Abstract: A method for manufacturing a magnet includes (1) a step of preparing three or more unmagnetized magnet materials of which magnetization easy axes are oriented in predetermined directions, and adhering the unmagnetized magnet materials with each other to make an assembly, and (2) a step of applying a curved pulse magnetic field to the assembly to magnetize the assembly, wherein in the step (2), the unmagnetized magnet materials are magnetized into magnet blocks, and an angle ? (where 0???180 degrees holds) formed by magnetization directions of at least a pair of magnet blocks adjacent to each other is in a range of 30 degrees to 120 degrees.

Abstract: Disclosed is a rare earth-sintered magnet in which a plurality of magnetic material particles are sintered. Surface magnetic flux density has a greatest value of 350 mT to 600 mT, the rare earth-sintered magnet has a thickness of 1.5 mm to 6 mm, a cross section of the rare earth-sintered magnet taken along a thickness direction is non-circular, and the cross section has an area in which axes of easy magnetization of the magnetic material particles has polar anisotropic orientation.

Abstract: Provided is a method for producing a sintered body that forms a rare-earth permanent magnet, has a single sintered structure and an arbitrary shape, and has easy magnetization axis orientations of different directions applied to the magnet material particles in a plurality of arbitrary regions. This method forms a three-dimensional first molded article from a composite material formed by mixing a resin material and magnet material particles containing a rare-earth substance. The first molded article is then subjected to a deforming force and a second molded article is formed in which the orientation direction of the easy magnetization axis of the magnet material particles in at least the one section of the horizontal cross-section is changed to a direction which differs from the orientation direction of the first molded article. The second molded article is heated to a sintering temperature and kept at the temperature for a period of time.

Abstract: There are provided a rare-earth permanent magnet and a manufacturing method of a rare-earth permanent magnet capable of preventing deterioration of magnet properties. In the method, magnet material is milled into magnet powder. Next, a mixture 12 is prepared by mixing the magnet powder and a binder, and the mixture 12 is formed into a sheet-like shape to obtain a green sheet 14. Thereafter, magnetic field orientation is performed to the green sheet 14, which is then held for several hours in a non-oxidizing atmosphere at a pressure higher than normal atmospheric pressure, at 200 through 900 degrees Celsius for calcination. Thereafter, the calcined green sheet 14 is sintered at a sintering temperature. Thereby a permanent magnet 1 is manufactured.

Abstract: A method for manufacturing a magnet includes (1) a step of preparing three or more unmagnetized magnet materials of which magnetization easy axes are oriented in predetermined directions, and adhering the unmagnetized magnet materials with each other to make an assembly, and (2) a step of applying a curved pulse magnetic field to the assembly to magnetize the assembly, wherein in the step (2), the unmagnetized magnet materials are magnetized into magnet blocks, and an angle ? (where 0???180 degrees holds) formed by magnetization directions of at least a pair of magnet blocks adjacent to each other is in a range of 30 degrees to 120 degrees.

Abstract: There are provided a rare-earth permanent magnet and a manufacturing method of a rare-earth permanent magnet capable of preventing deterioration of magnet properties. In the method, magnet material is milled into magnet powder. Next, a mixture 12 is prepared by mixing the magnet powder and a binder, and the mixture 12 is formed into a sheet-like shape to obtain a green sheet 14. Thereafter, magnetic field orientation is performed to the green sheet 14, which is then held for several hours in a non-oxidizing atmosphere at a pressure higher than normal atmospheric pressure, at 200 through 900 degrees Celsius for calcination. Thereafter, the calcined green sheet 14 is sintered at a sintering temperature. Thereby a permanent magnet 1 is manufactured.

Abstract: The rare-earth sintered magnet has a configuration in which a large number of magnet material particles including a rare-earth substance and each having an axis of easy magnetization have been integrally sintered. The rare-earth sintered magnet is provided with a first surface and a second surface opposing each other in the thickness direction. In a plane in parallel with a width direction and the thickness direction, the magnet material particles are magnetized such that, in a region extending from each of both end portions in the width direction toward the center portion in the width direction, the orientation direction of the easy magnetization axis is gradually changed. A maximum surface magnetic flux density in the first surface and a maximum surface magnetic flux density in the second surface satisfy the relationship (D1/D2)?4.

