EP3414768B1 - Aimant hybride et procédé de fabrication - Google Patents

Aimant hybride et procédé de fabrication Download PDF

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Publication number
EP3414768B1
EP3414768B1 EP17700819.0A EP17700819A EP3414768B1 EP 3414768 B1 EP3414768 B1 EP 3414768B1 EP 17700819 A EP17700819 A EP 17700819A EP 3414768 B1 EP3414768 B1 EP 3414768B1
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Prior art keywords
soft magnetic
layer
hybrid magnet
hard magnetic
layers
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German (de)
English (en)
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EP3414768A1 (fr
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Branislav Zlatkov
Zoran Djinovic
Matthias Katter
Ana Maria Racu
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Vacuumschmelze GmbH and Co KG
Volkswagen AG
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Vacuumschmelze GmbH and Co KG
Volkswagen AG
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
    • H01F41/0273—Imparting anisotropy
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
    • H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
    • H01F1/047—Alloys characterised by their composition
    • H01F1/053—Alloys characterised by their composition containing rare earth metals
    • H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
    • H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
    • H01F1/0579—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B with exchange spin coupling between hard and soft nanophases, e.g. nanocomposite spring magnets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
    • H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
    • H01F1/06—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys in the form of particles, e.g. powder
    • H01F1/08—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together

Definitions

  • the invention relates to a hybrid magnet which comprises at least one soft magnetic and at least one hard magnetic material. Furthermore, the invention relates to a manufacturing method of such a hybrid magnet.
  • Magnetic materials can be produced using a melt metallurgical process (as cast magnetic materials) or a powder metallurgical process (as sintered magnetic materials or powder magnetic composite materials). Powder-metallurgical processes that include sintering can be used to produce magnetic components whose shape cannot be achieved by melt metallurgy. This applies e.g. B. especially for magnetic materials with crystal anisotropy (NdFeB, SmCo, etc.). Powder metallurgical manufacturing processes can include the following process steps: powdering a magnetic starting material, pressing the resulting powder into a green part to form a desired shape, sintering the green part, optional thermal treatment to reduce stress and optimize the structure, and optionally magnetization in an external magnetic field. Furthermore, magnets produced in this way can be mechanically post-treated if necessary, for example by grinding or polishing.
  • HcJ coercive field strength
  • hybrid magnets are also known.
  • a hybrid magnet is understood to mean a component which comprises at least two different magnetic materials, in particular at least one hard magnetic material and at least one soft magnetic material.
  • hybrid magnets are known in which the hard magnetic and the soft magnetic material are integrated in a matrix body made of plastic.
  • Hybrid magnets of this type can have the disadvantage that their magnetic properties are less pronounced than desired, that the temperature stability and mechanical strength can be limited due to the plastic material, and / or that such hybrid magnets cannot be exposed to media that could attack the plastic material.
  • WO 2012/159096 A2 envelops hard magnetic with soft magnetic materials and influences the exchange interaction through non-magnetic materials along the grain boundaries.
  • process step C) is carried out once after each process step A) and once after each process step B). This creates a (single) separating layer between two adjacent layers of hard magnetic material and / or soft magnetic material.
  • Hybrid magnets with a layer structure can be produced, in which the hard magnetic layers and the soft magnetic layers are combined in any layer sequence.
  • Hard magnetic layers and soft magnetic layers are preferably formed alternately or in another regular manner.
  • a hybrid magnet can have a pronounced effect as a permanent magnet (large remanent magnetization), which can only be destroyed with great difficulty by external influences (large coercive field strength).
  • the layer structure of the hybrid magnet in particular when the magnetization is oriented perpendicular to the layer structure, means that the soft magnetic layers are always in a supporting field of the hard magnetic layers and thus contribute to the overall magnetization of the hybrid magnet. If soft magnetic areas are arranged next to hard magnetic areas, e.g. in the extreme case that the hard magnetic layers are magnetized along their layer plane, the soft magnetic layers act as a magnetic short circuit and the hybrid magnet cannot produce a magnetic flux that can be used outdoors.
  • a hard magnetic layer is to be understood as an area of the hybrid magnet that consists predominantly or exclusively of a hard magnetic material.
  • a hard magnetic layer does not necessarily have to be a coherent area of hard magnetic material.
  • a hard magnetic layer can be formed from partial regions of hard magnetic material which are (partially) separated from one another in the layer plane by the matrix material.
  • all hard magnetic layers consist of the same hard magnetic material.
  • different hard magnetic materials can be used in a hybrid magnet. Different hard magnetic materials can be processed in one layer. However, differently constructed layers can also be present, each consisting of different hard magnetic materials.
