Magnetic member, rotary electric machine, compressor, blower, refrigeration device, and production method for magnetic material

Abstract

A magnetic member comprising a laminate obtained by layering a plurality of layers of a plate-shaped magnetic material that is an amorphous soft magnetic material or a nanocrystalline soft magnetic material, wherein the magnetic material is bonded to a bonding member, the magnetic material has a bonding region that is bonded to the bonding member, and the ratio of crystals per unit volume in the bonding region of the magnetic material is greater than the ratio of crystals per unit volume in the magnetic material.

Description

Magnetic member, rotating electrical machine, compressor, blower, refrigeration device, and method for manufacturing magnetic material

[0001] The present disclosure relates to a magnetic member, a rotating electrical machine, a compressor, a blower, a refrigeration device, and a method for manufacturing a magnetic material.

[0002] Patent Document 1 discloses a stator including a first core made of an electromagnetic steel sheet and a second core made of an amorphous metal or a nanocrystalline metal.

[0003] International Publication No. 2018 / 138864

[0004] In magnetic components used in devices such as motors and transformers, soft magnetic materials are used. As soft magnetic materials having excellent properties such as low loss and high magnetic flux density, amorphous soft magnetic materials and nanocrystalline soft magnetic materials have been developed.

[0005] It is required to use amorphous soft magnetic materials and nanocrystalline soft magnetic materials as soft magnetic materials. Amorphous soft magnetic materials and nanocrystalline soft magnetic materials are brittle. Therefore, when a magnetic member made of an amorphous soft magnetic material or a nanocrystalline soft magnetic material is joined to a joining member, the magnetic member may be broken or damaged by the force applied during joining.

[0006] The present disclosure provides a technique for suppressing breakage or damage of a magnetic member when joining to a joining member in a magnetic member made of an amorphous soft magnetic material and a nanocrystalline soft magnetic material.

[0007] The magnetic member of the first aspect includes a laminate in which a plurality of plate-like magnetic materials made of an amorphous soft magnetic material or a nanocrystalline soft magnetic material are laminated, the magnetic material is joined to a joining member, the magnetic material has a joining region joined to the joining member, and the ratio of crystals per unit volume in the joining region of the magnetic material is larger than the ratio of crystals per unit volume of the magnetic material, and is a magnetic member.

[0008] According to the magnetic member of the first viewpoint, in a laminate formed by stacking multiple plate-shaped magnetic materials, which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials, when joining them with a joining member, the destruction or damage of the magnetic materials can be suppressed.

[0009] The magnetic member in the second view is the magnetic member in the first view, wherein the magnetic material is joined to the joining member by an interlocking fit.

[0010] According to the magnetic member of the second perspective, in a laminate formed by stacking multiple plate-shaped magnetic materials, which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials, when interlocked with a joining member, the destruction or damage of the magnetic material can be suppressed.

[0011] The magnetic member in the third aspect is the magnetic member in the first aspect, wherein the magnetic material has a fitting portion consisting of a recess or a protrusion, and the magnetic material is joined by the joining member fitting into the fitting portion.

[0012] According to the magnetic member of the third perspective, in a laminate formed by stacking multiple plate-shaped magnetic materials, which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials, when fitted with a joining member, the destruction or damage of the magnetic material can be suppressed.

[0013] The magnetic member of the fourth aspect is the magnetic member of the first aspect, wherein the magnetic material and the bonding member are bonded so that they can slide against each other, and when the region in which the magnetic material contacts the bonding member during sliding is defined as the sliding region, the ratio of crystals per unit volume of the magnetic material in the sliding region is greater than the ratio of crystals per unit volume of the magnetic material.

[0014] According to the magnetic member of the fourth perspective, in a laminate formed by stacking multiple plate-shaped magnetic materials, which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials, when sliding with a bonding member, the fracture or damage of the magnetic material can be suppressed.

[0015] The rotating electric machine according to the first viewpoint is a rotating electric machine comprising a magnetic member according to any of the first to fourth viewpoints, wherein the magnetic member is a stator core or a rotor core.

[0016] According to the first aspect of the rotating electric machine, in a laminate formed by stacking multiple plate-shaped magnetic materials, which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials, when joining them with a joining member, the destruction or damage of the magnetic materials can be suppressed.

[0017] The compressor in the first view is a compressor comprising a rotating electric machine in the first view and a compression mechanism driven by the rotating electric machine.

[0018] According to the first aspect of the compressor, in a compressor equipped with a laminate formed by stacking multiple plate-shaped magnetic materials, which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials, when joining with a joining member, the destruction or damage of the magnetic material can be suppressed.

[0019] The blower according to the first perspective is a blower comprising a rotating electric machine according to the first perspective and a fan driven by the rotating electric machine.

[0020] According to the blower of the first perspective, in a blower equipped with a laminate formed by stacking multiple plate-shaped magnetic materials, which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials, when joining with a joining member, the destruction or damage of the magnetic material can be suppressed.

[0021] The refrigeration apparatus of the first perspective is a refrigeration apparatus that includes a rotating electric machine of the first perspective.

[0022] According to the first aspect of the refrigeration apparatus, in a refrigeration apparatus comprising a laminate formed by stacking multiple plate-shaped magnetic materials, which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials, when joining with a joining member, the destruction or damage of the magnetic material can be suppressed.

[0023] A method for manufacturing a magnetic member according to the first aspect is a method for manufacturing a magnetic member including a laminate in which a plurality of plate-shaped magnetic materials, which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials, are stacked, comprising: a first step of heating a part of the magnetic material to a temperature above the crystallization temperature of the magnetic material; and a second step of bending the magnetic material within the part of the magnetic material after the first step.

[0024] According to the manufacturing method of the magnetic member of the first aspect, when a laminate is formed by stacking multiple plate-shaped magnetic materials, which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials, the destruction or damage of the magnetic material can be suppressed when it is joined to a joining member.

