Rotor and process for manufacturing the same
A rotor comprising bonded magnet portions mainly composed of magnet powder and a binder, which are embedded in a soft magnetic portion mainly composed of soft magnetic powder and a binder, the rotor being produced by a compression-molding method, and the magnetic pole surfaces of the bonded magnet portions being embedded in the soft magnetic portion.
1. A method for producing a rotor comprising bonded magnet portions and a soft magnetic portion, the method comprising, in the order mentioned,
(a) preliminarily molding steps consisting of compressing a magnet powder compound mainly composed of magnet powder and a binder to mold said bonded magnet portions; charging a soft magnetic powder compound mainly composed of soft magnetic powder and a binder, such that said soft magnetic portion is in contact with said bonded magnet portions, and compressing said soft magnetic powder compound to mold said soft magnetic portion; and
(b) simultaneously compressing said bonded magnet portions and said soft magnetic portion to make said bonded magnet portions and said soft magnetic portion integral.
2. The method for producing a rotor according to claim 1 , wherein a thermosetting resin is used as said binder, and wherein a thermosetting treatment is conducted after said bonded magnet portions and said soft magnetic portion are made integral.
3. A method for producing a rotor comprising bonded magnet portions and a soft magnetic portion, the method comprising
(1) preliminarily molding steps consisting of compressing (a) a magnet powder compound mainly composed of magnet powder and a binder to mold said bonded magnet portions, and (b) a soft magnetic powder compound mainly composed of soft magnetic powder and a binder to mold said soft magnetic portion separately; assembling said bonded magnet portions and said soft magnetic portion; and
(2) simultaneously compressing said bonded magnet portions and said soft magnetic portion to make said bonded magnet portions and said soft magnetic portion integral.
4. The method for producing a rotor according to claim 3 , wherein a thermosetting resin is used as said binder, and wherein a thermosetting treatment is conducted after said bonded magnet portions and said soft magnetic portion are made integral.
5. A method for producing a rotor comprising bonded magnet portions and a soft magnetic portion, the method comprising, in the order mentioned,
(a) preliminarily molding steps consisting of compressing a soft magnetic powder compound mainly composed of soft magnetic powder and a binder to mold said soft magnetic portion; charging a magnetic powder compound mainly composed of magnet powder and a binder, such that said bonded magnet portions are in contact with said soft magnetic portion, and compressing said magnet powder compound to mold said bonded magnet portions; and
(b) simultaneously compressing said bonded magnet portions and said soft magnetic portion to make said bonded magnet portions and said soft magnetic portion integral.
6. The method for producing a rotor according to claim 5 , wherein a thermosetting resin is used as said binder, and wherein a thermosetting treatment is conducted after said bonded magnet portions and said soft magnetic portion are made integral.