  • Preferred hard magnetic materials are: martensitic steels; Alloys based on CuNiFe [copper, nickel, iron], CuNiCo [copper, nickel, cobalt], FeCoVCr [iron, cobalt, vanadium, chromium], MnAlC [manganese, aluminum, carbon], or AINiCo [aluminum, nickel, cobalt ]; Hard magnets based from PtCo [platinum, cobalt]; Rare earth magnets such as B.
  • NdFeB neodymium, iron, boron
  • SmCo samarium, cobalt
  • SmFeN samarium, iron, nitrogen
  • oxidic permanent magnets hard ferrites
  • new types of hard magnets such as B. MnBi [manganese, bismuth] or Fe 16 N 2 [iron, nitrogen].
  • a soft magnetic layer is to be understood as an area of the hybrid magnet that consists predominantly or exclusively of a soft magnetic material.
  • a soft magnetic layer does not necessarily have to be a coherent area of soft magnetic material.
  • a soft magnetic layer can be formed from subregions of soft magnetic material which are (partially) separated from one another in the layer plane by the matrix material.
  • all soft magnetic layers consist of the same soft magnetic material.
  • different soft magnetic materials can be used in a hybrid magnet. Different soft magnetic materials can be processed in one layer. However, differently constructed layers can also be present, each consisting of different soft magnetic materials.
  • Preferred soft magnetic materials are: soft iron, carbon steels, alloys based on FeAl [iron, aluminum], FeAlSi [iron, aluminum, silicon], FeNi [iron, nickel], FeCo [iron, cobalt]; amorphous soft magnetic materials such as B. FeNiBSi [iron, nickel, boron, silicon], FeBSi [iron, boron, silicon]; soft magnetic ferrite materials such as B. MnZn ferrites [manganese, zinc], MgZn ferrites [magnesium, zinc]; Spinel materials such as B. MnMgZn [manganese, magnesium, zinc], NiZn [nickel, zinc]; or garnet materials such as B. BiCa [bismuth, calcium], YGd [yttrium, gadollinium].
  • a magnetically semi-hard material can be used. If a magnetically semi-hard material is used, the explanations for the hard magnetic materials or the soft magnetic materials apply in an analogous manner.
  • Preferred magnetic semi-hard materials are: alloys based on FeNi [iron, nickel], FeMn [iron, manganese], FeNiMn [iron, nickel, manganese], CoFe [cobalt, iron], or FeCu [iron, copper]; Co 49 Fe 48 V 3 [cobalt, iron, vanadium; also known as Remendur]; Co 55 NiFe [cobalt, nickel, iron; also known as Vacozet], and Kovar.
  • the magnetically passive material can in particular be a diamagnetic material or a paramagnetic material.
  • a paramagnetic or diamagnetic metal can be used, such as Dy [dysprosium], Tb [terbium], Al [aluminum], Pt [platinum], Ti [titanium], Cu [copper], Pb [lead], Zn [zinc ], Sn [tin], Ga [gallium], Ge [germanium], Au [gold], Ag [silver], Mg [magnesium], Mo [molybdenum], Mn [manganese], Zr [zirconium], Li [lithium ]. Alloys or oxides of the specified materials can also be used. Further preferred materials are listed below. Preferably, but not necessarily, the same magnetically passive material is used for all separation layers.
  • An electrically non-conductive or poorly conductive magnetically passive material is preferably used.
  • a changing magnetic field can generate electrical currents (eddy currents) due to electromagnetic induction. These can lead to heating of the extended electrical conductor and / or adversely affect its magnetic properties. If separation layers made of an electrically non-conductive or poorly conductive material interrupt the electrical conductivity of the hybrid magnet, eddy currents can be reduced and / or locally restricted.
  • Eddy currents can be effectively suppressed, in particular in hybrid magnets, with a matrix body, since in them the individual magnetic layers are formed from partial areas of magnetic material which are (partially) separated from one another by the matrix material in the layer plane.
  • a coating technology is used in at least one of process steps A), B) and C).
  • the coating technology is preferably a wet technique, such as. B. a sol-gel process, a dry deposition process, and / or a chemical or physical vapor deposition process.
  • a physical vapor deposition process is understood to mean a vacuum-based coating process in which a starting material is converted into the gas phase and deposited on a substrate to be coated.
  • Chemical vapor deposition (CVD) methods are similar to physical vapor deposition methods, with the difference that a chemical reaction takes place here when the starting material is deposited on the substrate.
  • the coating technologies have in common that the material is supplied in small particles to the substrate and can be connected to the substrate there in such a way that a surface layer is firmly connected to the substrate.
  • a coating technology ie in particular a coating method of the above type
  • the same coating technology is used for all process steps.
  • Method step A) comprises at least the following sub-step: A1) Providing a hard magnetic powder comprising hard magnetic particles from the hard magnetic material.
  • Method step B) comprises at least the following sub-step: B1) Providing a soft magnetic powder comprising soft magnetic particles from the soft magnetic material.
