CN106409454A - 磁铁的制造方法及磁铁 - Google Patents

磁铁的制造方法及磁铁 Download PDF

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CN106409454A
CN106409454A CN201610460953.5A CN201610460953A CN106409454A CN 106409454 A CN106409454 A CN 106409454A CN 201610460953 A CN201610460953 A CN 201610460953A CN 106409454 A CN106409454 A CN 106409454A
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magnetic powder
magnet
powder
lubricant
temperature
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三尾巧美
西幸二
木元雄辅
田村高志
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JTEKT Corp
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Priority claimed from JP2015134252A external-priority patent/JP2017017920A/ja
Priority claimed from JP2015134251A external-priority patent/JP2017017919A/ja
Priority claimed from JP2015135757A external-priority patent/JP2017017294A/ja
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Abstract

一种磁铁(8)的制造方法，包括：得到磁粉(1)和润滑剂(2)的混合粉末的工序(S3)；混合由硅酮组合物构成的未固化的粘结材料(5)而在混合粉末的表面附着粘结材料的工序(S5)；将混合粉末加压成型而得到成型体(6)的工序(S6)；将硅酮组合物固化而粘结磁粉(1)的工序(S7)。

Description

磁铁的制造方法及磁铁
技术领域
本发明涉及磁铁的制造方法及磁铁。
背景技术
在日本特开2003-318012号公报中记载了由磁场取向用磁性粉末和合成树脂构成的永久磁铁(粘接磁铁)。记载了以钐-铁-氮为主成分作为磁性粉末(磁粉)。记载了选自聚酰胺树脂、丙烯腈-丁二烯-苯乙烯(ABS)树脂、聚氯乙烯树脂、聚苯硫醚(PPS)树脂、氯化聚乙烯树脂中的至少1种作为合成树脂。
日本特开2003-318012号公报中记载的粘接磁铁以在合成树脂中含有磁粉的状态下进行粘结。在通常的粘接磁铁中，将磁粉的体积设为100vol％时，以40vol％以上的比例含有合成树脂。粘接磁铁的磁特性取决于所含的磁粉的比例(磁粉的含有比例)。如果磁粉的含有比例变低，则粘接磁铁的磁特性降低。另外，如果磁粉的含有比例变高，则不仅磁铁的成型性(注塑成型的成型性)大幅降低，磁粉粒子的固定也变得不充分，无法保持粘接磁铁的形状。因此，在粘接磁铁中，磁特性的提高(剩余磁通密度的降低的抑制)有限制。
发明内容
本发明的目的之一是提供一种能够得到高的剩余磁通密度的磁铁的制造方法及磁铁。
本发明的一个方式的磁铁的制造方法，具有：
得到磁粉和润滑剂的混合粉末的工序、
将由硅酮组合物构成的未固化的粘结材料而在混合粉末的表面附着粘结材料的工序、
