CN103021610B - 一种新型复合永磁材料及其制备方法 - Google Patents

一种新型复合永磁材料及其制备方法 Download PDF

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CN103021610B
CN103021610B CN201110289248.0A CN201110289248A CN103021610B CN 103021610 B CN103021610 B CN 103021610B CN 201110289248 A CN201110289248 A CN 201110289248A CN 103021610 B CN103021610 B CN 103021610B
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magnetic material
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CN103021610A (zh
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胡永军
孟佳宏
胡云秀
周奕廷
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Ganzhou Xiexin superenergy Magnetic Industry Co., Ltd.
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DONGGUAN XUANYAO ELECTRONICS Co Ltd
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Abstract

本发明涉及永磁材料领域，公开了一种复合永磁磁性材料。所述材料由一个以上的永磁磁性材料拼接而成，永磁磁性材料之间为粘结剂。本发明提供的由不同磁性的磁体拼接在一起形成的新型复合永磁材料，极大的丰富了现有永磁体的体系，可以完全替代昂贵的稀有金属磁性材料，并且性能良好，而且通过调整拼接磁体的种类和长度可以调控磁体的磁性能，尤其是介于粘结钕铁硼和烧结钕铁硼中间的磁性能空白，使永磁电机设计和使用者有更为广阔和灵活的材料选择空间和成本选择空间。

