CN113140401A - 在没有磁场的情况下处理各向异性永磁体 - Google Patents

在没有磁场的情况下处理各向异性永磁体 Download PDF

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CN113140401A
CN113140401A CN202110041746.7A CN202110041746A CN113140401A CN 113140401 A CN113140401 A CN 113140401A CN 202110041746 A CN202110041746 A CN 202110041746A CN 113140401 A CN113140401 A CN 113140401A
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anisotropic
magnet
flakes
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李万锋
荣传兵
弗朗哥·伦纳迪
迈克尔·W·德格纳
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Abstract

本公开提供了“在没有磁场的情况下处理各向异性永磁体”。一种处理各向异性永磁体的方法包括：由块状各向异性磁体形成各向异性薄片，所述各向异性薄片中的每一个具有相对于所述薄片的表面的易磁化方向；以及将所述各向异性薄片与粘结剂组合以形成混合物。所述方法还包括：在不施加磁场的情况下挤出或轧制所述混合物使得所述各向异性薄片的所述易磁化方向对准以形成具有与所述各向异性薄片的所述易磁化方向对准的磁化方向的一个或多个层；以及由具有所述磁化方向的所述层制作所述各向异性永磁体，使得所述各向异性永磁体具有具特定取向的磁场。

Description

在没有磁场的情况下处理各向异性永磁体
技术领域
本公开涉及永磁体，并且特别地，涉及处理各向异性永磁体。
背景技术
永磁体具有许多应用，例如在马达、发电机和其他磁性装置中。
对于大多数用途，磁体在期望的方向上产生磁场。各向异性磁体通常用于需要改善的性能和更强磁场的情况。各向异性磁体常规上通过以下步骤来制备：在存在磁场的情况下将磁性粉末对准，之后进行常规固结步骤。影响永磁体的颗粒对准的因素包括可实现的场强度、粉末形状以及其他因素。此外，常规制备的永磁体的形状限于圆柱体、立方体和具有固定取向的其他规则形状。因此，控制永磁体的形状和易磁化方向的灵活性可以提高磁性装置的性能和效率。尽管诸如增材制造和其他新处理技术的材料处理的进步已经使得制作复杂形状不那么困难，但是控制磁化方向的灵活性仍然具有挑战性。
发明内容
根据一个或多个实施例，一种处理各向异性永磁体的方法包括：由块状各向异性磁体形成各向异性薄片，所述各向异性薄片中的每一个具有相对于所述薄片的表面的易磁化方向；以及将各向异性薄片与粘结剂组合以形成混合物。所述方法还包括：在不施加磁场的情况下挤出或轧制所述混合物使得各向异性薄片的易磁化方向对准以形成具有与各向异性薄片的易磁化方向对准的磁化方向的一个或多个层；以及由具有所述磁化方向的所述层制作各向异性永磁体，使得各向异性永磁体具有具特定取向的磁场。
根据至少一个实施例，粘结剂可以是环氧树脂、润滑剂或延展性合金粉末。在一个或多个实施例中，所述方法还可以包括按压所述层以进一步将所述薄片对准。在至少一个实施例中，块状各向异性磁体可以是Nd-Fe-B、Sm-Fe-N、Sm-Co、Al-Ni-Co、铁氧体或Mn-Bi。在某些实施例中，所述形成可以包括块状各向异性磁体的熔化和固化。在一些实施例中，在块状各向异性磁体可以是Al-Ni-Co或Mn-Bi的情况下，固化可以是快速固化过程，之后进行退火。在其他实施例中，在块状各向异性磁体可以是Nd-Fe-B、Sm-Fe-N或Sm-Co的情况下，固化可以是定向固化或研磨。在一个或多个实施例中，所述制作可以包括加工所述层、将所述层堆叠、按压所述层、使所述层弯曲或其组合以调整特定取向。在至少一个实施例中，挤出混合物可以包括使各向异性薄片的表面平行于挤出表面对准。在一些实施例中，轧制混合物可以包括使各向异性薄片的表面平行于轧制表面对准。
