JP2009176960A - Magnetoplumbite type ferrite particle powder for bond magnet, method of manufacturing same, and resin composition, bond magnet, and magnet roll using magnetoplumbite type ferrite particle powder - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide magnetoplumbite type ferrite particle powder for a bond magnet and a method of manufacturing the same, excellent in the magnetic characteristics and in the mechanical strength, and at the same time, capable of obtaining a bond magnet excellent in a coercive force iHc. <P>SOLUTION: Ferrite particle powder, in which the calcium content of magnetoplumbite type ferrite particle powder is 900 to 2,500 mg/kg as Ca, the pH is 10.5 to 12.5, and the average particle diameter is 1.0 to 3.0 μm, is obtained by blending and mixing raw material powder, temporarily baking the obtained raw material mixture power in the atmosphere at temperatures 900 to 1,250°C, and then, cracking and processing with water, adding Ca compound, and subjecting it to anneal heating processing in the atmosphere at temperatures 700 to 1,100°C. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a magnetoplumbite-type ferrite particle powder for bonded magnets that can provide a bonded magnet with excellent magnetic properties, excellent mechanical strength, and excellent coercive force iHc, and a method for producing the same. The present invention relates to a resin composition for bonded magnets using a plumbite type ferrite particle powder, a bonded magnet, and a magnet roll.

  As is well known, bonded magnets have advantages such as light weight, good dimensional accuracy, and easy mass production of complex shapes compared to sintered magnets. Widely used in various applications.

  As magnetic powders used in bond magnets, rare earth magnet powders and ferrite particle powders typified by Nd—Fe—B are known. Although rare earth magnet powder has high magnetic properties, it is also expensive and has limited uses. On the other hand, ferrite particle powder is inferior in terms of magnetic properties as compared with rare earth magnet powder, but it is inexpensive and chemically stable, so it is used in a wide range of applications.

  Bond magnets are generally manufactured by kneading a rubber or plastics material and magnetic powder and then molding them in a magnetic field or by mechanical means.

  In recent years, along with the downsizing and weight reduction of tools and equipment in various fields, it is required that the bonded magnets used have high performance and excellent mechanical strength.

  That is, bond magnets in downsized equipment are often used under severe conditions, and mechanical strength is required. For example, although a magnet roll is used in a copying machine, a printer, and the like, it is strongly required to have a high mechanical strength because it is used for extending the life of the apparatus and rotating at high speed.

  Therefore, there is a demand for a ferrite particle powder that can satisfy the above-described requirements also in the magnetoplumbite type ferrite particle powder used for the bond magnet.

So far, various improvements have been made to ferrite particle powders for bonded magnets. For example, a method of producing ferrite particle powder using an alkali metal compound or an alkaline earth metal compound as a flux (Patent Document 1), ferrite A method in which the particle powder is alkali-treated and then surface-treated with a coupling agent (Patent Document 2), a method in which CaO and SiO ₂ are added to the calcined ferrite powder and sintered to obtain a ferrite magnet (Patent Document 3), ferrite A method for controlling the particle size distribution of the particle powder (Patent Document 4) is known.

JP 55-145303 A JP-A-5-41314 JP-A-5-275221 JP-A-4-224116

  Magnetplumbite type ferrite particle powders for bonded magnets that satisfy the above requirements are currently in the most demanded state, but those that sufficiently satisfy the above requirements have not yet been obtained.

  That is, it is difficult to say that the bonded magnet using the ferrite particle powder described in the aforementioned Patent Documents 1 to 4 is excellent in mechanical strength.

  Then, this invention makes it a technical subject to obtain the magnetoplumbite type ferrite particle powder for bonded magnets from which the bonded magnet excellent in mechanical strength is obtained.

  The technical problem can be achieved by the present invention as follows.

  That is, according to the present invention, the calcium content of the magnetoplumbite type ferrite particle powder is 900 to 2500 mg / kg (0.09 to 0.25 wt%) as Ca, and the pH is 10.5 to 12.5. And a magnetoplumbite type ferrite particle powder for bonded magnets, characterized in that the average particle size is 1.0 to 3.0 μm (Invention 1).

