative Example 2, a sheet magnet having a thickness of about 700 μm is the molding limit and, of course, is not flexible. On the other hand, a film magnet having a thickness of 200 μm can be easily produced. Certainly, the magnetic flux with the same thickness is rarely compared with the comparative example, but magnetically anisotropic HDDR-Nd such as Powder B (Powder-B). ₂ Fe ₁₄ If it is 3 using B system rare earth magnet powder, more magnetic flux than 2 will be obtained.
[0129]
Since Powder B (Powder-B) has a large average powder particle size of 80 μm, in the region of a film magnet of about 200 μm, the decrease in magnetic flux with respect to the thickness tends to be slightly increased. In such a case, it is preferable to obtain a magnet heat-treated after rolling containing powder C (Powder-C) having an average particle diameter of 2 to 5 μm such as 4 in order to obtain a stronger static magnetic field.
[0130]
(Characteristics of permanent magnet type motor)
The characteristics of the embodiment of the permanent magnet type motor of the present invention will be described below.
[0131]
(BH) of spherical rare earth magnet powder powder A (Powder-A) by spinning cup gas atomization in this example _max Is 85kJ / m ^Three Flakes by one melt spinning method (alloy composition Nd ₁₂ Fe ₇₇ Co _Five B ₆ ) Powder D (Powder-D) (BH) _max Is 130 kJ / m ^Three It is. In addition, the magnetic properties of the sheet magnet using the powder A (Powder-A) shown in this example after 4 MA / m pulsed magnetization are residual magnetization 550 mT, coercive force 648 kA / m, (BH) _max 40 kJ / m ^Three Met.
[0132]
This value is (BH) for sheet magnets using flakes. _max 61kJ / m ^Three Compared to (BH) _max Is about 2/3. The ratio of the magnetic flux generated in the gap with the armature core (BH) _max The magnetic flux of the sheet magnet using the powder A (Powder-A) according to the present invention is estimated to be about 81% of the magnet using the powder D (Powder-D). However, when comparing the current and torque-speed characteristics of the permanent magnet field type small DC motor having a diameter of 23.8 mm and a height of 12.5 mm shown in FIG. 13B, as shown in FIG. The starting torque of the sheet magnet using) is Nd by melt spinning ₂ Fe ₁₄ The bond magnet motor using the B-based rare earth magnet powder is reduced by 5.6%, and the torque constant is reduced by 6.2%, and the motor characteristics can be reduced by 5 to 10%.
[0133]
This is due to the fact that the sheet magnet according to the present invention is almost in a saturated magnetization state, whereas the comparative powder B (Powder-B) is in an unsaturated magnetization state. Considering the difference between the irreversible magnetic flux losses shown in FIG. 16, it is expected that the difference in motor characteristics after long-time high temperature exposure will almost disappear.
[0134]
By the way, in general, Nd by melt spinning ₂ Fe ₁₄ The bonded magnet using the B-based rare earth magnet powder is provided with a surface layer made of a nonmagnetic different material on the surface for rust resistance. Usually, an epoxy resin having a thickness of 15 to 20 μm is formed by spray coating or electrodeposition coating. However, the sheet magnet according to the present invention has high reliability as shown in FIG. Therefore, it is not necessary to provide a nonmagnetic protective film, and the gap with the armature core can be reduced by 30 to 40 μm. This difference is also at a level that can compensate for the difference in starting torque of 5 to 6%.
[0135]
Next, magnetically anisotropic HDDR-Nd ₂ Fe ₁₄ A 0.82 mm thick sheet magnet containing 97% of B-based rare earth magnet powder powder B (Powder-B) is stamped at 120 ° C. to form an arc shape, and then heat-treated at 120 ° C. for 5 min. Such a thin arc magnet was obtained. F. Yamashita, Y. et al. Sasaki, H .; Fukunaga, “Isotropic Nd-Fe-B ThinArc-shaped Bonded Magnets for Small DCM Motors Prepared by Powder Compacting Press with Metal Ion-Ion. 25, no. 4-2, pp. 683-686 (2001), and a thin-walled arc magnet having a maximum thickness of 0.9 mm, that is, rare earth magnet powder (1) -c (powder D) and hard thermosetting resin (2 ) -C and compression molding (3) -c. The characteristics of a permanent magnet field type small DC motor as shown in FIG.