根据一个或多个实施例，一种处理各向异性永磁体的方法包括：由块状各向异性磁体形成各向异性薄片，所述各向异性薄片各自具有易磁化方向；以及将各向异性薄片与粘结剂组合以形成混合物。所述方法还包括：在不施加磁场的情况下挤出或轧制所述混合物以形成具有基于易磁化方向的集体磁化方向的各向异性薄片的一个或多个各向异性层；以及由具有所述集体磁化方向的所述层制作各向异性永磁体，使得所述各向异性永磁体具有具特定取向的磁场。
根据至少一个实施例，块状各向异性磁体可以是Nd-Fe-B、Sm-Fe-N、Sm-Co、Al-Ni-Co、铁氧体或Mn-Bi。在一个或多个实施例中，所述制作可以包括加工所述层、将所述层堆叠、按压所述层、使所述层弯曲或其组合以调整特定取向。在一些实施例中，在块状各向异性磁体可以是Al-Ni-Co或Mn-Bi的情况下，固化可以是快速固化过程，之后进行退火。在其他实施例中，在块状各向异性磁体可以是Nd-Fe-B、Sm-Fe-N或Sm-Co的情况下，固化可以是定向固化或研磨。在某些实施例中，所述方法还可以包括在不改变集体磁化方向的情况下烧结磁体以去除粘结剂以增加固定磁场的强度。根据至少一个实施例，粘结剂可以是环氧树脂、润滑剂或延展性合金粉末。
根据一个或多个实施例，各向异性永磁体包括：磁性各向异性薄片的一个或多个层，所述磁性各向异性薄片中的每一个具有易磁化方向，其中所述层中的每一个具有与所述磁性各向异性薄片的易磁化方向对准的相应磁化方向，使得各向异性永磁体具有具特定取向的磁场，所述特定取向是基于相应的磁化方向。
根据至少一个实施例，磁性各向异性薄片可以是Nd-Fe-B、Sm-Fe-N、Sm-Co、Al-Ni-Co、铁氧体或Mn-Bi。在一个或多个实施例中，所述至少一个层可以包括与所述各向异性薄片混合的粘结剂，所述粘结剂是环氧树脂、润滑剂或延展性合金粉末。
附图说明
图1是根据一个实施例的形成具有对准的磁化方向的永磁体的方法的流程图；
图2是具有对准的磁化方向的Nd2Fe14B永磁体的晶体结构的示意图；
图3A至图3C是根据实施例的具有对准的磁化方向的各向异性薄片的示意图；
图4A至图4C是根据实施例的薄片对准的示意图；
图5A是根据一个实施例的对准的各向异性磁体的示意图；
图5B是图5A的各向异性磁体的薄片的局部放大示意图；
图6是根据一个实施例的对准的各向异性磁体的扫描电子显微镜图像；以及
图7A至图7C是根据实施例的具有不同的场方向的各向异性磁体的示意图。
具体实施方式
根据需要，本文中公开了本发明的详细实施例；然而，应理解，所公开的实施例仅仅是可以以各种形式和替代形式体现的本发明的示例。附图不一定按比例绘制；一些特征可能会被放大或最小化以示出特定部件的细节。因此，本文所公开的特定结构细节和功能细节不应被解释为是限制性的，而仅是解释为教导本领域技术人员以不同方式采用本发明的代表性基础。
根据一个实施例，公开了一种在不使用磁场的情况下在形成永磁体期间控制易磁化方向(或可互换地，磁化方向)的方法。在不需要磁场的情况下，可以制备具有受控磁化取向分布的更复杂形状的磁体。
参考图1，方法100包括制备各向异性永磁体薄片的步骤110。各向异性永磁体薄片是其形状与块状磁体的易磁化方向关联而不是随机分布的薄片。对于永磁体合金，例如像Nd-Fe-B、Sm-Co和铁氧体，磁相具有各向异性晶体结构，这意味着存在一条唯一的轴线。因此，沿着该轴线的物理性质不同于沿着其他方向的物理性质。例如，当经研磨形成粉末或薄片时，合金通常容易从垂直于该轴线的方向破碎，并且在固化期间，沿着该独特轴线的生长速率不同于沿着其他方向的生长速率。磁体破碎和固化可以用于通过控制处理参数来开发具有类似于块状磁体合金的性质的各向异性薄片。一种制备各向异性薄片的方法是通过受控固化，因为沿着易磁化方向的生长速率不同于其他方向。可以通过控制温度梯度和冷却速率来制备磁性薄片。对于这种方法，要求稀土元素的比率比化学计量需要更高来防止软磁性粉末的形成。任何合适的常规处理技术或新颖技术(例如，增材制造方法)可以用于制备薄片。
