Bond magnet and method for manufacturing the same

Patent metadata

Field	Value
Publication number	US-10232538-B2
Application number	US-201615131029-A
Country	US
Kind code	B2
Filing date	Apr 18, 2016
Priority date	Apr 20, 2015
Publication date	Mar 19, 2019
Grant date	Mar 19, 2019

Abstract

A method for manufacturing a bond magnet includes providing a bond magnet composition including a magnetic material and a resin, extruding the bond magnet composition in one direction to produce a molded body while orienting the magnetic material in the one direction, magnetizing the molded body in the one direction using an axial magnetization to produce a magnetized molded body, and laminating the magnetized molded body to produce a laminated molded body including first magnetized molded layers and second magnetized molded layers. The first magnetized molded layers and the second magnetized molded layers are alternately laminated. A first magnetization direction of each of the first magnetized molded layers is opposite to a second magnetization direction of each of the second magnetized molded layers.

First claim

What is claimed is:

1. A method for manufacturing a bond magnet, the method comprising:
providing a bond magnet composition including a magnetic material and a resin;
extruding the bond magnet composition in one direction to produce a molded body while orienting the magnetic material in the one direction;
magnetizing the molded body in the one direction using an axial magnetization to produce a magnetized molded body; and
laminating the magnetized molded body to produce a laminated molded body including first magnetized molded layers and second magnetized molded layers, the first magnetized molded layers and the second magnetized molded layers being alternately laminated, and a first magnetization direction of each of the first magnetized molded layers being opposite to a second magnetization direction of each of the second magnetized molded layers.

2. The method according to claim 1 , wherein the molded body formed by extruding has a thickness of 1 mm or less.

3. The method according to claim 1 , wherein an average particle diameter of the magnetic material is 10% or less of a thickness of the molded body.

4. The method according to claim 1 , wherein the magnetic material comprises an Sm—Fe—N based magnetic material.

5. The method according to claim 1 , further comprising:
cutting the laminated molded body along a plane including a laminating direction of the laminated molded body to produce the bond magnet including N-poles and S-poles which are arranged alternately on a cutting face of the laminated molded body.

6. A bond magnet comprising:
a plurality of magnet pieces magnetized by axial magnetization and laminated such that N-poles and S-poles of the plurality of magnet pieces are alternately arranged, the plurality of magnet pieces comprising:
an anisotropic Sm—Fe—N-based magnetic material; and
a resin; and

a distance λ between an N-pole among the N-poles and an S-pole adjacent to the N-pole among the S-poles is equal to or more than 0.1 mm and equal to or less than 1.0 mm.

7. The bond magnet according to claim 6 , wherein an orientation rate of the magnetic material of the plurality of magnet pieces is 85% or more.

8. The bond magnet according to claim 6 , wherein a magnetization rate of the plurality of magnet pieces is 95% or more.

9. The bond magnet according to claim 6 , wherein a surface magnetic flux density B (gauss) at a position away from the bond magnet by λ/2 satisfies a following expression (1):
B (gauss)>1520λ−20   (1)

10. A method for manufacturing a bond magnet, the method comprising:
providing a bond magnet composition including a magnetic material and a resin;
extruding the bond magnet composition in one direction to produce a molded body;
orienting the magnetic material in the one direction;
magnetizing the molded body in the one direction using an axial magnetization to produce a magnetized molded body; and
laminating the magnetized molded body to produce a laminated molded body including a first magnetized molded layer and a second magnetized molded layer adjacent to the first magnetized molded layer such that a first magnetization direction of the first magnetized molded layer is opposite to a second magnetization direction of the second magnetized molded layer.

11. The method according to claim 10 , wherein extruding the bond magnet composition in the one direction while orienting the magnetic material in the one direction.

Assignees

• Nichia Corp

Inventors

• Ihara Kohei
• Kume Michiya

Classifications

• B29C47/0076 Primary

  Operations & Transport · mapped topic

• B29C47/0021

  Operations & Transport · mapped topic

• B29C47/0066

  Operations & Transport · mapped topic

• B29C47/92

  Operations & Transport · mapped topic

• B29C47/40

  Operations & Transport · mapped topic