  • Method step C) comprises at least the following sub-step: C1) coating at least one of the hard magnetic particles or the soft magnetic particles with at least one coating made of the magnetically passive material.
  • the shaping of the hybrid magnet in method step D) can optionally take place in an external magnetic field.
  • Sub-step A1) can include formulation preparation, mixing and / or portioning of the hard magnetic material used. Furthermore, a powder of the hard magnetic material can be produced in sub-step A1) be, e.g. B. by crushing a solid made of this hard magnetic material.
  • sub-step A1 can also be used for the provision of the soft magnetic material in sub-step B1).
  • sub-step C1 the coating of the particles is preferably carried out using one of the following coating processes: B. “vacuum deposition”, “plasma deposition”, “sputtering”, “molecular beam epitaxy (MBE)", “vapor phase epitaxy”, or “liquid phase epitaxy”; CVD such as B. “sol-gel deposition”, or “metallo-organic chemical vapor deposition (MOCVD)". These methods are well known to those skilled in the art.
  • a single coating layer is preferably applied to the particles.
  • two coating layers made of different materials are preferably applied in sub-step C1).
  • the coating of the particles can prevent neighboring particles from agglomerating. This can make the manufacturing process easier. Furthermore, the coating of the particles can reduce a magnetic exchange interaction of neighboring particles, in particular neighboring particles of different materials. The coating of the particles can likewise lead to passivation of the surfaces of the particles. This can reduce the risk of self-ignition of the particles when in contact with air. This can make it easier to carry out the method because an inert gas atmosphere can be dispensed with. In particular, eddy currents can be reduced and / or locally restricted by the electrically insulating coating of the particles.
  • the body is shaped in that the soft magnetic powder and the hard magnetic powder are applied one above the other in the desired order of the layer structure.
  • the distribution of the powder forming this layer can be improved.
  • the separating layers are formed by coating the particles, so that only layers of the hard magnetic powder and layers of the soft magnetic powder have to be layered one above the other, with exactly one (uniform and / or coherent) separating layer being formed between adjacent layers. In particular, this means that each time step A) is carried out and step B) is carried out, step C) is also carried out.
  • a hybrid magnet is formed from the body formed in process step D) by sintering.
  • Sintering means that the body is exposed to an elevated temperature, the coating of the particles being formed into a matrix body surrounding the particles.
  • the temperature selected for sintering is preferably selected such that the hard magnetic and soft magnetic materials do not sinter. This means in particular that the temperature selected for sintering preferably corresponds at most to the melting temperature of the magnetically passive material or, if such a melting temperature is not well-defined for the material in question, to the transformation temperature.
  • the latter relates to such amorphous materials, such as. B. glass in which a melt does not occur at a certain melting temperature. Instead, the mechanical properties of these materials change continuously over a temperature range.
  • the temperature used for sintering is preferably selected depending on all materials used. For example, the transformation temperature of many glasses is in the range up to 900 ° C. If such a glass is used as a magnetically passive material, a preferred temperature range for the sintering (material-specific) is 400 ° C. to 800 ° C. at normal pressure (1013 hPa), in particular 550 ° C. to 650 ° C. Before step E) the body commonly referred to as pellet. After the sintering has been carried out in step E), the body is usually referred to as sintering.
  • the entire process, including all process steps, is preferably carried out under conditions in which no (significant or widespread) sintering of the hard magnetic or soft magnetic material used occurs. It should be taken into account that the sintering temperature of a material can be pressure-dependent. The temperature is preferably significantly lower during the entire process, in particular at least 50 ° C. lower and preferably at least 100 ° C. lower than the sintering temperature of each hard magnetic or soft magnetic material used.
  • the coating has a coating thickness which is in the range from 1 nm to 300 nm, in particular in the range from 2 nm to 50 nm.
  • the coating thickness is usually to be understood as the spatial extent of the coating, which is the smallest Dimension.
  • the body is pressed between method steps D) and E) to form an intermediate product, a so-called compact.
  • an increased pressure applied from the outside can lead to a compression of the particles. This can improve the sintering activity and thus increase the stability of the finished sintered hybrid magnet.
  • a compact is to be understood here as a body which is produced by pressing powder, it being possible in particular to use a die press.
  • the pressing takes place in an external magnetic field.
  • the external magnetic field can be generated, for example, by an electrical coil.
  • the external magnetic field preferably has an extent which surrounds the entire compact.
  • the external magnetic field is likewise preferably a homogeneous magnetic field which points in the direction of the magnetization desired for the hybrid magnet.
  • the method is particularly preferred if the external magnetic field is oriented perpendicular to the layer plane.
  • the external magnetic field can cause the magnetization of the magnetic particles to align along the external magnetic field.
