Stock material or miscellaneous articles – All metal or with adjacent metals – Composite; i.e. – plural – adjacent – spatially distinct metal...
Reexamination Certificate
1998-04-21
2001-04-10
Jones, Deborah (Department: 1775)
Stock material or miscellaneous articles
All metal or with adjacent metals
Composite; i.e., plural, adjacent, spatially distinct metal...
C428S693100, C428S332000, C420S416000
Reexamination Certificate
active
06214480
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an article made by joining two members together, and particularly, to an article containing two members bound to each other with a binding layer formed through a heating step between one of the members made of a metal and the other member made of a material of the same type or a different type as the one member. The present invention also relates to a brazing filler metal for forming that binding layer.
2. Description of the Prior Art
A rotor for a motor is a conventionally known article of this type. In this rotor, one member is a permanent magnet containing a rare earth element, and the other member is a rotor body made of a steel which is a different material than the permanent magnet.
The permanent magnet containing the rare earth element has a nature that the machinability thereof is poor, because the permanent magnet is very brittle, and that if the permanent magnet is exposed to a high temperature, the metallographic structure thereof is changed, and as a result, the magnetic characteristic of the permanent magnet is influenced.
In mounting the permanent magnet to the steel rotor body, a mounting means such as a dovetail structure, a screwing, a welding and the like cannot be employed and hence, an adhesive has conventionally been employed.
However, if an adhesive is used, the following problems are encountered: the strength of bonding between the permanent magnet and the rotor body is low, because of a poor wettability of the permanent magnet, and the bonding strength is significantly reduced with a rise in temperature. In such a situation, it is not possible to meet the demand for an increase in speed of rotation of the motor.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an article in which the strength of bonding between two members is increased.
To achieve the above object, according to the present invention, there is provided an article made by joining two members together, including a binding layer formed through a heating step between one of the members which is made of a metal and the other member which is made of the same material or a different material as the one member, wherein the binding layer is formed by production of a liquid phase in the heating step from a brazing filler metal of a rare earth element-based alloy, and the article further includes diffusion areas existing between the one member and the binding layer and between the other members and the binding layer, respectively, the thickness t of each of the diffusion areas being in a range of t≧5 &mgr;m.
The liquid phase produced from the rare earth element-based alloy is highly active and exhibits an excellent wettability to various types of members to be bound, thereby inducing a mutual diffusion between these members to be bound, which is accompanied by an active migration of atoms.
In this manner, the members are bound with the binding layer in a diffusion fashion and therefore, the strength of bonding between the members is greatly enhanced.
However, if the thickness t of each diffusion area is smaller than 5 &mgr;m, the strength of bonding between both the members is decreased. The upper limit value of the thickness t of the diffusion area is substantially equal to the thickness of the brazing filler metal used. Therefore, the entire binding layer may be a diffusion area in some cases.
The above objects, features and advantages of the invention will become apparent from the following description of the preferred embodiment taken in conjunction with the accompanying drawings.
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Hosoe Mitsuya
Kimura Naomasa
Nosaki Katsutoshi
Honda Giken Kogyo Kabushiki Kaisha
Jones Deborah
LaVilla Michael
Lyon & Lyon LLP
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