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1. 发明申请

US20160293329A1 POWDER-FILLING SYSTEM 审中-公开
公开(公告)号：US20160293329A1
公开(公告)日：2016-10-06
申请号：US15168555
申请日：2016-05-31
申请人： INTERMETALLICS CO., LTD. , DAIDO STEEL CO., LTD.
发明人： Masato SAGAWA , Osamu ITATANI , Norio YOSHIKAWA
IPC分类号： H01F41/02 , B22F3/00
CPC分类号： H01F41/0273 , B22F3/004 , B30B15/302 , B65B1/04 , B65B1/16 , B65B7/28 , H01F41/0266
摘要： A powder-filling system capable of filling a container with powder at an approximately uniform filling density has: a hopper having an opening removably and hermetically closably attached to the container, the hopper communicating with the container at the opening for supplying powder to a container; a powder supplier for supplying powder to the hopper; a gas supplier for repeatedly supplying compressed gas in a pulsed form to the hopper, with the hopper hermetically closably attached to the container; and a sieve member provided at the opening and having a smaller openings in a region near a side wall of the hopper than in its central region. The smaller openings in the region near the side wall of the hopper where the powder more easily falls from the hopper into the container impedes the fall of the powder in that region and improves the overall uniformity in the filling density.

2. 发明申请

US20150371774A1 SINTERED MAGNET PRODUCTION SYSTEM AND SINTERED MAGNET PRODUCTION METHOD 审中-公开
标题翻译：烧结磁体生产系统和烧结磁铁生产方法
公开(公告)号：US20150371774A1
公开(公告)日：2015-12-24
申请号：US14765100
申请日：2014-02-03
申请人： INTERMETALLICS CO., LTD. , DAIDO STEEL CO., LTD.
发明人： Masato SAGAWA , Tetsuhiko MIZOGUCHI , Norio YOSHIKAWA
IPC分类号： H01F41/02 , B22F3/10
CPC分类号： H01F41/0273 , B22F3/10 , C22C2202/02 , F27B9/067 , F27B9/20 , F27B9/36 , F27B9/38 , F27D5/00 , Y02P10/253
摘要： A sintered magnet production system using a press-less method capable of minimizing the distortion of a sintered magnet includes: a filling device for filling a container cavity with alloy powder for a sintered magnet; an orienting section for orienting the powder in the cavity by applying a magnetic field without applying a mechanical pressure to the powder; and a sintering section for sintering the powder oriented by the orienting section, by heating the powder without applying a mechanical pressure to the powder. The orienting section includes: an air-core coil; and two ferromagnetic members made of a ferromagnetic material arranged within the coil at respective open ends of the coil with a space for containing the container in between. The ferromagnetic members adjust the magnetic field within the coil toward a direction parallel to the axis of the coil, whereby distortion of a sintered magnet is minimized.
摘要翻译：使用能够最小化烧结磁体的变形的无压力法的烧结磁体制造系统包括：填充装置，其用于对用于烧结磁体的合金粉末填充容器腔; 定向部分，用于通过施加磁场而不对粉末施加机械压力来将粉末定向在空腔中; 以及烧结部，其通过在不对所述粉末施加机械压力的情况下加热所述粉末来烧结由所述取向部取向的粉末。定向部分包括：空心线圈; 以及由铁磁材料制成的两个铁磁构件，其在线圈的相应开口端布置在线圈中，并具有用于容纳容器的空间。铁磁部件将线圈内的磁场调整成与线圈的轴线平行的方向，从而使烧结磁体的变形最小化。

3. 发明申请

US20150364252A1 POWDER-FILLING SYSTEM 有权
标题翻译：粉末填充系统
公开(公告)号：US20150364252A1
公开(公告)日：2015-12-17
申请号：US14765130
申请日：2014-02-03
申请人： INTERMETALLICS CO., LTD. , DAIDO STEEL CO., LTD.
发明人： Masato SAGAWA , Osamu ITATANI , Norio YOSHIKAWA
IPC分类号： H01F41/02 , B22F3/00 , B65B1/04
CPC分类号： H01F41/0273 , B22F3/004 , B30B15/302 , B65B1/04 , B65B1/16 , B65B7/28 , H01F41/0266
摘要： A powder-filling system capable of filling a container with powder at an approximately uniform filling density has: a hopper having an opening removably and hermetically closably attached to the container, the hopper communicating with the container at the opening for supplying powder to a container; a powder supplier for supplying powder to the hopper; a gas supplier for repeatedly supplying compressed gas in a pulsed form to the hopper, with the hopper hermetically closably attached to the container; and a sieve member provided at the opening and having a smaller openings in a region near a side wall of the hopper than in its central region. The smaller openings in the region near the side wall of the hopper where the powder more easily falls from the hopper into the container impedes the fall of the powder in that region and improves the overall uniformity in the filling density.
摘要翻译：能够以大致均匀的填充密度填充粉末的容器的粉末填充系统具有：具有可拆卸地且气密地连接到容器的开口的料斗，料斗在开口处与容器连通以将粉末供应到容器; 用于向料斗供应粉末的粉末供应商; 用于将脉冲形式的压缩气体重复供应到料斗的气体供应器，料斗气密地附接到容器; 以及设置在所述开口处并且在所述料斗的侧壁附近的区域中比在其中心区域具有较小开口的筛子构件。在料斗的侧壁附近的较小的开口，其中粉末更容易从料斗落入容器中，阻碍了该区域中的粉末的下降，并且提高了填充密度的整体均匀性。

