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1. 发明公开

US20240312704A1 METHOD OF PRODUCING SmFeN-BASED RARE EARTH MAGNET 审中-公开
公开(公告)号：US20240312704A1
公开(公告)日：2024-09-19
申请号：US18600937
申请日：2024-03-11
申请人： TOYOTA JIDOSHA KABUSHIKI KAISHA , NICHIA CORPORATION
发明人： Tomonori INUZUKA , Masaaki ITO , Motoki HIRAOKA , Hisashi MAEHARA
IPC分类号： H01F41/02 , B22F1/00 , B22F1/052 , B22F1/145 , B22F1/16 , B22F3/16 , B22F3/24 , H01F1/059
CPC分类号： H01F41/0266 , B22F1/052 , B22F1/09 , B22F1/145 , B22F1/16 , B22F3/16 , B22F3/24 , H01F1/059 , B22F2003/248 , B22F2201/20 , B22F2202/05 , B22F2301/35 , B22F2304/10 , B22F2998/10 , B22F2999/00
摘要： A method of producing a SmFeN-based rare earth magnet having excellent magnetic properties is provided.
The present disclosure relates to a method of producing a SmFeN-based rare earth magnet in which a powder having a large particle size and a powder having a small particle size are used as SmFeN-based anisotropic magnetic powders, and the powders are separately dry treated at temperatures appropriate for the respective particle sizes when the powders are surface treated using phosphoric acid source to perform phosphoric acid coating.

2. 发明公开

US20240062936A1 METHOD OF PRODUCING RARE EARTH MAGNETIC POWDER AND RARE EARTH MAGNETIC POWDER 审中-公开
公开(公告)号：US20240062936A1
公开(公告)日：2024-02-22
申请号：US18448689
申请日：2023-08-11
申请人： NICHIA CORPORATION , TOYOTA JIDOSHA KABUSHIKI KAISHA
发明人： Hisashi MAEHARA , Masaaki ITO , Tomonori INUZUKA , Motoki HIRAOKA
IPC分类号： H01F1/059 , H01F1/055 , H01F41/02
CPC分类号： H01F1/059 , H01F1/0552 , H01F1/0558 , H01F41/0266 , H01F41/026
摘要： A method of producing a rare earth magnetic powder, the method including: heat-treating a mixture containing a SmFeN-based magnetic powder containing Sm, Fe, and N and a modifier powder containing Zn; and dispersing the heat-treated SmFeN-based magnetic powder using a resin-coated metal media or a resin-coated ceramic media.

3. 发明公开

US20240161975A1 SmFeN BASED RARE EARTH MAGNET AND PRODUCTION METHOD THEREOF 审中-公开
公开(公告)号：US20240161975A1
公开(公告)日：2024-05-16
申请号：US18506354
申请日：2023-11-10
申请人： NICHIA CORPORATION , TOYOTA JIDOSHA KABUSHIKI KAISHA
发明人： Hisashi MAEHARA , Tomonori INUZUKA , Masaaki ITO , Motoki HIRAOKA
IPC分类号： H01F41/02 , B22F1/052 , B22F1/142 , B22F1/145 , B22F1/16 , B22F3/14 , B22F3/16 , B22F3/24 , B22F9/22 , H01F1/059
CPC分类号： H01F41/0266 , B22F1/052 , B22F1/142 , B22F1/145 , B22F1/16 , B22F3/14 , B22F3/16 , B22F3/24 , B22F9/22 , H01F1/059 , H01F41/0273 , B22F2003/248 , B22F2201/013 , B22F2201/02 , B22F2201/11 , B22F2202/05 , B22F2301/355 , B22F2302/45 , B22F2998/10 , B22F2999/00
摘要： A method of producing a SmFeN-based rare earth magnet, the method including: heat-treating a SmFeN-based anisotropic magnetic powder having a surface coated with a phosphate at a temperature of at least 80° C. but lower than 150° C.; mixing the heat-treated SmFeN-based anisotropic magnetic powder and a Zn-containing modifier powder by dispersion using resin-coated metal media or resin-coated ceramic media to obtain a powder mixture containing the SmFeN-based anisotropic magnetic powder and the modifier powder; compacting the powder mixture in a magnetic field to obtain a magnetic field compact; and pressure-sintering the magnetic field compact to obtain a sintered compact.