  Moreover, this invention mix | blends and mixes raw material powder, After calcining the obtained raw material mixed powder in the temperature range of 900-1250 degreeC in air | atmosphere, it grind | pulverizes and water-washes, Then, in air | atmosphere, 700- In the manufacturing method of the magnetoplumbite type ferrite particle powder material for bonded magnet that is annealed and heated in a temperature range of 1100 ° C., a Ca compound is added to the magnetoplumbite type ferrite particle powder in any step after the calcination. The method for producing a magnetoplumbite-type ferrite particle powder material for bonded magnets according to claim 1, wherein 1500 to 30000 mg / kg (0.15 to 3.00 wt%) is added to the ferrite particle powder. (Invention 2).

  Moreover, this invention is a resin composition using the said magnetoplumbite-type ferrite particle powder for bonded magnets (this invention 3).

  Moreover, this invention is a bonded magnet using the said magnetoplumbite type ferrite particle powder for bonded magnets (this invention 4).

  Moreover, this invention is a magnet roll using the magnetoplumbite type ferrite particle powder for said bonded magnets (this invention 5).

  The ferrite particle powder for bonded magnet according to the present invention contains 900 to 2500 mg / kg (0.09 to 0.25% by weight) of calcium in terms of Ca. A magnetic powder that is chemically bonded and interacts with an organic binder and / or a silane coupling agent, and is suitable as a magnetic powder for a bond magnet.

  The resin composition according to the present invention is suitable as a bonded magnet because a molded body having excellent strength can be obtained.

  The magnet roll according to the present invention is suitable because it is excellent in mechanical strength.

  Hereinafter, the present invention will be described in detail.

  First, the magnetoplumbite type ferrite particle powder for bonded magnets according to the present invention (hereinafter referred to as “ferrite particle powder”) will be described.

  The composition of the ferrite particle powder according to the present invention is not particularly limited, and may be either Sr-based ferrite particle powder or Ba-based ferrite particle powder. Moreover, you may contain dissimilar elements, such as La, Nd, Pr, Co, Zn. Either isotropic or anisotropic ferrite may be used, but it is preferable to use anisotropic ferrite in order to increase the magnetic force on the surface of a molded body such as a magnet roll.

  The calcium content of the ferrite particle powder according to the present invention is 900 to 2500 mg (0.09 to 0.25% by weight) in terms of Ca. When the Ca abundance is less than 900 mg / kg (0.09% by weight), since the reactivity with the resin is low, a molded article having excellent mechanical strength cannot be obtained. If it exceeds 2500 mg / kg (0.25% by weight), the reactivity with the resin becomes too high, so that a molded article having excellent mechanical strength cannot be obtained. It is preferably 900 to 2000 mg / kg (0.09 to 0.20% by weight).

  The average particle diameter of the ferrite particle powder according to the present invention is 1.0 to 3.0 μm. When the average particle size is outside the range of 1.0 to 3.0 μm, it becomes difficult to obtain a bonded magnet having high magnetic properties because high filling cannot be performed when the bonded magnet is formed. More preferably, it is 1.0-2.5 micrometers, More preferably, it is 1.0-2.0 micrometers.

  The powder pH of the ferrite particle powder according to the present invention is 10.5 to 12.5. When the powder pH of the ferrite particle powder is out of the above range, a molded body having excellent mechanical strength cannot be obtained when a bonded magnet is formed. More preferably, it is 10.5 to 12.0.

The BET specific surface area value of the ferrite particle powder according to the present invention is preferably 1.0 to 3.0 m ² / g. More preferably, it is 1.0-2.5 m < ² > / g.

The compression density CD of the ferrite particle powder according to the present invention is preferably 3000 to 3500 kg / m ³ (3.00 to 3.50 g / cm ³ ). When the compression density is less than 3000 kg / m ³ (3.00 g / cm ³ ), the filling property is lowered, so that a bonded magnet having high magnetic properties cannot be obtained. When the compression density exceeds 3500 kg / m ³ (3.50 g / cm ³ ), there is no problem in magnetic properties and the like, but industrially stable production is difficult. The compression density of the ferrite particle powder is more preferably 3100 to 3500 kg / m ³ (3.00 to 3.50 g / cm ³ ), and further preferably 3200 to 3450 kg / m ³ (3.00 to 3.45 g / cm ³ ). ³ ).

The saturation magnetization value σ _s of the ferrite particle powder according to the present invention is preferably 65.0 to 73.0 Am ² / kg (65.0 to 73.0 emu / g), and the coercive force iHc is 135 to 279 kA / m (1700). ~ 3500 Oe) is preferred.

  Next, a method for producing a ferrite particle powder according to the present invention will be described.