[0025] Figure 1 is a perspective view of a magnetic member according to the first embodiment. Figure 2 is a plan view of the magnetic material in the magnetic member according to the first embodiment, viewed from the thickness direction. Figure 3 is a flow diagram showing a first example of a method for manufacturing the magnetic member according to the first embodiment. Figure 4 is a flow diagram showing a second example of a method for manufacturing the magnetic member according to the first embodiment. Figure 5 is a perspective view of a magnetic member according to the second embodiment. Figure 6 is a plan view of the magnetic material in the magnetic member according to the second embodiment, viewed from the thickness direction. Figure 7 is a cross-sectional view of a compressor using the magnetic member according to the third embodiment. Figure 8 is a cross-sectional view of the cylinder portion of the compressor using the magnetic member according to the third embodiment. Figure 9 is a cross-sectional view of the rotating electromechanical portion of the compressor using the magnetic member according to the third embodiment. Figure 10 is a diagram illustrating a first example of heat treatment in the rotating electromechanical portion of the compressor using the magnetic member according to the third embodiment. Figure 11 is a diagram illustrating a second example of heat treatment in the rotating electromechanical portion of the compressor using the magnetic member according to the third embodiment. Figure 12 is a diagram illustrating a first modified example of the rotating electromechanical portion of the compressor using the magnetic member according to the third embodiment. Figure 13 illustrates a second modified example of a rotating electric machine for a compressor using a magnetic member according to the third embodiment. Figure 14 illustrates a third modified example of a rotating electric machine for a compressor using a magnetic member according to the third embodiment. Figure 15 illustrates a fourth modified example of a rotating electric machine for a compressor using a magnetic member according to the third embodiment. Figure 16 illustrates a rotating electric machine for a compressor using a magnetic member according to the fourth embodiment. Figure 17A illustrates a heat treatment in a first example of a rotating electric machine for a compressor using a magnetic member according to the fourth embodiment. Figure 17B illustrates a heat treatment in a second example of a rotating electric machine for a compressor using a magnetic member according to the fourth embodiment. Figure 18A illustrates a heat treatment in a first modified example of a rotating electric machine for a compressor using a magnetic member according to the fourth embodiment. Figure 18B illustrates a heat treatment in a second modified example of a rotating electric machine for a compressor using a magnetic member according to the fourth embodiment. Figure 19 illustrates a rotating electric machine for a compressor using a magnetic member according to the fifth embodiment.Figure 20 illustrates the heat treatment in a rotating electric machine for a compressor using a magnetic member according to the fifth embodiment. Figure 21 illustrates the heat treatment in a rotating electric machine for a compressor using a magnetic member according to the sixth embodiment. Figure 22 illustrates the heat treatment in a rotating electric machine for a compressor using a magnetic member according to the sixth embodiment. Figure 23 illustrates a first modified example of a rotating electric machine for a compressor using a magnetic member according to the sixth embodiment. Figure 24 illustrates the heat treatment in the first modified example of a rotating electric machine for a compressor using a magnetic member according to the sixth embodiment. Figure 25 illustrates the heat treatment in a rotating electric machine for a compressor using a magnetic member according to the seventh embodiment. Figure 26 illustrates the heat treatment in a rotating electric machine for a compressor using a magnetic member according to the eighth embodiment. Figure 27 illustrates an example of use of a rotating electric machine using a magnetic member according to the ninth embodiment.

[0026] The embodiments will be described below with reference to the attached drawings. Note that, in the description and drawings of each embodiment, components having substantially the same or corresponding functional configurations may be denoted by the same reference numerals, thereby omitting redundant explanations. Furthermore, for ease of understanding, the scale of each part in the drawings may differ from that of the actual parts.

[0027] The magnetic members of this disclosure will now be described. The magnetic members of this disclosure include a laminate formed by stacking multiple plate-shaped magnetic materials, which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials. The magnetic materials in the magnetic members of this disclosure are bonded to a bonding member and have a bonding region bonded to the bonding member. Furthermore, in the magnetic members of this disclosure, the ratio of crystals per unit volume of the bonding region of the magnetic material is greater than the ratio of crystals per unit volume of the magnetic material.

[0028] The magnetic member of this disclosure will be described in detail with reference to the drawings.

[0029] <First Embodiment> The magnetic member according to the first embodiment will now be described. In the magnetic member according to the first embodiment, the joining member is a rod-shaped member, and the magnetic material is joined to the joining member by inserting the joining member into a hole formed in the magnetic material and then tightening and fitting the joining member into that hole.

[0030] Figure 1 is a perspective view of a magnetic member 1, which is an example of a magnetic member according to the first embodiment. Figure 2 is a plan view of the magnetic material 11 in the magnetic member 1, which is an example of a magnetic member according to the first embodiment, as seen from the thickness direction. The thickness direction is the thickness direction of the plate-shaped magnetic material. The surface direction is the direction along the surface of the plate-shaped magnetic material. The thickness direction and the surface direction are perpendicular to each other.

[0031] The magnetic member 1 is a magnetic member used in, for example, motors, generators, transformers, noise filters, and choke coils. The magnetic member 1 comprises a laminate 10 in which multiple plate-shaped magnetic materials 11 are stacked. Each of the multiple magnetic materials 11 is joined to a joining member JM1. The multiple magnetic materials 11 and the joining member JM1 are joined by a interference fit.

[0032] The laminate 10 in the magnetic member 1 comprises a plurality of magnetic materials 11. The number of magnetic materials in the laminate in the magnetic member according to the first embodiment is not limited to the example of the laminate 10.

[0033] The magnetic material 11 is an amorphous soft magnetic material or a nanocrystalline soft magnetic material. The amorphous soft magnetic material or nanocrystalline soft magnetic material used in the magnetic material 11 is composed of, for example, at least one magnetic metal selected from the group consisting of iron, cobalt, and nickel, and at least one non-magnetic metal. The at least one non-magnetic metal is selected from the group consisting of, for example, boron, carbon, phosphorus, aluminum, silicon, titanium, vanadium, chromium, manganese, copper, yttrium, zirconium, niobium, molybdenum, hafnium, tantalum, and tungsten. The amorphous soft magnetic material or nanocrystalline soft magnetic material in the magnetic member according to the first embodiment is not limited to the above examples.