将混合粉末加压成型得到成型体的工序、
将硅酮组合物固化而粘结磁粉的工序。
在上述方式的磁铁的制造方法中，在磁粉与润滑剂的混合粉末的表面附着未固化的粘结材料，其后，将混合粉末加压成型得到成型体。将混合粉末加压成型时，位于混合粉末的磁粉的粒子间的润滑剂和粘结材料发挥润滑性。利用该润滑性可促进磁粉的粒子的移动，进行粒子的再排列。提高使成型体成型的成型性，得到致密的成型体。用致密的成型体可制造致密的磁铁。因此，根据本发明的制造方法，可制造具备高的剩余磁通密度的磁铁。
本发明的另一方式的磁铁可利用上述方式的磁铁的制造方法制造。
上述方式的磁铁成为剩余磁通密度高的磁铁。
附图说明
以下参照附图对本发明的优选实施方式进行详细描述，由此本发明前述的和其它的特点和优点得以进一步明确。其中，附图标记表示本发明的要素，其中：
图1是表示实施方式的磁铁的制造方法的各工序的图。
图2是表示将实施方式的磁粉与润滑剂混合的工序的示意图。
图3是表示将实施方式的磁粉与润滑剂混合的工序的示意图。
图4是示意地表示实施方式的磁粉和粘结材料混合的状态的截面图。
图5是表示实施方式的磁粉的加压工序的示意图。
图6是表示实施方式的磁粉的加压工序的示意图。
图7是示意地表示实施方式的成型体的磁粉的排列状态的放大图。
图8是示意地表示实施方式的磁铁的构成的放大图。
具体实施方式
关于本发明的磁铁的制造方法，参照图1～图8，通过实施方式进行具体说明。图1是表示本方式的磁铁的制造方法的各工序的图。
如图1的步骤S1所示，准备作为磁铁的材料的磁粉1。
磁粉1可使用作为磁性材料的粒子的集合体的粉末。磁粉1的磁性材料没有限定，但优选由硬磁性体构成。作为硬磁性体，例如可举出铁氧体磁铁、Al-Ni-Co系磁铁、含有稀土类元素的稀土类磁铁、氮化铁磁铁。
作为硬磁性体的磁粉1，优选使用由Fe-N系化合物、R-Fe-N系化合物(R：稀土类元素)的一种以上构成的化合物。应予说明，作为由R表示的稀土类元素，只要是作为所谓的稀土类元素已知的元素(Sc、Y、La、Ce、Pr、Nd、Pm、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm、Yb、Lu、Ac、Th、Pa、U、Np、Pu、Am、Cm、Bk、Cf、Es、Fm、Md、No、Lr)即可，更优选Dy以外的稀土类元素(R：不包括Dy的稀土类元素)。其中，特别优选为轻稀土类元素，其中，最优选Sm。这里所说的轻稀土类元素，是在镧系元素中原子量小于Gd的元素，即La～Eu。Fe-N系化合物包含于氮化铁磁铁中。R-Fe-N系化合物包含于稀土类磁铁中。
磁粉1只要是Fe-N系化合物、R-Fe-N系化合物，则具体的组成没有限定。磁粉1最优选为Sm2Fe17N3或者Fe16N2的粉末。
磁粉1的粒径(平均粒径)没有限定。优选平均粒径(D50)为2～5μm左右。另外，磁粉1使用在全部粒子表面不形成氧化膜的磁粉。
如图1的步骤S2所示，准备润滑剂2。润滑剂2在通常的条件下(大气气氛下，室温)可使用固体的物质(固体润滑剂)。润滑剂2使用粉末状的润滑剂。
润滑剂2使用金属皂系的润滑剂(固体润滑剂粉末)。润滑剂2使用例如硬脂酸锌等的硬脂酸系金属的粉末。润滑剂2的粉末的平均粒径(D50)为10μm左右。这里，优选润滑剂2的平均粒径大于磁粉1的平均粒径。润滑剂2的比重小于磁粉1的比重。因此，通过一定程度上增大润滑剂2的初始状态的大小，能够增大润滑剂2的每1粒的质量，并能够抑制在后述的步骤S3的工序中混合时润滑剂2飞散。
磁粉1与润滑剂2的混合比例可任意设定。磁粉1与润滑剂2的混合比例以体积比例计，优选设为磁粉1：80～90体积％、润滑剂2：5～15体积％。应予说明，除磁粉1和润滑剂2以外，也可以添加添加剂。作为添加剂，可举出因其后的加热而消失的有机溶剂等添加剂。