  The ferrite particle powder according to the present invention is prepared by mixing and mixing raw material powder at a predetermined mixing ratio, and calcining the obtained raw material mixed powder in the air at a temperature range of 900 to 1250 ° C. Then, in the production method of annealing and heating in the temperature range of 700 to 1100 ° C. in the atmosphere, it can be obtained by adding 1500 to 30000 mg / kg (0.15 to 3.00 wt%) of the Ca compound. . The Ca compound may be added in any process as long as it is after the calcination process.

  The raw material powder may be appropriately selected from oxide powders, hydroxide powders, carbonate powders, nitrate powders, sulfate powders, chloride powders and the like of various metals forming magnetoplumbite-type ferrite. In consideration of improvement in reactivity during calcination, the particle size is preferably 2.0 μm or less.

The Ca compound is not particularly limited, such as Ca (OH) ₂ , CaO, CaCO ₃ , but Ca (OH) ₂ and CaO excellent in reactivity are preferable, and Ca (OH) ₂ is more preferable.

Moreover, in this invention, it is preferable to calcine by adding a flux to raw material mixed powder. As the flux, various fluxes can be used, for example, SrCl ₂ · 2H ₂ O, CaCl ₂ · 2H ₂ O, MgCl ₂ , KCl, NaCl, BaCl ₂ · 2H ₂ O and Na ₂ B ₄ O _7. It is. The addition amount is preferably 1 to 10 parts by weight per 100 parts by weight of the raw material mixed powder. More preferably, it is 1 to 8 parts by weight.

In the present invention, Bi ₂ O ₃ may be added to and mixed with the raw material mixed powder or the pulverized powder after calcination.

  In the present invention, large particles and small particles may be mixed from the viewpoint of particle size distribution control.

  The addition amount of Ca compound is 1500-30000 mg / kg (0.15-3.00 weight%) with respect to ferrite particle powder. When the amount of Ca added is less than 1500 mg (0.15% by weight), the molded body using the obtained ferrite particle powder has a low reactivity with the resin, so it is difficult to say that the mechanical strength is sufficient. When it exceeds 30000 mg (3.00% by weight), the reactivity with the resin becomes too high, so that a molded article having excellent mechanical strength cannot be obtained. More preferably, it is 3000-20000 mg / kg (0.30-2.00 weight%).

  Next, the composition for bonded magnets using the ferrite particle powder according to the present invention will be described.

  In the bonded magnet composition according to the present invention, the ratio of the ferrite particle powder in the bonded magnet composition is 70 to 95 parts by weight, and the total amount of the organic binder component and the silane coupling agent component is 5 to 30 parts by weight. And kneaded.

  The organic binder is not particularly limited as long as it is used in conventional bonded magnets. Rubber, vinyl chloride resin, ethylene-vinyl acetate copolymer resin, ethylene-ethyl acrylate copolymer resin, PPS resin, polyamide ( Nylon) resin, polyamide elastomer, polymerized fatty acid polyamide and the like can be selected and used according to the application. Moreover, well-known mold release agents, such as a zinc stearate and a calcium stearate, can be added as needed.

The residual magnetic flux density Br of the bonded magnet according to the present invention is preferably 230 mT (2300 G) or more, more preferably 235 mT (2350 G) or more. The coercive force iHc is preferably 119 to 279 kA / m (1500 to 3500 Oe), more preferably 127 to 259 kA / m (1600 to 3250 Oe). The maximum energy product BHmax is preferably 10.3 kJ / m ³ (1.30 MGOe) or more, more preferably 10.7 kJ / m ³ (1.35 MGOe) or more.

  Next, a method for producing a bonded magnet composition using the ferrite particle powder, resin binder, and silane coupling agent according to the present invention will be described.

  The bond magnet according to the present invention can be obtained by a known bond magnet manufacturing method. For example, the ferrite particle powder according to the present invention and the binding resin are mixed and then melt-kneaded using a kneading extruder or the like. It can be obtained by crushing or cutting the kneaded product into a granular or pellet form.

  Next, it describes about a magnet roll.

  The magnet roll is prepared by mixing ferrite magnetic powder for bonded magnet and organic binder component in advance, and / or carrying out the process up to melt kneading after mixing them, and pulverizing or cutting them into a pellet to obtain a bonded magnet composition in a molten state. Columnar body portions having a plurality of magnetic poles on the peripheral surface in so-called magnetic field injection molding that is injected into the magnetic field of the mold cavity and orients the magnetic powder, and shaft portions provided on both end faces of the body portion; Was obtained by integrally molding. The molded body is integrally molded having a body portion having a diameter of 13.6 mm and a length of 220 mm and a shaft portion having a diameter of 5 mm (the center is the same as the body portion having a diameter of 13.6 mm) at both ends.