4. 发明申请

US20160297028A1 RFeB-BASED SINTERED MAGNET PRODUCTION METHOD AND RFeB-BASED SINTERED MAGNETS 审中-公开
标题翻译：基于RFeB的烧结磁体生产方法和基于RFeB的烧结磁体
公开(公告)号：US20160297028A1
公开(公告)日：2016-10-13
申请号：US14777556
申请日：2014-03-13
申请人： INTERMETALLICS CO., LTD. , DAIDO STEEL CO., LTD.
发明人： Masato SAGAWA , Shinobu TAKAGI
IPC分类号： B23K20/02 , C22C38/10 , C22C38/06 , C22C38/00 , B22F9/04 , B22F9/08 , B22F1/00 , B22F3/00 , B22F3/10 , B22F5/00 , C22C28/00 , B23K20/00 , B23K20/14 , H01F1/053 , H01F7/02 , C22C38/16
CPC分类号： B23K20/02 , B22F1/0011 , B22F1/0059 , B22F1/0062 , B22F3/004 , B22F3/10 , B22F5/006 , B22F7/064 , B22F9/04 , B22F9/08 , B22F2009/044 , B22F2302/45 , B22F2304/058 , B22F2304/10 , B22F2998/10 , B22F2999/00 , B23K20/002 , B23K20/14 , C22C28/00 , C22C38/00 , C22C38/002 , C22C38/005 , C22C38/02 , C22C38/06 , C22C38/10 , C22C38/16 , C22C2202/02 , H01F1/0536 , H01F1/0577 , H01F7/021 , H01F41/0293 , B22F2202/05
摘要： A method for producing RFeB system sintered magnet composed of at least two unit sintered magnets bonded to each other at flat bonding surfaces, each unit sintered magnet composed of crystal grains whose main phase is made of R2Fe14B containing, as a main rare-earth element R, light rare-earth element RL wherein at least one element selected from the group of Nd and Pr. Paste prepared by mixing organic matter and metallic powder containing at least one element selected from heavy rare-earth elements RH of Dy, Ho and Tb is sandwiched between neighboring unit sintered magnets, and a grain boundary diffusion treatment is performed. Coercivity is improved by this grain boundary diffusion treatment. Since an oxide or similar compound of RH and/or RL is formed at boundary of unit sintered magnets, the influence of eddy current during a period of use is suppressed, and unit sintered magnets are strongly bonded together.
摘要翻译：一种用于制造RFeB系烧结磁体的方法，所述烧结磁体由在平坦接合表面处彼此结合的至少两个单元烧结磁体组成，每个单元烧结磁体由主相由R 2 Fe 14 B构成的晶粒构成，所述晶体主要含有作为主稀土元素R ，轻稀土元素RL，其中选自Nd和Pr中的至少一种元素。通过混合有机物和含有选自Dy，Ho和Tb的重稀土元素RH中的至少一种元素的金属粉末制成的浆料夹在相邻单元烧结磁体之间，并进行晶界扩散处理。通过这种晶界扩散处理提高矫顽力。由于在单位烧结磁体的边界处形成了RH和/或RL的氧化物或类似化合物，因此抑制了使用期间的涡流的影响，并且单位烧结磁体牢固地结合在一起。

