JP2017135358A - Flat magnetic metal particle, dust material, dynamo-electric machine, motor, generator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide flat magnetic metal particles having high thermal stability.SOLUTION: Multiple flat magnetic metal particles 10 contain a flat surface 6, and at least one first element from a group consisting of Fe, Co and Ni, and include multiple magnetic metal particles 2 where the ratio of the maximum length to the minimum length in the flat surface is 1-5 in average, the average thickness is between 10 nm and 100 μm, and the average aspect ratio is 5-10000, and multiple magnetic metal small particles 4 of five or more, in average, placed on the flat surface 6, and containing at least one first element from a group consisting of Fe, Co and Ni, and having an average grain size between 10 nm and 1 μm.SELECTED DRAWING: Figure 1

Description

  Embodiments of the present invention relate to flat magnetic metal particles, a dust material, a rotating electrical machine, a motor, and a generator.

  Currently, soft magnetic materials are very important materials applied to various systems and device parts such as rotating electrical machines (eg, motors, generators, etc.), transformers, inductors, transformers, magnetic inks, antenna devices, etc. It is. In these components, since the magnetic permeability real part (relative magnetic permeability real part) μ ′ of the soft magnetic material is used, it is preferable to control μ ′ according to the use frequency band when actually used. . In order to realize a highly efficient system, it is preferable to use a material with as low a loss as possible. That is, it is preferable to make the imaginary part of permeability (imaginary part of relative permeability) μ ″ (corresponding to loss) as small as possible. Regarding loss, the loss coefficient tan δ (= μ ″ / μ ′ × 100 (%)) is one. The smaller the μ ″ relative to μ ′, the smaller the loss coefficient tan δ, which is preferable. For this purpose, it is preferable to reduce the iron loss under actual operating conditions, that is, eddy current loss, hysteresis It is preferable to reduce loss, ferromagnetic resonance loss, and residual loss (other losses) as much as possible, in order to reduce eddy current loss, increase the electrical resistance, reduce the size of the metal part, In order to reduce hysteresis loss, it is effective to reduce the coercive force or increase the saturation magnetization. In order to reduce the loss, it is effective to increase the frequency of the ferromagnetic resonance by increasing the anisotropic magnetic field of the material.In recent years, the demand for handling high power power is increasing, In particular, the loss is required to be small under operating conditions where the effective magnetic field applied to the material is large, such as high current, high voltage, etc. For this purpose, the saturation magnetization of the soft magnetic material can be as small as possible so as not to cause magnetic saturation. Furthermore, in recent years, since the size of equipment can be reduced by increasing the frequency, the use frequency band of the system and device equipment has been increased, and high permeability and low loss at high frequencies have been promoted. There is an urgent need to develop magnetic materials with excellent characteristics.

  Further, in recent years, with the growing awareness of energy saving issues and environmental issues, it is required to increase the efficiency of the system as much as possible. In particular, since the motor system is responsible for much of the world's power consumption, it is very important to improve the efficiency of the motor. Among them, the core and the like constituting the motor are made of a soft magnetic material, and it is required to increase the permeability and saturation magnetization of the soft magnetic material as much as possible and to reduce the loss as much as possible. In addition, it is required to reduce the loss as much as possible in the magnetic wedge (magnetic wedge) used in a part of the motor. The same thing is required in a system using a transformer. In motors and transformers, there is a great demand for high efficiency and miniaturization. In order to achieve downsizing, it is important to increase the permeability and saturation magnetization of the soft magnetic material as much as possible. In order to prevent magnetic saturation, it is important to increase the saturation magnetization as much as possible. Furthermore, there is a great demand for increasing the operating frequency of the system, and there is a demand for the development of a material with low loss in the high frequency band.

