Patent Publication Number: US-7719395-B2

Title: Magnetizer and magnetizing method

Description:
CROSS REFERENCE TO RELATED APPLICATION 
   This application is based on and incorporates herein by reference Japanese Patent Application No. 2006-287238 filed on Oct. 23, 2006. 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to a magnetizer and a magnetizing method. 
   2. Description of Related Art 
   A magnetizing method for magnetizing a magnet using a magnetizing yoke is known (see, for example, Japanese Unexamined Patent Publication No. H10-248216 and Japanese Unexamined Patent Publication No. H10-232141). According to the magnetizing method recited in Japanese Unexamined Patent Publication No. H10-248216 and Japanese Unexamined Patent Publication No. H10-232141, a parallel magnetic field, which is parallel to a magnetization direction, is generated around an annular magnet using a magnetizing coil and a magnetizing yoke to form two magnetic poles of different polarities, which are opposed to each other in the magnetization direction of the annular magnet. However, at the time of magnetizing the magnet, a magnetic potential (magnetization) of the magnetizing yoke is higher than a magnetic potential (magnetization) of the magnet, so that the magnetic field is disturbed due to a difference between the magnetic potential of the magnetizing yoke and the magnetic potential of the magnet. Even in a case of a magnetizing method for magnetizing a magnet  530  shown in  FIG. 5  where a magnetizing yoke is not used, the above-described type of disturbance in the magnetic field occurs due to a difference between a magnetic potential of air and a magnetic potential of the magnet  530 . Therefore, even when the parallel magnetic field is generated by the magnetizing coil, some magnetic lines of force are not parallel to the magnetization direction at some locations, so that the magnet cannot be magnetized with a high accuracy in the magnetization direction. 
   SUMMARY OF THE INVENTION 
   The present invention addresses the above disadvantage. Thus, it is an objective of the present invention to provide a magnetizer and a magnetizing method for magnetizing a magnet in a magnetization direction with a relatively high accuracy. 
   To achieve the objective of the present invention, there is provided a magnetizer for magnetizing a magnet. The magnetizer includes a magnetic field generating means and a magnetizing yoke. The magnetic field generating means is for generating a magnetic field to magnetize the magnet in a magnetizing area. A direction of the magnetic field is generally parallel to a magnetization direction of the magnet in the magnetizing area. The magnetizing yoke holds the magnet and is made of a magnetic material, which exhibits a magnetic potential that is generally equal to a magnetic potential of the magnet in the magnetic field at time of magnetizing the magnet. The magnetizing yoke and the magnet substantially fill a projected area of the magnet in the magnetizing area on each of first and second sides of the magnet that are opposite from each other in the magnetization direction of the magnet in the magnetizing area. 
   To achieve the objective of the present invention, there is also provided another magnetizer for magnetizing a generally planar annular magnet. The magnetizer includes a magnetizing coil and a magnetizing yoke. The magnetizing coil generates a magnetic field upon energization thereof to magnetize the magnet in a magnetizing area. A direction of the magnetic field is generally parallel to a magnetization direction of the magnet in the magnetizing area. The magnetizing yoke holds the magnet and is made of a magnetic material, which exhibits a magnetic potential that is generally equal to a magnetic potential of the magnet in the magnetic field at time of magnetizing the magnet. The magnetizing yoke contacts both of an outer circumferential surface and an inner circumferential surface of the magnet. 
   To achieve the objective of the present invention, there is also provided a magnetizing method for creating magnetic poles in a magnet by placing the magnet in a magnetizing area, in which a direction of a magnetic field is generally parallel to a magnetization direction of the magnet. According to the method, first, the magnet is received in a magnetizing yoke made of a magnetic material, which exhibits a magnetic potential that is generally equal to a magnetic potential of the magnet in the magnetic field at time of magnetizing the magnet. Then, the magnetizing yoke is placed in the magnetizing area, so that the magnetizing yoke and the magnet substantially fill a projected area of the magnet in the magnetizing area on each of first and second sides of the magnet that are opposite from each other in the magnetization direction of the magnet in the magnetizing area. Thereafter, the magnetic field is applied to the magnet, which is received in the magnetizing yoke. 
