公开(公告)号：US20220093298A1

公开(公告)日：2022-03-24

申请号：US17480568

申请日：2021-09-21

申请人： TOYOTA JIDOSHA KABUSHIKI KAISHA

发明人： Daisuke Ichigozaki ,  Tetsuya Shoji ,  Noritsugu Sakuma ,  Akihito Kinoshita ,  Masaaki Ito

IPC分类号： H01F1/059 ,  H01F41/02 ,  C22C38/00 ,  C22C38/10 ,  C23C8/26

摘要： An Sm—Fe—N-based magnetic material according to the present disclosure includes a main phase having a predetermined crystal structure. The main phase has a composition represented by a molar ratio formula (Sm(1-x-y-z)LaxCeyR1z)2(Fe(1-p-q-s)CopNiqMs)17Nh (where, R1 is a predetermined rare earth element, M is a predetermined element, and 0≤x+y

公开(公告)号：US11087922B2

公开(公告)日：2021-08-10

申请号：US15953183

申请日：2018-04-13

申请人： TOYOTA JIDOSHA KABUSHIKI KAISHA

发明人： Masaaki Ito ,  Noritsugu Sakuma ,  Masao Yano ,  Hidefumi Kishimoto ,  Tetsuya Shoji

IPC分类号： H01F41/02 ,  H01F1/057 ,  C22C38/16 ,  C22C38/06 ,  B22F1/00 ,  B22F9/04 ,  C22C1/04 ,  C22C38/00

摘要： A method for producing a rare earth magnet, including preparing a melt of a first alloy having a composition represented by (R1vR2wR3x)yTzBsM1t (wherein R1 is a light rare earth element, R2 is an intermediate rare earth element, R3 is a heavy rare earth element, T is an iron group element, and M1 is an impurity element, etc.), cooling the melt of the first alloy at a rate of from 100 to 102 K/sec to obtain a first alloy ingot, pulverizing the first alloy ingot to obtain a first alloy powder having a particle diameter of 1 to 20 μm, preparing a melt of a second alloy having a composition represented by (R4pR5q)100-uM2u (wherein R4 is a light rare earth element, R5 is an intermediate or heavy rare earth element, M2 is an alloy element, etc.), and putting the first alloy powder into contact with the melt of the second alloy.

公开(公告)号：US10748684B2

公开(公告)日：2020-08-18

申请号：US16532651

申请日：2019-08-06

申请人： TOYOTA JIDOSHA KABUSHIKI KAISHA

发明人： Masaaki Ito ,  Masao Yano ,  Hidefumi Kishimoto ,  Noritsugu Sakuma ,  Tetsuya Shoji ,  Akira Manabe

IPC分类号： H01F41/02 ,  B22F3/14 ,  H01F1/055 ,  C22C33/02 ,  C22C38/00 ,  H01F1/057 ,  C22C38/10 ,  B22F5/00

摘要： To provide a rare earth magnet ensuring excellent magnetic anisotropy while reducing the amount of Nd, etc., and a manufacturing method thereof.A rare earth magnet comprising a crystal grain having an overall composition of (R2(1-x)R1x)yFe100-y-w-z-vCowBzTMv (wherein R2 is at least one of Nd, Pr, Dy and Tb, R1 is an alloy of at least one or two or more of Ce, La, Gd, Y and Sc, TM is at least one of Ga, Al, Cu, Au, Ag, Zn, In and Mn, 0

公开(公告)号：US10062504B2

公开(公告)日：2018-08-28

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 ,  B22F3/12 ,  B22F3/24 ,  H01F1/053 ,  B22F3/17 ,  H01F1/08

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.

公开(公告)号：US10056177B2

公开(公告)日：2018-08-21

申请号：US14610229

申请日：2015-01-30

申请人： TOYOTA JIDOSHA KABUSHIKI KAISHA

发明人： Noritsugu Sakuma ,  Tetsuya Shoji ,  Kazuaki Haga

IPC分类号： B22F3/26 ,  B22F3/10 ,  B22F3/24 ,  H01F1/057 ,  H01F41/02 ,  H01F1/055 ,  C22C38/00 ,  C22C38/10

CPC分类号： H01F1/0577 ,  B22F1/0044 ,  B22F3/10 ,  B22F3/24 ,  B22F3/26 ,  B22F2009/048 ,  B22F2998/10 ,  B22F2999/00 ,  C22C33/025 ,  C22C33/0257 ,  C22C38/001 ,  C22C38/002 ,  C22C38/005 ,  C22C38/10 ,  C22C2202/02 ,  H01F1/0557 ,  H01F41/0266 ,  H01F41/0293 ,  B22F3/02