如图1的步骤S3所示，混合先前2个工序中准备的磁粉1和润滑剂2得到混合粉末。
关于磁粉1与润滑剂2的混合，边将两粉末1、2磨碎边进行混合。形成混合粉末的方法如图2所示，用混合用容器4边将磁粉1和润滑剂2磨碎边进行混合。通过边磨碎边混合，从而如图3所示，结合强度低的润滑剂2被细分化，并且润滑剂2的粒径整体上变小。在本工序结束时，存在粒子大小不同的润滑剂2。
进而，混合粉末1、2能够减少仅由磁粉1所致的块状的部分(粉碎磁粉1的二次粒子)，能够减小润滑剂2的大小。即，能够使被细化的润滑剂2存在于与磁粉1的各粒子接近的位置。
接着，如图1的步骤S4所示，加热混合粉末1、2在磁粉1的表面形成吸附膜3。
将在之前的工序(步骤S3)中混合的磁粉1和润滑剂2的混合粉末1，2在加热温度T1下加热，在磁粉1的表面形成润滑剂2的吸附膜3。此时的混合粉末1、2的加热温度T1小于磁粉1的分解温度T2且为润滑剂2的熔点T3以上的温度(T3≤T1＜T2)。
如果在加热温度T1下对混合粉末1、2进行加热，则磁粉1不会发生分解而润滑剂2熔融。熔融的润滑剂2沿磁粉1的粒子的表面流动并被覆磁粉1的表面。而且，在磁粉1的表面形成(生成)吸附膜3。其后，在小于熔点T3的温度下冷却后将吸附膜3固化。
加热温度T1下的加热时间t取决于混合粉末1、2所赋予的热量，因此，并没有限定。即，加热温度T1如果为高温，则给予混合粉末1、2的每单位时间中的热量增加，加热时间t变短。另外，加热温度T1为较低温度的情况下，优选延长加热时间t。
关于加热温度T1和加热时间t，对混合粉末1、2赋予的热量越大，越能够生成凝聚于磁粉1的表面的吸附膜3，在加压工序(步骤S6)中不产生被膜破裂。进而，能够制造高密度的成型体6和磁铁8。
接着，如图1的步骤S5所示，在形成有吸附膜3的磁粉1的表面配置未固化的粘结材料5。
粘结材料5可使用由硅酮组合物构成的未固化的粘结材料。该粘结材料5在室温下不是凝胶状而是液体状，具有流动性。通过将粘结材料5与磁粉1混合，从而将粘结材料5配置于磁粉1的粒子的表面。在该状态下，如在图4中用示意图表示截面所示，在邻接的磁粉1的粒子彼此间夹设粘结材料5。
粘结材料5的硅酮组合物使用具有基于硅氧烷键的主骨架的组合物。硅酮组合物例如使用硅酮树脂。硅酮组合物配置于磁粉1的表面时未固化(不是凝胶状而是液体状)，在其后的工序(本方式中为步骤S7的加热固化的工序)中进行固化。
将粘结材料5固化的方法没有限定。例如，可举出加热、紫外线的照射、接触水等反应引发剂而开始进行固化等的方法。本方式中使用利用因加热而固化的热固化型硅酮组合物。与紫外线的照射相比，加热容易传递到成型体6的内部，能够可靠地固化。
热固化型的硅酮组合物的固化温度(固化开始温度)T4小于磁粉1的分解温度T2。
粘结材料5的混合比例可任意设定。例如，将磁粉1(形成吸附膜3的状态)的体积设为100vol％时，可以设为5～15vol％，优选设为8～12vol％。
接着，如图1的步骤S6所示，将磁粉1加压而形成成型体6(图5～图6)。本工序中加压的磁粉1在粒子间夹设粘结材料5。
如图5以示意图所示，加压工序中，在加压模具7(加压下模71(模具))的腔室内配置磁粉1。加压模具7由非磁性钢构成。用加压模具7进行的加压在磁粉1透过磁力线的条件下(进行磁场取向的条件下)进行。
接着，如图6以示意图所示，在加压下模71安装加压上模72，使加压下模71与加压上模72沿着彼此接近的方向移动，从而利用加压模具7(71、72)将磁粉1加压成型。此时，基于加压模具7(71、72)的加压力是破坏磁粉1的破坏压力以下的压力。本方式中，为1GPa以下。