[0034] Typical amorphous soft magnetic materials or nanocrystalline soft magnetic materials used in magnetic material 11 include, for example, iron-cobalt alloys, iron-nickel alloys, iron-aluminum alloys, iron-silicon alloys, iron-tantalum alloys, or iron-zirconium alloys. Examples of iron-cobalt alloys include Fe・Co alloys and Fe・Co・V alloys. Examples of iron-nickel alloys include Fe・Ni alloys, Fe・Ni・Mo alloys, Fe・Ni・Cr alloys, and Fe・Ni・Si alloys. Examples of iron-aluminum alloys or iron-silicon alloys include Fe・Al alloys, Fe・Al・Si alloys, Fe・Al・Si・Cr alloys, Fe・Al・Si・Ti・Ru alloys, and Fe・Al・O alloys. Iron-tantalum alloys include, for example, Fe·Ta alloys, Fe·Ta·C alloys, and Fe·Ta·N alloys. Iron-zirconium alloys include, for example, Fe·Zr·N alloys.

[0035] Furthermore, a typical amorphous soft magnetic material or nanocrystalline soft magnetic material used in the magnetic material 11 may be, for example, a cobalt alloy containing cobalt and at least one element from the group consisting of zirconium, hafnium, niobium, tantalum, titanium, and yttrium. The cobalt alloy preferably contains 80 at% or more cobalt. Cobalt alloys containing 80 at% or more cobalt tend to become amorphous when formed into a film. In addition, cobalt alloys containing 80 at% or more cobalt have excellent magnetic properties because they have low crystalline magnetic anisotropy, fewer crystalline defects, and fewer grain boundaries. Suitable cobalt alloys as amorphous soft magnetic materials include, for example, Co·Zr alloys, Co·Zr·Nb alloys, and Co·Zr·Ta alloys.

[0036] Amorphous soft magnetic materials have an amorphous structure as their main structure. When observing the X-ray diffraction pattern of amorphous soft magnetic materials, they do not have clear peaks in the X-ray diffraction pattern. When observing the X-ray diffraction pattern of amorphous soft magnetic materials, they have a broad halo pattern.

[0037] Nanocrystalline soft magnetic materials are formed by applying heat treatment to amorphous soft magnetic materials that have an amorphous structure. Nanocrystalline soft magnetic materials are soft magnetic materials in which nanocrystals are deposited by heat treatment of amorphous soft magnetic materials. Nanocrystalline soft magnetic materials have a nanocrystalline structure. Nanocrystals are polycrystalline materials with particle sizes ranging from several nanometers to tens of nanometers.

[0038] When observing the X-ray diffraction pattern of nanocrystalline soft magnetic materials, X-ray diffraction peaks are found at positions corresponding to the lattice spacing of the crystal planes. The crystallite size can be calculated from the width of the X-ray diffraction peaks using Scherrer's equation. A nanocrystal is defined as a material whose crystallite size, calculated from the full width at half maximum of the diffraction peaks using Scherrer's equation, is less than 1 micrometer. In this disclosure, the crystallite size of the nanocrystal (the crystallite size calculated from the full width at half maximum of the diffraction peaks using Scherrer's equation) is preferably 100 nanometers or less, and more preferably 50 nanometers or less. Furthermore, the crystallite size of the nanocrystal is preferably 5 nanometers or more.

[0039] Nanocrystalline soft magnetic materials can improve magnetic properties because the crystallite size of the nanocrystals is 100 nanometers or less, as described above. In contrast, the crystallite size of conventional electrical steel sheets is on the order of micrometers, and is generally 50 micrometers or larger.

[0040] It is known that both amorphous soft magnetic materials and nanocrystalline soft magnetic materials undergo crystallization when heated to temperatures above their crystallization temperature, through the formation of crystal nuclei and the growth of crystal grains (coarsening of grain size).

[0041] In both amorphous and nanocrystalline soft magnetic materials, as crystallization progresses, changes in mechanical properties occur in the crystallized regions, such as a decrease in Vickers hardness and an increase in malleability or ductility.

[0042] Amorphous soft magnetic materials are hard and brittle. Nanocrystalline soft magnetic materials are brittle and easily fractured. Because amorphous soft magnetic materials and nanocrystalline soft magnetic materials are brittle, when joining a magnetic member to a bonding member, the force applied during joining may cause the magnetic member to break or be damaged. Because amorphous soft magnetic materials are hard, when joining a magnetic member to a bonding member, the force applied during joining may cause the bonding member to break or be damaged. Therefore, the inventors found that by heating the bonding region to be joined with the bonding member to promote crystallization, the mechanical properties in the bonding region can be changed. By changing the mechanical properties in the bonding region, the inventors found that it is possible to suppress the breakage or damage of the magnetic member in amorphous soft magnetic materials and nanocrystalline soft magnetic materials, and that it is possible to suppress the breakage or damage of the bonding member in amorphous soft magnetic materials.

[0043] Specifically, in Figure 2, the region H1 of the magnetic material 11 is heated to a temperature above the crystallization temperature, including the bonding region R1 near the through hole 12 where the bonding member JM1 is joined. In the region H1 heated to a temperature above the crystallization temperature, i.e., in a portion of the region including the bonding region R1, crystallization of the magnetic material 11 progresses. The ratio of crystals per unit volume in the heated region H1 of the magnetic material 11 is greater than that in the unheated region of the magnetic material 11. The ratio of crystals per unit volume is the proportion occupied by crystals in a unit volume. The ratio of crystals per unit volume in a predetermined region can be calculated, for example, by (sum of the volume of crystals included in the predetermined region) ÷ (volume of the predetermined region). The ratio of crystals per unit volume in the heated region H1 of the magnetic material 11 is greater than the ratio of crystals per unit volume in the entire region of the magnetic material 11. The ratio of crystals per unit volume in the bonding region R1 of the magnetic material 11 is greater than the ratio of crystals per unit volume in the region of the magnetic material 11 other than the bonding region R1. The ratio of crystals per unit volume in the bonding region R1 of the magnetic material 11 is greater than the ratio of crystals per unit volume in the entire region of the magnetic material 11.