Description

一种新型复合永磁材料及其制备方法
技术领域
本发明涉及永磁材料领域，尤其是一种用于电机方面的永磁材料。
背景技术
磁性材料是电子行业的基础功能材料。永磁材料作为磁性材料的一个重要组成部分，在电子工业、信息产业、摩托车、电动工具行业、汽车工业等行业发挥着重要的作用。永磁材料就是产生磁场的功能材料，传统的直流电机使用的永磁材料，无论是烧结产品还是塑磁产品，都是采用整体一致的材料。当电机的尺寸确定后，相应永磁材料的外形几何尺寸也就确定了。这样永磁材料在磁特性方面只能通过材料本身(材料的种类和同种材料的牌号)的变化进行调节。例如使用烧结钕铁硼N35SH、N42SH；铁氧体；粘结钕铁硼BNM-10(对应MQ磁粉B粉)、BNM-8SR(对应MQ磁粉14-12)、铝镍钴或钐钴等。而实际上不同种类的磁性材料各自在此特性，包括最大磁能积(BH)max、剩磁Br、矫顽力Hcj、磁感矫顽力Hcb等方面存在比较大的差异，例如目前最为常用的铁氧体、粘结钕铁硼和烧结钕铁硼主要代表此特性见下表：
表1目前商业化主要磁体特性
从表1中可以看出，粘结钕铁硼在磁能积方面基本上可以同铁氧体对接。但烧结钕铁硼同粘结钕铁硼之间明显存在较大性能空白。因此，这些材料对电机的磁路设计和实际应用都存在比较大的制约。
目前最为常用的是铁氧体永磁体，虽然磁性能相对来说较低，但其低廉的价格决定了其在常规领域的绝对占有率。随着科技的进步及人类对轻、薄、短、小等自动化设备和用品的要求的不断提升，对拥有较高磁能积的稀土类磁体的需求不断提升，但是高磁能积的稀土类磁体价格昂贵，制约了很多电机或者永磁磁体行业的发展。所以亟待有一种价格低廉但是磁能积又高的磁性材料的出现。
发明内容
为了解决上述问题，本发明实施例提供了一种与
本发明是这样实现的：
一种复合永磁材料，所述材料由一个以上的永磁磁性材料拼接而成，永磁磁性材料之间为粘结剂。
可选的，所述拼接的永磁磁性材料为相同材料不同磁性能的永磁磁性材料。
可选的，所述拼接的永磁磁性材料为不同材料的永磁磁性材料。
所述永磁磁性材料为但不限定于各向同性烧结铁氧体、各向异性烧结铁氧体、各项同性粘结铁氧体、各向异性粘结铁氧体、铝镍钴、烧结钕铁硼、各项同性粘结钕铁硼、各向异性粘结钕铁硼、烧结钐钴、粘结钐钴、钐铁氮、通过压制、注射、挤出等工艺制成的粘结磁体中的一种或者多种。本发明中只要是具有永磁磁性的材料就可以。
可选的，所述粘结剂为聚氨酯类粘结剂或者双组份的改性丙烯酸酯固化剂或者环氧型粘结剂或者厌氧型粘结剂。
本发明的另一目的是提供一种制备所述复合永磁材料的方法，所述方法为：将一个以上的永磁磁性材料根据目标磁体要求顺序排列，采用粘结剂拼接，所述永磁磁性材料采用奇数间隔排列的方式或者偶数间隔排列的方式进行拼接。
奇数间隔排列的方式即：两种材质的磁体总数为M＝2*N+1(N≥1)，两种材质的磁体间隔排列形成整体磁体。如N＝2，排列顺序为强磁+弱磁+强磁+弱磁+强磁，或者弱磁+强磁+弱磁+强磁+弱磁；N＝3，排列为弱磁+强磁+弱磁+强磁+弱磁+强磁+弱磁，或者强磁+弱磁+强磁+弱磁+强磁+弱磁+强磁，以此类推。同时强磁体和弱磁体的长度可根据总体磁体的具体要求进行调整。
偶数间隔排列的方式即：两种材质的磁体总数为M＝2*N(N≥1)，同种材质的磁体两两一组，不同材质的磁体间隔排列。如N＝2，强磁+强磁+弱磁+弱磁+强磁+强磁+弱磁+弱磁，或者弱磁+弱磁+强磁+强磁+弱磁+弱磁+强磁+强磁。以此类推。同时强磁体和弱磁体的长度可根据总体磁体的具体要求进行调整。
可选的，所述粘结剂采用厌氧胶进行粘合，在粘合之前将永磁磁性材料进行活化处理：
(1)将各永磁磁性材料分别进行电泳；
(2)将电泳后的各永磁磁性材料浸泡在厌氧胶促进剂中进行磁体表面活化处理；
(3)在各永磁磁性材料需要进行粘接的部位均匀涂上厌氧胶，校对好位置后粘在一起，然后再进行固化。
本发明提供的由不同磁性的磁体拼接在一起形成的新型复合永磁材料，极大的丰富了现有永磁体的体系，可以完全替代昂贵的稀有金属磁性材料，并且性能良好，解决了目前磁体及电机行业发展受资源短缺的约束的问题，大大降低了磁体的成本。而且通过调整拼接磁体的种类和长度可以调控磁体的磁性能，尤其是介于粘结钕铁硼和烧结钕铁硼中间的磁性能空白，使永磁电机设计和使用者有更为广阔和灵活的材料选择空间和成本选择空间。例如：采用弱磁+强磁+弱磁的拼接方式形成的复合磁体在进行充磁后，可以达到中间磁性较强，两边磁性相对较弱的特性，并且这种中间强两边弱的特性表现可以通过中间强磁体和两边弱磁体的相对大小的变化进行调整。
具体实施方式
发明实施例中的复合永磁材料由不同磁性能的永磁材料拼接而成，各磁性材料之间采用厌氧胶(如采用乐泰圆柱形固持胶-6系列和乐泰结构粘接胶-3系列)作为粘结剂粘合，在粘合之前将永磁磁性材料进行活化处理：
(1)将各永磁磁性材料分别进行电泳；
(2)将电泳后的各永磁磁性材料浸泡在厌氧胶促进剂(如乐泰Loctitie7649)中进行磁体表面活化处理；
(3)在各永磁磁性材料需要进行粘接的部位均匀涂上厌氧胶，校对好位置后粘在一起，10分钟后用碎布沾丙酮擦干净工件上面粘结部位挤出来的多余的胶，1小时候再在120℃下固化10min。
对于电机永磁体的简单表征：中心磁场是一个重要的参数，不同种类的磁体拼接后测试的一个主要参数是产品充磁后装入机壳内的中心磁场值。
当实施例中的弱磁体为粘结钕铁硼(如BNM-10)，强磁体为烧结钕铁硼(如N35SH)，通过不同比例的调整可以实现从粘结钕铁硼(如BNM-10)到烧结钕铁硼(如N35SH)的磁特性变化。
