IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0871592
(2001-05-30)
|
우선권정보 |
JP-0159772 (2000-05-30); JP-0399881 (2000-12-28) |
발명자
/ 주소 |
- Arai, Akira
- Kato, Hiroshi
|
출원인 / 주소 |
|
대리인 / 주소 |
Harness, Dickey & Pierce, P.L.C.
|
인용정보 |
피인용 횟수 :
2 인용 특허 :
5 |
초록
▼
A magnetic material manufacturing method, a ribbon-shaped magnetic material manufactured by the method, a powdered magnetic material formed from the ribbon-shaped magnetic material and a bonded magnet manufactured using the powdered magnet material are disclosed. The method and the magnetic material
A magnetic material manufacturing method, a ribbon-shaped magnetic material manufactured by the method, a powdered magnetic material formed from the ribbon-shaped magnetic material and a bonded magnet manufactured using the powdered magnet material are disclosed. The method and the magnetic materials can provide magnets having excellent magnetic properties and reliability. A melt spinning apparatus 1 is provided with a tube 2 having a nozzle 3 at the bottom thereof, a coil 4 for heating the tube and a cooling roll 5 having a circumferential surface 53 on which dimple correcting means is provided. A melt spun ribbon 8 is formed by injecting the molten alloy 6 from the nozzle 3 so as to be collided with the circumferential surface 53 of the cooling roll 5 in an inert gas atmosphere (ambient gas) such as helium gas, so that the molten alloy 6 is cooled and then solidified. In this process, dimples to be produced on a roll contact surface of the melt spun ribbon are divided by the dimple correcting means, thereby preventing formation of huge dimples.
대표청구항
▼
1. A magnetic material manufacturing method for manufacturing a ribbon-shaped magnetic material comprising:colliding a molten alloy to a circumferential surface of a cooling roll so as to cool and then solidify the molten alloy, wherein the ribbon-shaped magnetic material having an alloy composition
1. A magnetic material manufacturing method for manufacturing a ribbon-shaped magnetic material comprising:colliding a molten alloy to a circumferential surface of a cooling roll so as to cool and then solidify the molten alloy, wherein the ribbon-shaped magnetic material having an alloy composition represented by the formula of R x (Fe 1-y Co y ) 100-x-z B z (where R is at least one rare earth element, x is 10-15 at %, y is 0-0.30 and z is 4-10 at %);dividing dimples that are produced on a roll contact surface of the ribbon-shaped magnetic material which is in contact with the circumferential surface of the cooling roll with dimple correcting means, the dimple correcting means defined by a plurality of redges that are formed by grooves formed in the circumferential surface of the cooling roll at an angle less than or equal to 30° relative to an edge of the cooling roll, wherein an average width of each groove is 0.5-90 μm for discontinuous, discreet, and spaced apart regions, wherein the ratio of the area of the grooves with respect to the area of the circumferential surface when they are projected on the same plane is in the range of 30-99.5%. 2. The manufacturing method as claimed in claim 1, wherein the cooling roll includes a roll base and an outer surface layer provided on an outer peripheral portion of the roll base, and the outer surface layer has said dimple correcting means. 3. The manufacturing method as claimed in claim 1, wherein the outer surface layer of the cooling roll is formed of a material having a heat conductivity lower than a heat conductivity of the structural material of the roll base at room temperature. 4. The manufacturing method as claimed in claim 2, wherein the outer surface layer of the cooling roll is formed of a ceramic. 5. The manufacturing method as claimed in claim 2, wherein the outer surface layer of the cooling roll is formed of a material having a heat conductivity equal to or less than 80 Wm −1 K −1 at room temperature. 6. The manufacturing method as claimed in claim 2, wherein the outer surface layer of the cooling roll is formed of a material having a coefficient of thermal expansion in a range of 3.5-18[×10 −6 K −1 ] at room temperature. 7. The manufacturing method as claimed in claim 2, wherein an average thickness of the outer surface layer of the cooling roll is 0.5 to 50 μm. 8. The manufacturing method as claimed in claim 2, wherein the outer surface layer of the cooling roll is manufactured without experiencing a machining process. 9. The manufacturing method as claimed in claim 1, wherein the average width of the ridge is 0.5-90 μm. 10. The manufacturing method as claimed in claim 1, wherein the average height of the ridge or the average depth of the groove is 0.5-20 μm. 11. The manufacturing method as claimed in claim 1, wherein the ridge or groove is formed spirally with respect to the rotation axis of the cooling roll. 12. The manufacturing method as claimed in claim 1, wherein the at least one ridge or groove includes a plurality of ridges or grooves which are arranged in parallel with each other through an average pitch of 0.5-100 μm. 13. The manufacturing method as claimed in claim 1, wherein the ratio of the projected area of the ridge or groove with respect to the projected area of the circumferential surface is equal to or greater than 10%. 14. The manufacturing method as claimed in claim 1, wherein the method includes a step for milling the ribbon-shaped magnetic material. 15. The manufacturing method as claimed in claim 1, wherein a cross-section of the grooves is square-shaped. 16. The manufacturing method as claimed in claim 1, wherein a cross-section of the grooves is triangle-shaped. 17. The manufacturing method as claimed in claim 1, wherein a cross-section of the grooves is round-shaped. 18. A magnetic material manufacturing method for manufacturing a ribbon-shaped magnetic material comprising:colliding a molten alloy to a circumferential surface of a cooling roll so as to cool and then solidify the molten alloy, wherein the ribbon-shaped magnetic material has an alloy composition represented by the formula of R x (Fe 1-y CO y ) 100-x-z B z (where R is at least one rare earth element, x is 10-15 at %, y is 0-0.30 and z if 4-10 at %); anddividing dimples that are produced on a roll contact surface of the ribbon-shaped magnetic material which is in contact with the circumferential surface of the cooling roll with dimple correcting means, the dimple correcting means defined by a plurality of redges provided on a circumferential surface of the cooling roll for dividing dimples that are produced on a roll contact surface of the cooling roll;wherein the plurality of ridges are provided by forming at least two spiral grooves of which a direction of each spiral groove is different so that the grooves intersect on the circumferential surface of the cooling roll, the grooves having an average width of 0.5-90 μm to prevent a molten alloy of the magnetic material from entering the groove; anda ratio of an area of the grooves with respect to an area of the circumferential surface when they are projected on the same plane is in the range of 30-99.5%. 19. The magnetic material manufacturing method of claim 18, wherein each spiral groove has angle relative to an edge of the cooling roll that is less than or equal to 30°; andthe angle of each spiral groove is different. 20. The magnetic material manufacturing method of claim 18, wherein a cross-section of the grooves is square-shaped. 21. The magnetic material manufacturing method of claim 18, wherein a cross-section of the grooves is triangle-shaped. 22. The magnetic material manufacturing method of claim 18, wherein a cross-section of the grooves is round-shaped.
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