Coating Method and Apparatus, a Permanent Magnet, and Manufacturing Method Thereof

a technology of permanent magnets and coating methods, applied in the direction of magnetic materials, evaporation applications, magnetic bodies, etc., can solve the problems of greatly reduced maximum energy products exhibiting magnetic properties, heat deformation, and reduced magnetic field strength, so as to achieve high efficiency, low cost, and high speed

Inactive Publication Date: 2008-10-23
ULVAC INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0037]The permanent magnet and its manufacturing method of the present invention have effects that the magnet can be manufactured at a high productivity and a low cost with effectively using Dy and Tb of coating materials and coating them at a high speed on the surface of magnet of Fe—B-rare earth elements having a predetermined configuration and that the magnet has excellent corrosion resistance and weather resistance without any additional protective fil

Problems solved by technology

On the other hand the sintered magnet of Nd—Fe—B has a problem that it is demagnetized by heat when it is heated beyond its predetermined temperature since its Curie temperature is low such as 300° C.
However, since Dy and Tb take the ferrimagnetism structu

Method used

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  • Coating Method and Apparatus, a Permanent Magnet, and Manufacturing Method Thereof
  • Coating Method and Apparatus, a Permanent Magnet, and Manufacturing Method Thereof
  • Coating Method and Apparatus, a Permanent Magnet, and Manufacturing Method Thereof

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embodiment 1

[0082]Each sintered magnet of Fe—B-rare earth elements was made as a rectangular parallelopiped of 50×50×8 mm using a raw material having a composition of 31Nd-1Co-1B-0.1Cu-bal.Fe (“NEOMAX-50 manufactured by NEOMAX Co.). The surface of sintered magnet S was cleaned using acetone after having finished it as having a surface roughness of less than 20 μm.

[0083]Dy was coated on the surface of sintered magnet S using the coating apparatus 1 and method of the present invention. Dy of 99.9% degree of purity was used as the coating material and Dy of gross 500 g was laid on the receptor 24. A wire forming the mesh type supporting member 62 of the supporting means 6 is made of Mo and has a diameter of 1 mm. Then four (4) cleaned sintered magnets S were laid on each supporting members 62 on a circle of a diameter (80 mm) oppositely in a diametrical direction each other (totally eight (8) sintered magnets S were placed on two supporting members 62 of upper and lower stages. A space between the...

embodiment 2

[0087]In this embodiment 2, permanent magnets were manufactured at same conditions as those in the embodiment 1 except for that heat treatment was not carried out. However, the holding time duration of the permanent magnets within the Dy vapor atmosphere was set at one (1) minute and the temperature within the process chamber was varied. FIG. 6 is a table showing average values of a coating thickness of Dy when the coating was carried out under these conditions, and the magnetic properties of permanent magnets manufactured in this embodiment. According to this embodiment 2, it can be found that little coating is formed at a temperature lower than 1,000° C., but coating can be formed at a high speed more than 20 μm / sec at a temperature higher than 1,200° C. In this case, it is found that it is possible to obtain a permanent magnet having a maximum energy product of about 50 MG0 e of little loss and a high coercive force of 17 K0 e or more in a range of 1,100˜1,700° C.

embodiment 3

[0088]In this embodiment 3, permanent magnets were manufactured at same conditions as those in the embodiment 1 except for that pretreatment (cleaning treatment) was not carried out. However, the holding time duration of the permanent magnets within the Dy vapor atmosphere was varied. FIG. 7 is a table showing average values of the coating thickness of Dy coated with the holding time duration being varied, the maximum and the magnetic properties of permanent magnets manufactured in this embodiment. According to this embodiment 3, it can be found that a vapor depositing velocity exceeding 17 μm can be obtained and the temperature rise of sintered magnet itself is at most 743° C. although it is held for 60 seconds. In this case, it is found that it is possible to obtain a permanent magnet of high coercive force having a maximum energy product of about 50 MG0 e, a remanent magnetic flux density of 14.5 kG and a coercive force of 15.4˜21.3 K0 e.

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Abstract

A film is formed at a high rate on the surface of an iron-boron-rare-earth-metal magnet having a given shape, while effectively using dysprosium or terbium as a film-forming material. Thus, productivity is improved and a permanent magnet can be produced at low cost. A permanent magnet is produced through a film formation step in which a film of dysprosium is formed on the surface of an iron-boron-rare-earth-metal magnet of a given shape and a diffusion step in which the magnet coated is subjected to a heat treatment at a given temperature to cause the dysprosium deposited on the surface to diffuse into the grain boundary phase of the magnet. The film formation step comprises: a first step in which a treating chamber where this film formation is performed is heated to vaporize dysprosium which has been disposed in this treating chamber and thereby form a dysprosium vapor atmosphere having a given vapor pressure in the treating chamber; and a second step in which a magnet kept at a temperature lower than the internal temperature of the treating chamber is introduced into this treating chamber and the dysprosium is selectively deposited on the magnet surface based on a temperature difference between the treating chamber and the magnet until the magnet temperature reaches a given value.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]The present invention relates to coating method and apparatus, a permanent magnet, and a manufacturing method thereof, and more particularly to a permanent magnet and a manufacturing method thereof in which the permanent magnet is manufactured by coating vaporizable metallic material including at least one of Dy and Tb on a surface of a magnet of Fe—B-rare earth elements, and then diffusing at least one of Dy and Tb into crystal grain boundary phases of a sintered magnet by heat treating the vaporizable metallic material at a predetermined temperature, as well as to coating method and apparatus suitable for coating vaporizable metallic material including at least one of Dy and Tb on the surface of the magnet.[0003]2. Description of Background Art[0004]A sintered magnet of Nd—Fe—B (a so-called “neodymium magnet”) has been used in various products e.g. motors for a hybrid vehicle and generators etc. recently since the neo...

Claims

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Application Information

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IPC IPC(8): C23C14/54C23C14/22H01F1/053H01F10/12H01F41/20
CPCC23C14/16C23C14/243C23C14/541H01F41/0293H01F10/126H01F41/20H01F1/0571C23C14/54C23C14/22H01F10/12
Inventor NAGATA, HIROSHISHINGAKI, YOSHINORI
Owner ULVAC INC
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