In addition, soft magnetic materials having high magnetic permeability and low loss are used for inductance elements and antenna devices. Among them, attention has recently been focused on application to power inductance elements used in power semiconductors. In recent years, the importance of energy saving and environmental protection has been widely advocated, and reduction of CO ₂ emission amount and dependence on fossil fuel has been demanded. As a result, development of electric vehicles and hybrid vehicles to replace gasoline vehicles has been energetically advanced. In addition, natural energy utilization technologies such as solar power generation and wind power generation are said to be key technologies for an energy-saving society, and advanced countries are actively promoting the development of natural energy utilization technologies. Furthermore, as an environmentally friendly power-saving system, HEMS (Home Energy Management System) and BEMS (BEMS) that control the power generated by solar power generation, wind power generation, etc. with a smart grid and supply and supply at high efficiency to homes, offices and factories. The importance of building and building energy management systems has been actively proposed. Power semiconductors play an important role in this trend of energy saving. Power semiconductors are semiconductors that control high power and energy with high efficiency. In addition to power individual semiconductors such as IGBTs (insulated gate bipolar transistors), MOSFETs, power bipolar transistors, and power diodes, linear regulators and switching A power supply circuit such as a regulator and a power management logic LSI for controlling them are included. Power semiconductors are widely used in various devices such as home appliances, computers, automobiles, railroads, etc., and the spread of these applied devices can be expected, and further the mounting ratio of power semiconductors to these devices can be expected. Big market growth is expected. For example, power semiconductors are used in almost all inverters installed in many home appliances, which enables significant energy savings. Currently, Si is the main power semiconductor, but it is considered that the use of SiC and GaN is effective for further increasing the efficiency and miniaturization of equipment. SiC and GaN have a larger band gap and dielectric breakdown field than Si, and can increase the breakdown voltage, so that the device can be made thinner. As a result, the on-resistance of the semiconductor can be reduced, which is effective for reducing loss and increasing efficiency. Further, since SiC and GaN have high carrier mobility, it is possible to increase the switching frequency, which is effective for miniaturization of the element. Furthermore, in particular, SiC has a higher thermal conductivity than Si, and thus has a high heat dissipation capability and can be operated at a high temperature, which simplifies the cooling mechanism and is effective for miniaturization. From the above viewpoint, SiC and GaN power semiconductors have been vigorously developed. However, in order to realize this, it is indispensable to develop a power inductor element used together with a power semiconductor, that is, development of a high magnetic permeability soft magnetic material (high magnetic permeability and low loss). At this time, as the characteristics required for the magnetic material, high saturation magnetization capable of handling a large current as well as high magnetic permeability and low magnetic loss in the driving frequency band are preferable. When the saturation magnetization is high, even when a high magnetic field is applied, magnetic saturation is unlikely to occur, and an effective decrease in inductance value can be suppressed. This improves the DC superposition characteristics of the device and improves the efficiency of the system.

  In addition, magnetic materials having high magnetic permeability and low loss at high frequencies are expected to be applied to devices of high-frequency communication equipment such as antenna devices. As a method for reducing the size and power consumption of antennas, an insulating substrate with high magnetic permeability (high magnetic permeability and low loss) is used as an antenna substrate, and electronic components that involve radio waves that reach the electronic components in the communication equipment and the substrate from the antenna There is a method for transmitting and receiving without transmitting radio waves to the board. As a result, it is possible to reduce the size and power consumption of the antenna, but at the same time, it is possible to widen the resonance frequency of the antenna, which is preferable.

  Other characteristics required when incorporated in each of the above systems and devices include high thermal stability, high strength, high toughness, and the like. Moreover, in order to apply to a complicated shape, the compact is preferable to the shape of a plate or ribbon. However, it is generally known that when a compact is used, characteristics are deteriorated in terms of saturation magnetization, magnetic permeability, loss, strength, toughness, etc., and improvement of characteristics is preferable.

  Next, the types and problems of existing soft magnetic materials will be described.

  An existing soft magnetic material for a system of 10 kHz or less includes a silicon steel plate (FeSi). Silicon steel sheets have a long history and are used in most core materials for rotating electrical machines and transformers that handle high power. High performance has been achieved from non-oriented silicon steel sheets to directional silicon steel sheets, which have evolved compared to the initial discovery, but in recent years, the improvement in characteristics has reached a peak. As characteristics, it is particularly important to satisfy high saturation magnetization, high magnetic permeability, and low loss at the same time. In the world, research on materials exceeding silicon steel sheets has been actively conducted centering on amorphous and nanocrystal-based compositions, but no material composition exceeding silicon steel sheets has been found yet. In addition, research on a compact that can be applied to a complicated shape has been conducted, but the compact has a defect that the characteristics are poor compared to a plate or a ribbon.

  Existing soft magnetic materials for 10 kHz to 100 kHz systems include Sendust (Fe-Si-Al), nanocrystal-based finemet (Fe-Si-B-Cu-Nb), Fe-based or Co-based amorphous glass. Examples include ribbons and green compacts, or MnZn-based ferrite materials. However, none of them does not completely satisfy high permeability, low loss, high saturation magnetization, high thermal stability, high strength, and high toughness.

  Examples of existing soft magnetic materials of 100 kHz or higher (MHz band or higher) include NiZn-based ferrite and hexagonal ferrite, but their magnetic properties at high frequencies are insufficient.

  In view of the above, it is preferable to develop a magnetic material having high saturation magnetization, high magnetic permeability, low loss, high thermal stability, and excellent mechanical properties.

JP 2013-65844 A

  The problem to be solved by the present invention is to provide flat magnetic metal particles having high thermal stability, and a rotating electrical machine, a motor and a generator using the same.

