RADIAL ANISOTROPIC CYLINDER TYPE FERRITE MAGNETS AND THEIR MANUFACTURING METHODS AND MOTORS

Abstract: This invention concerns the high performance radial anisotropic cylinder shape ferrite magnet and its manufacturing method, in which improving the performance of the radial anisotropic cylinder shape ferrite magnet to be able to use the powder composition which will bring about the high magnetic performance in a uniform body and without cracking when sintering. Also, the invention intends to provide motor with the efficient assembly, lowering the noise, and the accomplishment of miniaturization. Considering the shrinkage due to sintering, apart of the circumference in the axial direction is eliminated by a predetermined width from the cylindrical molding and a slit is created and sintered. Thus, the internal stress due to shrinkage is relieved through a slit, and when a slit closes after sintering it forms a uniform cylindrical sintered body. For example, after sintering, the out-of-roundness process is applied to the uniform radial anisotropic ferrite magnet, and it is pressure fastened to the inner circumference of the cylindrical yoke to comprise stator, and placing rotor in the space inside the said ferrite magnet to form the object motor. In comparison to the usual segment magnets, the magnet assembly is simplified, and the total magnetic flux increased, and provided the consideration is given to the magnetic pole position and the placement of the slit to the neutral magnetic position, the magnetic disturbance due to the slit is non existent.

Description: DESCRIPTION RADIAL ANISOTROPIC CYLINDER TYPE FERRITE MAGNETS AND THEIR MANUFACTURING METHODS AND MOTORS Technical Field This invention concerns the improvement of the Sr ferrite and Ba ferrite compositions that are used for motors, etc. and magnetic characteristics or radial inisotropic cylinder type ferrite magnets which consists of these compositions. Taking consideration of the shrinkage which takes after sintering magnets, the radial cross sectional shape is molded into the letter C and sintered to obtain the non-cracking cylinder. This invention further concerns the high performance radial anisotropic cylinder type ferrite magnets and their manufacturing methods and motors, which does not required to assemble the usual segment magnets and which enables us to efficiently manufacture motors. Background Art As the usual compositions of motors in which ferrite magnets are positioned in stators and rotors, the compositions such as Fig. 8, Fig. 9 and Fig. 10 are known. That is to say, the composition in Fig. 8 is an example of motor utilizing the cylindrical ferrite magnet 1 on the stator side. The magnet is fastened to the inner circumference of the cylindrical yoke 2, and rotor (not shown here) is placed in space 3 in the inner circumference side of the said magnet. Usually, for a motor with such composition the usage of the strong magnetic radial anisotropic ferrite magnet is difficult for the reasons explained later, and the isotropic cylinder type ferrite magnet 1 is utilized, as a relatively low output motor. The composition shown in Fig. 9 is an example of which a pair of segment magnets, 1a, and ab are used on the stator side. Each magnet is fastened to the inner circumference of the yoke 2, and rotor (not shown) is positioned in the opposing space 3 on the inner circumference side where the said magnetic pole system, but there are other motors which uses multiple segment magnets according to the number of magnetic poles. In such segment magnet, since it is possible to use the strong magnetic radial anisotropic ferrite magnet, it is used in the relatively high output motors. The composition shown in Fig. 10 is an example in which a pair of segment magnets 1c and 1d are used on the rotor side. Each magnet is fastened to the outer circumference of the magnet support 5 and positioned within stator (not shown) of the specified shape to configure a motor. Segment magnets 1c and 1d as in ferrite magnets shown in Fig.9, since it can utilize the strong magnetic radial anisotropic ferrite magnets, it is used for relatively high output motors. However, recently even forthe high output motors, from the point of view of the simplified assembly (making the assembly operation more efficient) and the cogging preventions, it has been sought to find the motor composition which positions radial anisotropic cylinder type ferrite magnets which have equivalent or better magnetic properties than the above stated radial anisotropic ferrite magnets. As a method of manufacturing such radial anisotropic cylinder type ferrite magnets, raw material powder