Abstract: A stacking die comprises a stacked multiple stacking plates and a side plate(s) which fixes the multiple stacking plates in a stacked state, wherein at least one or more processing object(s) is retained in a space(s) formed between the multiple stacking plates. Further, surfaces where the stacking plates and the side plate(s) abut each other are preferably tapered so that they form tapered shapes in a direction opposite to the approach direction of the side plate(s).

Abstract: Provided are a rare-earth permanent magnet whose magnet density after sintering is very high and a method for manufacturing a rare-earth permanent magnet. Thus, a magnet raw material is milled into magnet powder, and then, a compound 12 is formed by mixing the magnet powder thus milled with a binder. Next, the compound 12 thus formed is subjected to a hot-melt molding onto a supporting substrate 13 so as to form a green sheet 14 molded to a sheet-like shape. Thereafter, while the green sheet 14 thus molded is softened by heating, magnetic field orientation is carried out by applying a magnetic field to the green sheet 14 thus heated; and further, the green sheet 14 having been subjected to the magnetic field orientation is calcined by a vacuum sintering, which is further followed by a pressure sintering to produce a permanent magnet 1.

Abstract: There are provided a rare-earth permanent magnet, and a method for manufacturing a rare-earth permanent magnet and a system for manufacturing a rare-earth permanent magnet, capable of achieving improved shape uniformity. Magnet material is milled into magnet powder, and the milled magnet powder is formed into a formed body 40. The formed body 40 is calcined and then sintered using a spark plasma sintering apparatus 45, so that a permanent magnet 1 is manufactured. A die unit 46 included in the spark plasma sintering apparatus 45 that performs spark plasma sintering at least includes in one direction an inflow hole 50 configured to receive inflow of part of the pressurized formed body.

Abstract: There are provided a rare-earth permanent magnet and a manufacturing method thereof capable of preventing deterioration of magnet properties. In the method, magnet material is milled into magnet powder. Next, a mixture is prepared by mixing the magnet powder and a binder made of long-chain hydrocarbon and/or of a polymer or a copolymer consisting of monomers having no oxygen atoms. Next, the mixture is formed into a sheet-like shape so as to obtain a green sheet. After that, the green sheet is held for a predetermined length of time at binder decomposition temperature in a non-oxidizing atmosphere so as to remove the binder by causing depolymerization reaction or the like to the binder, which turns into monomer. The green sheet from which the binder has been removed is sintered by raising temperature up to sintering temperature. Thereby a permanent magnet 1 is obtained.

Abstract: There are provided a rare-earth permanent magnet and a manufacturing method thereof capable of preventing deterioration of magnet properties. In the method, magnet material is milled into magnet powder. Next, a mixture is prepared by mixing the magnet powder and a binder made of long-chain hydrocarbon and/or of a polymer or a copolymer consisting of monomers having no oxygen atoms. Next, the mixture is formed into a sheet-like shape so as to obtain a green sheet. After that, the green sheet is held for a predetermined length of time at binder decomposition temperature in a non-oxidizing atmosphere so as to remove the binder by causing depolymerization reaction or the like to the binder, which turns into monomer. The green sheet from which the binder has been removed is sintered by raising temperature up to sintering temperature. Thereby a permanent magnet 1 is obtained.

Abstract: Provided is a method for producing a sintered body that forms a rare-earth permanent magnet, has a single sintered structure and an arbitrary shape, and has easy magnetization axis orientations of different directions applied to the magnet material particles in a plurality of arbitrary regions. This method forms a three-dimensional first molded article from a composite material formed by mixing a resin material and magnet material particles containing a rare-earth substance. The first molded article is then subjected to a deforming force and a second molded article is formed in which the orientation direction of the easy magnetization axis of the magnet material particles in at least the one section of the horizontal cross-section is changed to a direction which differs from the orientation direction of the first molded article. The second molded article is heated to a sintering temperature and kept at the temperature for a period of time.

Abstract: Raw material magnet is milled to magnet powder, and the magnet powder thus milled is mixed with a binder to form a compound 12. Then, the compound 12 thus formed is molded to a green sheet 14 having a sheet shape. Thereafter, a magnetic field orientation is carried out by applying a magnetic field to the green sheet 14 thus molded, and then, the green sheet 14 having been subjected to the magnetic field orientation is shaped to a product shape by deforming thereof. Thereafter, the permanent magnet 1 is produced by sintering thereof. The permanent magnet 1 has a ring shape, and is constituted such that an axis of easy magnetization may be orientated at a slant so as to converge in a direction along a converging axis P which is set to a radius direction as well as to a center direction of the ring shape.