  The plurality of flat magnetic metal particles according to the embodiment includes a flat plane and at least one first element selected from the group consisting of Fe, Co, and Ni, and has a maximum length with respect to a minimum length in the flat plane. The average ratio is 1 or more and 5 or less, the average thickness is 10 nm or more and 100 μm or less, the average aspect ratio is 5 or more and 10000 or less, and the average flat surface is 5 or more And a plurality of small magnetic metal particles having at least one first element selected from the group consisting of Fe, Co, and Ni and having an average particle size of 10 nm to 1 μm.

It is a schematic diagram of the flat magnetic metal particle of 1st Embodiment. It is a microscope picture of the flat magnetic metal particle of 1st Embodiment. It is a microscope picture of the flat magnetic metal particle used as a comparison with a 1st embodiment. It is the microscope picture which expanded the surface of the flat magnetic metal particle used as a comparison with 1st Embodiment. In 1st Embodiment, it is a microscope picture which shows the difference in the manufactured flat magnetic metal particle by the difference in the method of a grinding | pulverization. It is a figure which shows the particle size distribution of the flat magnetic metal particle of 1st Embodiment. It is a schematic diagram of the flat magnetic metal particle of 2nd Embodiment. It is a schematic diagram of the compacting material of 3rd Embodiment. It is a schematic diagram of the compacting material of 3rd Embodiment which has a eutectic particle. It is a schematic diagram of the compacting material of 3rd Embodiment which has intermediate intervening particles. It is a figure explaining the orientation of a flat magnetic metal particle in the compacting material of 3rd Embodiment. It is an example of a key map of a motor system of a 4th embodiment. It is a schematic diagram of the motor of 4th Embodiment. It is a schematic diagram of the motor core of 4th Embodiment. It is a schematic diagram of the transformer and transformer of 4th Embodiment. It is a schematic diagram of the inductor of 4th Embodiment. It is a schematic diagram of the generator of 4th Embodiment. It is a conceptual diagram which shows the relationship between the direction of magnetic flux, and the arrangement | positioning direction of a compacting material.

  Hereinafter, embodiments will be described with reference to the drawings. In the drawings, the same or similar parts are denoted by the same or similar reference numerals.

(First embodiment)
The plurality of flat magnetic metal particles according to the present embodiment includes a flat plane and at least one first element selected from the group consisting of Fe, Co, and Ni, and has a maximum length with respect to a minimum length in the flat plane. The average thickness ratio is 1 or more and 5 or less, the average thickness is 10 nm or more and 100 μm or less, the average aspect ratio is 5 or more and 10000 or less, and an average of 5 on the flat surface A plurality of small magnetic metal particles including at least one first element selected from the group consisting of Fe, Co, and Ni and having an average particle size of 10 nm to 1 μm.

  The thickness, aspect ratio, ratio of maximum length to minimum length, and number of magnetic metal small particles are all average values. Specifically, a value obtained by averaging 10 or more values is employed.

  FIG. 1 is a schematic diagram of the flat magnetic metal particles of the present embodiment. FIG. 1A is a schematic perspective view of the flat magnetic metal particles of the present embodiment. FIG.1 (b) is a schematic diagram at the time of seeing the flat magnetic metal particle of this embodiment from upper direction. FIG.1 (c) is a schematic diagram which shows the maximum length a of the flat surface of this embodiment, minimum length b, and thickness t. FIG.1 (d) is a schematic diagram when the magnetic metal small particle has arranged in one direction in the flat magnetic metal particle of this embodiment.

  FIG. 2A and FIG. 2B are examples of micrographs of the flat magnetic metal particles of the present embodiment. Magnetic metal small particles 4 are shown at the tip of the arrow in FIG.

  The flat magnetic metal particle 10 includes a plurality of magnetic metal particles 2 and a plurality of magnetic metal small particles 4. The flat magnetic metal particle 10 is a flat particle (flaky particle, flattened particle) having a flat shape (flaky shape, flattened shape).

  The magnetic metal particle 2 includes a flat surface 6 and at least one first element selected from the group consisting of Fe (iron), Co (cobalt), and Ni (nickel).

  The ratio a / b of the maximum length a to the minimum length b in the flat surface 6 is 1 or more and 5 or less on average. This reduces bending and compaction when the particles are compacted, and the stress on the particles is likely to be reduced. That is, distortion is reduced, coercive force and hysteresis loss are reduced, and stress is reduced, so that mechanical characteristics such as thermal stability, strength, and toughness are easily improved.

  The maximum length a and the minimum length b are obtained as follows. The flat plane 6 is observed with a transmission electron microscope (TEM) or a scanning electron microscope (SEM), and a line is perpendicular to the tangent of each point of the outline of the flat plane 6. Pull and measure the length to the point where it intersects the opposite contour line. This is performed at all points on the contour line, and the maximum length a and the minimum length b are determined.