such as Sr ferrite pulverized powder and Ba ferrite pulverized powder with the average particle size of less than 2 micro meter are molded into a cylindrical form using the dry method underthe magnetic field and sintered can be considered. Since the shrinkage factors for the circumferential and radial direction differs in sintering, internal stress accumulates to cause easy cracking, preventing the implementation of this method. To prevent cracking in the sintering process, it was proposed to use the mixture of 50 ~ 80 wt% Sr ferrite pulverized powder with the average particle size less than 2 micro meter and 50 ~ 20 wt% Ba ferrite isotropic granulated powderwith the particle size of 14 ~ 200 mesh in presence of the magnetic field and to mold it using the dry method (Patent Bulletin Hejsei 1-48643). However, the magnetic characteristic of radial anisotropic cylinder shape ferrite magnets industrially sintered utilizing this method had the upper limits of Br = 3.4kG, βHc = 2.9kG, and (BH)max = 2.6MGOe, and these were not enough to satisfy the recent demand of high performance. That is to say, unless radial anisotropic cylinder shape ferrite magnets with strong magnetic properties, which is indispensable to realization of sought after high power out-put motors, it was difficult to satisfy this demand. As explained above, for example, one body high performance radial anisotropic cylinder shape ferrite magnets consist of Sr ferrite were hard to manufacture, so that segment magnets which are generally less susceptible to cracking were manufactured from said compositions, and as shown in Fig. 9, a pair were positioned at opposing ends, or these magnets were assembled into a cylinder shape. Therefore, the utilization of multiple segment magnets not only complicated the assembly processes, but as shown in Fig.9 when a pair were positioned at opposing ends, a large space is created between magnets in circumferential directions. Also, when magnets were assembled in a cylindrical shape, many patches (connecting parts) were unavoidably made in the circumferential directions; thus, creating the problem of coggings in motors. Particularly, when these motors were used as wiper motors and fan motors, etc., noise associated with coggings generated; and it was necessary to consider the environmental impact for those who work close to said motors. As the other manufacturing method for radial anisotropic cylinder chape ferrite magnets for motors, a special molding die has been proposed (Patent Bulleten Heisei 4-19684). That is to say, in order to avoid cracking when sintered, to the rod of extrusion molding die or the mandrel of the rolling device, 2 or 3 pieces of sharp edged protrusions are placed radially. When the cylindrical molding is slided toward the axis to be released, inside the inner circumference the cross sectional V shaped 2 or 3 cuts which are extended axially are formed; and when sintered, and particularly in the cooling process, the internal stress is alt focused on these cuts to prevent micro crackings in other parts of the molding. However, the above stated method prevents complex cracking, and to make repair by adhesives easy, for example, to obtain above stated segment magnets by making cuts and crack magnets at predetermined places by focussing the internal stress. Therefore, this is not the method to obtain a uniform cylindrical shape ferrite magnet, and it does not solve problems of segment magnets and their assembly. This invention concerns the development of the high performance radial anisotropic cylinder shape ferrite magnets, and the objective is to be able to utilize the powder composition that has the strong magnetic properties; and to provide the high performance radial anisotropic ferrite magnets in one uniform body without having to assemble segment magnets and their manufacturing method. Also, this invention eliminates the problems mentioned above, it aims to provide motors that can make the assembly more efficient, and lower noise and the miniaturization possible. Disclosure of Invention Radial anisotropic cylinder shape ferrite magnets which consists this invented motor, by cutting work of the ferrite powder which contains Sr and/or Ba is being molded or after molded, a predetermined circumeferential part of the cylinder is eliminated to axialdimension to take into consideration of the shrinkage after sintering. The radial cross sectional shape of the molding is made into letter C and sintered, and as sintered or afterthe out of roundness processing, the uniform cylindrical magnet is obtained except slits as shown in Fig.2 ~ Fig.4. In this invention the object ferrite