5. 发明申请

US20160273091A1 RFeB SYSTEM SINTERED MAGNET PRODUCTION METHOD AND RFeB SYSTEM SINTERED MAGNET 审中-公开
标题翻译： RFeB系统烧结磁体生产方法和RFeB系统烧结磁体
公开(公告)号：US20160273091A1
公开(公告)日：2016-09-22
申请号：US14777624
申请日：2014-03-13
申请人： INTERMETALLICS CO., LTD. , DAIDO STEEL CO., LTD
发明人： Masato SAGAWA , Shinobu TAKAGI
IPC分类号： C23C10/30 , C22C38/10 , C22C38/06 , H01F1/057 , C22C28/00 , B22F1/00 , B22F3/16 , B22F3/24 , C22C38/16 , C22C38/00
CPC分类号： C23C10/30 , B22F1/0059 , B22F3/16 , B22F3/24 , B22F2003/248 , B22F2301/355 , B22F2301/45 , B22F2302/45 , B22F2303/20 , B22F2303/40 , B22F2998/10 , C22C28/00 , C22C38/00 , C22C38/002 , C22C38/005 , C22C38/02 , C22C38/06 , C22C38/10 , C22C38/16 , C22C2202/02 , H01F1/0577 , H01F41/0293
摘要： Producing an RFeB system sintered magnet with high corrosion resistance and low loss of energy in an RFeB system sintered magnet with high magnetic properties produced by a grain boundary diffusion process. A paste prepared by mixing an organic matter having a molecular structure including an oxygen atom and a metallic powder containing a heavy rare-earth element which is at least one element selected from the group of Dy, Ho and Tb, is applied to the surface of an RFeB system sintered compact composed of crystal grains whose main phase is R2Fe14B containing, as a main rare-earth element, a light rare-earth element which is at least one element selected from the group of Nd and Pr. A heating process for a grain boundary diffusion treatment is performed. As a result, a protective layer containing an oxide of the light rare-earth element is formed on the surface.
摘要翻译：在晶界扩散过程产生的具有高磁特性的RFeB系烧结磁体中，生产出具有高耐腐蚀性和低能量损耗的RFeB系烧结磁体。通过将含有氧原子的分子结构的有机物和含有选自Dy，Ho和Tb中的至少一种元素的重稀土元素的金属粉末混合而制备的糊料涂覆在由主晶相R 2 Fe 14 B的晶粒构成的RFeB系烧结体作为主稀土元素，含有选自Nd和Pr中的至少一种元素的轻稀土元素。进行晶界扩散处理的加热处理。结果，在表面上形成含有轻稀土类元素的氧化物的保护层。

6. 发明申请

US20170194094A1 RFeB SYSTEM MAGNET AND METHOD FOR PRODUCING RFeB SYSTEM MAGNET 审中-公开
公开(公告)号：US20170194094A1
公开(公告)日：2017-07-06
申请号：US15315214
申请日：2015-05-25
申请人： INTERMETALLICS CO., LTD. , DAIDO STEEL CO., LTD.
发明人： Tetsuhiko MIZOGUCHI , Masato SAGAWA
IPC分类号： H01F41/02 , C22C38/10 , C22C38/02 , C22C38/06 , C23C10/30 , C22C38/00
CPC分类号： H01F41/0293 , B22F3/24 , C22C28/00 , C22C38/00 , C22C38/02 , C22C38/06 , C22C38/10 , C23C10/30
摘要： An RFeB system sintered magnet wherein heavy rare-earth element RH which is at least one kind of rare-earth element selected from Dy, Tb and Ho is diffused into base material through the grain boundaries of base material made of a sintered compact of an RFeB system magnet containing RL, Fe and B, where RL represents a light rare-earth element which is at least one kind of rare-earth element selected from Nd and Pr, wherein: size of the RFeB system sintered magnet at smallest-size portion is greater than 3 mm; the amount of heavy rare-earth element RH contained in RFeB system sintered magnet divided by volume of RFeB system sintered magnet is ≧25 mg/cm3; and the difference between local coercivity at the surface of the smallest-size portion and in the central region of the smallest-size portion is equal to or less than 15% of local coercivity at the surface.