参考图2，示出了Nd2Fe14B结构的易磁化方向M。SmCo5、Sm2Co17、MnBi和铁氧体的结构具有类似的轴线和易磁化方向。由于永磁相100的晶体结构的对称性，固化期间的颗粒生长是各向异性的，并且因此，机械性质也是各向异性的。因此，可以在步骤110处通过控制方向梯度以促进各向异性来通过定向固化来制备各向异性薄片。为了使易磁化方向M垂直于薄片的表面，例如，可以将冷却期间的温度梯度控制为垂直于表面，同时使横向方向上的温度梯度最小化。这样，合金将仅朝向表面方向生长，并且所得薄片将是各向异性的。在各种实施例中，如图3A至图3C所示，易磁化方向可以相对于层的表面310变化。在一些实施例中，如图3A所示，磁化方向MA可以基本上垂直于表面310，在另一个实施例中，如图3B所示，磁化方向MB可以与表面310成一定角度，并且在如图3C所示的又一个实施例中，使不同的磁化方向MC1、MC2、MCX等与表面310成不同角度。
替代地，也可以在步骤110处通过自上而下方法制造各向异性永磁体薄片。所述自上而下方法包括将块状磁体破碎成薄片，其中块状磁体是单晶的或至少是各向异性的。可以研磨块状合金，因为与上面类似，永磁体材料的机械性质也是各向异性的，在研磨期间，合金更容易沿着垂直于易磁化方向的界面进行切片。在其中块状永磁体材料是Nd-Fe-B、Sm-Fe-N或Sm-Co的实施例中，可以通过熔化和定向固化/研磨来制备薄片。也可以在步骤110处通过化学/物理沉积方法来制备所述薄片。类似于固化方法，当适当地控制处理参数时，沿着不同轴线的生长速率差异将导致各向异性薄片。
再次参考图1，可以进行选项后处理步骤120以改善各向异性薄片的磁性质。例如，可以在磁场中对Al-Ni-Co或Mn-Bi材料的薄片进行退火，以实现具有特定磁化方向的薄片。在某些实施例中，诸如对于Nd-Fe-B或Sm-Fe合金薄片，薄片可能需要另外的处理，诸如但不限于GBD或氮化。在其中块状永磁体材料是Al-Ni-Co或Mn-Bi的实施例中，可以通过熔化和快速固化来制备薄片。
在步骤130处，将各向异性薄片与粘结剂混合以形成混合物。粘结剂可以是环氧树脂或润滑剂，并且可以以合适的量包括。在一些实施例中，粘结剂还可以是延展性合金粉末。值得注意的是，粉末与粘结剂之比不像常规粘结磁体中那样影响薄片的对准，因为对准在步骤140中在没有磁场的情况下发生。
所述方法还包括在步骤140处根据基于薄片的易磁化方向的所得磁体的期望磁场来对薄片进行取向。因为薄片的取向是固定的，所以所得磁体的易磁化方向也是固定的，而无需暴露于磁场来将薄片的颗粒对准。通过控制薄片的取向，可以控制易磁化方向，并且因此可以根据设计要求调制由磁体产生的磁场。参考图4A至图4C，步骤140的机构被示出为在没有磁场的情况下对薄片400进行取向，使得(粘结剂和薄片的)混合物被挤出或轧制。挤出或轧制由辊或轮410完成。因此，挤出或轧制可以将薄片400对准成对准层405。在某些实施例中，薄片400的表面将被对准成平行于表面420，从机器410对表面420施加应力。由于薄片400的表面与磁体的易磁化方向之间的取向关系，由对准的薄片400制备的所得磁体将是各向异性的。因此，施加磁场和加热薄片是进一步将薄片对准的可选步骤，而不是必需的。
参考图5A至图5B，对准层500包括对准薄片505和基于薄片505的易磁化方向Mx、My和Mz的总体磁化方向M5。参考图6，示出了在轧制期间对准的薄片600的示例。在该示例中，将薄片600与环氧树脂混合并进行轧制(如图4C中所示)。轧制之后的薄片600与薄片600的表面基本上平行于轧制表面620对准以形成对准层。