[0136]
FIG. 21 is a characteristic diagram showing a comparison result of arc-shaped magnets. However, in the figure, 1 is a motor characteristic using an arc magnet according to the present invention, and 2 is a comparative example. In addition, the subscript a for each of 1 and 2 indicates mechanical output, b indicates efficiency, c indicates torque, and d indicates current. As is apparent from the figure, the thin arc magnet according to the present invention is approximately 10% thinner, while achieving a high efficiency of 4 to 5% by improving the machine output.
[0137]
As described above, from the sheet containing powder A (Powder-A), -B and C, which is heat-cured and heat-treated after rolling and stamping, or after rolling or stamping, to a film If it is a rare earth bonded magnet, Nd by conventional isotropic melt spinning ₂ Fe ₁₄ It is possible to provide a high performance permanent magnet type motor having both performance and reliability exceeding those of a conventional permanent magnet type motor equipped with a B-based bonded magnet.
[0138]
【The invention's effect】
As described above, the concept of the production method according to the present invention can exhibit the effect of further improving performance and characteristics based on the contents of another invention invented by the present inventors prior to the present invention. Nd widely used as a permanent magnet motor ₂ Fe ₁₄ The form of the rare earth magnet powder of the B-based bonded magnet is changed from flake shape to spherical shape or a shape close thereto, and the green sheet obtained by compression-molding this powder compound is heat-cured, and the obtained sheet magnet is rolled and stamped, or When a specific heat treatment is applied to the rare earth bonded magnet from the sheet to be rolled or stamped to the film, the reliability of the permanent magnet motor can be greatly improved.
[0139]
In particular, the rare earth bonded magnets from the sheet to the film of the present invention need not be processed in a high temperature range exceeding 200 ° C., such as the conventional molding method (calendering, extrusion molding), including the heat treatment as the final step. Thus, the original high magnetic performance of the rare earth magnet powder having thermal stability such as irreversible magnetic flux loss can be reflected in the motor performance.
[0140]
Therefore, Nd by ferrite magnet or magnetically isotropic melt spinning ₂ Fe ₁₄ An efficient small motor exceeding the conventional permanent magnet type motor equipped with the B-based bonded magnet can be provided with high reliability. Therefore, it is expected not only to contribute to electrical and electronic equipment, but also to reduce power consumption and save resources by widespread use.
[Brief description of the drawings]
FIG. 1 is a conceptual diagram showing the cooperation of three major element technologies in bond magnet production, that is, magnet powder, binder, and molding method.
[Fig. 2] Cross-sectional view of a small motor
FIG. 3 is an external view showing the form of magnet powder.
FIG. 4 Process diagram for preparing a magnet
FIG. 5 is a characteristic diagram showing the particle size distribution of the compound, intermediate, and magnet powder.
FIG. 6 is a characteristic diagram showing the relationship between compound filling amounts.
FIG. 7 is a characteristic diagram showing the weight variation of the green sheet.
FIG. 8 is a characteristic diagram showing the relationship between the amount of lubricant added and the shrinkage rate due to heat curing.
FIG. 9 is a characteristic diagram showing the rate of change in thickness of a magnet and a rolled magnet exposed to a high temperature.
FIG. 10 is a characteristic diagram showing the change in thickness of a rolled magnet with respect to the heat treatment temperature.
FIG. 11 is a characteristic diagram showing dimensional stability after heat treatment with respect to the rolling rate of a rolled magnet and after high temperature exposure.
FIG. 12A is a characteristic diagram showing a dimensional change of a rolled magnet after high-temperature and long-term exposure.
(B) is a perspective overview showing a permanent magnet type motor and a corresponding field magnet
FIG. 13 is a characteristic diagram showing the thickness change after heat treatment with respect to the rolling rate.
FIG. 14 is a characteristic diagram showing mechanical properties of a sheet magnet after heat treatment with respect to the rolling rate.
FIG. 15 is a characteristic diagram showing the rate of change in weight after long-term exposure to high temperatures.
FIG. 16 is a characteristic diagram showing irreversible magnetic flux loss after high temperature and long exposure.
FIG. 17 is a characteristic diagram showing the change in weight of long-term exposure in a humid environment.