  • the external magnetic field applied during pressing can advantageously influence the properties of the hybrid magnet. In particular in the case of magnetic materials with a pronounced crystal anisotropy, an external magnetic field applied during the pressing can align the particles in such a way that a preferred direction of magnetization is the same for all particles.
  • the alignment of the particles can be fixed. Even if the magnetization is lost again in a later process step (in particular due to the effect of temperature), the alignment of the particles can remain. In the case of a subsequent magnetization, this can be used to benefit from the preferred direction of magnetization common to all particles.
  • the hard magnetic particles and the soft magnetic particles are acted on at least temporarily with ultrasound.
  • Exposure to ultrasound can increase the packing density of the powder. This can improve the stability of the hybrid magnet.
  • the ultrasound is preferably generated by an ultrasound probe in the vicinity of the hybrid magnet. The action with ultrasound preferably takes place before and / or during the pressing.
  • the separating layer has a separating layer thickness which is in the range from 1 nm to 300 nm, in particular in the range from 2 nm to 50 nm.
  • the separating layer thickness is to be understood as the spatial dimension which has the smallest dimension, this also regularly relates to the expansion of the separating layer perpendicular to the layer structure. If the hybrid magnet is made from powder, the separating layer thickness depends in particular on the coating thickness described above. In any case, i. H. For hybrid magnets that are produced in a different way, the advantages described above in connection with the choice of the coating thickness apply in a corresponding manner to the choice of the separating layer thickness.
  • the hybrid magnet is magnetized in an external magnetic field.
  • the magnetization is preferably carried out when the hybrid magnet has already been sintered.
  • the method is particularly preferred if the external magnetic field is oriented perpendicular to the layer plane.
  • the magnetization can in a z. B. generated by an electrical coil, external magnetic field, which is preferably homogeneous and encloses the entire hybrid magnet.
  • This external magnetic field can differ from the external magnetic field described above both in orientation and in strength.
  • the external magnetic field could also be referred to here as a second external magnetic field in order to distinguish it from the magnetic field described above.
  • the external magnetic field used here is preferably sufficiently strong to be parallel To achieve alignment of the magnetization of the particles, which remains even without an external magnetic field (remanent magnetization).
  • the method can include an (additional) thermal treatment in a further external magnetic field (material-specific, e.g. for Alnico alloys.
  • a further aspect of the invention relates to a hybrid magnet, comprising a layer structure composed of layers, at least one of the layers being a hard magnetic layer and at least one of the layers being a soft magnetic layer, and adjacent layers being separated by a magnetically passive material.
  • Such a hybrid magnet is preferably, but not necessarily, produced using the method proposed here.
  • the explanations described in connection with the method can be used individually or in combination for explanations of the structure, the properties and the advantages of the proposed hybrid magnet.
  • each hard magnetic layer is formed from hard magnetic particles and each soft magnetic layer from soft magnetic particles, the hard magnetic particles and the soft magnetic particles being surrounded by a matrix body.
  • a hybrid magnet is preferably produced by the method according to the invention in an embodiment which comprises the use of powder.
  • the particles in the hybrid magnet correspond to the particles of the powder.
  • the hard magnetic particles and the soft magnetic particles have an (average) diameter (or a grain size) in the range from 0.2 ⁇ m to 250 ⁇ m.
  • the magnetically passive material forming the matrix body is one of the following materials in particular: glass, glass-ceramic, metallic glass or ceramic.
  • the execution of the matrix body with one of these materials can be achieved, for example, by sintering a body formed from powder with a corresponding coating.
  • Glasses are understood to mean, in particular, amorphous substances which are structurally present as an irregular structure (network). In contrast, there are in particular crystalline substances that are present in an ordered lattice structure.
  • Metallic glasses are primarily understood to mean metal alloys which, unlike ordinary metals or metal alloys, are amorphous, i. H. have no ordered lattice structure. Glasses, glass ceramics or ceramics are characterized by a particularly high level of corrosion protection and protection against ignition.
  • each layer has a layer thickness and a (spatial) width, the width corresponding to at least ten times the layer thickness for each layer.
  • the layer thickness is regularly to be understood as the extent of a layer perpendicular to the layer structure.
  • the width is then the extent of the layer perpendicular to the direction in which the layer thickness is measured. This means in particular that with a layer of any shape in any direction perpendicular to the layer structure, the width must be greater than ten times the layer thickness.
  • the layers are aligned perpendicular to the magnetization of the hybrid magnet.
  • the alignment of the magnetization perpendicular to the layer structure means that the soft magnetic layers are always in a supporting field of the hard magnetic layers and thus contribute to the overall magnetization of the hybrid magnet.
  • the described advantages of a hybrid magnet with a layer structure can be used to the maximum.