   To achieve the objective of the present invention, there is also provided another magnetizing method for creating magnetic poles in a magnet by placing the magnet in a magnetizing area, in which a direction of a magnetic field is generally parallel to a magnetization direction of the magnet. According to the method, the magnet is received in a magnetizing yoke made of a magnetic material. Then, the magnetizing yoke is placed in the magnetizing area, so that the magnetizing yoke and the magnet substantially fill a projected area of the magnet in the magnetizing area on each of first and second sides of the magnet that are opposite from each other in the magnetization direction of the magnet in the magnetizing area. Thereafter, the magnetic field is applied to the magnet, which is received in the magnetizing yoke. A strength of the applied magnetic field makes a magnetic potential of the magnet and a magnetic potential of the magnetizing yoke to be generally the same. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention, together with additional objectives, features and advantages thereof, will be best understood from the following description, the appended claims and the accompanying drawings in which: 
       FIG. 1A  is a cross sectional view of a magnetizer according to a first embodiment of the present invention; 
       FIG. 1B  is a cross sectional view taken along line IB-IB in  FIG. 1A ; 
       FIG. 2A  is a cross sectional view similar to  FIG. 1B , showing a modification of the first embodiment; 
       FIG. 2B  is a cross sectional view similar to  FIG. 2A , showing another modification of the first embodiment; 
       FIG. 3A  is a cross sectional view of a magnetizer according to a second embodiment of the present invention; 
       FIG. 3B  is a cross sectional view taken along line IIIB-IIIB in  FIG. 3A ; 
       FIG. 4A  is a cross sectional view of a magnetizer according to a third embodiment of the present invention; 
       FIG. 4B  is a cross sectional view taken along line IVB-IVB in  FIG. 4A ; 
       FIG. 5  is a schematic diagram showing a magnetizing magnetic field according to a prior art magnetizing method. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Various embodiments of the present invention will be described with reference to the accompanying drawings. 
   First Embodiment 
   With reference to  FIGS. 1A and 1B , a magnetizer  1  according to a first embodiment of the present invention is used to magnetize an isotropic magnet (hereinafter, referred to as a magnet)  30 . The magnet  30 , which serves as a magnetizing subject, is, for example, a neodymium magnet. The magnet  30 , which is magnetized by the magnetizer  1 , is used as, for example, a magnetic rotor that generates a rotating magnetic field in a rotational angle sensing apparatus. In the following description, the neodymium magnet  30  of a generally planar annular shape will be described as the magnetizing subject. However, it should be noted that the shape and the material of the magnet are not limited to those of this particular magnet  30  and may be modified within a scope and spirit of the present invention. 
   The magnetizer  1  includes a magnetizing coil (serving as a magnetic field generating means)  10  and a magnetizing yoke  20 . 
   The magnetizing coil  10  is a hollow coil, which is wound into a cylindrical shape. The magnetizing coil  10  generates a parallel magnetic field that is generally parallel to a magnetization direction  52  of the magnet  30  in a magnetizing area  50  defined radially inward of the magnetizing coil  10 . In the following description, the magnetic field, which is created by the magnetizing coil  10 , will be simply referred to as a magnetic field. 
   The magnetizing yoke  20 , which is placed in the magnetizing area  50 , is made of a magnetic material, which exhibits a magnetic potential (magnetization) that is generally equal to a magnetic potential (magnetization) of the magnet  30  in the magnetic field at the time of magnetizing the magnet  30 . A receiver  20   a,  which receives the magnet  30 , is created in the magnetizing yoke  20 . A shape of the receiver  20   a  is a transcribed shape of the shape of the magnet  30 , i.e., the shape of the receiver  20   a  corresponds to the shape of the magnet  30 . The magnetizing yoke  20  is formed into a cylindrical shape, which is adapted to substantially fill the magnetizing area  50  together with the magnet  30  received in the magnetizing yoke  20 . Although not illustrated in the drawings for the sake of simplicity, the magnetizing yoke  20  may be separable into two halves, which may be divided along, for example, a plane that includes a top surface of the magnet  30  in  FIG. 1B . In such a case, the receiver  20   a  is created in the lower half of the magnetizing yoke  20  in  FIG. 1B . After, the magnet  30  is placed in the receiver  20   a  in the lower half of the magnetizing yoke  20 , the upper half of the magnetizing yoke  20  may be placed over the lower half of the magnetizing yoke  20 , so that the magnet  30  is entirely covered with the magnetizing yoke  20 . Alternatively, the magnetizing yoke  20  may be configured to be separable in a longitudinal direction (a top to bottom direction in  FIG. 1A ) of the magnetizing yoke  20  at, for example, a plane that extends along the line IB-IB in  FIG. 1A . Furthermore, the magnetizing yoke  20  may be configured in any other ways to receive the magnet  30  in the receiver  20   a.    
   (Manufacturing Method of Magnetizing Yoke) 
   Next, a manufacturing method of the magnetizing yoke  20  will be described. The magnetizing yoke  20 , the magnetic potential of which in the magnetizing magnetic field is generally the same as that of the magnet  30 , can be manufactured by the following three manufacturing methods. 