  The outline of the flat surface 6 is preferably slightly rounded. As an extreme example, it is preferable to have a rounded outline such as a circle or an ellipse rather than a square or rectangular outline. As a result, it is desirable that stress is less likely to concentrate around the contour, magnetic distortion of the flat magnetic metal particles is reduced, coercivity is reduced, and hysteresis loss is reduced. Since stress concentration is reduced, thermal stability, mechanical properties such as strength and toughness are easily improved, which is desirable.

  The average thickness t of the magnetic metal particles 2 is 10 nm or more and 100 μm or less. More preferably, they are 10 nm or more and 1 micrometer or less, More preferably, they are 10 nm or more and 100 nm or less. Thereby, when a magnetic field is applied in a direction parallel to the flat surface, the eddy current loss can be sufficiently reduced, which is preferable. A smaller thickness is preferred because the magnetic moment is confined in the direction parallel to the flat surface, and the magnetization is likely to proceed by rotational magnetization. When the magnetization proceeds by rotational magnetization, the magnetization is likely to proceed reversibly, so that the coercive force is reduced, thereby reducing the hysteresis loss, which is preferable.

  The average thickness t is determined by observing the magnetic metal particles 2 with a TEM or SEM.

  The average aspect ratio (((a + b) / 2) / t) of the magnetic metal particles 2 is 5 or more and 10,000 or less. This is because the magnetic permeability increases. Further, since the ferromagnetic resonance frequency can be increased, the ferromagnetic resonance loss can be reduced. A larger aspect ratio is preferable because the magnetic moment is confined in a direction parallel to the flat surface, and magnetization is likely to proceed due to rotational magnetization. When the magnetization proceeds by rotational magnetization, the magnetization is likely to proceed reversibly, so that the coercive force is reduced, thereby reducing the hysteresis loss, which is preferable.

  The average aspect ratio (((a + b) / 2) / t) is determined by observing the magnetic metal particles 2 with a TEM or SEM.

  On average, five or more magnetic metal small particles 4 are arranged on the flat surface 6.

  The magnetic metal small particles 4 are arranged on the flat surface 6. Alternatively, the magnetic metal small particles 4 are provided on the surface of the flat surface 6. Alternatively, the magnetic metal small particles 4 are disposed on the surface of the flat surface 6. Alternatively, the magnetic metal small particles 4 are disposed on the surface of the flat surface 6. Alternatively, the magnetic metal small particles 4 are arranged on the flat surface 6. Alternatively, the magnetic metal small particles 4 are integrated with the flat surface 6.

  The magnetic metal small particles 4 include at least one first element selected from the group consisting of Fe, Co, and Ni, and have an average particle size of 10 nm to 1 μm. More preferably, the magnetic metal small particles 4 have the same composition as the magnetic metal particles 2. The state in which the surface of the flat magnetic metal particle 10 is slightly roughened by providing the magnetic metal small particle 4 on the surface of the flat surface 6 or by integrating the magnetic metal small particle 4 with the magnetic metal particle 2. Thus, the adhesion when the flat magnetic metal particles 10 are compacted together with the intervening phase 20 described later is greatly improved. Thereby, mechanical properties such as thermal stability, strength, and toughness are easily improved. In order to maximize such an effect, the average particle diameter of the magnetic metal small particles 4 is set to 10 nm or more and 1 μm or less, and five or more magnetic metal small particles 4 are averaged on the flat magnetic metal particles 10. It is desirable to be integrated with the surface, that is, the flat surface 6. As shown in FIG. 1 (d), when the magnetic metal small particles 4 are arranged in one direction in the flat surface 6, magnetic anisotropy is easily imparted in the flat surface 6, and high magnetic permeability and low Since loss is easy to realize, it is more preferable.

  The average particle diameter of the magnetic metal small particles 4 is determined by observing the magnetic metal small particles 4 with a TEM or SEM.

  The flat magnetic metal particles 10 and the magnetic metal small particles 4 contain Fe and Co, and the amount of Co is preferably 10 atomic percent or more and 60 atomic percent or less with respect to the total amount of Fe and Co, and is preferably 10 atomic percent or more. More preferably, it is contained at 40 atom% or less. This is preferable because the magnetic anisotropy is easily imparted to a reasonably large value and the magnetic characteristics are improved. In addition, the Fe—Co system is preferable because high saturation magnetization is easily realized. Furthermore, when the composition range of Fe and Co falls within the above range, higher saturation magnetization can be realized, which is preferable.