[0044] A large ratio of crystals per unit volume means, for example, that the ratio of the volume of crystals per unit volume in the joining region R1, which is a partial region of the magnetic material 11, is larger than the ratio of the volume of crystals per unit volume in the entire region of the magnetic material 11. A large ratio of crystals per unit volume means, for example, that the number of crystals per unit volume in the joining region R1, which is a partial region of the magnetic material 11, is larger than the number of crystals per unit volume in the entire region of the magnetic material 11. Further, a large ratio of crystals per unit volume means, for example, that when the magnetic material 11 is a nanocrystalline soft magnetic material, the average value of the crystal grain size in the joining region R1, which is a partial region of the magnetic material 11, is larger than the average value of the crystal grain size in the entire region of the magnetic material 11.

[0045] The manufacturing method of the magnetic member according to the first embodiment will be described. By describing the manufacturing method of the magnetic material, the steps included in the manufacturing method of the magnetic member will be described. First, the first example of the manufacturing method of the magnetic member according to the first embodiment will be described. FIG. 3 is a flowchart showing the first example of the manufacturing method of the magnetic member according to the first embodiment. In the first example of the manufacturing method of the magnetic member according to the first embodiment, by heating the magnetic material before lamination, a region where crystallization has progressed in the magnetic material is formed.

[0046] (Step S10) For a plate-shaped magnetic material that is an amorphous soft magnetic material or a nanocrystalline soft magnetic material, in each of the plurality of magnetic materials, a joining region, which is a partial region, is heated so that the crystallization temperature in the magnetic material becomes, for example, 400° C. or higher. The heating is performed, for example, by bringing a heated jig into contact with the location to be heated (heating location). Further, the heating may be performed, for example, by irradiating the heating location with a laser. Further, the heating may be performed, for example, by so-called induction heating in which a high-frequency electromagnetic wave is irradiated to the heating location.

[0047] (Step S20) The heated magnetic materials with the joining regions are laminated to form a laminate.

[0048] (Step S30) After step S20, a joining member is joined to the laminate. The joining of the laminate and the joining member is performed by interference fitting. The interference fitting may be, for example, shrink fitting or expansion fitting. When performing shrink fitting, it is preferable to perform shrink fitting at a temperature at which the temperature of the magnetic material is less than the crystallization temperature. Also, the joining member may be press-fitted into the through-hole of the laminate.

[0049] Next, a second example of the manufacturing method of the magnetic member according to the first embodiment will be described. FIG. 4 is a flowchart showing a second example of the manufacturing method of the magnetic member according to the first embodiment. In the second example of the manufacturing method of the magnetic member according to the first embodiment, first, a magnetic material is laminated to form a laminate, and then the magnetic material is heated to form a region where crystallization has progressed in the magnetic material.

[0050] (Step S110) First, a plate-shaped magnetic material, which is an amorphous soft magnetic material or a nanocrystalline soft magnetic material, is laminated to form a laminate.

[0051] (Step S120) Next, the joining region in the laminate is heated so that the temperature becomes equal to or higher than the crystallization temperature of the magnetic material, for example, 400°C. The heating is performed, for example, by bringing a heated jig into contact with the portion to be heated (heating portion). Also, the heating may be performed, for example, by irradiating the heating portion with a laser. Also, the heating may be performed, for example, by so-called induction heating in which a high-frequency electromagnetic wave is irradiated to the heating portion.

[0052] (Step S130) After step S120, a joining member is joined to the laminate. The joining of the laminate and the joining member is performed by interference fitting. The interference fitting may be, for example, shrink fitting or expansion fitting. Also, the joining member may be press-fitted into the through-hole of the laminate.

[0053] <Second Embodiment> The magnetic material according to the second embodiment will be described. In the magnetic member according to the second embodiment, the joining member is a cylindrical member, and the magnetic material in the laminate is joined to the joining member by interference fitting between the outer surface of the magnetic material and the joining member.

[0054] Figure 5 is a perspective view of a magnetic member 2, which is an example of a magnetic member according to the second embodiment. Figure 6 is a plan view of the magnetic material 21 in the magnetic member 2, which is an example of a magnetic member according to the second embodiment, as seen from the plate thickness direction.

[0055] The magnetic member 2 comprises a laminate 20 in which multiple plate-shaped magnetic materials 21 are stacked. Each of the multiple magnetic materials 21 is joined to a joining member JM2. The multiple magnetic materials 21 and the joining member JM2 are joined by an interference fit.

[0056] The laminate 20 in the magnetic member 2 comprises a plurality of magnetic materials 21. The number of magnetic materials in the laminate in the magnetic member according to the second embodiment is not limited to the example of the laminate 20.

[0057] Regarding the materials of magnetic material 21, please refer to the explanation of magnetic material 11, and the explanation will be omitted here.

[0058] In Figure 6, the region H2 of the magnetic material 21 is heated to a temperature above its crystallization temperature so that it includes the bonding region R2 outside the magnetic material 21 to which the bonding member JM2 is to be bonded.

[0059] As explained with reference to Figure 3, the laminate 20 may be formed after heat treatment has been performed on multiple magnetic materials 21, or, as explained with reference to Figure 4, the laminate 20 may be formed using multiple magnetic materials 21 and then heat treatment may be performed. When the laminate 20 is formed using multiple magnetic materials 21 and then heat treatment is performed, for example, the joining member JM2 is heated and the heat treatment of region H2 is performed using the heated joining member JM2, thereby enabling simultaneous heat treatment and shrink fitting.