所述方法还包括在步骤150处通过堆叠对准磁体层的多个层来制备最终所得磁体。可以制备不同形状的最终永磁体，因为可以容易地将对准薄片的按压片材加工成不同形状。磁体可以例如是矩形700(图7A)，其中对准层701、702、703、704、705具有磁化方向M7A，或者其可以是具有层712、714、716的弧形710(图7B)，每个层具有相应的磁化方向M7B1、M7B2、M7B3，或者是在机器730狭槽中的U形或V形磁体720(图C)以在各个区域处基于所述形状经由磁化方向M7C1、M7C2、M7C3聚焦磁体通量。尽管图7A至图7C所示的层具有类似的材料，但是不同的层可以具有不同的材料，并且此外，在每个层中，可以根据设计要求使用不同薄片的混合物。由于磁化方向的取向由对准的薄片的每个层的表面取向确定，因此可以通过控制所得磁体的形状来控制所得磁体的磁化取向。因此，可以控制由磁体产生的场取向。参考图7B，例如，将薄片的对准条带700弯曲，使得所得磁体可以在径向方向MR上产生磁场。参考图7C，在某些实施例中，例如对于电机应用，内部永磁体(IPM)机器730中的V形磁体凹坑732可能需要独特的磁体形状。通过形成具有特定对准的各向异性薄片，以及将它们对准以形成用于堆叠的所得磁体的层，可以经由将层堆叠以形成特定形状以配合在V形凹穴732中来制备高性能各向异性磁体。
由于对准层中的每一个的灵活性以及为形成特定形状对堆叠的控制，与常规方法相比，可以控制由磁体产生的磁场以满足各种设计要求而无需额外的处理。尽管堆叠的分层磁体的磁场已经根据设计要求对准，但是在某些实施例中，为了实现更高的场强度，可以进一步烧结所得的堆叠磁体以烧掉环氧树脂或润滑剂以增加磁场强度而不改变所得磁体的易磁化方向。磁体可以可选地在步骤160处经历进一步处理，例如，诸如固化或热处理，以去除粘结剂或改善磁体性质。
根据一个或多个实施例，公开了一种用于在没有磁场的情况下形成各向异性磁体的方法。此外，各向异性磁体可以具有复杂的形状并且可以在受控的磁化方向上制备。所述各向异性磁体还可以根据设计要求粘结或烧结。在根据所述方法制备的粘结磁体中，当与常规粘结磁体相比时，粉末与粘结剂的比率更高，并且因此由于高粉末密度而具有更高的能量密度。此外，粉末与粘结剂之比不像常规粘结磁体中那样影响薄片的对准。
虽然上文描述了示例性实施例，但是这些实施例并不意图描述本发明的所有可能形式。相反，本说明书中所使用的字词为描述性的而非限制性的字词，并且应理解，可以在不脱离本发明的精神和范围的情况下做出各种改变。另外，可以将各种实施的实施例的特征进行组合，以形成本发明的另外的实施例。
根据本发明，提供了一种处理各向异性永磁体的方法，所述方法具有：由块状各向异性磁体形成各向异性薄片，所述各向异性薄片中的每一个相对于薄片的表面具有易磁化方向；将各向异性薄片与粘结剂组合以形成混合物；在不施加磁场的情况下挤出或轧制混合物，使得各向异性薄片的易磁化方向对准以形成具有与各向异性薄片的易磁化方向对准的磁化方向的一个或多个层；以及由具有所述磁化方向的层制作各向异性永磁体，使得各向异性永磁体具有具特定取向的磁场。
根据一个实施例，粘结剂是环氧树脂、润滑剂或延展性合金粉末。
根据一个实施例，本发明的特征还在于按压所述层以进一步将薄片对准。
根据一个实施例，块状各向异性磁体是Nd-Fe-B、Sm-Fe-N、Sm-Co、Al-Ni-Co、铁氧体或Mn-Bi。
根据一个实施例，所述形成包括块状各向异性磁体的熔化和固化。
根据一个实施例，块状各向异性磁体是Al-Ni-Co或Mn-Bi，并且固化是快速固化过程，之后进行退火。
根据一个实施例，块状各向异性磁体是Nd-Fe-B、Sm-Fe-N或Sm-Co，并且固化是定向固化或研磨。
根据一个实施例，所述制作包括加工所述层、将所述层堆叠、按压所述层、使所述层弯曲或其组合以调整特定取向。
根据一个实施例，挤出混合物包括使各向异性薄片的表面平行于挤出表面对准。
根据一个实施例，轧制混合物包括使各向异性薄片的表面平行于轧制表面对准。
根据本发明，一种处理各向异性永磁体的方法包括：由块状各向异性磁体形成各向异性薄片，所述各向异性薄片各自具有易磁化方向；将各向异性薄片与粘结剂组合以形成混合物；在不施加磁场的情况下挤出或轧制混合物以形成具有基于易磁化方向的集体磁化方向的各向异性薄片的一个或多个各向异性层；以及由具有所述集体磁化方向的层制作各向异性永磁体，使得所述各向异性永磁体具有具特定取向的磁场。
在本发明的一个方面，块状各向异性磁体是Nd-Fe-B、Sm-Fe-N、Sm-Co、Al-Ni-Co、铁氧体或Mn-Bi。