  • starting materials for the manufacturing process are selected and made available in a recipe manufacturing according to component and material requirements (in particular with regard to magnetic properties such as e.g. retentive magnetization and a coercive field strength as well as with regard to temperature properties such as a transformation temperature) .
  • component and material requirements in particular with regard to magnetic properties such as e.g. retentive magnetization and a coercive field strength as well as with regard to temperature properties such as a transformation temperature.
  • a second embodiment of a manufacturing process the previously described formulation manufacturing is carried out first. This is followed by building up a layer structure and producing layers using coating technologies, which can optionally be carried out in a magnetic field. Finally, as before, sintering, optional tempering, optional post-treatment and optional magnetization follow. Two examples of this second embodiment of the manufacturing method are described below.
  • a first example of a hybrid magnet relates to a hybrid magnet made of powder, consisting of NdFeB [neodymium, iron, boron] as a hard magnetic material. 90% of the particles of this material have a diameter of less than 3 ⁇ m, 50% of less than 1 ⁇ m and 30% of 0.2 to 0.5 ⁇ m. Furthermore, the hybrid magnet consists of pure iron [Fe] as a soft magnetic material. 90% of the particles of this material have a diameter of less than 2 ⁇ m and 30% of 0.2 to 0.8 ⁇ m.
  • the coating is formed from an oxide composition comprising the following proportions: 30 to 60 mol% Bi 2 O 3 [bismuth oxide], 30 to 40 mol% B 2 O 3 [boron oxide], 10 to 20 mol% ZnO [zinc oxide] and 5 to 10 mol% SiO 2 [silicon dioxide].
  • the layer structure alternately has a hard magnetic and a soft magnetic layer, with adjacent layers being separated from each other by a separating layer (indirectly by coating the Powder).
  • the body is 100 mm by 300 mm wide and has a height of 8 mm.
  • the individual layers (together with a separating layer) each have a layer thickness of 2.5 ⁇ m.
  • the layer structure comprises 3200 layers, i.e. 1600 layers per material.
  • the NdFeB particles are aligned by means of an external magnetic field with a strength of 1200 kA / m generated with an electromagnet. No pressing takes place.
  • the sintering (“pressless sintering" or “bulk sintering") is carried out over a period of one hour at 400 to 500 ° C. in an argon atmosphere.
  • the body is then divided into parts by cutting with a width of 20 mm by 10 mm and a height of 5 mm. Another magnetization optionally follows.
  • a second example of a hybrid magnet is a hybrid magnet made of powder, consisting of NdFeB [neodymium, iron, boron] as the hard magnetic material. 90% of the particles of this material have a diameter of less than 3 ⁇ m, 50% of less than 2 ⁇ m and 30% of 0.2 to 1 ⁇ m. Furthermore, the hybrid magnet consists of a composition of 90% Fe [iron], 5% Ni [nickel], 2% Co [cobalt] and 3% Si [silicon] as a soft magnetic material. 90% of the particles of this composition have a diameter of less than 2 ⁇ m and 30% of 0.2 to 0.1 ⁇ m.
  • the coating is formed from an oxide composition, comprising the following proportions: 40 to 60 mol% PbO [lead oxide], 30 to 40 mol% B 2 O 3 [boron oxide], 5 to 10 mol% ZnO [zinc oxide].
  • the layer structure alternately has one hard magnetic and two soft magnetic layers.
  • the body is 100 mm by 300 mm wide and has a height of 9.9 mm.
  • the individual layers have a layer thickness (together with a separating layer) of 3 ⁇ m each.
  • the layer structure comprises 3300 layers, i.e. 1100 layers of the hard magnetic material and 2200 layers of the soft magnetic material. Pressing takes place in the form of a die press. The sintering is carried out for one hour at 400 to 500 ° C in an argon atmosphere. Then the body is divided into parts cut by cutting with a width of 20 mm by 10 mm and a height of 9 mm. Another magnetization optionally follows.
  • a third example of a hybrid magnet is a hybrid magnet made of powder, consisting of NdFeB [neodymium, iron, boron] as a hard magnetic material with a layer thickness of 300 nm and 90% Fe [iron], 5% Ni [nickel], 2 % Co [cobalt], 3% Si [silicon] as a soft magnetic material with a layer thickness of 350 nm.
  • the separating layers are formed from an oxide composition, comprising the following proportions: 40 to 60 mol% PbO [lead oxide], 30 to 40 mol% B 2 O 3 [boron oxide], 5 to 10 mol% SiO 2 [silicon dioxide] with a separating layer thickness of 10 nm.
  • the layer structure alternately has a hard magnetic and a soft magnetic layer.
  • the body is 10 mm by 25 mm wide and 6 mm high. Alignment takes place in the magnetic field before sintering. The sintering is carried out for one hour at 400 to 900 ° C in an argon atmosphere. Another magnetization optionally follows.