7. 发明申请

US20160300649A1 RFeB SYSTEM MAGNET PRODUCTION METHOD, RFeB SYSTEM MAGNET, AND COATING MATERIAL FOR GRAIN BOUNDARY DIFFUSION TREATMENT 审中-公开
标题翻译： RFeB系统磁铁生产方法，RFeB系统磁体和用于颗粒边界扩散处理的涂层材料
公开(公告)号：US20160300649A1
公开(公告)日：2016-10-13
申请号：US14777638
申请日：2014-03-13
申请人： INTERMETALLICS CO., LTD , DAIDO STEEL CO., LTD.
发明人： Masato SAGAWA , Shinobu TAKAGI , Hayato HASHINO
IPC分类号： H01F1/057 , H01F41/02 , B22F1/02
CPC分类号： H01F1/0571 , B22F1/02 , B22F3/14 , B22F2998/00 , B22F2999/00 , C22C28/00 , C22C38/00 , C22C2202/02 , H01F1/0576 , H01F1/0577 , H01F41/0253 , H01F41/0293 , B22F3/02 , B22F3/10 , B22F2003/242 , B22F1/0059 , B22F1/0088
摘要： A method for producing an RFeB system magnet with high coercivity by preventing a coating material from peeling off the surface of a base material during a grain boundary diffusion treatment is provided. A method for producing an RL2Fe14B system magnet which is a sintered magnet or a hot-deformed magnet containing, as the main rare-earth element, a light rare-earth element RL which is at least one of the two elements of Nd and Pr, the method including: applying, to a surface of a base material M of the RL2Fe14B system magnet, a coating material prepared by mixing a silicone grease and an RH-containing powder containing a heavy rare-earth element RH composed of at least one element selected from the group of Dy, Tb and Ho; and heating the base material together with the coating material. Improved coating and base materials adhesion facilitates transfer of RH into base material grain boundaries.
摘要翻译：提供了一种通过在晶界扩散处理期间防止涂层材料从基材表面剥离而制造具有高矫顽力的RFeB系磁体的方法。作为主要稀土类元素的烧结磁体或热变形磁体的RL2Fe14B系磁体的制造方法，是作为Nd和Pr的两种元素中的至少一种的轻稀土类元素RL，该方法包括：向RL2Fe14B系统磁体的基材M的表面施加通过混合硅油和含有选自至少一种元素的重稀土元素RH的RH的粉末制备的涂料，从Dy，Tb和Ho组; 并且与涂覆材料一起加热基材。改进的涂层和基材粘附有助于将RH转移到基材晶粒边界。

8. 发明申请

US20150364251A1 SINTERED MAGNET PRODUCTION METHOD 审中-公开
标题翻译：烧结磁铁生产方法
公开(公告)号：US20150364251A1
公开(公告)日：2015-12-17
申请号：US14765160
申请日：2014-02-03
申请人： INTERMETALLICS CO., LTD. , DAIDO STEEL CO., LTD.
发明人： Masato SAGAWA , Norio YOSHIKAWA
IPC分类号： H01F41/02 , B22F3/10 , B22F3/24 , H01F1/08 , C22C38/00 , H01F1/053 , H01F1/057 , B22F9/04 , C22C33/02
CPC分类号： H01F41/0253 , B22F3/1007 , B22F3/24 , B22F9/04 , B22F2003/248 , B22F2998/10 , B22F2999/00 , C22C33/02 , C22C38/00 , C22C38/002 , C22C38/005 , C22C2202/02 , H01F1/0536 , H01F1/0573 , H01F1/0577 , H01F1/086 , B22F3/10 , B22F2201/10 , B22F2201/02
摘要： A method having a pulverizing process in which a lump of alloy of a material for a sintered magnet is pulverized by a method including a hydrogen pulverization method, filling process wherein a cavity is filled with alloy powder obtained by pulverizing process, an orienting process wherein alloy powder is magnetically oriented by applying magnetic field to alloy powder, and sintering process wherein alloy powder is sintered by heating it according to predetermined temperature history. In the sintering process, alloy powder is heated in inert-gas atmosphere at higher pressure than atmospheric pressure until temperature reaches predetermined pressurization maintenance temperature which is higher than hydrogen desorption temperature and equal to or lower than sintering temperature. By performing the heating treatment in a pressurized inert gas, hydrogen-gas molecules remaining in the alloy powder are prevented from suddenly desorbing from alloy powder, so that the cracking of the sintered magnets hardly occurs.
摘要翻译：一种粉碎工艺的方法，其中通过包括氢粉碎法的方法粉碎用于烧结磁体的材料的合金块，其中通过粉碎工艺填充由合金粉末填充的空腔的填充工艺，其中合金粉末通过向合金粉末施加磁场而磁性取向，并且其中合金粉末根据预定温度历史加热而烧结。在烧结过程中，合金粉末在比大气压力高的惰性气体气氛中加热直到温度达到高于氢解吸温度并等于或低于烧结温度的预定加压维持温度。通过在加压惰性气体中进行加热处理，可以防止残留在合金粉末中的氢气分子从合金粉末突然解吸，从而几乎不发生烧结磁体的破裂。