在本发明的一个方面，所述制作包括加工所述层、将所述层堆叠、按压所述层、使所述层弯曲或其组合以调整特定取向。
在本发明的一个方面，所述块状各向异性磁体是Al-Ni-Co或Mn-Bi，并且所述形成包括熔化和快速固化过程，之后进行退火。
在本发明的一个方面，所述块状各向异性磁体是Nd-Fe-B、Sm-Fe-N或Sm-Co，并且所述形成包括熔化和定向固化或研磨。
在本发明的一个方面，所述方法包括在不改变集体磁化方向的情况下烧结磁体以移除粘结剂以增加固定磁场的强度。
在本发明的一个方面，所述粘结剂是环氧树脂、润滑剂或延展性合金粉末。
根据本发明，提供了一种各向异性永磁体，其具有：磁性各向异性薄片的一个或多个层，所述磁性各向异性薄片中的每一个具有易磁化方向，其中所述层中的每一个具有与所述磁性各向异性薄片的易磁化方向对准的相应磁化方向，使得各向异性永磁体具有具特定取向的磁场，所述特定取向是基于相应的磁化方向。
根据一个实施例，磁性各向异性薄片可以是Nd-Fe-B、Sm-Fe-N、Sm-Co、Al-Ni-Co、铁氧体或Mn-Bi。
根据一个实施例，至少一个层包括与各向异性薄片混合的粘结剂，所述粘结剂是环氧树脂、润滑剂或延展性合金粉末。

Claims (15)

1.一种处理各向异性永磁体的方法，所述方法包括：
由块状各向异性磁体形成各向异性薄片，所述各向异性薄片中的每一个相对于所述薄片的表面具有易磁化方向；
将所述各向异性薄片与粘结剂混合以形成混合物；
在不施加磁场的情况下挤出或轧制所述混合物使得所述各向异性薄片的所述易磁化方向对准以形成具有与所述各向异性薄片的所述易磁化方向对准的磁化方向的一个或多个层；以及
由具有所述磁化方向的所述层制作所述各向异性永磁体，使得所述各向异性永磁体具有具特定取向的磁场。
2.如权利要求1所述的方法，其还包括按压所述层以进一步将所述薄片对准。
3.如权利要求1所述的方法，其中所述块状各向异性磁体是Nd-Fe-B、Sm-Fe-N、Sm-Co、Al-Ni-Co、铁氧体或Mn-Bi。
4.如权利要求1所述的方法，其中所述形成包括所述块状各向异性磁体的熔化和固化。
5.如权利要求4所述的方法，其中所述块状各向异性磁体是Al-Ni-Co或Mn-Bi，并且所述固化是快速固化过程，之后进行退火。
6.如权利要求4所述的方法，其中所述块状各向异性磁体是Nd-Fe-B、Sm-Fe-N或Sm-Co，并且所述固化是定向固化或研磨。
7.如权利要求1所述的方法，其中挤出所述混合物包括使所述各向异性薄片的所述表面平行于挤出表面对准。
8.如权利要求1所述的方法，其中轧制所述混合物包括使所述各向异性薄片的所述表面平行于轧制表面对准。
9.一种处理各向异性永磁体的方法，所述方法包括：
由块状各向异性磁体形成各向异性薄片，所述各向异性薄片各自具有易磁化方向；
将所述各向异性薄片与粘结剂混合以形成混合物；
在不施加磁场的情况下挤出或轧制所述混合物以形成具有基于所述易磁化方向的集体磁化方向的各向异性薄片的一个或多个各向异性层；以及
由具有所述集体磁化方向的所述层制作所述各向异性永磁体，使得所述各向异性永磁体具有具特定取向的磁场。
10.如权利要求9所述的方法，其中所述块状各向异性磁体是Nd-Fe-B、Sm-Fe-N、Sm-Co、Al-Ni-Co、铁氧体或Mn-Bi。
11.如权利要求9所述的方法，其中所述块状各向异性磁体是Al-Ni-Co或Mn-Bi，并且所述形成包括熔化和快速固化过程，之后进行退火。
12.如权利要求9所述的方法，其中所述块状各向异性磁体是Nd-Fe-B、Sm-Fe-N或Sm-Co，并且所述形成包括熔化和定向固化或研磨。
13.如权利要求9所述的方法，其还包括在不改变所述集体磁化方向的情况下烧结所述磁体以移除所述粘结剂以增加所述固定磁场的强度。
14.如权利要求1或9所述的方法，其中所述粘结剂是环氧树脂、润滑剂或延展性合金粉末。
15.如权利要求1或9所述的方法，其中所述制作包括加工所述层、将所述层堆叠、按压所述层、使所述层弯曲或其组合以调整所述特定取向。
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