  The flat magnetic metal particles 10 preferably have magnetic anisotropy in one direction within the flat surface 6, which will be described in detail. First, when the magnetic domain structure of the flat magnetic metal particle 10 is a multi-domain structure, the magnetization process proceeds by domain wall movement. In this case, the coercive force is smaller in the easy axis direction in the flat plane 6 than in the difficult axis direction. Thus, the loss (hysteresis loss) is reduced. Further, the permeability in the easy axis direction is larger than that in the difficult axis direction. Compared to the case of the isotropic flat magnetic metal particle 10, the coercive force is smaller in the case of the flat magnetic metal particle 10 having magnetic anisotropy, particularly in the easy axis direction, thereby reducing the loss. It is preferable. Moreover, the magnetic permeability is increased, which is preferable. That is, by having magnetic anisotropy in the flat plane 6 inward direction, the magnetic characteristics are improved as compared with isotropic materials. In particular, the easy axis direction in the flat surface 6 is preferable because the magnetic characteristics are superior to the difficult axis direction. Next, when the magnetic domain structure of the flat magnetic metal particle 10 is a single magnetic domain structure, the magnetization process proceeds by rotational magnetization. In this case, the hard axis direction in the flat plane 6 is more preserved than the easy axis direction. Magnetic force is reduced and loss is reduced. When the magnetization proceeds completely by rotational magnetization, the coercive force becomes zero and the hysteresis loss becomes zero, which is preferable. Whether magnetization proceeds by domain wall motion (domain wall motion type) or rotational magnetization (rotation magnetization type) is determined by whether the domain structure is a multi-domain structure or a single domain structure. . At this time, whether the structure is a multi-domain structure or a single-domain structure is determined by the size (thickness and aspect ratio) of the flat magnetic metal particles 10, the composition, the state of interaction between the particles, and the like. For example, the smaller the thickness t of the flat magnetic metal particles 10 is, the more easily a single domain structure is formed. When the thickness is 10 nm or more and 1 μm or less, particularly when the thickness is 10 nm or more and 100 nm or less, the single domain structure is easily formed. As a composition, it is easy to maintain a single domain structure even when the thickness is large in a composition having a large magnetocrystalline anisotropy, and a single domain structure is maintained unless the thickness is small in a composition having a small magnetocrystalline anisotropy. It tends to be difficult. That is, the thickness of the boundary between the single-domain structure and the multi-domain structure varies depending on the composition. In addition, the single magnetic domain structure is more likely when the flat magnetic metal particles 10 are magnetically coupled to stabilize the magnetic domain structure. Whether the magnetization behavior is a domain wall motion type or a rotational magnetization type can be easily determined as follows. First, in the material plane (a plane parallel to the flat surface of the flat magnetic metal particle), the magnetization is measured by changing the direction in which the magnetic field is applied, and the two directions in which the difference in the magnetization curve is largest (the two directions are Search for directions that are tilted 90 degrees from each other. Next, by comparing the curves in the two directions, it can be determined whether the domain wall motion type or the rotational magnetization type.

  In addition, the magnitude of the uniaxial magnetic anisotropy in the flat plane 6 is preferably 0.1 Oe or more and 10 kOe or less, more preferably 1 Oe or more and 1 kOe or less, and further preferably 1 Oe or more and 100 Oe or less. Whether or not the magnetic anisotropy is present and how much the magnetic anisotropy is present can be determined by using, for example, a vibrating sample magnetometer (VSM). It can be easily evaluated by changing and measuring. Since the inside of the flat surface is magnetically isotropic in a compact using normal flat particles, it is fundamentally different from the present embodiment. By having magnetic anisotropy in the flat plane, the magnetic characteristics are greatly improved.

  The particle size distribution variation of the plurality of flat magnetic metal particles 10 can be defined by a coefficient of variation (CV value). That is, CV value (%) = [standard deviation of particle size distribution (μm) / average particle size (μm)] × 100. It can be said that the smaller the CV value, the smaller the particle size distribution variation and the sharper the particle size distribution. When the CV value defined above is 0.1% or more and 60% or less, low coercive force, low hysteresis loss, high magnetic permeability, and high thermal stability are preferable. Moreover, since there is little variation, it is easy to realize a high yield. A more preferable range of the CV value is 0.1% or more and 40% or less.

  In order to induce the magnetic anisotropy, there is a method in which the crystallinity of the flat magnetic metal particles is made as amorphous as possible and the magnetic anisotropy is induced in one in-plane direction by a magnetic field or strain. In this case, it is desirable that the flat magnetic metal particles have a composition that can be made amorphous as much as possible. In such a viewpoint, the magnetic metal contained in the flat magnetic metal particles is B (boron), Si (silicon), C (carbon), Ti (titanium), Zr (zirconium), Hf (hafnium), Nb ( Addition of at least one selected from niobium, Ta (tantalum), Mo (molybdenum), Cr (chromium), Cu (copper), W (tungsten), P (phosphorus), N (nitrogen), and Ga (gallium) It is preferable that the element is contained in an amount of 0.001 atomic% to 25 atomic% with respect to the total amount of the first element and the additive element.

  The flat magnetic metal particle 10 preferably has a portion containing Fe and Co and having a body-centered cubic (bcc) crystal structure. This is preferable because the magnetic anisotropy is easily imparted to a reasonably large value and the magnetic characteristics are improved.