[0060] According to the magnetic members of the first and second embodiments, by heat-treating the magnetic material so that the hardness of the magnetic material in the bonding region exceeds the crystallization temperature, the hardness of the magnetic material in the bonding region can be reduced and its malleability or ductility can be increased. By reducing the hardness of the magnetic material and increasing its malleability or ductility in the bonding region, the fracture or damage of the magnetic material can be suppressed when bonding with the bonding member. If the magnetic material is an amorphous soft magnetic material, by reducing the hardness of the magnetic material and increasing its malleability or ductility in the bonding region, the fracture or damage of the bonding member can be suppressed when bonding with the bonding member.

[0061] <Third Embodiment> Next, a compressor will be described as a specific example of equipment in which the magnetic member of the present disclosure is used. Figures 7 to 9 are partial cross-sectional views of a compressor 101, which is an example of a compressor in which the magnetic member of the present disclosure is used. Figure 7 is a cross-sectional view showing a cross section along the drive shaft 112 of the compressor 101, and Figure 8 is a cross-sectional view showing a cross section of the cylinder 221 portion of the compressor 101 along a direction perpendicular to the drive shaft 112. Figure 9 is a cross-sectional view showing a cross section of the rotating electric machine 203 portion of the compressor 101 along a direction perpendicular to the drive shaft 112.

[0062] <Compressor 101> Compressor 101 is a vertical, high-pressure, dome-type rotary compressor. Compressor 101 draws in a refrigerant, such as carbon dioxide, a fluorocarbon refrigerant, a hydrofluoroolefin refrigerant, or a hydrocarbon refrigerant. Compressor 101 then compresses the drawn-in refrigerant and discharges it.

[0063] The compressor 101 includes a sealed container 201. The compressor 101 includes a compression mechanism 202 and a rotating electric machine 203 located inside the sealed container 201. The compression mechanism 202 is driven by the rotating electric machine 203. The compressor 101 includes an accumulator 110. In the compressor 101, the refrigerant is drawn in through the accumulator 110 from the suction pipe 111. The refrigerant drawn in from the suction pipe 111 is compressed by the compression mechanism 202. The refrigerant compressed by the compression mechanism 202 is discharged from the discharge pipe 113.

[0064] [Compression mechanism 202] The compression mechanism 202 comprises a muffler 240, a bearing 250, a cylinder 221, and a bearing 260. The bearing 250, cylinder 221, and bearing 260 are arranged in order from top to bottom of the paper. The compression mechanism 202 has a cylinder chamber 222 surrounded by the bearing 250, cylinder 221, and bearing 260. The compression mechanism 202 is equipped with a roller 227 in the cylinder chamber 222.

[0065] The bearing 250 comprises a main body portion 251 and a main bearing portion 252. The main body portion 251 has a disc shape. The drive shaft 112 passes through the center of the main body portion 251. The main bearing portion 252 has a cylindrical shape. The main bearing portion 252 extends upward from the main body portion 251. The main bearing portion 252 rotatably supports the drive shaft 112. The main bearing portion 252 constitutes a radial bearing. The main body portion 251 has a discharge hole 251a that penetrates vertically and connects to the cylinder chamber 222. The bearing 250 is provided with a discharge valve 231 on the upper side of the main body portion 251 (opposite the cylinder chamber 222) that opens and closes the discharge hole 251a. The discharge valve 231 is, for example, a reed valve.

[0066] The muffler 240 is located on the side of the main body 251 of the bearing 250 opposite to the cylinder 221. The muffler 240 covers the discharge valve 231. The muffler 240 has a cup-shaped form. The muffler 240 is fixed by bolts 235. A muffler chamber 242 is formed between the main body 251 of the bearing 250 and the muffler 240. The muffler chamber 242 is connected to the cylinder chamber 222 via the discharge hole 251a. The muffler 240 has an opening 243 that leads upward from the muffler chamber 242.

[0067] The cylinder 221 has a plate-like shape. The cylinder 221 has a cylinder opening in the center. A roller 227 is arranged inside the cylinder 221 to rotate eccentrically. A blade 228 is integrally formed on the roller 227. The blade 228 divides the cylinder chamber 222 into a low-pressure chamber 222a and a high-pressure chamber 222b. The blade 228 is held in close contact by a pair of bushings 225.

[0068] Low-pressure refrigerant is supplied to the low-pressure chamber 222a from the suction pipe 111. The high-pressure refrigerant, compressed in the high-pressure chamber 222b, is discharged from the discharge port 251a.

[0069] The bearing 260 comprises a main body 261 and a sub-bearing portion 262. The main body 261 has a disc-like shape. The drive shaft 112 passes through the center of the main body 261. The sub-bearing portion 262 has a cylindrical shape. The sub-bearing portion 262 extends downward from the main body 261. The sub-bearing portion 262 rotatably supports the drive shaft 112. The sub-bearing portion 262 constitutes a radial bearing.

[0070] [Rotating Electrical Machine 203] The rotating electrical machine 203 comprises a stator 205 and a rotor 206. The rotor 206 is positioned inside the stator 205 at a distance from it. The rotating electrical machine 203 is a 6-pole, 9-slot motor. The number of poles and slots are not limited to the above example and may be selected as appropriate.

[0071] The stator 205 comprises a stator core 510, a coil 520, and an insulator 530.

[0072] The stator core 510 is composed of a laminate in which multiple plate-shaped magnetic materials 510i, which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials, are stacked. The stator core 510 comprises an annular portion 511 and a plurality of tooth portions 512. The tooth portions 512 are provided projecting radially inward from the inner surface of the annular portion 511. The tooth portions 512 are arranged at equal intervals along the circumferential direction. The stator 205, for example, comprises nine tooth portions 512.

[0073] The stator core 510 is joined to the sealed container 201 by an interlocking fit. By joining the stator core 510 to the sealed container 201 by an interlocking fit, the stator 205 is fixed to the sealed container 201.