<Action>
Although it is not yet clear that the ferrite particles powder according to the present invention contains Ca and the mechanical strength of the molded body containing the ferrite particles powder is excellent, the present inventor presumes as follows: Yes.

  The ferrite particle powder for bonded magnet according to the present invention improves the reactivity of the organic binder component and the silane coupling agent by containing Ca, and the three-component phase of the ferrite particle powder, the organic binder and the silane coupling agent. It is presumed that the ferrite particles powder and the organic binder were firmly bonded because the solubility was synergistically improved.

  A typical embodiment of the present invention is as follows.

  The average particle size of the ferrite particle powder according to the present invention was measured using “Powder Specific Surface Area Measuring Device SS-100” (manufactured by Shimadzu Corporation).

  The BET specific surface area of the ferrite particle powder according to the present invention was measured using “4 specimen fully automatic specific surface area measuring device 4 Sorb U2” (manufactured by Yuasa Ionics Co., Ltd.).

As the compression density of the ferrite particle powder according to the present invention, the density when the particle powder was compressed at a pressure of 1 t / cm ² was adopted.

  The powder pH of the ferrite particle powder according to the present invention was measured using a “glass electrode type hydrogen ion concentration meter M8E” (manufactured by Horiba, Ltd.) in accordance with JIS K5101-17-1.

  The molding density of the bonded magnet composition is such that the core formed by melting the bonded magnet composition in a mold with a diameter of 25 mmφ and 10.5 mm is “electronic hydrometer EW-120SG” (Yasuda Seiki Seisakusho Co., Ltd.) Measured).

  The magnetic properties (residual magnetic flux density Br, coercive force iHc, coercive force bHc, maximum energy product BHmax) of the bonded magnet composition are as follows. The bonded magnet composition is melted in a mold having a height of 25 mmφ and 10.5 mm. After magnetic field orientation at 4 kOe, measurement was performed in a magnetic field of 14 kOe using a “DC magnetization characteristic automatic recording device 3257” (manufactured by Yokogawa Hokushin Electric Co., Ltd.).

The injection molding using the bonded magnet composition was performed using an injection molding machine 110ELII manufactured by Nippon Steel Co., Ltd., and a body portion having a diameter of 13.6 mm and a length of 220 mm and a diameter of 5 mm (the center of the diameter is 13. (Same as 6mm body part) Shaft part is integrally molded at both ends, and the body part is magnetized to 4 poles like S1, S2, N1, N2 in the injection molding machine, then cooled and taken out as a magnet roll It was.
The set temperature of the mold was 100 ° C., and the surface temperature of the magnet roll was also cooled to near 100 ° C.

  The mechanical strength of the magnet roll is determined as the bending strength after being left in the atmosphere for 24 hours and then measuring the three-point bending strength of the magnet roll body with the Autograph AG-I series (manufactured by Shimadzu Corporation). It was.

Example 1
<Manufacture of ferrite particle powder>
Powdered α-Fe ₂ O ₃ and SrCO ₃ were weighed so that the composition was SrO · nFe ₂ O ₃ [n = 6.3], mixed for 30 minutes with a wet attritor, filtered and dried. (First wet mixing and grinding step).
A mixed aqueous solution of SrCl ₂ and Na ₂ B ₄ O ₇ was added to the obtained mixed powder and mixed well, followed by granulation. At this time, the addition amounts of SrCl ₂ and Na ₂ B ₄ O ₇ were 3 parts by weight and 0.5 parts by weight, respectively, with respect to 100 parts by weight of the raw material mixed powder. The obtained granulated material was calcined in the atmosphere at 1200 ° C. for 2 hours (calcination step).
The obtained calcined product was roughly pulverized and then pulverized with a wet attritor for 30 minutes, washed with water, filtered and dehydrated. Thereafter, Ca (OH) ₂ was added, mixed and pulverized with a wet attritor for 5 minutes, filtered and dehydrated (second wet mixed pulverization step). At this time, the addition amount of Ca (OH) ₂ was 0.5 parts by weight with respect to 100 parts by weight of the coarsely pulverized product.
Thereafter, the mixture was further pulverized with a vibration mill for 30 minutes (dry mixing and pulverizing step). The obtained pulverized product was annealed and heated in the atmosphere at 900 ° C. for 1.5 hours (heat treatment step), and then uniformly mixed with a Henschel mixer for 10 minutes (uniform mixing step).

