JP2009224670A - 永久磁石及び永久磁石の製造方法 - Google Patents
永久磁石及び永久磁石の製造方法 Download PDFInfo
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Abstract
【解決手段】Nd27〜30wt%−Fe60〜70wt%−B1〜2wt%からなる磁石原料を湿式粉砕することにより溶媒中で分散させ、粉砕された磁石粉末に樹脂バインダーを添加し、磁石粉末と樹脂バインダーとを混練することによりスラリー41を生成し、生成したスラリーをシート状に成形したグリーンシート42を焼結することにより永久磁石1を製造するように構成する。
【選択図】図3
Description
そして、上記VCMにおいて小型化、薄型化を実現するに当たって、VCMに埋設される永久磁石について、薄膜化と更なる磁気特性の向上が求められている。尚、永久磁石としてはフェライト磁石、Sm−Co系磁石、Nd−Fe−B系磁石、Sm2Fe17Nx系磁石等があるが、特に保磁力の高いNd−Fe−B系磁石が永久磁石モータ用の永久磁石として用いられる。
先ず、図1〜図4を用いて永久磁石1の構成について説明する。尚、本実施形態では特にVCMに埋設される永久磁石1を例に挙げて説明する。
本実施形態に係る永久磁石1はNd−Fe−B系磁石である。また、永久磁石1の保磁力を高める為のDy(ジスプロシウム)が添加されている。尚、各成分の含有量はNd:27〜30wt%、Dy(又はTb):0.01〜8wt%、B:1〜2wt%、Fe(電解鉄):60〜70wt%とする。また、永久磁石1は、図1に示すように扇形で且つ薄膜状の磁石から構成される。図1は本実施形態に係る永久磁石1を示した全体図である。
図3に示すように永久磁石の保磁力は、磁化された状態から逆方向への磁場を加えていった際に、磁気分極を0にする(即ち、磁化反転する)のに必要な磁場の強さである。従って、磁化反転を抑制することができれば、高い保磁力を得ることができる。尚、磁性体の磁化過程には、磁気モーメントの回転に基づく回転磁化と、磁区の境界である磁壁(90°磁壁と180°磁壁からなる)が移動する磁壁移動がある。
また、本実施形態ではDy化合物を磁石原料と共に溶媒中で湿式混合したグリーンシートを適切な焼成条件で焼成すれば、Dyが磁石粒子35内へと拡散浸透(固溶化)することを防止できる。ここで、Dyが磁石粒子35内へと拡散浸透すると、その磁石の残留磁化(磁場の強さを0にしたときの磁化)が低下することが知られている。従って、本実施形態では、永久磁石1の残留磁化が低下することを防止できる。
尚、Dy層36はDy化合物のみから構成される層である必要はなく、DyとNdとの混合体からなる層であっても良い。また、Dy化合物の替わりにTb(テルビウム)化合物を添加することによっても、同様に永久磁石1の保磁力を向上させることが可能である。Tbが添加された場合には、Nd磁石粒子35の表面にTb化合物の層が同様に形成される。そして、Tb層を形成することにより、永久磁石1の保磁力を更に向上させることができる。
次に、本実施形態に係る永久磁石1の製造方法について図5を用いて説明する。図8は本実施形態に係る永久磁石1の製造工程を示した説明図である。
・分散装置:ビーズミル
・分散メディア:ジルコニアビーズ
また、溶媒に非可溶でも、微粒子に粉砕したDy、又はDy化合物を湿式分散時に添加し、均一分散する事でNd磁石粒子表面に均一付着させることが可能となる。
・塗工方式:ドクターブレード
・ギャップ:1mm
・支持基材:シリコーン処理ポリエステルフィルム
・乾燥条件:90℃×10分の後、130℃×30分
また、希土類磁石の内でも特に高保磁力を確保することができるNd系磁石に対して、製造工程を簡略化することができ、高い寸法精度で成形可能となる。
例えば、本実施形態では磁石粉末やDy化合物を溶媒中に分散させる方法として、図5に示すように粗粉砕した磁石粉末をDy化合物とともに溶媒中で湿式粉砕することにより溶媒中で分散させているが、以下の方法により行うことも可能である。
(1)先ず、粗粉砕した磁石粉末をボールミルやジェットミル等を用いて乾式粉砕により0.3〜5μm程度の大きさに微粉砕する。
(2)次に、微粉砕した磁石粉末を溶媒に添加し、溶媒中に均一に分散させる。その際、分散剤やDy化合物についても溶媒中に添加する。
(3)溶媒中に分散された磁石粉末と樹脂バインダーを混練し、スラリー41を生成する。
以降は、本実施形態と同様の処理を行うことにより、本実施形態と同様の構成を備えた永久磁石を製造することが可能となる。
例えば、作製したグリーンシート42の表面にDy化合物を均一塗布する構成としても良い。或いは、焼成後の磁石にDy化合物を均一塗布し、その後に熱処理を行う構成としても良い。その結果、シート状の磁石表面にDyが被覆、偏在化されることにより磁石の保磁力を向上させることができ、また、Dyの総量を低減することができる。