[0074] The coil 520 is wound around each of the multiple teeth 512 in the stator core 510.

[0075] The insulator 530 is provided on the upper and lower sides of the stator core 510. The insulator 530 is provided between the stator core 510 and the coil 520. The insulator 530 insulates the stator core 510 from the coil 520. The insulator 530 is formed of, for example, resin.

[0076] The rotor 206 comprises a rotor core 610 and a plurality of magnets 620. Each of the plurality of magnets 620 is embedded in the rotor core 610. The rotor 206 comprises, for example, six magnets 620.

[0077] The rotor core 610 is composed of a laminate of multiple plate-shaped magnetic materials 610i, which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials. The rotor core 610 has a cylindrical shape. A drive shaft 112 passes through the center of the rotor core 610. The drive shaft 112 is joined to the rotor core 610 by an interference fit.

[0078] The magnet 620 has a flat plate shape. The magnet 620 is a permanent magnet. The magnet 620 is, for example, a rare earth magnet such as a neodymium magnet or a ferrite magnet. The magnet 620 is, for example, a bonded magnet formed by molding magnetic powder with an organic or inorganic binder.

[0079] The stator core 510 is joined to the sealed container 201 by a press-fit. Figure 10 is a diagram illustrating a first example of heat treatment in the rotating electric machine 203 portion of a compressor 101, which is an example of a compressor using a magnetic member according to the third embodiment. In the stator core 510, a heat treatment process is performed in which region H11 in Figure 10 is heated to a temperature above the crystallization temperature. Region H11 includes the region in contact with the sealed container 201. By heating region H11 to a temperature above the crystallization temperature, the hardness of the magnetic material in the region in contact with the sealed container 201 can be reduced, thereby increasing its malleability or ductility.

[0080] Furthermore, the rotor core 610 is joined to the drive shaft 112 by an interference fit. In the rotor core 610, a heat treatment process is performed in which region H12 in Figure 10 is heated to a temperature above the crystallization temperature. By heating region H12 to a temperature above the crystallization temperature, the hardness of the magnetic material in the stator core 510 can be reduced and its malleability or ductility increased in the region that comes into contact with the drive shaft 112.

[0081] In both the stator core 510 and the rotor core 610, heating the interlocking joint area above its crystallization temperature can suppress the destruction or damage of the magnetic material when joining it to the joining member. If the magnetic material is an amorphous soft magnetic material, heating the interlocking joint area above its crystallization temperature in both the stator core 510 and the rotor core 610 can suppress the destruction or damage of the joining member when joining it to the joining member.

[0082] Next, we will describe the case in which the stator core 510 is joined to the sealed container 201 by welding such as arc welding (plug welding). Figure 11 is a diagram illustrating a second example of heat treatment in the rotating electric machine 203 portion of a compressor 101, which is an example of a compressor in which a magnetic member according to the third embodiment is used.

[0083] When arc welding (plug welding) the sealed container 201 and the stator core 510 in region B21, the region H21 of the stator core 510 to be joined by arc welding is heat-treated to a temperature above the crystallization temperature.

[0084] When arc welding is performed, compressive stress is applied radially inward to the stator core 510 when the arc welding electrode is pressed against the stator core 510. Therefore, by increasing the proportion of crystals in the area of ​​the stator core 510 where arc welding is performed, the fracture or damage of the stator core 510 due to compressive stress can be suppressed.

[0085] As shown in Figures 12 to 15, the shape of the stator core in the portion that is joined to the sealed container 201 by welding may be changed as appropriate.

[0086] As shown in Figure 12, in the stator core 510A, a protrusion 511a may be formed that protrudes radially outward from the annular portion 511A, and this protrusion 511a may be designated as a heating region H21A. Also, as shown in Figure 13, in the stator core 510B, a protrusion 511b with an opening that protrudes radially outward from the annular portion 511B may be formed, and this protrusion 511b may be designated as a heating region H21B. Furthermore, as shown in Figure 14, in the stator core 510C, a protrusion 511c may be formed that protrudes radially outward from the annular portion 511C and extends to both sides in the circumferential direction, and this protrusion 511c may be designated as a heating region H21C. Also, as shown in Figure 15, in the stator core 510D, a protrusion 511d may be formed that protrudes radially outward from the annular portion 511D and extends to one side in the circumferential direction, and this protrusion 511d may be designated as a heating region H21D.

[0087] <Fourth Embodiment> The stator core may also be formed in sections. As shown in Figure 16, the stator core 710 may be formed from a plurality of sectioned cores 710u. The plurality of sectioned cores 710u are joined together by a joining member 716. Figure 17A shows a cross-section of the sectioned cores 710u joined together by the joining member 716. The sectioned cores 710u are made up of alternating layers of magnetic material 713i and magnetic material 714i. Each of the magnetic material 713i and magnetic material 714i is either an amorphous soft magnetic material or a nanocrystalline soft magnetic material.

[0088] The divided cores 710u are joined together by fastening the joining member 716 into through holes formed in the magnetic material 713i and magnetic material 714i, respectively. In the joining region where the joining member 716 is joined in the magnetic material 713i and magnetic material 714i, region H31 in Figure 17A is heated to a temperature above the crystallization temperature. Region H31 includes the joining region.

[0089] The divided core 710u is joined by a joining member 716. The divided core 710u also rotates around the joining member 716. When the divided core 710u rotates, the areas around the through-hole into which the joining member 716 is fitted slide between the magnetic materials 713i and 714i. When the divided core 710u rotates, the wall surface of the through-hole slides against the joining member 716 in either the magnetic material 713i or the magnetic material 714i. In the sliding region of each of the magnetic materials 713i and 714i that slides when the divided core 710u rotates, region H31 in Figure 17A is heated to a temperature above the crystallization temperature. Region H31 includes the sliding region. Therefore, in the joining region and the sliding region where the magnetic materials 713i and 714i are joined, the ratio of crystals per unit volume of the magnetic material is high. Therefore, the fracture or damage of the magnetic material can be suppressed in the bonding region during joining and in the sliding region during sliding. When the magnetic material is an amorphous soft magnetic material, the fracture or damage of the bonding material can be suppressed in the bonding region during joining and in the sliding region during sliding.