The obtained ferrite particle powder had a coercive force iHc of 214.1 kA / m (2690 Oe). The average particle size Ps was 1.57 μm, and the BET specific surface area was 1.30 m ² / g. The compression density CD was 3420 kg / m ³ (3.42 g / cm ³ ). The pH was 10.8. Moreover, Ca content was 1000 mg / kg (0.10 wt%).

Examples 2-5, Comparative Examples 1-4:
Ferrite particle powder was prepared in the same manner as in Example 1 except that the composition, calcining time, type of Ca compound, addition amount and addition time, pulverization time, and the like were variously changed. Table 1 shows the properties of the prepared ferrite particle powder.

Example 6
<Manufacture of composition for bonded magnet>
25,000 g of the obtained ferrite particle powder was put in a dry mixer, 0.6 parts by weight of a silane coupling agent was added to ferrite and mixed until uniform for 1 hour, and 2507 g of 6-nylon resin was added. Then, it further mixed for 1 hour and prepared the mixture for the composition for bond magnets.

  The obtained mixture for the bonded magnet composition is quantitatively fed to a biaxial kneader and kneaded at a temperature at which 6-nylon is melted. The kneaded product is taken out into a strand shape and taken out as a pellet having a size of 2 mmφ × 3 mm. The composition for bonded magnets was obtained by cutting.

The bond magnet had a residual magnetic flux density Br of 294 mT (2940 G), a coercive force iHc of 208.5 kA / m (2620 Oe), and a maximum energy product BHmax of 16.7 kJ / m ³ (2.10 MGOe). .

<Molding of magnet roll>
The obtained bonded magnet resin composition was dried at 100 ° C. for 8 hours, and then the bonded magnet resin composition was melted at 290 ° C. in an injection molding machine, and the injection time was set to 100 ° C. in 1.8 seconds. An integrally molded magnet roll having a diameter of 13.6 mm and a length of 220 mm and a shaft having a diameter of 5.0 mm (the axis is the same as that of the diameter of 13.6 mm) are formed at both ends. Prepared.

  The bending strength of the obtained integrally molded magnet roll was 752N.

Examples 7-10, Comparative Examples 5-8:
<Manufacture of composition for bonded magnet>
Resin compositions for bonded magnets comprising various ferrite particle powders, 6-nylon resin, and silane coupling agent were prepared in the same manner as in Example 6.

  Table 2 shows the properties of the resin composition for bonded magnets.

<Molding of magnet roll>
Magnet rolls were prepared in the same manner as in Example 6 using various resin compositions for bonded magnets. Table 2 shows the characteristics of the magnet roll.

Since the bonded magnet manufactured using the ferrite particle powder according to the present invention is excellent in bending strength, it is suitable as a bonded magnet, particularly as a ferrite particle powder for a magnet roll.

Claims (5)

The magnetoplumbite type ferrite particle powder has a calcium content of 900 to 2500 mg / kg (0.09 to 0.25 wt%) as Ca, a pH of 10.5 to 12.5, and an average particle size. A magnetoplumbite type ferrite particle powder for bonded magnets, characterized in that is 1.0 to 3.0 μm. After mixing and mixing the raw material powder, the obtained raw material mixed powder was calcined in the temperature range of 900 to 1250 ° C. in the atmosphere, then pulverized and washed, and then in the temperature range of 700 to 1100 ° C. in the air. In the manufacturing method of the magnetoplumbite type ferrite particle powder material for bonded magnet to be annealed and heated, the Ca compound is added to the ferrite particle powder with respect to the magnetoplumbite type ferrite particle powder in any step after the calcination. The method for producing a magnetoplumbite-type ferrite particle powder material for bonded magnets according to claim 1, wherein 1500 to 30000 mg / kg (0.15 to 3.00% by weight) is added. A resin composition using the magnetoplumbite type ferrite particle powder for bonded magnets according to claim 1. A bonded magnet using the magnetoplumbite type ferrite particle powder for bonded magnet according to claim 1. A magnet roll using the magnetoplumbite type ferrite particle powder for bonded magnets according to claim 1.