实施例1：
对于外半径为19.8mm、内半径为16.8mm、弧面为135°、壁厚为3.5mm、宽度为35mm、高度为19.5mm的磁体产品：
单采用粘结钕铁硼BNM-10产品(对应MQ磁粉B粉)采用辐射充磁，N、S极配对装在电机机壳中，形成内半径为16.8的圆形磁体，测得的中心磁场为650-670Gs；
单采用粘结钕铁硼BNM-12产品(对应MQB+磁粉)采用辐射充磁，N、S极配对装在电机机壳中，形成内半径为16.8的圆形磁体，测得的中心磁场为750-770Gs；
单采用烧结钕铁硼N35SH采用平行充磁，N、S极配对装在电机机壳中，形成内半径为16.8的圆形磁体，测得的中心磁场为950-980Gs；
使用高度H为7.7mm的粘结钕铁硼BNM-10+高度为4mm的烧结钕铁硼N38S+高度为7.7mm粘结钕铁硼BNM-10拼接而成的复合永磁材料，采用辐射充磁，N、S极配对装在电机机壳中，形成内半径为16.8的圆形磁体，测得的中心磁场为750-770Gs；
使用H＝7.7mm的粘结钕铁硼BNM-12+H＝4mm的烧结钕铁硼N38S+H＝7.7mm的粘结钕铁硼BNM-12拼接而成的复合永磁材料，采用辐射充磁，N、S极配对装在电机机壳中，形成内半径为16.8的圆形磁体，测得的中心磁场为810-830Gs；
使用H＝6.7mm的粘结钕铁硼BNM-10产品+H＝6mm的烧结钕铁硼N38S+H＝6.7mm的粘结钕铁硼BNM-10拼接而成的复合永磁材料，采用辐射充磁，N、S极配对装在电机机壳中，形成内半径为16.8的圆形磁体，测得的中心磁场为850-870Gs；
使用H＝6.7mm的粘结钕铁硼BNM-12产品+H＝6mm烧结钕铁硼N38S+H＝6.7mm的粘结钕铁硼BNM-12拼接而成的复合永磁材料，采用辐射充磁，N、S极配对装在电机机壳中，形成内半径为16.8的圆形磁体，测得的中心磁场为920-950Gs。
不同的粘结钕铁硼磁体和烧结钕铁硼磁体拼接复合，在实体使用的中心磁场方面，可以实现由粘结钕铁硼特性到烧结钕铁硼特性的过度，使永磁电机设计和使用者有更为广阔和灵活的材料选择空间和成本选择空间。
实施例2：
对于外半径为16.9mm、内半径为12.9mm、弧面为135°、壁厚4.05mm、宽度30mm、高度32mm的产品：
单独采用H＝32mm的粘结钕铁硼BNM-10产品，采用辐射充磁，N、S极配对装在电机机壳中，形成内半径为12.9的圆形磁体，测得的中心磁场为1160-1170Gs；
采用两个粘结钕铁硼BNM-10拼接后的复合永磁材料，拼接后达到32mm高度，采用辐射充磁，N、S极配对装在电机机壳中，形成内半径为12.9的圆形磁体，测得的中心磁场为1210-1230Gs；
单独采用H＝32mm的粘结钕铁硼BNM-12产品，采用辐射充磁，N、S极配对装在电机机壳中，形成内半径为12.9的圆形磁体，测得的中心磁场为1230-1240Gs；
使用两个H＝16mm的粘结钕铁硼BNM-12材料，产品拼接后达到32mm高度，采用辐射充磁，N、S极配对装在电机机壳中，形成内半径为12.9的圆形磁体，测得的中心磁场为1290-1300Gs；
使用H＝11mm的粘结钕铁硼BNM-12+H＝10mm烧结钕铁硼N38S+H＝11mm的粘结钕铁硼BNM-12拼接而成的复合永磁材料，采用辐射充磁，N、S极配对装在电机机壳中，形成内半径为12.9的圆形磁体，测得的中心磁场为1590-1610Gs；
使用H＝10mm的粘结钕铁硼BNM-12+H＝12mm的烧结钕铁硼N38S+粘H＝10mm的结钕铁硼BNM-12拼接而成的复合永磁材料，采用辐射充磁，N、S极配对装在电机机壳中，形成内半径为12.9的圆形磁体，测得的中心磁场为1660-1680Gs。
对于使用单独一个高度为32mm的粘结钕铁硼磁体，如本例中的瓦型磁体，采用立式成型，因为是双向压制成型，产品两端密度高，中间密度低，并且产品高度比较高，产品总密度不高。而使用两个H＝16mm粘结钕铁硼磁体拼接成H＝32的复合永磁材料，每个16mm的粘结钕铁硼磁体的密度相应提高。并且拼接后，中间密度最高(对应磁力较强)。这样拼接的产品较整体一次成型的产品重量提高4-5％，因为粘结钕铁硼同性产品的此特性基本同重量成正相关，充磁后中心磁场高4-5％。
实施例2中第5种和第6种方式的复合永磁磁体较两片粘结钕铁硼BNM-12拼接的复合永磁磁体中心磁场高28.5％，较单独的粘结钕铁硼BNM-12产品中心磁场高35％。
以上对本发明实施例所提供的技术方案进行了详细介绍，本文中应用了具体个例对本发明实施例的原理以及实施方式进行了阐述，以上实施例的说明只适用于帮助理解本发明实施例的原理；同时，对于本领域的一般技术人员，依据本发明实施例，在具体实施方式以及应用范围上均会有改变之处，综上所述，本说明书内容不应理解为对本发明的限制。

Claims (1)

1.一种复合永磁材料，用作电机永磁体，所述电机永磁体的横截面为圆弧形，其特征在于：所述材料由一个以上的永磁磁性材料沿电机永磁体高度的方向按奇数间隔排列的方式或者偶数间隔排列的方式拼接而成，永磁磁性材料之间为粘结剂；
其中，所述永磁磁性材料为烧结钕铁硼、各项同性粘结钕铁硼、各向异性粘结钕铁硼中的至少一种；
所述粘结剂为聚氨酯类粘结剂或者双组份的改性丙烯酸酯固化剂或者环氧型粘结剂或者厌氧型粘结剂。
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