Abstract: Provided are: a permanent magnet wherein the magnetic field orientation process can be made simple and a degree of orientation thereof can be improved; a method for manufacturing a permanent magnet, an SPM motor using a permanent magnet, and a method for manufacturing an SPM motor. Raw material magnet is milled to magnet powder, and the magnet powder is mixed with a binder to form a compound. Then, the compound is molded by hot-melt molding to a green sheet in a shape of a sheet onto a supporting substrate. Thereafter, a magnetic field is applied to the green sheet thus molded to carry out magnetic field orientation. Further, with fixing plural green sheets after the magnetic field orientation by lamination under a deformed state thereof, the plural green sheets thus laminated are cut for shaping to a prescribed shape, which is followed by sintering to produce a permanent magnet.

Abstract: Provided are a rare-earth permanent magnet whose magnet density after sintering is very high and a method for manufacturing a rare-earth permanent magnet. Thus, a magnet raw material is milled into magnet powder, and then, a compound 12 is formed by mixing the magnet powder thus milled with a binder. Next, the compound 12 thus formed is subjected to a hot-melt molding onto a supporting substrate 13 so as to form a green sheet 14 molded to a sheet-like shape. Thereafter, while the green sheet 14 thus molded is softened by heating, magnetic field orientation is carried out by applying a magnetic field to the green sheet 14 thus heated; and further, the green sheet 14 having been subjected to the magnetic field orientation is calcined by a vacuum sintering, which is further followed by a pressure sintering to produce a permanent magnet 1.

Abstract: Provided are: a ring magnet for an SPM motor with which high output power, high efficiency, and low torque ripple of the SPM motor can be realized; a method for manufacturing a ring magnet for an SPM motor; an SPM motor using a ring magnet for an SPM motor; and a method for manufacturing an SPM motor. Raw material magnet is milled to magnet powder, and the magnet powder is molded to a shape of a sheet thereby forming a green sheet. Then, a magnetic field is applied to the green sheet to perform magnetic field orientation. Further, with fixing plural green sheets after the magnetic field orientation by lamination under deformed state thereof, the plural laminated green sheets are cut to a fan-like shape, which is then followed by connecting with each other to form a ring shape and further followed by sintering to produce a permanent magnet.

Abstract: Provided are a rare earth permanent magnet whose permanent magnetic properties are improved by making density of the magnet very high and a method for manufacturing a rare earth permanent magnet. Thus, magnet raw material is milled into magnet powder, and then a compound is formed by mixing the magnet powder thus milled with a binder. Next, the compound thus formed is subjected to hot-melt molding onto a supporting substrate so as to form a green sheet molded to a sheet-like shape. Thereafter, while the green sheet thus molded is softened by heating, magnetic field orientation is carried out by applying a magnetic field to the green sheet thus heated; and further, the green sheet having been subjected to the magnetic field orientation is calcined in non-oxidizing atmosphere, and then, sintering thereof is carried out at a sintering temperature to produce a permanent magnet having density of 95% or more.

Abstract: There are provided a rare-earth permanent magnet and a manufacturing method thereof capable of preventing deterioration of magnet properties. In the method, magnet material is milled into magnet powder. Next, a mixture is prepared by mixing the magnet powder and a binder made of long-chain hydrocarbon and/or of a polymer or a copolymer consisting of monomers having no oxygen atoms. Next, the mixture is formed into a sheet-like shape so as to obtain a green sheet. After that, the green sheet is held for a predetermined length of time at binder decomposition temperature in a non-oxidizing atmosphere so as to remove the binder by causing depolymerization reaction or the like to the binder, which turns into monomer. The green sheet from which the binder has been removed is sintered by raising temperature up to sintering temperature. Thereby a permanent magnet 1 is obtained.

Abstract: There are provided a rare-earth permanent magnet and a manufacturing method thereof capable of preventing deterioration of magnet properties. In the method, magnet material is milled into magnet powder. Next, a mixture is prepared by mixing the magnet powder and a binder made of long-chain hydrocarbon and/or of a polymer or a copolymer consisting of monomers having no oxygen atoms. Next, the mixture is formed into a sheet-like shape so as to obtain a green sheet. After that, the green sheet is held for a predetermined length of time at binder decomposition temperature in a non-oxidizing atmosphere so as to remove the binder by causing depolymerization reaction or the like to the binder, which turns into monomer. The green sheet from which the binder has been removed is sintered by raising temperature up to sintering temperature. Thereby a permanent magnet 1 is obtained.