摘要： The present invention is a method capable of producing a rare-earth magnet with excellent magnetization and coercivity. The method includes producing a sintered body including a main phase and grain boundary phase and represented by (R11-xR2x)aTMbBcMd (where R1 represents one or more rare-earth elements including Y, R2 represents a rare-earth element different than R1, TM represents transition metal including at least one of Fe, Ni, or Co, B represents boron, M represents at least one of Ti, Ga, Zn, Si, Al, etc., 0.01≤x≤1, 12≤a≤20, b=100−a−c−d, 5≤c≤20, and 0≤d≤3 (all at %)); applying hot deformation processing to the sintered body to produce a precursor of the magnet; and diffusing/infiltrating melt of a R3-M modifying alloy (rare-earth element where R3 includes R1 and R2) into the grain boundary phase of the precursor.

公开(公告)号：US20140260800A1

公开(公告)日：2014-09-18

申请号：US14350447

申请日：2012-10-09

申请人： TOYOTA JIDOSHA KABUSHIKI KAISHA

发明人： Noritsugu Sakuma ,  Hidefumi Kishimoto ,  Noritaka Miyamoto ,  Akira Kato ,  Akira Manabe ,  Daisuke Ichigozaki ,  Tetsuya Shoji ,  Shoichi Harakawa

IPC分类号： H01F1/20 ,  B22F9/04

CPC分类号： H01F1/20 ,  B22F9/04 ,  B22F2009/048 ,  C22C33/0278 ,  C22C38/002 ,  C22C38/005 ,  C22C38/10 ,  C22C2202/02 ,  H01F1/0571 ,  H01F1/0577

摘要： A method for producing magnetic powder for forming a sintered body that is a precursor of a rare-earth magnet. Provided is a method for producing magnetic powder for forming a sintered body that is a precursor of a rare-earth magnet, which can produce magnetic powder with a structure containing optimal nanosized crystal grains by accurately and efficiently sorting out magnetic powder containing no coarse grains in the structure thereof. A method for producing magnetic powder p for forming a sintered body S that is a precursor of a rare-earth magnet, the sintered body S including an Nd—Fe—B-based main phase with a nanocrystalline structure, and a grain boundary phase around the main phase, and the rare-earth magnet being adapted to be formed by applying hot deformation processing to the sintered body S for imparting anisotropy thereto and diffusing an alloy for improving coercivity therein, the method including discharging a metal melt onto a chill roll R to produce a quenched ribbon B, and grinding the quenched ribbon B into grains in the size range of 50 to 1000 μm to produce magnetic powder in the mass range of 0.0003 to 03 mg; conducting a test to see whether or not the magnetic powder in the mass range adsorbs onto a magnet with a surface magnetic flux density of 2 mT or less, and sorting out magnetic powder p that has not adsorbed onto the magnet, as the magnetic powder for forming the sintered body S.

摘要翻译： 一种用于形成作为稀土类磁体的前体的烧结体的磁性粉末的制造方法。 提供一种用于形成作为稀土类磁体的前体的烧结体的磁性粉末的制造方法，其可以通过精确有效地分选不含粗粒的磁性粉末来制造具有包含最佳纳米晶粒的结构的磁粉 其结构。 用于形成作为稀土类磁体的前体的烧结体S的磁性粉末p的制造方法，包括具有纳米晶体结构的Nd-Fe-B系主相和包含晶界相的烧结体S 主相和稀土磁体适用于通过向烧结体S施加热变形处理以赋予其各向异性并且扩散用于提高矫顽力的合金，所述方法包括将金属熔体排出到冷却辊R上 制造淬火带B，将淬火带B研磨成粒径为50〜1000μm的粒子，制成质量范围为0.0003〜03mg的磁性粉末; 进行试验，以观察质量范围内的磁粉是否吸附在表面磁通密度为2mT以下的磁体上，并将未吸附在磁铁上的磁性粉末p进行分选，作为磁粉 形成烧结体S.