4. 发明申请

US20160008885A1 MANUFACTURING METHOD FOR SINTERED COMPACT 审中-公开
标题翻译：烧结紧固件的制造方法
公开(公告)号：US20160008885A1
公开(公告)日：2016-01-14
申请号：US14793091
申请日：2015-07-07
申请人： TOYOTA JIDOSHA KABUSHIKI KAISHA
发明人： Tomonori INUZUKA , Akira KANO
IPC分类号： B22F3/10 , H01F1/053 , B22F9/00 , H01F41/02
CPC分类号： B22F3/1017 , B22F3/03 , B22F3/14 , B22F9/04 , B22F2009/048 , H01F1/0571 , H01F1/0577 , H01F41/0266
摘要： A manufacturing method for a sintered compact includes a first step in which magnetic powder is fabricated by rapid solidification, a second step in which a mass of the magnetic powder is housed in a forming mold, and preliminary heating is performed by placing the mass of the magnetic powder in a preliminary heating part of the forming mold at first temperature that is lower than coarse crystal particle generation temperature, and a third step in which main heating is performed by placing the preliminarily heated mass of the magnetic powder at second temperature that is lower than the coarse crystal particle generation temperature and higher than the first temperature, and press forming is performed while keeping temperature of the magnetic powder at densification temperature or higher.
摘要翻译：烧结体的制造方法包括：通过快速凝固来制造磁性粉末的第一步骤，将第二步骤将磁粉的质量容纳在成型模具中，并且通过将所述质量的在第一温度低于粗晶粒产生温度的成型模的初加热部分中的磁粉，以及通过将预先加热的磁粉的质量置于低于第二温度的第二温度进行主加热的第三步骤比粗晶粒发生温度高于第一温度，并且在将磁粉的温度保持在致密化温度以上的同时进行压制成形。

5. 发明申请

US20170011848A1 PRODUCTION METHOD OF COMPACT 审中-公开
标题翻译：紧凑的生产方法
公开(公告)号：US20170011848A1
公开(公告)日：2017-01-12
申请号：US15202176
申请日：2016-07-05
申请人： TOYOTA JIDOSHA KABUSHIKI KAISHA
发明人： Tomonori INUZUKA , Akira KANO
IPC分类号： H01F41/02 , B22F3/02
CPC分类号： H01F41/0266 , B22F3/02 , B22F2003/026 , C22C2202/02 , H01F1/0577
摘要： The method including: applying a graphite-based lubricant to a cavity surface of a die; forming a first graphite-based powder layer by disposing graphite-based powder that does not contain a binder on a cavity surface of a lower punch, forming a magnet powder body by putting magnet powder on the first graphite-based powder layer, and forming a second graphite-based powder layer by disposing graphite-based powder that does not contain a binder on the magnet powder body; and producing a compact by performing press forming using the lower punch and a upper punch while heating the magnet powder body surrounded by the graphite-based lubricant applied to the cavity surface of the die, the first graphite-based powder layer, and the second graphite-based powder layer, and releasing the compact from a forming die.
摘要翻译：该方法包括：将石墨基润滑剂施加到模具的空腔表面; 通过在下冲头的空腔表面上配置不含粘合剂的石墨基粉末，通过在第一石墨基粉末层上放置磁铁粉末形成磁体粉末体来形成第一石墨基粉末层，形成通过在所述磁体粉体上设置不含有粘合剂的石墨类粉末来形成第二石墨类粉末层; 并且通过使用下冲头和上冲头进行冲压成形来制造压块，同时加热被施加到模具的空腔表面的石墨基润滑剂包围的磁体粉末体，第一石墨基粉末层和第二石墨的粉末层，并从成形模上释放压块。

6. 发明申请

US20160055969A1 MANUFACTURING METHOD OF RARE-EARTH MAGNET 审中-公开
标题翻译：稀土磁铁制造方法
公开(公告)号：US20160055969A1
公开(公告)日：2016-02-25
申请号：US14833548
申请日：2015-08-24
申请人： TOYOTA JIDOSHA KABUSHIKI KAISHA
发明人： Kazuaki HAGA , Noriyuki UENO , Akira KANO , Tomonori INUZUKA , Noritsugu SAKUMA
IPC分类号： H01F41/02 , B22F3/24 , H01F1/053 , B22F3/12
CPC分类号： H01F41/0266 , B22F3/1216 , B22F3/1258 , B22F3/17 , B22F3/24 , B22F2998/10 , B22F2999/00 , H01F1/0536 , H01F1/086 , B22F2009/048 , B22F3/02 , B22F3/14 , B22F2202/06 , B22F2202/05
摘要： A manufacturing method of a rare-earth magnet includes: manufacturing a first sealing body by filling a graphite container with a magnetic powder to be a rare-earth magnet material and by sealing the graphite container; manufacturing a sintered body by sintering the first sealing body to manufacture a second sealing body in which the sintered body is accommodated; and manufacturing a rare-earth magnet by performing hot plastic working on the second sealing body to give magnetic anisotropy to the sintered body.
摘要翻译：稀土类磁体的制造方法包括：通过将具有磁性粉末的石墨容器填充为稀土类磁体材料并密封石墨容器来制造第一密封体; 通过烧结所述第一密封体来制造烧结体，以制造容纳所述烧结体的第二密封体; 并通过在第二密封体上进行热塑性加工来制造稀土磁体，从而对烧结体产生磁各向异性。