   (First Manufacturing Method) 
   First, the magnetic material, the magnetic potential of which in the magnetizing magnetic field is generally the same as that of the magnet  30 , is selected from magnetic materials, such as iron steel, soft ferrite. Then, the magnetizing yoke  20  is formed from the selected magnetic material. In this way, the magnetizing yoke  20 , the magnetic potential of which in the magnetizing magnetic field is generally the same as that of the magnet  30 , can be formed. 
   (Second Manufacturing Method) 
   Austenitic stainless steel, such as SUS304, is cold-worked to form the magnetizing yoke  20 , the magnetic potential of which in the magnetizing magnetic field is generally the same as that of the magnet  30 . Here, the magnetization characteristic of the austenitic stainless steel changes in response to a processing rate of the cold-working. Thus, by controlling the processing rate of the cold-working applied to the austenitic stainless steel, it is possible to form the magnetizing yoke  20 , the magnetic potential of which in the magnetizing magnetic field is generally the same as that of the magnet  30 . 
   (Third Manufacturing Method) 
   A composite material, which is a mixture of resin and magnetic powder, is injection molded to form the magnetizing yoke  20 . In such a case, the magnetization characteristic of the magnetizing yoke  20  changes in response to a mixing rate of the magnetic powder relative to the resin (hereinafter, simply referred to as the mixing rate of the magnetic powder). Specifically, when the mixing rate of the magnetic powder is increased, the magnetic potential of the magnetizing yoke in the magnetizing magnetic field is increased. Thus, by controlling the mixing rate of the magnetic powder, it is possible to form the magnetizing yoke  20 , the magnetic potential of which in the magnetizing magnetic field is generally the same as that of the magnet  30 . 
   Furthermore, in a case where the magnetizing yoke  20  is formed by the above first or second manufacturing methods, the magnetizing yoke  20  may be formed by stacking and joining a plurality of plates (also sometimes referred to as sheets), each of which is made of a magnetic material, in a direction perpendicular to the magnetization direction  52 . For example, with reference to  FIG. 2A , which is a cross sectional view similar to  FIG. 1B , a plurality of plates  20   b , each of which is made of a magnetic material, may be stacked one after another in a direction (a top to bottom direction in  FIG. 2A ), which is perpendicular to the magnetization direction  52  (see  FIG. 1A ) and is perpendicular to the plane of the magnet  30 . Alternatively, with reference to  FIG. 2B , which is a cross sectional view similar to  FIG. 2A , the plates  20   b  may be stacked one after another in a direction (a left to right direction in  FIG. 2B ), which is perpendicular to the magnetization direction  52  in the plane of the magnet  30 . When the magnetizing yoke  20  is formed by the stacking of the magnetic plates to create a laminate structure of the magnetizing yoke  20 , an eddy current, which is generated in the magnetizing yoke  20  by the magnetizing magnetic field, can be reduced or limited. 
   (Magnetizing Method of Magnet) 
   Next, a magnetizing method of the magnet  30  will be described. 
   First, the magnet  30  is received in the magnetizing yoke  20 . For example, in a case where the annular magnet  30  is magnetized in the radial direction to create two magnetic poles of opposite polarities in the annular magnet  30 , the magnet  30  is received in the magnetizing yoke  20  in such a manner that the plane of the magnet  30  is generally parallel to the magnetization direction  52 . In this way, the magnet  30  (including both of the outer circumferential surface and the inner circumferential surface of the magnet  30 ) contacts closely with the magnetizing yoke  20 , so that the magnet  30  is entirely covered with the magnetizing yoke  20 . At this time, an outer magnetizing yoke segment  20   x  of the magnetizing yoke  20 , which is placed radially outward of the magnet  30  contacts the outer circumferential surface of the magnet  30 , and an inner magnetizing yoke segment  20   y  of the magnetizing yoke  20 , which is placed radially inward of the magnet  30 , contacts the inner circumferential surface of the magnet  30 . In the present embodiment, the outer magnetizing yoke segment  20   x  and the inner magnetizing yoke segment  20   y  are integrated together to define the receiver  20   a , which receives the magnet  30 , in, for example, the above-described lower half of the magnetizing yoke  20  in  FIG. 1B . 
   Then, the magnetizing yoke  20  is placed in the magnetizing area  50 . In this way, the magnetizing area  50  is substantially filled with the magnetizing yoke  20  and the magnet  30 . It should be noted that the magnetizing yoke  20  may be held stationary in the magnetizing area  50 , and the magnet  30  may be received in the stationary magnetizing yoke  20 , if desired. 