  • a layer structure with coating technologies is produced by first growing a thin hard magnetic layer in a first step, e.g. B. from Nd 2 Fe 14 B [neodymium, iron, boron] with a thickness of 250 to 300 nm. This layer thickness corresponds to a single-domain particle diameter of Nd 2 Fe 14 B.
  • a first step e.g. B. from Nd 2 Fe 14 B [neodymium, iron, boron] with a thickness of 250 to 300 nm.
  • This layer thickness corresponds to a single-domain particle diameter of Nd 2 Fe 14 B.
  • One of the following coating technologies introduced above can be used: "atomic layer deposition "(ALD),” metal-organic chemical vapor deposition "(MOCVD) or” chemical vapor deposition "(CVD).
  • organometallic compounds can be used for these coating technologies: tris- [N, N-bis (trimethylsilyl) amido] neodymium (III) for neodymium [Nd], iron (III) tris (2,2,6,6- tetramethyl-3,5-heptanedionate) for iron [Fe] and triisopropylborate for boron [B].
  • a second step e.g. B. applied by CVD a 5 to 10 nm thin separation layer.
  • oxides can be used: SiO 2 [silicon oxide], B 2 O 3
  • TEOS Tetraethyl orthosilicate
  • TEB triethyl borate
  • potassium ethanolate for KO [ Cobalt oxide].
  • Oxide mixtures with PbO [lead oxide], Bi 2 O 3 [bismuth oxide], P 2 O 5 [phosphorus oxide], ZnO [zinc oxide] or SnO [tin oxide] can also be used here in order to be able to produce low-melting glasses.
  • the following precursors are possible: lead (II) acetate trihydrate for PbO [lead oxide], bismuth (III) acetates for Bi 2 O 3 [bismuth oxide], phosphorus trichloride for P 2 O 5 [phosphorus oxide], zinc acetate for ZnO [zinc oxide] , Tin (II) acetate for SnO [tin oxide].
  • Rare earth oxides can also be built into the separating layer, which in turn arise from precursors such as neodymium (III) isopropoxide and dysprosium (III) acetate hydrate.
  • precursors such as neodymium (III) isopropoxide and dysprosium (III) acetate hydrate.
  • a thin layer of a soft magnetic phase e.g. B.
  • a separating layer of binary, ternary or quaternary oxide mixtures is then applied again, from which a glass, a glass ceramic or a ceramic phase forms in the further course of the process. The sequence of the layer structure is repeated until the desired total thickness is reached. This creates a layer structure in which hard magnetic layers and soft magnetic layers always alternate, which are separated from one another by separating layers.
  • a fifth example is a hybrid magnet similar to that previously described in the fourth example. The only difference is the sequence and the number of different layers. Instead of always arranging hard magnetic layers and soft magnetic layers alternately, several soft magnetic layers can also be arranged Layers or several hard magnetic layers follow one another, which can also be separated from one another by a separating layer. Adjacent layers of the same material are therefore grouped together.
  • Fig. 1 shows an intermediate product of a hybrid magnet 1, having hard magnetic layers 13 and soft magnetic layers 14.
  • the hard magnetic layers 13 are (essentially) formed by hard magnetic particles 2.
  • the hard magnetic particles 2 are (only) made of a hard magnetic material 5.
  • the soft magnetic layers 14 are (essentially) made of soft magnetic particles 3, which themselves (only) are made of a soft magnetic material 6.
  • the soft magnetic material 6 is represented by hatching.
  • the hard magnetic particles 2 and the soft magnetic particles 3 each have a coating 4 made of a magnetically passive material 7.
  • the coating 4 has a coating thickness 8.
  • the hard magnetic particles 2 and the soft magnetic particles 3 each have approximately a diameter 12, which in this embodiment is the same size for all hard magnetic particles 2 and all soft magnetic particles 3. Also shown is a layer thickness 19 as the distance between adjacent layers.
  • Hard magnetic layers 13 have a hard magnetic layer thickness 33 and soft magnetic layers 14 have a soft magnetic layer thickness 16, which does not have to be identical to the hard magnetic layer thickness 33.
  • a width 20 is shown here as the extent of the hybrid magnet 1 perpendicular to the direction in which the layer thickness 19 is measured.
  • the hybrid magnet 1 is in this Fig. 1 shown as a cross section through the layer structure, a situation before the sintering of the hybrid magnet semi-finished product is shown, so that the hard magnetic particles 2, the soft magnetic particles 3 and the coating 4 can still be recognized as such.
  • an applied external magnetic field 11 which leads to the alignment of the hard magnetic particles 2 and to the magnetization of the soft magnetic particles 3.
  • the arrows 34 in the particles 2 and 3 indicate the direction of the magnetization.
  • the external magnetic field 11 is homogeneous and encloses the volume of the entire body 17.