[0090] Furthermore, as shown in Figure 17B, the magnetic material 715i may be fitted in a gap with the joining member 716. When the magnetic material 715i is fitted in a gap with the joining member 716, the magnetic material 715i does not need to be heat-treated, as shown in region H32 of Figure 17B.

[0091] The divided core 710u may be joined by fitting the recess and the protrusion together. The recess and the protrusion may be joined, for example, by dowel crimping. Figure 18A shows an example in which the divided core 710u is joined by crimping. The divided core 710u is made up of alternating layers of magnetic material 717i and magnetic material 718i. The divided core 710u is joined by the crimping portion 719. In the first modified example, the joining member is a single divided core 710u. In the divided core 710u, the region H33 including the joining region where the recess and the protrusion are fitted together and the sliding region where it slides when rotated around the joining region is heated. When the magnetic material is an amorphous soft magnetic material, the destruction or damage of the joining material can be suppressed in the joining region during joining and in the sliding region during sliding.

[0092] Furthermore, as shown in Figure 18B, the crimped portion 720 may be constructed by smoothly bending the concave and convex portions. Smooth bending means, for example, that the curvature of the bent portion is less than or equal to a predetermined value. Smooth bending also means, for example, that the cross-section of the bent portion is free of folds or sharp points. In the second modified example, the joining member is a single divided core 710u.

[0093] <Fifth Embodiment> As shown in Figure 19, the stator core 810 may be formed by a plurality of segmented cores 810u joined by fitting. As shown in Figure 20, the plurality of segmented cores 810u have a protrusion 810a and a recess 810b at the boundary between adjacent segmented cores 810u. The segmented cores 810u are joined by fitting the protrusion 810a and the recess 810b together. In the fifth embodiment, the joining member is a single segmented core 810u. As shown in Figure 20 as regions H41 and H42, damage to the protrusion 810a and recess 810b can be suppressed by performing heat treatment on each of the fitting protrusions 810a and recess 810b. The protrusion 810a and recess 810b are examples of fitting portions.

[0094] In the example above, both the convex portion 810a and the concave portion 810b are heat-treated, but heat treatment may be applied to only one of the convex portion 810a or the concave portion 810b.

[0095] <Sixth Embodiment> As shown in Figure 21, the stator core 910 may be formed by a plurality of divided cores 910u joined by combining portions having cylindrical surfaces. As shown in Figure 22, the plurality of divided cores 910u have convex portions 910a and 910b having convex cylindrical surfaces, and concave portions 910c and 910d having concave cylindrical surfaces at the boundary between adjacent divided cores 910u. The divided cores 910u are joined by the fitting of the convex portion 910a and the concave portion 910d or the fitting of the convex portion 910b and the concave portion 910c. The joining member in the sixth embodiment is a single divided core 910u. As shown in Figure 22 as regions H51 and H52, by performing heat treatment on each of the fitting protrusions 910a, 910b, recess 910c, and recess 910d, the destruction or damage of the protrusions 910a, 910b, recess 910c, and recess 910d can be suppressed.

[0096] In the above example, heat treatment is performed on the protrusions 910a, 910b, recesses 910c and 910d. However, heat treatment may be performed only on the protrusions 910a and 910c, or only on the protrusions 910b and 910d. Alternatively, heat treatment may be performed on only one of the protrusions 910a, 910b, 910c and 910d.

[0097] As shown in Figure 23, the stator core 940 may be formed by a plurality of segmented cores 940u joined together by combining portions having cylindrical surfaces. As shown in Figure 24, the plurality of segmented cores 940u have convex portions 940a and 940b having a convex cylindrical surface, and concave portions 940c and 940d having a concave cylindrical surface at the boundary between adjacent segmented cores 940u. The segmented cores 940u are joined by the fitting of the convex portion 940a and the concave portion 940d, or the fitting of the convex portion 940b and the concave portion 940c. As shown in Figure 24 as regions H61 and H62, by performing heat treatment on each of the fitting convex portions 940a, 940b, 940c and 940d, the destruction or damage of the convex portions 940a, 940b, 940c and 940d can be suppressed.

[0098] The divided core 940u has inner circumferential portions 940e and 940f that have not undergone heat treatment on the inside. By having inner circumferential portions 940e and 940f, deterioration of the magnetic properties in the stator core 940 can be suppressed.

[0099] <Seventh Embodiment> As shown in Figure 25, in the divided core 950u, when the outermost magnetic material is bent and fitted into the groove, the region H71 fitted into the groove may be heat-treated. The joining member in the seventh embodiment is a magnetic member with a groove formed therein. There may be friction at the part fitted into the groove, but damage to the magnetic material in the event of friction can be suppressed.

[0100] <Eighth Embodiment> As shown in Figure 26, the rotor core 630 may be joined by a key 114 provided on the drive shaft 112A. In the eighth embodiment, the joining member is the key 114. The rotor core 630 is made up of laminated magnetic material 630i. The magnetic material 630i has a recess 631. The recess 631 becomes a keyway that engages with the key 114. By heat-treating the area H81 around the recess 631, it is possible to suppress the destruction or damage of the magnetic material 630i of the rotor core 630.

[0101] <Ninth Embodiment> The magnetic member of this disclosure is used, for example, in the stator core or rotor core of a rotating electric machine such as a motor or a generator. The rotating electric machine using the magnetic member of this disclosure can also be used as a compressor in combination with a compression mechanism driven by the rotating electric machine, for example. An example of the use of a rotating electric machine using the magnetic member of this disclosure is shown.