9. 发明申请

US20160300650A1 NDFEB SYSTEM SINTERED MAGNET 审中-公开
标题翻译： NDFEB系统烧结磁体
公开(公告)号：US20160300650A1
公开(公告)日：2016-10-13
申请号：US15189801
申请日：2016-06-22
申请人： INTERMETALLICS CO., LTD.
发明人： Masato SAGAWA , Tetsuhiko MIZOGUCHI
IPC分类号： H01F1/057 , C22C33/02
CPC分类号： H01F1/0577 , C22C33/0278 , C22C38/00 , C22C38/005 , C22C38/06 , C22C38/10 , C22C38/16 , C22C2202/02 , H01F1/057 , H01F41/0293
摘要： A NdFeB system sintered magnet produced by the grain boundary diffusion method and has a high coercive force and squareness ratio with only a small decrease in the maximum energy product. A NdFeB system sintered magnet having a base material produced by orienting powder of a NdFeB system alloy and sintering the powder, with Dy and/or Tb (the “Dy and/or Tb” is hereinafter called RH) attached to and diffused from a surface of the base material through the grain boundary inside the base material by a grain boundary diffusion treatment, wherein the difference Cgx-Cx between the RH content Cgx (wt %) in the grain boundary and the RH content Cx (wt %) in main-phase grains which are grains constituting the base material at the same depth within a range from the surface to which RH is attached to a depth of 3 mm is equal to or larger than 3 wt %.
摘要翻译：由晶界扩散法生产的NdFeB系烧结磁体，具有高的矫顽力和矩形比，其最大能量积只有很小的降低。一种NdFeB系烧结磁体，其具有通过使NdFeB系合金的粉末取向并烧结粉末而制造的基体，Dy和/或Tb（“Dy和/或Tb”在下文中称为RH）附着并从表面扩散通过晶界扩散处理通过基材内部的晶界而使晶粒边界的RH含量Cgx（wt％）与主晶相中的RH含量Cx（wt％）之间的差Cgx-Cx，在从RH附着的表面到3mm的深度的范围内，构成基材的颗粒的相位晶粒等于或大于3重量％。

10. 发明申请

US20130189426A1 METHOD FOR PRODUCING SINTERED NDFEB MAGNET 审中-公开
标题翻译：生产烧结NDFEB磁铁的方法
公开(公告)号：US20130189426A1
公开(公告)日：2013-07-25
申请号：US13791376
申请日：2013-03-08
申请人： INTERMETALLICS CO., LTD.
发明人： Masato SAGAWA
IPC分类号： H01F41/00
CPC分类号： H01F41/005 , B22F3/1039 , B22F7/06 , B22F2003/248 , B22F2999/00 , C22C38/005 , C22C38/06 , C22C38/08 , C22C38/10 , H01F1/0577 , H01F41/0293 , B22F2202/01 , B22F2201/20
摘要： A method for producing a sintered NdFeB magnet having high coercivity and capable of being brought into applications without lowering its residual magnetic flux density or maximum energy product and without reprocessing. The method includes applying a substance containing dysprosium (Dy) and/or terbium (Tb) to the surface of the sintered NdFeB magnet forming a base body and then heating the magnet to diffuse Dy and/or Tb through the grain boundary and thereby increase the coercivity of the magnet. This method is characterized in that: (1) the substance containing Dy or Tb to be applied to the surface of the sintered NdFeB magnet is substantially a metal powder; (2) the metal powder is composed of a rare-earth element R and an iron-group transition element T, or composed of R, T and another element X, the element X capable of forming an alloy or intermetallic compound with R and/or T; and (3) the oxygen content of the sintered NdFeB magnet forming the base body is 5000 ppm or lower. The element T may contain nickel (Ni) or cobalt (Co) to produce an anticorrosion effect.
摘要翻译：一种制造具有高矫顽力并能够在不降低其剩余磁通密度或最大能量产物而不再加工的情况下应用的NdFeB烧结磁体的方法。该方法包括将含有镝（Dy）和/或铽（Tb）的物质施加到形成基体的烧结NdFeB磁体的表面，然后加热磁体以通过晶界扩散Dy和/或Tb，从而增加磁铁的矫顽力。该方法的特征在于：（1）应用于烧结NdFeB磁体表面的含有Dy或Tb的物质基本上是金属粉末; （2）金属粉末由稀土元素R和铁基过渡元素T构成，或由R，T和另一元素X构成，能够与R和/ 或T; 和（3）形成基体的烧结NdFeB磁体的氧含量为5000ppm以下。元素T可以含有镍（Ni）或钴（Co）以产生抗腐蚀效果。

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