  • Fig. 2 shows the hybrid magnet 1 Fig. 1 after pressing and sintering.
  • a matrix body 9 made of the magnetically passive material 7.
  • the matrix body 9 as well as the hard magnetic particles 2 and the soft magnetic particles 3 together now form a sintered part 10.
  • the sintered part 10 is formed from the hard magnetic particles 2 and the soft magnetic particles 3 and the coating 4 by pressing and sintering.
  • the sintered body 10 forms the body 17 of the hybrid magnet 1.
  • the hard magnetic particles 2 made of the hard magnetic material 5 form the hard magnetic layers 13.
  • the hard magnetic particles 2 represent partial regions of the hard magnetic layers 13 which are magnetically passive in the layer plane through the magnetically passive body forming the matrix body 9
  • Material 7 are separated from each other.
  • the soft magnetic particles 3 made of the soft magnetic material 6 form the soft magnetic layers 14. In between there are separating layers 15, which in this embodiment are formed as part of the matrix body 9. This applies in particular to the first three examples of a hybrid magnet.
  • Fig. 3 shows a hybrid magnet 1, which has arisen from a manufacturing process using a coating technology.
  • the hybrid magnet 1 comprises a body 17 which comprises hard magnetic layers 13 made of a hard magnetic material 5, soft magnetic layers 14 made of a soft magnetic material 6 and separating layers 15 made of a magnetically passive material 7.
  • the soft magnetic material 6 is represented by hatching.
  • the separating layers 15 have a separating layer thickness 18.
  • the hard magnetic layers 13 and the soft magnetic layers 14 have a layer thickness 19, which in this embodiment is the same for all layers.
  • the width 20 of the hybrid magnet 1 is also shown.
  • an external magnetic field 11 which can be applied during the production of the hybrid magnet 1.
  • Fig. 3 relates in particular to the fourth example of a hybrid magnet explained above.
  • Fig. 4 shows a hybrid magnet 1 in a further embodiment. Compared to Fig. 3 another layer sequence is only shown as an example. Accordingly, adjacent layers of the same material can also be present in groups. Fig. 4 relates in particular to the fifth example of a hybrid magnet explained above. The in Fig. 4 The adapted layer structure shown with grouped layers of the same material can also be applied to hybrid magnets according to the first three examples. Grouped layers can also be provided with such hybrid magnets.
  • Fig. 5 shows the first embodiment of a manufacturing method described above.
  • a recipe manufacture 22 starting materials for the manufacturing process are selected and made available in accordance with component and material requirements (in particular with regard to magnetic properties such as, for example, retentive magnetization and a coercive field strength, and with regard to temperature properties such as a transformation temperature).
  • the starting materials are then pulverized in a powder supply 23. This happens e.g. B. with conventional techniques.
  • powder particles are coated, for. B. with a single or multiple coating.
  • a green compact is built up layer by layer in a layer structure made of powder 25.
  • a pressing 26 optionally follows to form a compact. This is followed by a sintering 27 of the green body, an optional annealing 28, an optional aftertreatment 29 and an optional magnetization 30.
  • the first embodiment of a manufacturing method applies in particular to the first three examples of a hybrid magnet.
  • Fig. 6 shows the second embodiment of a manufacturing method described above.
  • the second embodiment of a manufacturing method applies in particular to the fourth and fifth example of a hybrid magnet.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Composite Materials (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)
  • Hard Magnetic Materials (AREA)
  • Powder Metallurgy (AREA)

Claims (13)

  1. Procédé de fabrication d'un aimant hybride (1), comprenant au moins les étapes de procédé suivantes :
    A) la création d'une couche magnétique dure (13) en un matériau magnétique dur (5),
    B) la création d'une couche magnétique douce (14) en un matériau magnétique doux (6), et
    C) la création d'une couche de séparation (15) en un matériau magnétiquement passif (7),
    une application multiple respectivement des étapes de procédé A), B) et C) permettant de former un aimant hybride (1), qui présente une structure de couches ; l'étape de procédé A) comprenant au moins l'étape partielle suivante :
    A1) la mise à disposition d'une poudre magnétique dure comprenant des particules magnétiques dures (2) en le matériau magnétique dur (5),
    l'étape de procédé B) comprenant au moins l'étape partielle suivante :
    B1) la mise à disposition d'une poudre magnétique douce comprenant des particules magnétiques douces (3) en le matériau magnétique doux (6),
    l'étape de procédé C) comprenant au moins l'étape partielle suivante :
    C1) le revêtement d'au moins une des particules magnétiques dures (2) ou des particules magnétiques douces (3) avec au moins un revêtement (4) en le matériau magnétiquement passif (7) ;
    l'étape C) étant réalisée respectivement une fois après chaque réalisation de l'étape de procédé A) et respectivement une fois après chaque réalisation de l'étape de procédé B).
