Production method for anisotropic resin-bonded magnets

• US 5,886,070 A
• Filed: 07/01/1997
• Issued: 03/23/1999
• Est. Priority Date: 07/04/1996
• Status: Expired due to Term

• Current Assignee: Aichi Steel Works Limited
• Original Assignee: Aichi Steel Works Limited
• Inventors: Sugiura, Yoshinobu, Maekawa, Koichi, Honkura, Yoshinobu, Mitarai, Hironari
• Primary Examiner(s): MERRIAM, ANDREW EDWIN
• Application Number:
  US08/886,509
• Time in Patent Office: 630 Days
• Field of Search: 523/300, 524/431, 524/440, 264/429, 264/436, 264/DIG. 58, 264/435, 264/108, 422/3
• US Class Current: 523/300
• CPC Class Codes: B29C 2043/3618 plurality of counteracting elements
• CPC Class Codes: B29C 2791/004 Shaping under special conditions
• CPC Class Codes: B29C 43/14 in several steps
• CPC Class Codes: B29C 70/62 the filler being oriented during moulding for short fibres B29C70/14
• CPC Class Codes: B29K 2303/06 Metal powders, metal carbides or the like
• CPC Class Codes: B29K 2503/06 Metal powders, metal carbides or the like
• CPC Class Codes: B29K 2995/0008 Magnetic or paramagnetic
• CPC Class Codes: B29L 2031/3406 Components, e.g. resistors
• CPC Class Codes: H01F 41/0253 for manufacturing permanent magnets
• CPC Class Codes: Y10S 264/58 Processes of forming magnets

Abstract

The present invention offers a production method for anisotropic resin-bonded magnets with precise dimensions in high productivity. It comprises the aligning step in which the preform is preliminary compression-molded in the preforming molding die 22 in the preforming press 20 with an applied magnetic field to align the magnetization direction of the magnet powder at a temperature in which the thermosetting resin in the compound becomes liquid state, the transferring step in which said preform is transferred from preforming press 20 to densifying molding die 32 in a densifying press 30, and densifying step in which said partly cured preform is compression-molded by applying pressure in a densifying press 30 to obtain desired shape of magnet.

Claims

1. A method for producing an anisotropic resin-bonded magnet, comprising molding a mixture of anisotropic magnet powder and a thermosetting resin in a hot mold by applying a pressure and a magnetic field in a hot mold by applying a pressure and a magnetic field to align the magnetization direction of said anisotropic magnet powder, wherein the improvement comprises:

forming said mixture in a preliminary hot mold by applying a pressure and a magnetic field to align the magnetization direction of said anisotropic magnet powder at a temperature in which the thermosetting resin becomes liquid state and then partly cures,

transferring said mixture into a densifying mold in a densifying press, and

densifying said partly cured mixture in said densifying mold by applying a pressure which is higher than the pressure in said forming step without said magnetic field.

2. A production method as set forth in claim 1, wherein the preform is demagnetized after the alignment step in which the magnetization direction of said magnet powder is aligned.

3. A production method as set forth in claim 1, wherein a curing step is added by heating the magnet after the densifying step so that the thermosetting reaction in said magnet is completed.

4. A production method as set forth in claim 1, wherein a magnetizing step of said magnet is added.