magnets are, as long as it has the ferrite composition which includes Sr or Ba, all magnets containing the ferrite composition regardless of its magnetic properties, and the manufacturing method of this invention can be applied. That is to say as the raw material powder, Sr ferrite pulverized powder with less than 2 micro meter average particle size and only Ba Ferrite pulverized powder can be used, and the mixture of these powder and Sr ferrite granulated powder which was difficult to manufacture without cracking using the conventional method (Patent Bulletin Heisei 1-48648) can also be used; furthermore, it is possible to use the raw material powder which contains other specified additives than Sr ferrite and Ba ferrite, and it is desirable to select according to desired molding dimensions and magnetic properties. In this invention, a slit means a through slit which is formed thoroughly in radial and axial directions and not a hollow. It means a slit which is made by removing a part of the circumferential of the cylinder shape molding and closed after sintering, but it is not limited to those slits that are totally closed prior to the said sintering and it can have a small space. The proposal is made actively to utilize these small space in the following examples. Also, it is not limited to those which form parallel to the radial direction or to the axial direction, but as it is shown in the actual example later, many shapes can be applied. According to the shapes, in addition to the effect due to a slit existence, other effects can also be attained. Furthermore, the radial anisotropic cylinder shape ferrite magnet with a slit, the molding of which must be made into the letter C prior to sintering. But, this can be accomplished by first making the molding die into required shape, or after it is molded into a cylindrical form, a slit with necessary width is made by the cutting work and grinding work. Whichever method is chosen, these slits are determined inconsideration of shrinkage after sintering. Since the shrinkage rate is determined by the ferrite compositions, the molding dimension, and the sintering condition, they must be determined carefully with each factors. Moreover, these moldings are not only limited to the dry molding method but the same effect can be obtained from the wet method. The sintering condition for the radial anisotropic cylinder shaped ferrite magnet used forthis invented motor is selected according to the above stated ferrite composition or the molding dimensions. It is recommended, particularly, that the internal stress due to the difference of shrinkage rate of cϊrcumferencial and radial direction in sintering can easily released through a slit made on the molding, so that the sintering condition and the shape of a jig must be carefully designed to accomplish it. Also, the sintering process alone produces a required cylinder shape, but to make it further into a cylinder shaped ferrite magnet with the specified inside and outside diameters, the out of roundness process is applied by the usual cutting and grinding work. This invention is characterized by preventing accumulation of the internal stress when sintering a cylinder shaped powder molding consisting of Sr and/or Ba ferrite, for example, by eliminating a circumferential section of the cylinder shaped molding axially along to make the cross sectional shape into the letter C, and sintering it. By making the shape of the molding into the letter C, the space in which to alleviate the internal stress due to differences int he shrinkage rate of circumferencial and radial direction is installed by a slit to release the stress. Thus, even using the raw material which has the strong magnetic properties, cracking will not result in sintering, the high performance radial anisotropic cylinder shape magnet can be easily obtained, and the high performance motor can be made by effectively positioning the said high performance radial anisotropic cylinder shape ferrite magnets. Brief Description of Drawings Fig. 1 is a stator plan of an example of this invented motor. Fig. 2 is a partially expanded plan of a slit in this invented radial anisotropic cylinder shape ferrite magnet. Fig. 3 is a partially expanded plan of a slit in this invented radial anisotropic cylinder shape ferrite magnet. Fig.4 is a partially expanded plan of a slit in this invented radial anisotropic cylinder shape ferrite magnet. Fig. 5 is a partially expanded plan which shows the connection of magnet and yoke which consists stator in this invented motor. Fig. 6 is a plan which shows the composition to illustrate the mechanical strength of magnet which