  2. Procédé selon la revendication 1, dans lequel le procédé comprend en outre les étapes de procédé suivantes :
    D) le façonnage d'un corps (17) formant l'aimant hybride (1) selon les étapes de procédé A), B) et C) ; et
    E) le frittage du corps (17), une température qui est suffisamment élevée pour déformer le revêtement (4) en un corps de matrice (9) entourant les particules magnétiques dures (2) et les particules magnétiques douces (3) étant utilisée,
    une température de frittage pour le matériau magnétique dur (5) et une température de frittage pour le matériau magnétique doux (6) n'étant pas dépassées pendant l'ensemble du procédé, et une température de frittage du matériau magnétiquement passif (7) n'étant pas dépassée lors de l'étape de procédé E).
  3. Procédé selon les revendications 1 à 2, dans lequel le revêtement (4) présente une épaisseur de revêtement (8) qui se situe dans la plage allant de 1 nm à 300 nm.
  4. Procédé selon l'une quelconque des revendications 2 ou 3, dans lequel le corps (17) est comprimé en une pièce comprimée (10) entre les étapes de procédé D) et E) .
  5. Procédé selon la revendication 4, dans lequel la compression a lieu dans un champ magnétique externe (11) .
  6. Procédé selon l'une quelconque des revendications 4 ou 5, dans lequel des ultrasons agissent au moins temporairement sur les particules magnétiques dures (2) et les particules magnétiques douces (3).
  7. Procédé selon l'une quelconque des revendications précédentes, dans lequel la couche de séparation (15) présente une épaisseur de couche de séparation (18) qui se situe dans la plage allant de 1 nm à 300 nm.
  8. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'aimant hybride (1) est magnétisé dans un champ magnétique externe (11).
  9. Aimant hybride (1), présentant une structure de couches constituée par des couches (21), au moins une des couches (21) étant une couche magnétique dure (13) et au moins une des couches (21) étant une couche magnétique douce (14), et des couches (21) voisines étant séparées par un matériau magnétiquement passif (7) ; chaque couche magnétique dure (13) étant formée par des particules magnétiques dures (2) qui comprennent au moins un revêtement en le matériau magnétiquement passif (7) ; chaque couche magnétique douce (14) étant formée par des particules magnétiques douces (3) qui comprennent au moins un revêtement en le matériau magnétiquement passif (7) ; et les particules magnétiques dures (2) et les particules magnétiques douces (3) étant entourées par un corps de matrice (9), le corps de matrice (9) étant formé par le matériau magnétiquement passif (7).
  10. Aimant hybride (1) selon la revendication 9, dans lequel les particules magnétiques dures (2) et les particules magnétiques douces (3) présentent un diamètre (12) qui se situe dans la plage allant de 0,2 µm à 250 µm.
  11. Aimant hybride (1) selon l'une quelconque des revendications 9 ou 10, dans lequel le matériau magnétiquement passif (7) formant le corps de matrice (9) est un des matériaux suivants : verre, vitrocéramique, verre métallique ou céramique.
  12. Aimant hybride (1) selon l'une quelconque des revendications 9 à 11, dans lequel chaque couche (21) présente une épaisseur de couche (19) et une largeur (20), et dans lequel, pour chaque couche (21), la largeur (20) correspond à au moins dix fois l'épaisseur de couche (19).
  13. Aimant hybride (1) selon l'une quelconque des revendications 9 à 12, dans lequel les couches (21) sont orientées perpendiculairement à la direction de la magnétisation (34) de l'aimant hybride (1).
EP17700819.0A 2016-02-11 2017-01-18 Aimant hybride et procédé de fabrication Active EP3414768B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102016102386.8A DE102016102386A1 (de) 2016-02-11 2016-02-11 Hybridmagnet und Verfahren zu dessen Herstellung
PCT/EP2017/050939 WO2017137220A1 (fr) 2016-02-11 2017-01-18 Aimant hybride et procédé de fabrication

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EP3414768B1 true EP3414768B1 (fr) 2020-04-15

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CN (1) CN108780687B (fr)
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JP7003543B2 (ja) * 2017-09-29 2022-02-04 セイコーエプソン株式会社 絶縁物被覆軟磁性粉末、圧粉磁心、磁性素子、電子機器および移動体
DE102022115198A1 (de) 2022-06-17 2023-12-28 Ford Global Technologies, Llc Verfahren zum Herstellen eines Rotorelements für einen Rotor einer elektrischen Maschine, Rotorelement, Rotor, elektrische Maschine und Kraftfahrzeug

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CN108780687A (zh) 2018-11-09
WO2017137220A1 (fr) 2017-08-17
DE102016102386A1 (de) 2017-08-17
EP3414768A1 (fr) 2018-12-19
CN108780687B (zh) 2020-12-29

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