[0102] This section describes a refrigeration system that uses a rotating electric machine employing the magnetic member of the present disclosure. Figure 27 illustrates an example of the use of a rotating electric machine employing the magnetic member according to the ninth embodiment.

[0103] The refrigeration system 100 includes a compressor 101, a four-way valve 102, a heat exchanger 103, an expansion valve 104, and a heat exchanger 105. The refrigeration system 100 is, for example, an air conditioner (a cooling-only unit, a heating-only unit, or a cooling and heating unit that switches between cooling and heating), a water heater, a chiller unit, or a cooling device for cooling the air inside a storage area (cooling the air inside a refrigerator, freezer, display case, container, etc.).

[0104] First, we will explain the case where the refrigeration system 100 is cooled by the heat exchanger 105. Figure 27 shows the connections when the refrigeration system 100 is cooled by the heat exchanger 105.

[0105] The refrigerant compressed by the compressor 101 is supplied to the heat exchanger 103 through the four-way valve 102. In the heat exchanger 103, the refrigerant supplied to the heat exchanger 103 is cooled by heat exchange with air or the like. A blower 103b, consisting of a motor 103m to which a fan 103f is attached, blows air to the heat exchanger 103. The fan 103f is, for example, a propeller fan, turbo fan, sirocco fan, or cross-flow fan. The motor 103m may have the same configuration as the rotating electric machine 203. The refrigerant cooled by the heat exchanger 103 condenses and liquefies, and is supplied to the expansion valve 104. The refrigerant is depressurized by the expansion valve 104. The depressurized refrigerant is supplied to the heat exchanger 105. In the heat exchanger 105, the refrigerant evaporates and vaporizes. The blower 105b, which consists of a motor 105m to which a fan 105f is attached, blows air to the heat exchanger 105. The motor 105m may have the same configuration as the rotating electric machine 203. The refrigerant discharged from the heat exchanger 105 is then returned to the compressor 101 and compressed again. In the heat exchanger 105, the refrigeration system 100 cools the object by the heat of vaporization caused by the evaporation of the refrigerant.

[0106] Next, we will explain the case where the refrigeration system 100 is heated by the heat exchanger 105. The refrigerant compressed by the compressor 101 is supplied to the heat exchanger 105 through the four-way valve 102. In the heat exchanger 105, the refrigeration system 100 heats the object by supplying the compressed, high-temperature refrigerant. The refrigerant that has undergone heat exchange in the heat exchanger 105 condenses and liquefies, and is supplied to the expansion valve 104. The refrigerant is depressurized by the expansion valve 104. The depressurized refrigerant is supplied to the heat exchanger 103. In the heat exchanger 103, the refrigerant evaporates and vaporizes by exchanging heat with air or the like. The refrigerant discharged from the heat exchanger 103 then passes through the four-way valve 102 and returns to the compressor 101 to be compressed again.

[0107] While embodiments have been described above, it will be understood that various modifications to the form and details are possible without departing from the spirit and scope of the claims. Various modifications and improvements are possible, such as combinations or substitutions with some or all of other embodiments.

[0108] This application claims priority to Basic Patent Application No. 2024-168409, filed with the Japan Patent Office on September 27, 2024, the entire contents of which are incorporated herein by reference.

[0109] 1, 2 Magnetic members 10, 20 Laminates 11, 21 Magnetic material 12 Through hole 100 Refrigeration device 101 Compressor 103f, 105f Fan 103m, 105m Motor 203 Rotating electric machine 205 Stator 206 Rotor 510 Stator core 511 Annular part 512 Teeth part 520 Coil 530 Insulator 610 Rotor core 620 Magnet JM1, JM2 Joining members R1, R2 Joining area

Claims

1. A magnetic member (1, 2) comprising a laminate (10, 20) formed by stacking multiple plate-shaped magnetic materials (11, 21) which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials, wherein the magnetic materials (11, 21) are bonded to bonding members (JM1, JM2), the magnetic materials (11, 21) have bonding regions bonded to the bonding members (JM1, JM2), and the ratio of crystals per unit volume of the bonding region of the magnetic materials (11, 21) is greater than the ratio of crystals per unit volume of the magnetic materials (11, 21).

2. The magnetic members (1, 2) according to claim 1, wherein the magnetic materials (11, 21) are joined to the joining members (JM1, JM2) by interference fit.

3. The magnetic material (630i) has a fitting portion (631) consisting of a recess or a protrusion, and the magnetic material (630i) is joined by the joining member (114) fitting into the fitting portion (631), as described in claim 1.

4. The magnetic material (713i, 714i) is joined to the joining member (716) so that the magnetic material (713i, 714i) and the joining member (716) can slide against each other, and when the region in which the magnetic material (713i, 714i) contacts the joining member (713i, 714i) during sliding is defined as the sliding region, the ratio of crystals per unit volume of the magnetic material (713i, 714i) in the sliding region is greater than the ratio of crystals per unit volume of the magnetic material (713i, 714i), as described in claim 1.

5. A rotating electric machine (203, 103m, 105m) comprising a magnetic member according to any one of claims 1 to 4, wherein the magnetic member is a stator core or a rotor core.

6. A compressor (101) comprising a rotating electric machine (203) as described in claim 5, and a compression mechanism (202) driven by the rotating electric machine (203).

7. A blower (103b, 105b) comprising a rotating electric machine (103m, 105m) as described in claim 5, and fans (103f, 105f) driven by the rotating electric machine.

8. A refrigeration apparatus (100) comprising the rotating electric machine (203) described in claim 5.

9. A method for manufacturing a magnetic member, comprising a laminate (10, 20) in which a plurality of plate-shaped magnetic materials (11, 21) which are amorphous soft magnetic materials or nanocrystalline soft magnetic materials are stacked, the method comprising: a first step of heating a portion of the magnetic materials (11, 21) to a temperature above the crystallization temperature of the magnetic materials (11, 21); and a second step, after the first step, of joining the magnetic materials (11, 21) and joining members (JM1, JM2) in the portion of the magnetic material.

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