   Then, the magnetizing coil  10  is energized to generate the magnetizing magnetic field. Here, as described above, the magnetic potential of the magnetizing yoke  20  and the magnetic potential of the magnet  30  in the magnetizing magnetic field are generally the same. That is, the magnetic potential in the magnetizing area  50  is generally uniform. In this way, disturbances in the magnetic field are limited, so that magnetic lines of force, which are generally parallel to the magnetization direction  52 , extend through the magnet  30 . The thus created magnetizing magnetic field, which is generally parallel to the magnetization direction  52 , can be effectively used to magnetize the magnet  30  in the magnetization direction  52  with a relatively high accuracy. 
   Second Embodiment 
   With reference to  FIGS. 3A and 3B , a magnetizer  2  according to a second embodiment of the present invention includes a magnetizing coil  210  and magnetizing yokes  221 ,  222 . The magnetizing coil  210  is generally the same as the magnetizing coil  10  of the first embodiment except a shape of the magnetizing coil  210 . The magnetizing coil  210  is a hollow coil, which is wound into a quadrangular prism shape. 
   The magnetizing yoke (outer magnetizing yoke segment)  221  is generally the same as the magnetizing yoke  20  of the first embodiment except a shape of the magnetizing yoke  221 . The magnetizing yoke  221  is formed into a plate shape (a generally planar shape) that extends in the magnetization direction  52  in the magnetizing area  250 , and a through hole  221   a  extends through the magnetizing yoke  221  in a plate thickness direction of the magnetizing yoke  221 . 
   The magnet  30  is fitted into the through hole  221   a  of the magnetizing yoke  221 . The magnetizing yoke (inner magnetizing yoke segment)  222 , which is made of the same material as that of the magnetizing yoke  221 , is fitted to an inner peripheral surface of the annular magnet  30 . In this way, end surfaces of the magnet  30 , which are located at the ends of the magnet  30  in a direction of the plane of the magnet  30 , are covered with the magnetizing yokes  221 ,  222 . More specifically, the outer circumferential surface and the inner circumferential surface (the outer peripheral surface and the inner peripheral surface) of the magnet  30  are covered with and contact with the magnetizing yokes  221 ,  222 , which are placed radially outward and radially inward, respectively of the magnet  30 . When the magnetizing yokes  221 ,  222 , which receive the magnet  30 , are placed in the magnetizing area  250 , a generally planar area  251  in the magnetizing area  250  is substantially filled with the magnetizing yokes  221 ,  222  and the magnet  30 . In this way, the magnetic potential in the planar area  251  becomes generally uniform. 
   However, opposed side surfaces of the magnet  30 , which are opposed to each other in the plate thickness direction of the magnet  30 , are exposed from the magnetizing yokes  221 ,  222 . In this way, the magnetic potential in the magnetizing area  250  varies in the plate thickness direction of the magnet  30 , so that the magnetizing magnetic field is disturbed. However, even when the magnetic potential in the magnetizing area  250  varies in the direction perpendicular to the magnetization direction  52 , the disturbances in the magnetizing magnetic field are relatively small, so that the result of the magnetization of the magnet  30  is not significantly influenced. Particularly, the plate-shaped magnet  30  is relatively thin (e.g., about 5 mm in one instance) in the plate thickness direction of the magnet  30 , so that the disturbances in the plate thickness direction will not have a significant influence on the result of the magnetization of the magnet  30 . 
   Thus, when the magnetic potential in the planar area  251  is made generally uniform, the disturbances in the magnetizing magnetic field can be advantageously limited, so that the magnet  30  can be magnetized in the magnetization direction  52  with the relatively high accuracy. 
   Third Embodiment 
   With reference to  FIGS. 4A and 4B , a magnetizer  3  according to a third embodiment of the present invention includes a magnetizing coil and magnetizing yokes  321 - 323 . The magnetizing coil of the third embodiment is generally the same as the magnetizing coil  210  of the second embodiment. Hereinafter, the magnetizing coil of the third embodiment will be indicated by the same reference numeral (i.e., numeral  210 ) as that of the magnetizing coil  210  of the second embodiment. 