  It is preferable that the flat surface 6 is crystallographically oriented. The orientation direction is preferably (110) plane orientation or (111) plane orientation, more preferably (110) plane orientation. When the crystal structure of the flat magnetic metal particle 10 is a body-centered cubic structure (bcc), the (110) plane orientation is preferable, and when the crystal structure of the flat magnetic metal particle 10 is a face-centered cubic structure (fcc), the (111) plane is preferred. Orientation is preferred. This is preferable because the magnetic anisotropy is easily imparted to a reasonably large value and the magnetic characteristics are improved.

  Further, as preferred orientation directions, the (110) [111] direction and the (111) [110] direction are preferred, but the (110) [111] direction is more preferred. When the crystal structure of the flat magnetic metal particle 10 is a body-centered cubic structure (bcc), orientation in the (110) [111] direction is preferable, and when the crystal structure of the flat magnetic metal particle 10 is a face-centered cubic structure (fcc) Is preferably oriented in the (111) [110] direction. This is preferable because the magnetic anisotropy is easily imparted to a reasonably large value and the magnetic characteristics are improved. In this specification, the “(110) [111] direction” means that the slip plane is the (110) plane or a crystallographically equivalent plane, that is, the {110} plane, and the slip direction is the [111] direction or The crystallographically equivalent direction, that is, the <111> direction. The same applies to the (111) [110] direction. That is, the slip plane is the (111) plane or a crystallographically equivalent plane, that is, the {111} plane, and the slip direction is the [110] direction or the crystallographically equivalent direction, that is, the <110> plane.

  The lattice strain of the magnetic metal phase of the flat magnetic metal particle 10 is preferably 0.01% or more and 10% or less, more preferably 0.01% or more and 5% or less, further preferably 0.01% or more and 1% or less, Preferably it is 0.01% or more and 0.5% or less. This is preferable because the magnetic anisotropy is easily imparted to a moderately large value and the magnetic characteristics are improved.

The lattice distortion can be calculated by analyzing in detail the line width obtained by the X-ray diffraction method (XRD: X-Ray Diffraction). That is, by performing the Halder-Wagner plot and the Hall-Williamson plot, it is possible to separate the contribution of the broadening of the line width into the crystal grain size and the lattice strain. Thereby, the lattice distortion can be calculated. The Halder-Wagner plot is preferred from the viewpoint of reliability. For the Halder-Wagner plot, see for example N.W. C. Halder, C.I. N. J. et al. Wagner, Acta Cryst. 20 (1966) 312-313. See etc. Here, the Halder-Wagner plot is expressed by the following equation.

That is, plotting is performed with β ² / tan ² θ on the vertical axis and β / tan θ sin θ on the horizontal axis, and the crystal grain size D is calculated from the slope of the approximate straight line, and the lattice strain ε is calculated from the vertical axis intercept. The lattice strain (lattice strain (root mean square)) according to the Halder-Wagner plot of the above formula is 0.01% or more and 10% or less, more preferably 0.01% or more and 5% or less, and further preferably 0.01% or more and 1 % Or less, more preferably 0.01% or more and 0.5% or less, since magnetic anisotropy is easily imparted to a moderately large value, and the above magnetic characteristics are improved.

The above lattice distortion analysis is an effective technique when a plurality of XRD peaks can be detected. On the other hand, when the XRD peak intensity is weak and the number of detectable peaks is small (for example, when only one is detected), the analysis is performed. Is difficult. In such a case, it is preferable to calculate the lattice distortion by the following procedure. First, the composition is obtained by high frequency inductively coupled plasma (ICP) emission analysis, energy dispersive X-ray spectroscopy (EDX), etc., and magnetic metal elements Fe, Co, Ni, The composition ratio is calculated (when there are only two magnetic metal elements, two composition ratios. When there is only one magnetic metal element, one composition ratio (= 100%)). Next, an ideal lattice spacing d ₀ is calculated from the composition of Fe—Co—Ni (see literature values and the like. In some cases, an alloy having the composition is prepared, and the lattice spacing is calculated by measurement). . Thereafter, the amount of distortion can be determined by determining the difference between the measured lattice peak distance d of the sample and the ideal lattice distance d ₀ . That is, in this case, the distortion amount is calculated as (d−d ₀ ) / d ₀ × 100 (%). As described above, it is preferable to analyze the lattice distortion by using the above two methods depending on the state of the peak intensity, and in some cases using both in combination.

The lattice plane spacing in the flat plane 6 varies depending on the direction, and the ratio of the difference between the maximum lattice plane spacing d _max and the minimum lattice plane spacing d _min (= (d _max −d _min ) / d _min × 100 (% )) Is preferably 0.01% or more and 10% or less, more preferably 0.01% or more and 5% or less, still more preferably 0.01% or more and 1% or less, and still more preferably 0.01% or more and 0.5% or less. % Or less is preferable. This is preferable because the magnetic anisotropy is easily imparted to a moderately large value and the magnetic characteristics are improved. The lattice spacing can be easily determined by XRD measurement. By performing the XRD measurement while changing the direction in the plane, the difference in lattice constant depending on the direction can be obtained.