然后，进行多次(2次以上)利用加压模具7(71、72)的加压。向加压上模72附加压力后，松开附加于加压上模72的压力，再次对加压上模72附加压力。然后，重复该动作。应予说明，松开附加于加压上模72的压力时，可以使加压上模72向上侧移动，也可以不使加压上模72向上侧移动而仅减少压力。
利用加压模具7(71、72)的加压次数可以设为使成型体6的密度提高效果达到饱和的次数。例如，可以进行2～30次。
进而，在加压工序中，例如从外侧面通过加热器(未图示)等对加压模具7(71、72)进行加热，从而对加压模具7(71、72)内的磁粉1进行加热。此时的磁粉1的加热温度T5小于吸附膜3融化而液化的温度(熔点T3以上的温度)且小于粘结材料5的固化温度T4。该加热温度T5也小于磁粉1的分解温度T2(T3＜T5＜T4＜T2)。因此，即使进行加热磁粉1也不分解，不仅如此，粘结材料5也不固化。
如图7中放大图所示，如果重复用加压模具7进行加压，则可形成磁粉1的粒子间的缝隙变小的成型体6。其原因在于，通过进行多次加压，相对于前次加压时的磁粉1的粒子的排列状态，磁粉1的粒子进行再排列。
在磁粉1的粒子的再排列中，通过邻接的磁粉1的粒子彼此间的抵接表面(滑动接触表面)夹设润滑剂2的吸附膜3，从而能使磁粉1的粒子彼此非常顺利地移动。通过该磁粉1的粒子的再排列与吸附膜3的滑动的协同作用，在成型体6中磁粉1的粒子的缝隙变小。
另外，在磁粉1的粒子之间以未固化的状态夹设粘结材料5。未固化的状态的粘结材料5发挥硅油的特性，也发挥润滑性。即，通过在邻接的磁粉1的粒子间夹设吸附膜3和未固化的粘结材料5，从而可促进磁粉1的粒子的移动(再排列)。利用该作用，也可使在成型体6中磁粉1的粒子的缝隙变小。即，可得到磁粉1的粒子的缝隙小的成型体6。
接着，如图1的步骤S7所示，加热成型体6将粘结材料5固化。
成型体6的加热温度T6为热固化型的硅酮组合物的固化温度(固化开始温度)T4以上且小于磁粉1的分解温度T2。(T4≤T6＜T2)。
本工序的加热通过在加热温度T6下对成型体6进行加热而进行。例如，将用之前的加压工序(步骤S6)的加压模具7成型而得的成型体6不从加压模具7中取出，将加压模具7的温度设为加热温度T6而进行。
另外，也可以将成型体6从加压模具7中取出而配置于利用微波的加热炉、电炉、等离子体加热炉、高频淬火炉、利用红外线加热器的加热炉等中来进行。
在加热温度T6下的加热时间设为粘结材料5固化结束为止的时间。
通过实施以上各工序可制造本方式的磁铁8。
对于上述制造方法中制造的本方式的磁铁8，其构成如图8中示意图所示，固化的粘结材料50粘结磁粉1的粒子彼此。磁粉1的粒子不与其他粒子直接接合。
粘结材料50仅夹设于磁粉1的粒子的抵接部附近。即，磁粉1的粒子的表面的一部分露出。另外，也可以在粒子间残留有微细的空隙。该情况下，磁粉1在其表面使吸附膜3成膜而抑制露出磁性材料。即，可抑制因气氛所致的氧化等的磁粉1的磁特性降低。
本方式的制造方法中，从磁粉1与润滑剂2的混合粉末1、2在磁粉1的表面生成吸附膜3，进而在粒子表面附着未固化的粘结材料5。其后，将磁粉1加压成型而得到成型体6。根据该构成，对磁粉1进行加压成型时，位于磁粉1的粒子间的吸附膜3和粘结材料5发挥润滑性。利用该润滑性可促进磁粉1的粒子的移动，进行粒子的再排列。即，根据本方式，提高使成型体6成型的成型性，能够得到致密的成型体6。用致密的成型体6可制造致密的磁铁8。因此，根据本方式的制造方法，可制造具备高的剩余磁通密度的磁铁8。
在本方式的制造方法中，润滑剂2中可使用金属皂系的润滑剂(硬脂酸系金属)，加热至润滑剂2的熔点T3以上的温度T1而在磁粉1的表面附着熔融的润滑剂2，其后，降温至小于熔点T3的温度进行凝固来生成吸附膜3。该吸附膜3吸附于磁粉1的粒子，即使在加压工序中磁粉1的粒子彼此滑动，也可抑制吸附膜3的剥离(润滑性的降低)。并且，可促进磁粉1的粒子彼此的移动(粒子的再排列)，能够可靠地得到缝隙减少的致密的成型体6。