FIG. 18 is a characteristic diagram showing a fracture surface of a film magnet.
FIG. 19 is a characteristic diagram showing the current and torque-speed relationship of an annular magnet field motor.
FIG. 20 is an external view of a permanent magnet field type small DC motor using an arc magnet.
FIG. 21 is a characteristic diagram showing the current and torque-speed relationship of an arc magnet field motor.
[Explanation of symbols]
(1) Magnet powder
(1) -a Ferrite magnet powder
(1) -b Alnico magnet powder
(1) -c rare earth magnet powder (according to the present invention)
(2) Binder
(2) -a Flexible binder (flexible system) (rubber, thermoplastic elastomer)
(2) -b Hard thermoplastic resin binder
(2) -c Hard thermosetting resin binder (epoxy resin)
(2) -d Binder for flexible thermosetting resin composition according to the present invention
(3) Molding method
(3) -a Calendering and / or extrusion molding
(3) -b Injection molding
(3) -c Compression molding
(3) -d compression molding and rolling or / and stamping and heat treatment
(4) Efficient small motor (high performance, small permanent magnet motor)

Claims (31)

(1) The magnet powder is a rare earth magnet powder,
(2) Thermocompression bonding polyamide powder that has been bonded to an epoxy oligomer that is solid at room temperature at least at room temperature, or a thermocompression bonding polyamideimide that has been bonded to an epoxy oligomer that is solid at least at room temperature at room temperature. It is a thermosetting resin composition composed of powder and a powdery latent epoxy curing agent to be added as necessary.
(3) In the method for producing a rare earth bonded magnet, wherein the molding (molding) processing method comprises warm compression molding, warm rolling and heat treatment,
A powdered compound comprising the rare earth magnet powder and the thermosetting resin composition as main components is prepared, a green sheet is prepared by warm compression molding the powdered compound, and the binder component of the green sheet is used as a binder component. A method for producing a rare earth bonded magnet, wherein a sheet magnet is produced by thermosetting, the sheet magnet is warm-rolled and then heat treated to produce a rare earth bonded magnet from a sheet having a thickness of 2.5 mm to 0.2 mm to a film. . (1) The magnet powder is a rare earth magnet powder,
(2) Thermocompression bonding polyamide powder that has been bonded to an epoxy oligomer that is solid at room temperature at least at room temperature, or a thermocompression bonding polyamideimide that has been bonded to an epoxy oligomer that is solid at least at room temperature at room temperature. It is a thermosetting resin composition composed of powder and a powdery latent epoxy curing agent to be added as necessary.
(3) In a method for producing a rare earth bonded magnet, wherein the forming method comprises warm compression molding, warm stamping and heat treatment,
A powdery compound comprising a rare earth magnet powder and the thermosetting resin composition as a main component is produced, a green sheet is produced by warm compression molding the compound, and the binder component of the green sheet is thermoset. Then, a sheet magnet is produced, and the sheet magnet is warm stamped and then heat treated to produce a rare earth bonded magnet from a sheet having a thickness of 2.5 mm to 0.2 mm to a film. In the manufacturing method of the rare earth bond magnet according to any one of claims 1 to 2,
A method for producing a rare earth bonded magnet, wherein the difference between the average particle diameter of the rare earth magnet powder and the average particle diameter of the powdered compound is within 10 μm. The method for producing a rare earth bonded magnet according to any one of claims 1 to 2, wherein the apparent density of the powdered compound is 2.6 to 3.0 Mg / m3, and the powder fluidity of the powdered compound. A method for producing a rare earth bonded magnet having a magnetism of 40 sec / 50 g or less. In the manufacturing method of the rare earth bond magnet according to any one of claims 1 to 2,