  The crystallites of the flat magnetic metal particles 10 are either connected in a single direction within the flat plane 6 or the crystallites are rod-shaped and oriented in one direction within the flat plane 6. Is preferred. This is preferable because the magnetic anisotropy is easily imparted to a reasonably large value and the magnetic characteristics are improved.

  Next, the manufacturing method of the flat magnetic metal particle 10 of this embodiment is described.

  The method for producing flat magnetic metal particles of the present embodiment produces a magnetic metal ribbon containing at least one first element of the group consisting of Fe, Co, and Ni, and the magnetic metal ribbon is 50 ° C. or higher and 800 ° C. or lower. The magnetic metal ribbon thus heat-treated is pulverized while being cooled to 0 ° C. or lower to produce flat magnetic metal particles.

  Hereinafter, the manufacturing method will be specifically described. In addition, regarding a manufacturing method, it does not specifically limit, It demonstrates as an example to the last.

  The first step is a step of manufacturing a magnetic metal ribbon containing at least one first element in the group consisting of Fe, Co, and Ni. This step is a step of producing a ribbon or a thin film using a film forming apparatus such as a single roll quenching apparatus or a sputtering apparatus. At this time, in a film formation method using a film formation apparatus, it is desirable to form a film with uniaxial anisotropy in the film surface by film formation in a magnetic field, rotation film formation, or the like. Note that when a film forming apparatus is used, the film thickness can be reduced, the structure is easily refined, and rotation magnetization is likely to occur. Therefore, a film formation method is used when making a rotation magnetization type. Is desirable.

The second step is a step of heat-treating the magnetic metal ribbon at a temperature of 50 ° C. or higher and 800 ° C. or lower. In this step, the ribbon may be cut to an appropriate size so that it can be easily placed in an electric furnace for heat treatment. For example, you may cut | disconnect to a suitable magnitude | size using a mixer apparatus etc. By performing this step, the pulverization is easily improved in the pulverization step which is the next third step, which is desirable. The heat treatment atmosphere is preferably a low oxygen concentration vacuum atmosphere, an inert atmosphere, or a reducing atmosphere, and more preferably H ₂ (hydrogen), CO (carbon monoxide), CH ₄ (methane), or the like. The reducing atmosphere is preferable. This is because even if the magnetic metal ribbon is oxidized, the oxidized metal can be reduced and returned to the metal by performing heat treatment in a reducing atmosphere. As a result, the saturation magnetization can be recovered by reducing the magnetic metal ribbon that has been oxidized to reduce the saturation magnetization. In addition, if the crystallization of the magnetic metal ribbon progresses remarkably due to heat treatment, the properties deteriorate (coercivity increases, magnetic permeability decreases), so conditions are selected to suppress excessive crystallization. It is preferable to do. More preferably, it is more desirable to perform heat treatment in a magnetic field. The larger the applied magnetic field, the better. However, it is preferable to apply 1 kOe or more, more preferably 10 kOe or more. This is preferable because magnetic anisotropy can be expressed in the plane of the magnetic metal ribbon and excellent magnetic properties can be realized.

  The third step is a step of producing flat magnetic metal particles 10 by pulverizing the heat-treated magnetic metal ribbon while cooling to 0 ° C. or lower. In this step, the magnetic metal ribbon or thin film may be cut into an appropriate size using a mixer device or the like before the main pulverization. In this step, pulverization is performed by a pulverizer such as a bead mill or a planetary mill. The type of the pulverizer is not particularly limited. Examples thereof include a planetary mill, a bead mill, a rotating ball mill, a vibrating ball mill, a stirring ball mill (Attritor), a jet mill, a centrifuge, or a method combining a mill and a centrifugal separator. During pulverization, pulverization is performed while cooling at a temperature of 0 ° C. or lower. In particular, it is desirable to cool at a liquid nitrogen temperature (77K), a dry ice temperature (194K), etc. Among them, it is more desirable to cool to a liquid nitrogen temperature. As a result, the magnetic metal ribbon is likely to be brittle at low temperature, and is easily pulverized. That is, it is preferable because the magnetic metal ribbon can be efficiently pulverized without applying excessive stress or distortion.