comprises stator in this invented motor. Fig.7 is an another example plan of this invention, which shows only the rotor composition of the motor. Fig. 8 is a plan which shows a part of stator of motor using the usual ferrite magnets. Fig. 9 is a plan which shows a part of stator of motor using the usual ferrite magnets. Fig. 10 is a plan which shows a part of rotor of the motor composition using the ferrite magnet. Best Mode for Carrying Out the Invention Example 1 Using 100% pulverized powder of Sr ferrite with the average particle size of less than 2 micro meter, in order to manufacture a cylinder shaped ferrite magnetwith the dimension of 50mm (outer radius) x 40mm (inner radius) x 20mm (thickness), two groups of moldings with the identical dimension were made. One group was sintered as usual, while a circumferential section from the other molding group was eliminated to make a cross sectional letter C and sintered using the invented manufacturing method. Two types of the radial anisotropic cylinder shape ferrite magnets were manufactured. Magnets obtained from the same molding condition (molding pressure 1ton/cm2) and the sintering condition (1200°C x 1 hour) both had the magnetic characteristics of Br = 3.8kG, βHc = 3.05kG, and (BH) ax = 3.3MGOe. As far as the rate of cracking, while the usual method produced cracking in all, this invented method produced none. Example 2 Using 100% pulverized powder of Ba ferrite with the average particle size of less than 2 micro meter, in order to manufacture a cylinder shaped ferrite magnet with the dimension of 65mm (outer radius) X 50mm (inner radius) X 25mm (thickness), two groups of moldings with the identical dimension were made. As in Example 1, one group was sintered as usual, while the other group utilized the invented manufacturing method to obtain two types of the radial anisotropic cylinder shape ferrite magnets. Magnets obtained from the same molding condition (molding pressure 1ton/cm2) and the sintering condition (1200°C x 1 hour) both had the magnetic characteristics of Br = 3.6kG, βHc = 2.0kG, and (BH)max = 2.7MGOe. As far as the rate of cracking, while the usual method produced cracking in all, this invented method produced none. Example 3 Using the mixture of 50 — 80wt%, pulverized powder of Sr ferrite with the average particle size of less than 2 micro meter and 50 — 20wt% granulated Ba ferrite with 14 ~ 200 meshes, in order to 40mm (outer radius) x 32mm (inner radius) x 15mm (thickness), two groups of moldings with the identical dimensions were made. As in Example 1 , one group was sintered as usual, while the other group utilized the invented manufacturing method to obtain two types of the radial anisotropic cylinder shape ferrite magnets. Magnets obtained from the same molding condition (molding pressure 1ton/crrι2) and the sintering condition 1200°C x 1 hour) both had the magnetic characteristics of Br = 3.6kG, βHς = 2.95kG, and (BH)max = 2.75MGOe. As far as the rate of cracking, while this invented method produced none, the usual method produced cracking in all magnets. Example 4 In Fig. 1, 10 denotes ferrite magnet containing Sr which is made from the above manufacturing method, and except at a slit 11 it is a uniform radial anisotropic cylinder shape ferrite magnet. Here, the out of roundness process is administered after sintering, the magnet is pressure fastened to the inner circumference 2 of the cylinder shape yoke to comprise stator. Furthermore, by positioning rotor (not shown) in space 3 of the inner circumference of the said ferrite magnet 10, the object motor is obtained. The slit 11 which is formed on the radial anisotropic cylinder shape ferrite magnet 10, as shown in Fig. 2 is not limited to a slit 11a composition which is parallel to the radial or axial directions, but as shown in Fig. 3, a slit 11 b composition (the magnet thickness gradually changes in the axial direction) can be oblique to the axial direction, or as shown in Fig.4, a slit 11c composition (the magnet thickness gradually changes in the radial direction) which is oblique to the radial direction is possible. Particularly, in the compositions of Fig. 3 and Fig.4, it can moderate the magnetic disturbance from the existence of slit. In the composition of Fig. 3, since the mechanical strength improves against the axial force, when the said radial anisotropic cylinder shape ferrite magnet is pressure fastened to the inner circumference of the cylinder shape yoke 2, it can prevent damages. In Fig. 1 to Fig.4 the slits were shown magnified, in this invented motors whether slits are connected or disconnected as the figures the same effect can be obtained. Example 