41 スラリー
42 グリーンシート
Claims (4)
- 磁石原料と樹脂バインダーとを混合、成形したグリーンシートを焼結してなることを特徴とする永久磁石。
- 前記磁石原料がNd系磁石であることを特徴とする請求項1に記載の永久磁石。
- 磁石原料を湿式粉砕する工程と、
前記磁石原料に樹脂バインダーを添加する工程と、
前記磁石原料と前記樹脂バインダーとを混練することによりスラリーを生成する工程と、
前記スラリーをシート状に成形し、グリーンシートを作製する工程と、
前記グリーンシートを焼結する工程と、を有することを特徴とする永久磁石の製造方法。 - 磁石原料を乾式粉砕する工程と、
前記磁石原料に樹脂バインダーを添加する工程と、
前記磁石原料と前記樹脂バインダーとを混練することによりスラリーを生成する工程と、
前記スラリーをシート状に成形し、グリーンシートを作製する工程と、
前記グリーンシートを焼結する工程と、を有することを特徴とする永久磁石の製造方法。
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JP2008069382A JP4872109B2 (ja) | 2008-03-18 | 2008-03-18 | 永久磁石及び永久磁石の製造方法 |
EP09722877A EP2256758A4 (en) | 2008-03-18 | 2009-03-17 | PERMANENT MAGNET AND METHOD FOR MANUFACTURING THE SAME |
KR1020107020900A KR20100127233A (ko) | 2008-03-18 | 2009-03-17 | 영구 자석 및 영구 자석의 제조 방법 |
PCT/JP2009/055191 WO2009116539A1 (ja) | 2008-03-18 | 2009-03-17 | 永久磁石及び永久磁石の製造方法 |
CN200980109639.0A CN101978445B (zh) | 2008-03-18 | 2009-03-17 | 永久磁铁及永久磁铁的制造方法 |
US12/933,006 US20110012700A1 (en) | 2008-03-18 | 2009-03-17 | Permanent magnet and method for manufacturing the same |
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WO2013137132A1 (ja) * | 2012-03-12 | 2013-09-19 | 日東電工株式会社 | 希土類永久磁石及び希土類永久磁石の製造方法 |
JP5411957B2 (ja) * | 2012-03-12 | 2014-02-12 | 日東電工株式会社 | 希土類永久磁石及び希土類永久磁石の製造方法 |
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- 2009-03-17 CN CN200980109639.0A patent/CN101978445B/zh not_active Expired - Fee Related
- 2009-03-17 KR KR1020107020900A patent/KR20100127233A/ko not_active Application Discontinuation
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JP2009224671A (ja) * | 2008-03-18 | 2009-10-01 | Nitto Denko Corp | 永久磁石及び永久磁石の製造方法 |
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Also Published As
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WO2009116539A1 (ja) | 2009-09-24 |
EP2256758A1 (en) | 2010-12-01 |
JP4872109B2 (ja) | 2012-02-08 |
EP2256758A4 (en) | 2011-07-06 |
CN101978445B (zh) | 2013-10-23 |
KR20100127233A (ko) | 2010-12-03 |
CN101978445A (zh) | 2011-02-16 |
US20110012700A1 (en) | 2011-01-20 |
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