7. 发明公开

US20230317327A1 PRODUCTION METHOD OF RARE EARTH MAGNET 审中-公开
公开(公告)号：US20230317327A1
公开(公告)日：2023-10-05
申请号：US18124306
申请日：2023-03-21
申请人： TOYOTA JIDOSHA KABUSHIKI KAISHA
发明人： Masaaki ITO , Noritsugu SAKUMA , Akihito KINOSHITA , Reimi TABUCHI , Tomonori INUZUKA , Kunihiro MATSUYAMA , Masashi HARADA
IPC分类号： H01F1/053 , B22F3/14
CPC分类号： H01F1/0536 , B22F3/14 , B22F2202/05 , B22F2301/355
摘要： A production method of a Sm—Fe—N-based rare earth magnet, enabling to stably impart sufficient anisotropy, is provided.
The present disclosure provides a production method of a rare earth magnet, including preparing a raw material powder containing a magnetic powder (SmFeN powder 10) having a magnetic phase which contains Sm, Fe and N and at least partially has a crystal structure of at least either Th2Zn17 type or Th2Ni17 type, and pressure-sintering the raw material powder. In this production method, magnetic orientation is imparted to the raw material powder by applying a magnetic field before the pressure sintering, and the application of magnetic field is continued to maintain the magnetic orientation at least until the middle of the pressure sintering.

8. 发明申请

US20160099104A1 METHOD FOR MANUFACTURING RARE-EARTH MAGNETS 有权
标题翻译：制造稀土磁铁的方法
公开(公告)号：US20160099104A1
公开(公告)日：2016-04-07
申请号：US14829807
申请日：2015-08-19
申请人： TOYOTA JIDOSHA KABUSHIKI KAISHA
发明人： Kazuaki HAGA , Tomonori INUZUKA , Yuya IKEDA
IPC分类号： H01F41/02 , B22F3/14 , H01F1/053
CPC分类号： H01F1/0576 , B22F3/02 , B22F3/17 , B22F2003/026 , B22F2998/10 , C21D7/13 , C22C38/001 , C22C38/005 , C22C38/10 , H01F1/0577 , B22F2009/048 , B22F3/10 , B22F2003/175
摘要： Provided is a method for manufacturing a rare-earth magnet having good workability and capable of manufacturing a rare-earth magnet having low oxygen density. A method for manufacturing a rare-earth magnet includes: a first step of applying or spraying graphite-based lubricant GF on an inner face of a forming die M, and charging magnetic powder MF as a rare-earth magnet material in the forming die M, followed by cold forming, to form a cold-forming compact 10 having a surface on which a graphite-based lubricant coat 12 is formed; a second step of performing hot forming to the cold-forming compact 10 to form a sintered body 20 having a surface on which a graphite-based lubricant coat 22 is formed; and a third step of, in order to give the sintered body 20 anisotropy, performing hot deformation processing to the sintered body 20 to form the rare-earth magnet 30.
摘要翻译：本发明提供一种制造具有良好的加工性的稀土类磁铁的制造方法，能够制造氧浓度低的稀土类磁铁。稀土类磁体的制造方法包括：在成形模具M的内表面上涂敷或喷涂石墨系润滑剂GF的第一工序，在成形模M中加入作为稀土类磁铁材料的磁粉MF 然后冷成型，以形成其上形成有石墨基润滑剂涂层12的表面的冷成型压块10; 对冷成型体10进行热成形以形成其上形成有石墨基润滑剂涂层22的表面的烧结体20的第二步骤; 第3工序为了使烧结体20具有各向异性，对烧结体20进行热变形处理，形成稀土类磁体30。

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