5 In Fig. 5 shows the same when a slit is not connected and how effectively it is used. If the protrusion 21 to determine the magnet position is made in the inner circumference of the cylinder shape yoke 2, it is possible to align a slit 11 to the protrusion 21, which results in improving assembly accuracy of the radial anisotropic cylinder shaped ferrite magnet 10 and the cylinder shaped yoke 2. If further improves accuracy of positioning other composition materials (not shown) which are positioned using the cylinder shaped yoke 2 as the reference and the radial anisotropic cylinder shape ferrite magnet 10, and which will also decrease the torque disturbance generation of motors. Also, when magnetizing the radial anisotropic cylinder shaped ferrite magnet 10 by itself before pressure fastened to the cylinder shaped yoke 2, or magnetizing it after it is pressure fastened to the cylinder shape yoke 2, as in the case of the protrusion 21 which is to help determine the position of the magnet, by making a protrusion to determine the magnet position in the magnetizer (not shown) and aligning itwith the slit 11, it is possible to increase accuracy in the magnetic polar positioning. Furthermore, the protrusion 21 formed on the inner circumference of the above mentioned cylinder shape yoke 2, which is to determine the position of magnet, can also prevent the circumferential movement after the radial anisotropic cylinder shaped ferrite magnet 10 is fastened by pressure of ■ adhesivesto the cylinder shaped yoke 2. When concerned about the mechanical strength of the radial anisotropic cylinder type ferrite magnet 10 due to the presence of a slit 11, after sintering, adhesives and other resins can be filled into the said slit 11 and hardened; or as shown in Fig. 6,a magnetic thin plate 12 with a specified thickness can be inserted; furthermore, the outer circumference of the magnet 10 is surrounded by a magneticthin plate 13. It is possible to make handling of the radial anisotropic cylinder shape ferrite magnet easy by utilizing such compositions. In any of the above compositions, even not applying special shapes such as in Fig. 3 and Fig.4 to the slit 11 formed on the radial anisotropic cylinder shape magnet 10, if it is placed at the neutral position of the magnetic field made by the said magnet 10 and give consideration to the resultant magnetic pole positions, the magnetic disturbance due to the slit 11 will not occur and does not interfere with motor characteristics. Example 6 Fig. 7 shows other example of this invention, particularly, it only displays the rotor composition of motor. That is to say in Fig.7, the magnet 10 consists of the ferrite composition with Sr which is manufactured according to the above method, and except at a slit 11 at the radial and axial directions, it is a uniform radial anisotropic cylinder shape ferrite magnet. Here, the out of roundness process is applied after sintering, and fastened to the outer circumference of the magnet support 5 to which a rotor axis 4 is fastened in the center. They are positioned inside stator (not shown) to comprise motor. In this composition, too, for the radial anisotropic cylinder shape ferrite magnet 10, the same technology used forthe above stator composition can be utilized. Especially, a protrusion (not shown) to determine the magnet position is formed on the outer circumference of the magnet support 5, by fastening the slit 11 along the protrusion, the circumferential fastening strength of the radial anisotropic cylinder shaped ferrite magnet 10 improves and prevent the movement in the rotor revolution. Example 7 The sintered body obtained in Example 1 was further processed by the out- of-roundness method to attain the desired dimension, and pressure fastening it to the cylinder shape yoke to obtain the invented motor shown in Fig. 1. Positioning the radial anisotropic segment ferrite magnets which is equivalent in the magnetic properties as in the above stated radial anisotropic cylinder shape ferrite magnet, and the dimension such as the outside diameter, inside diameter, and the height with the angle θ 135° as shown in Fig. 9 the usual motor was made and compared. This invented motor, in comparison to the conventional motor, reduced the cogging noise by about 50 — 60%, and the increase total magnetic flux resulted in the improvement of 15 — 20% torque revolution. Example 8 The sintered body obtained in Example 2 was further processed by the out- of-roundness method to attain the desired dimension, and pressure fastening it to the cylinder shape yoke to obtain the invented motor shown in Fig. 1. Positioning the radial anisotropic