A method for producing a rare earth bonded magnet, wherein the powder compound lubricant is calcium stearate powder, and the amount of the calcium stearate powder added to the powder compound is 0.2 to 0.4 parts by weight. A sheet-like or film-like rare earth bonded magnet obtained by the method for producing a rare earth bonded magnet according to claim 1 is used to constitute a rotor having the rare earth bonded magnet and a cylindrical frame, The rare earth bond magnet wound around the inner peripheral surface of the cylindrical frame is fixed to the cylindrical frame, and the rare earth bond magnet fixed to the cylindrical frame is multipolar magnetized. A permanent magnet type motor comprising the annular magnet, the permanent magnet field of the rotor being composed of the rare earth bonded magnet. A sheet-like or film-like rare earth bonded magnet obtained by the method for producing a rare earth bonded magnet according to claim 1 is used to constitute a rotor having the rare earth bonded magnet and a cylindrical frame, The rare earth bond magnet wound around the inner peripheral surface of the cylindrical frame is fixed to the cylindrical frame, and the rare earth bond magnet fixed to the cylindrical frame is multipolar magnetized. A radial gap-type permanent magnet motor comprising an annular magnet, wherein the permanent magnet field of the rotor is constituted by the rare earth bonded magnet, and a gap is provided in the radial direction of the rotor. A sheet-like or film-like rare earth bonded magnet obtained by the method for producing a rare earth bonded magnet according to claim 1 is used to constitute a rotor having the rare earth bonded magnet and a cylindrical frame, The rare earth bonded magnet wound around the outer peripheral surface of the cylindrical frame is fixed to the cylindrical frame, and the rare earth bonded magnet fixed to the cylindrical frame is multipolar magnetized. A surface magnet type permanent magnet motor which comprises an annular magnet, the permanent magnet field of the rotor is constituted by the rare earth bonded magnet, and the annular magnet is provided on the surface of the rotor. The shape of the sheet-like or film-like rare earth bonded magnet obtained by the method for producing a rare earth bonded magnet according to claim 2 is an arc, and the arc-shaped rare earth bonded magnet is fixed to the radial surface of the rotor core. A surface magnet type permanent magnet motor in which the permanent magnet field of the rotor is composed of the field of the rare earth bonded magnet, and the rotor is provided with a permanent magnet field. A sheet-like or film-like rare earth bonded magnet obtained by the method for producing a rare earth bonded magnet according to claim 2 has an arc shape, and the arc-shaped rare earth bonded magnet is fixed inside a frame frame, and the frame frame A permanent magnet type motor in which the permanent magnet field is composed of the rare earth bonded magnet field and the frame frame is provided with a permanent magnet field. The shape of the sheet-like or film-like rare earth bonded magnet obtained by the method for producing a rare earth bonded magnet according to claim 2 is a hollow disk shape, and multipolar magnetization is performed on the rare earth bonded magnet of the hollow disk shape, An axial gap type permanent magnet motor in which a gap is provided in the axial direction of the rare earth bonded magnet having a multi-pole magnetized shape. The rotor is comprised from the said rare earth bond magnet and the rotor core using the sheet-like or film-like rare earth bond magnet obtained by the manufacturing method of the rare earth bond magnet according to claim 1, and a part of the rotor core A permanent magnet motor having a magnet-embedded rotor in which the rare earth bond magnet is embedded in a part of the rotor core. A rotor is composed of the rare earth bonded magnet and the rotor core using the sheet or film rare earth bonded magnet obtained by the method for manufacturing the rare earth bonded magnet according to claim 2, and a part of the rotor core. A permanent magnet motor having a magnet-embedded rotor in which the rare earth bond magnet is embedded in a part of the rotor core. A permanent magnet type motor using a sheet-like or film-like rare earth bonded magnet obtained by the method for producing a rare earth bonded magnet according to claim 1, wherein the rotor has a hole, a hole, or a slot in the rotation axis direction. The intermediate process of the rare earth bonded magnet is prepared after the intermediate core product or sheet magnet of the rare earth bonded magnet that has been prepared and warm-rolled is inserted into the hole, hole, or slot of the rotor core. The rotor core in which the rare earth bonded magnet is embedded is manufactured by heat-treating the object or the sheet magnet and the rotor core together, and the rotor core in which the rare earth bonded magnet is embedded is provided in the rotor. Permanent magnet type motor. In a permanent magnet type motor using a sheet-like or film-like rare earth bonded magnet obtained by the method for producing a rare earth bonded magnet according to claim 2,