另外，金属皂系的润滑剂2(硬脂酸系金属)在固体的温度域时不与粘结材料5(硅酮树脂组合物)混合。因此，在将成型体6成型之前的磁粉1中，即使将润滑剂2(吸附膜3)和粘结材料5混合存在，也能够充分发挥彼此的性能。这也表明不仅有加压时的粒子的再排列被促进这样的润滑性的效果，还不会发生粘结材料5(硅酮树脂组合物)的粘结性降低。
根据本方式的制造方法，使用由Fe-N系化合物、R-Fe-N系化合物(R：稀土类元素)的一种以上形成的化合物作为硬磁性体的磁粉1。根据该构成，可廉价地制造磁铁。在该基础上，在本方式的制造方法中，R可以不使用镝(Dy)。即，可廉价地制造磁铁。
根据本方式的制造方法，硅酮组合物为热固化型的硅酮组合物，将成型体6加热进行固化。根据该构成，能够将磁粉1的粒子简单地粘结。另外，加热可以使成型体6的内部温度也上升，成型体6的内部也能够可靠地固化。即，可抑制成型体6的外形形状的变化(尺寸精度的降低)。
根据本方式的制造方法，硅酮组合物的固化温度为小于磁粉的分解温度的温度。根据该构成，即使为了固化粘结材料5(硅酮组合物)而进行加热也能够抑制磁粉1的分解。即，在不发生磁粉1的磁性能力降低的情况下，能够将粘结材料5固化。因此，可制造剩余磁通密度的下降得以抑制的磁铁8。
本方式的磁铁8利用上述制造方法制造而成。根据该构成，形成具备上述全部效果的磁铁。
本方式的磁铁8具有磁粉1的粒子和粘结粒子彼此的固化的粘结材料50。根据该构成，粘结材料50将使磁粉1的粒子彼此粘结，并不形成磁铁8的形状。因此，可减少固化的粘结材料50(未固化的粘结材料5)的含有比例。作为结果，能够减少磁铁8的不发挥磁性能力的粘结材料50所占的体积，成为剩余磁通密度优异的磁铁。
特别是本方式的磁铁8可将粘结材料5的混合比例减少为5～15vol％。该构成表示本方式的磁铁8是仅粘结磁粉1的粒子的接点的、实质上与压粉成型体同等的构成。
与此相对，以往的粘接磁铁以40vol％以上的比例含有合成树脂。即，本方式的磁铁8与以往的粘接磁铁相比，能够将磁粉1的含有比例提高到25vol％以上，成为剩余磁通密度优异的磁铁。
更具体而言，在将合成树脂的混合比例设为40vol％的以往的粘接磁铁的剩余磁通密度设为100％的情况下，将粘结材料5的混合比例设为10vol％的本方式的磁铁8的剩余磁通密度约为150％。
换言之，本方式的磁铁8在含有相同量(同体积量)的磁粉1的情况下，与以往的粘接磁铁相比，体积减少至66.7％。即，以相同的剩余磁通密度的磁铁进行比较时，本方式的磁铁8与以往的粘接磁铁相比，能够将体积小型化为33.3％。

Claims (6)

1.一种磁铁的制造方法，包括：
得到磁粉和润滑剂的混合粉末的工序；
混合由硅酮组合物构成的未固化的粘结材料而在该混合粉末的表面附着该粘结材料的工序；
将该混合粉末加压成型得到成型体的工序；和
将该硅酮组合物固化而粘结该磁粉的工序。
2.根据权利要求1所述的磁铁的制造方法，其中，
所述润滑剂为金属皂系的润滑剂，
将所述混合粉末加热至该润滑剂的熔点以上的温度而在所述磁粉的表面附着该润滑剂，其后，降温至小于熔点的温度来进行凝固。
3.根据权利要求1或2所述的磁铁的制造方法，其中，所述磁粉由Fe-N系化合物、R-Fe-N系化合物中的一种以上的硬磁性体构成，其中，R：稀土类元素。
4.根据权利要求1或2所述的磁铁的制造方法，其中，
所述硅酮组合物为热固化型的硅酮组合物，
对所述成型体进行加热来固化该硅酮组合物。
5.根据权利要求4所述的磁铁的制造方法，其中，所述硅酮组合物的固化温度为小于所述磁粉的分解温度的温度。
6.一种磁铁，是利用权利要求1或2所述的磁铁的制造方法来制造的。
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