segment ferrite magnets which is equivalent in the magnetic properties as in the above stated radial anisotropic cylinder shape ferrite magnet, and the dimension such as the outside diameter, inside diameter, and the height with the angle 0 135° as shown in Fig.9 the usual motor was made and compared. This invented motor, in comparison to the conventional motor, reduced the cogging noise by about 60 ~ 70%, and the increase total magneticflux resulted in the improvement of 10 ~ 15% torque revolution. Industrial Applicability This invention, as it is obvious from examples mentioned above, enables the manufacturing of the high performance radial anisotropic cylinder shaped ferrite magnet, which hitherto could not be manufactured due to cracking in sintering. Also, the radial anisotropic cylinder shaped ferrite magnet according to this invention, as compared with using the usual ferrite compositions, it the cracking rate remarkable decreases while the magnet mechanical strength improves. ; This invented motor, as it is obvious from examples mentioned above, by positioning the high performance radial anisotropic cylinder shaped ferrite magnet which could not be produced to due to cracking, in comparison to the, high performance conventional cylinder shaped ferrite magnets which were assembled from segment magnets, its magnet assembly is simplified and can achieve the better efficiency in the motor assembly. Furthermore, it practically possesses the same magnetic field distribution as a uniform radial anisotropic cylinder shaped ferrite magnet, the cogging generation can be lowered and the noise due to coggings can be lowered. Furthermore, in comparison to segment magnets, since the total magnetic flux generated increased, if the same power out put is desired the minaturiztaion can be accomplished.

Claims: CLAIMS 1. A radial anisotropic cylinder shape ferrite magnet which is characterized by a ferrite composition which include Sr and/or Ba and used as sintered or processed by the out-of-roundness method after sintering to form a uniform cylinder except where a slit is formed. 2. The radial anisotropic cylinder shape ferrite magnet in Claim 1, which is characterized by a slit which is parallel to the radial and axial directions. 3. The radial anisotropic cylinder shape ferrite magnet in Claim 1, which is characterized by a slit which is oblique to the axial direction. 4. The radial anisotropic cylinder shape ferrite magnet in Claim 1, which is characterized by a slit which is oblique to the radial direction. 5. The radial anisotropic cylinder shape ferrite magnet in Claim 1, Claim 2, Claim 3, and Claim 4 which is characterized by a non-connected slit which is filled by resins or magnetic material. 6. The radial anisotropic cylinder shape ferrite magnet in Claim 1 , Claim 2, Claim 3, Claim 4 and Claim 5 which is characterized that the periphery being wrapped by a thin magnetic plate. 7. A method of producing for the radial anisotropic cylinder shape ferrite magnet which is characterized by obtaining a uniform cylinder shape magnet except at a slit after sintering it with or without applying the out-of-roundness method, which is created by cutting work of a powder molding consisting of a ferrite composition containing Sr and/or Ba when being molded or after molded, in which a circumferential section of the cylinder shaped molding is axially eliminated to compensate forthe shrinkage after sintering, and which makes the cross sectional shape into the letter C, and sintering it. 8. A motor which is characterized by positioning the radial anisotropic cylinder shape ferrite magnets, which consists of the ferrite composition including Sr and Ba, as sintered or after sintered and the out-of-roundness method is used, it has a uniform cylindrical form except at a slit and used for stator or rotor. 9. A motor in Claim 8 which is characterized by a protrusion for the determination of the magnet position which is formed in the inner circumference of the cylinder shaped yoke, and the non-connecting part of the radial anisotropic cylinder shape ferrite magnets are pressure fastened using the protrusion as a alignment tool. 10. A motor in Claim 8 which is characterized by filling the non-connecting slit with resins or magnetic material. 11. A motor in Claim 8 and Claim 10 which is characterized by being wrapped with a thin magnetic plate.

Inventors: HOSHIJIMA JUN, SAKAGUCHI TAKEHISA, SUNAGA TAKAHIRO, HOSHIJIMA, JUN, SAKAGUCHI, TAKEHISA, SUNAGA, TAKAHIRO
Applicants: SUMITOMO SPEC METALS, SUMITOMO SPECIAL METALS COMPANY LIMITED
Application year: 1993
Main classification: C04B35
IPC codes: C04B35, H02K1, H02K15