A rotor core having a hole, a hole or a slot in the direction of the rotation axis of the rotor is prepared, and an intermediate process product or sheet magnet of a rare-earth bonded magnet warm-stamped is the hole / hole of the rotor core. A rotor core in which a rare earth bond magnet is embedded is manufactured by heat-treating the intermediate magnet or the sheet magnet of the rare earth bond magnet together with the rotor core after being inserted into a portion or slot portion. A permanent magnet motor in which a rotor iron core in which the rare earth bonded magnet is embedded is provided in the rotor. In the manufacturing method of the rare earth bond magnet according to claim 1,
A method for producing a rare earth bonded magnet from a sheet to a film, wherein the heat treatment temperature is higher than the processing temperature of warm rolling. In the manufacturing method of the rare earth bond magnet according to claim 2,
A method for producing a rare earth bonded magnet from a sheet to a film, wherein the heat treatment temperature is higher than the processing temperature of warm stamping. In the manufacturing method of the rare earth bond magnet according to any one of claims 1 to 2,
A method for producing a rare earth bonded magnet from a sheet to a film, wherein the heat treatment temperature is higher than the durability temperature of the permanent magnet type motor. In the manufacturing method of the rare earth bond magnet according to any one of claims 1 to 2,
A method for producing a rare earth bonded magnet from a sheet to a film, wherein a part or all of the rare earth magnet powder is a magnetically isotropic Nd2Fe14B-based spherical powder prepared by spinning cup atomization. In the manufacturing method of the rare earth bond magnet according to any one of claims 1 to 2,
Production of rare earth bonded magnet from sheet to film, characterized in that part or all of rare earth magnet powder is magnetically anisotropic Nd2Fe14B based powder prepared by HDDR treatment (hydrogen decomposition / recombination) Method. In the method for producing a rare earth bonded magnet from the sheet to the film according to claim 16 or 17,
Part or all of the rare earth magnet powder is obtained by previously inactivating the surface of a magnetically anisotropic Nd2Fe14B-based powder prepared by HDDR treatment (hydrogen decomposition / recombination). Manufacturing method of rare earth bonded magnet from sheet to film. In the manufacturing method of the rare earth bond magnet according to any one of claims 1 to 2,
A part or all of the rare earth magnet powder is obtained by previously inactivating the surface of a magnetically anisotropic RD-Sm2Fe17N3 fine powder prepared by RD (oxidation reduction) treatment. Manufacturing method of rare earth bonded magnet from sheet to film. In the manufacturing method of the rare earth bond magnet according to any one of claims 1 to 2,
The rare earth magnet powder comprises anisotropic HDDR-Nd2Fe14B magnet powder and anisotropic RD-Sm2Fe17N3 fine powder, anisotropic HDDR-Nd2Fe14B magnet powder or anisotropic RD-Sm2Fe17N3 fine powder, and spinning cup atomizer. A method for producing a rare earth bonded magnet from a sheet to a film, characterized in that it is a mixed system with a magnetically isotropic Nd2Fe14B-based spherical powder prepared by an initialization. In the method for producing a rare earth bonded magnet from the sheet of claim 20 to the film,
A method for producing a rare earth bonded magnet from a sheet to a film, wherein a maximum energy product (BH) max at room temperature magnetized by a 4 MA / m pulsed magnetic field is adjusted to 80 kJ / m ³ or more. In the manufacturing method of the rare earth bond magnet according to any one of claims 1 to 2,
A method for producing a rare earth bonded magnet from a sheet to a film, characterized in that the content of the rare earth magnet powder is in the range of 92 wt% to 98 wt%. In the manufacturing method of the rare earth bond magnet according to any one of claims 1 to 2,
A method for producing a rare earth bonded magnet from a sheet to a film, characterized in that the surface of the rare earth bonded magnet is exposed on the surface without forming a surface layer made of a nonmagnetic different material. In the method for producing a rare earth bonded magnet from the sheet of claim 23 to the film,
A method for producing a rare earth bonded magnet from a sheet to a film, wherein the rare earth bonded magnet has a thickness of 1 mm to 0.2 mm. A permanent magnet motor having a rare earth bonded magnet produced by the method for producing a rare earth bonded magnet from a sheet to a film according to any one of claims 16 to 27. A mobile communication portable device comprising the permanent magnet motor according to any one of claims 6 to 15 and claim 28. An information device having the permanent magnet motor according to any one of claims 6 to 15 and claim 28. A household electrical appliance having the permanent magnet motor according to any one of claims 6 to 15 and claim 28.