   The magnetizing yokes (outer magnetizing yoke segments)  321 ,  322  clamp the magnet therebetween in the direction of the plane of the magnet  30 , so that the plane of the magnet  30  is held generally in parallel with the magnetization direction  52 . The magnetizing yoke (inner magnetizing yoke segment)  323  is fitted to the inner peripheral surface of the magnet  30 . In this way, a projected area  351  of the magnet  30  in the magnetizing area  250  on each of first and second sides of the magnet  30  that are opposite from each other in the magnetization direction  52 , is substantially filled with the magnetizing yokes  321 - 323  and the magnet  30 . Therefore, the magnetic potential in the projected area  351  becomes generally uniform. Here, the projected area is defined as an area that is created by rectilinear projection of a shape of the magnet  30  in the magnetization direction  52  in the magnetizing area. More specifically, in the case of  FIGS. 4A and 4B , one projected area (first projected area) is created on the upper side of the line IVB-IVB in  FIG. 4A  through rectilinear projection of the rectangular shape at the cross section of the magnet  30  shown in  FIG. 4B  in the magnetization direction. In other words, when a parallel light beam is irradiated to the magnet  30  from the lower side in  FIG. 4A , a shaded area is created above the line IVB-IVB in  FIG. 4A  to create the projected area (first projected area) in the magnetizing area  250 . Thus, the projected area has the same width (the left to right width in  FIG. 4A ) as that of the magnet  30  and the same thickness (the top to bottom thickness in  FIG. 4B ) as that of the magnet  30 . Similarly, another projected area (second projected area) is created on the lower side of the line IVB-IVB in  FIG. 4A  through rectilinear projection of the rectangular shape at the cross section of the magnet  30  shown in  FIG. 4B  along the magnetization direction. In  FIG. 4A , these projected areas are indicated by reference numeral  351  as a whole projected area for the illustrative purpose. Here, it should be also noted that although an extent of the projected area  351  in the magnetization direction  52  coincides with that of the magnetizing area  250  in  FIG. 4A , the extent of the projected are  351  in the magnetization direction  52  may be shorter than that of the magnetizing area  250  in this and other embodiments. 
   As discussed above, even when the magnetic potential in the magnetizing area  250  varies in the direction perpendicular to the magnetization direction  52 , the disturbances in the magnetizing magnetic field are relatively small, so that the result of the magnetization of the magnet  30  will not be substantially influenced. Therefore, when the magnetic potential in at least the projected area  351  of the magnetizing area  250  is made generally uniform, the disturbances in the magnetizing magnetic field can be limited. Thus, the magnet  30  can be magnetized with the relatively high accuracy in the magnetization direction  52  by the magnetizing magnetic field, which is generally parallel to the magnetization direction  52 . 
   Fourth Embodiment 
   Components of a magnetizer according to the fourth embodiment are substantially the same as those of the above embodiments except the material of the magnetizing yoke(s). The magnetizing yoke(s) of the fourth embodiment is made of a magnetic material, a magnetic potential of which relative to a strength of an ordinary magnetizing magnetic field, is different from that of the magnet. Here, the strength of the ordinary magnetic field refers to a strength of the magnetic field, which is set according to the material of the magnet and can effectively magnetize this magnet. 
   Therefore, according to the magnetizing method that uses the magnetizer of the fourth embodiment, a strength of the magnetic field, which is different from the strength of the ordinary magnetizing magnetic field and causes the magnetic potential of the magnetizing yoke and the magnetic potential of the magnet to be generally the same, is set as the strength of the magnetizing magnetic field. For example, in a case where the magnetization characteristic of the magnetizing yoke and the magnetization characteristic of the magnet cross with each other at a cross point, the strength of the magnetic field at this cross point is set as the strength of the magnetizing magnetic field. The electric current, which corresponds to the preset strength of the magnetic field, is supplied to the magnetizing coil, so that the magnetizing magnetic field is generated. 
   According to the magnetizing method of the magnet of the fourth embodiment, even in the case where the magnetic potential of the magnetizing yoke relative to the strength of the ordinary magnetizing magnetic field cannot be set to generally the same as that of the magnet, when the magnetic potential of the magnetizing yoke in the magnetic field, which has the strength that is different from the strength of the ordinary magnetic field, is generally the same as that of the magnet, the magnet can be magnetized with the relatively high accuracy in the magnetization direction by applying the magnetizing magnetic field, the strength of which causes the magnetic potential of the magnetizing yoke and the magnetic potential of the magnet to be generally the same, to the magnet. 
   Other Embodiments 
   In the above embodiments, the parallel magnetic field is generated in the magnetizing area by the coil, which is wound into the cylindrical shape or the quadrangular prism shape. However, the shape of the coil, which serves as the magnetic field generating means, is not limited to the cylindrical shape or the quadrangular shape. Also, the magnetic field generating means may be formed of a plurality of coils. 
   Additional advantages and modifications will readily occur to those skilled in the art. The invention in its broader terms is therefore not limited to the specific details, representative apparatus, and illustrative examples shown and described.