Composite structural body, method of manufacturing the structural body, and motor

Abstract

A composite structural body, comprising a rotor, a stator, and magnetic materials such as of magnet-buried type capable of providing excellent strength and thermal resistance and preventing a metal container from being deformed by a hot hydrostatic forming, wherein a specified part is formed of a material and formed with a thickness difficult to be deformed by a pressure at the time of hot hydrostatic forming so as to form a highly strong part and formed of a material and formed with a thickness easy to be deformed by the pressure so as to set a low strength part, and powder is put in the metal container, and the container is sealed and put in a high temperature and high pressure atmosphere, whereby, because the part weak against the pressure is deformed, the deformation of the part strong against the pressure, i.e., the preset highly strong part requiring a specified accuracy and shape is reduced, the metal container and the powder filled therein are fitted to each other and formed integrally with each other, and a magnetic structural body durable, heat resistant, and complicated more than a conventional structure can be provided and, because the metal container is not deformed, the working after forming is facilitated and the productivity is improved tremendously.

1 . A composite structure comprising a metal container having a high-strength part with a high resistance to deformation and a low-strength part which can be deformed under a required pressure and a powder formed body integrated with said container by filling said container with the powder, sealing the container, and conducting hot isostatic pressing.  
     
     
         2 . The composite structure according to  claim 1 , wherein the high-strength part and low-strength part of the metal container are composed of different materials or of the same material, but with different thickness.  
     
     
         3 . The composite structure according to  claim 1 , wherein the powder is a magnetic powder or a magnetic powder containing a non-magnetic powder added thereto.  
     
     
         4 . The composite structure according to  claim 1 , wherein the powder contains a powder with a different melting point added thereto.  
     
     
         5 . The composite structure according to  claim 3 , wherein the magnetic powder is at least one from among a Nd—Fe—B magnet powder, a Sm—Co magnet powder, a Pr—Fe—B magnet powder, an exchange-spring magnet powder, an Alnico magnet powder, and a ferrite magnet powder.  
     
     
         6 . A method for the manufacture of a composite structure, comprising the steps of: 
 filling a metal container having a high-strength part with a high resistance to deformation under a required pressure and a low-strength part which can be deformed with a powder and sealing the container;    and integrally forming the metal container and the powder by hot isostatic pressing.    
     
     
         7 . A method for the manufacture of a composite structure, comprising the steps of: 
 filling a metal container having a high-strength part with a high resistance to deformation under a required pressure and a low-strength part which can be deformed with a powder and sealing the container;    integrally forming the metal container and the powder by hot isostatic pressing; and    processing the integrally formed product.    
     
     
         8 . The method for the manufacture of a composite structure according to  claim 6  or  claim 7 , wherein the high-strength part and low-strength part of the metal container are composed of different materials or of the same material, but with different thickness.  
     
     
         9 . The method for the manufacture of a composite structure according to  claim 6  or  claim 7 , wherein the hot isostatic pressing is conducted under the conditions of temperature of no lower than 600° C. and no higher than 1000° C. and pressure of 1˜200 MPa.  
     
     
         10 . A motor comprising a composite structure according to  claim 5.