  In the third step, the thickness of the flat magnetic metal particles 10 can be reduced not only by simple grinding but also by combining rolling. Here, rolling may be performed at the same time, rolling after crushing, or crushing after rolling. In this case, a device capable of applying a strong gravitational acceleration is preferable. For example, a planetary mill, a bead mill, a rotating ball mill, a vibrating ball mill, a stirring ball mill (attritor), a jet mill, a centrifuge, or a combination of a mill and a centrifugal separator It can be done by techniques. For example, a high power planetary mill device is preferable because a gravitational acceleration of several tens of G can be easily applied. In the case of a high-power planetary mill device, a tilted planetary mill device is more preferable in which the direction of rotational gravity acceleration and the direction of revolutional gravity acceleration are not collinear and have an angled direction. In a normal planetary mill device, the direction of the rotational gravity acceleration and the direction of the revolutional gravity acceleration are on the same straight line.However, since the inclined planetary mill device performs a rotational motion with the container tilted, The direction and the direction of the revolving gravity acceleration are not on the same straight line but in an angled direction. This is preferable because power is efficiently transmitted to the sample, and pulverization and rolling proceed efficiently. In consideration of mass productivity, a bead mill apparatus that can easily perform mass processing is preferable.

  It is desirable to perform the above-described cutting, pulverization / rolling, and in some cases, the cutting, pulverization / rolling are repeated, so that the flat magnetic metal particles 10 having a predetermined thickness and aspect ratio are processed. At this time, if the pulverization / rolling is performed so that the thickness is 10 nm or more and 100 μm or less, more preferably 10 nm or more and 1 μm or less, and further preferably 10 nm or more and 100 nm or less.

Further, it is desirable that the obtained flat magnetic metal particles 10 appropriately remove lattice distortion by heat treatment. The heat treatment at this time is preferably performed at a temperature of 50 ° C. or higher and 800 ° C. or lower as in the second step. The heat treatment is performed in a low oxygen concentration vacuum atmosphere, an inert atmosphere, or a reducing atmosphere. The lower is desirable, and more desirably, a reducing atmosphere of H ₂ , CO, CH ₄ or the like is preferable. More preferably, it is more desirable to perform heat treatment in a magnetic field. Since these reasons and details are the same as in the case of the second step, description thereof is omitted here.

  FIG. 3 is a photomicrograph of the flat magnetic metal particle 80 for comparison with the present embodiment. FIG. 3A is a photomicrograph of the flat magnetic metal particles 80 pulverized by a mixer and then classified. Since this method alone is difficult to pulverize and nonuniformly pulverized, the ratio of the maximum length to the minimum length in the flat surface increases, and the CV value has a high distribution. FIG. 3B is a photomicrograph of the flat magnetic metal particles 80 pulverized by a planetary mill and then classified. As in the case of FIG. 3 (a), this method alone is difficult to pulverize and is pulverized non-uniformly, so that the ratio of the maximum length to the minimum length in the flat surface increases, and the CV increases. The value has a high distribution. In addition, the number of flat magnetic metal particles having an irregular shape is larger than in the case of FIG.

  FIGS. 4A and 4B are micrographs in which the surface of the flat magnetic metal particle 80 shown in FIGS. 3A and 3B is enlarged. In any case, the surface is smooth, and the appearance of the magnetic metal small particles arranged on the surface is not observed.

  FIG. 5 is an example of a micrograph showing the difference in the produced flat magnetic metal particles due to the difference in the pulverization technique in the present embodiment. For easy comparison, the magnifications of the photographs in FIGS. 5A, 5B, and 5C are the same. FIG. 5A is a photomicrograph of flat magnetic metal particles 80 pulverized by a mixer (first step) and then classified. In this case, it is difficult to pulverize the particle size to 250 μm or less. FIG. 5B is a photomicrograph of the flat magnetic metal particles 80 pulverized by a mixer (first step) and then pulverized while cooling at a liquid nitrogen temperature without performing heat treatment (third step). is there. In this case, the flat magnetic metal particles can be pulverized until the particle size becomes about 60 μm. FIG. 5C shows the flat magnetic metal particles 10 pulverized by a mixer (first step), subjected to heat treatment (second step), and then pulverized while cooling at a liquid nitrogen temperature (third step). It is a micrograph. In this case, the flat magnetic metal particles can be pulverized until the particle size becomes about 30 μm.

  FIG. 6 is a diagram showing an example of the particle size distribution of the flat magnetic metal particles. FIG. 6A is a particle size distribution of commercially available flat magnetic metal particles 80 that are pulverized by a planetary mill and then classified. FIG. 6B is a particle size distribution of the flat magnetic metal particles 10 of the present embodiment. When pulverized using liquid nitrogen, flat magnetic metal particles having a particle size distribution with a small CV value can be obtained without classification. The CV value can be further reduced by classification.

  As described above, according to this embodiment, it is possible to provide flat magnetic metal particles having high thermal stability and excellent mechanical properties.

(Second Embodiment)
In the flat magnetic metal particles of this embodiment, at least a part of the surface of the flat magnetic metal particles has a thickness of 0.1 nm to 1 μm, and oxygen (O), carbon (C), nitrogen (N), and fluorine (F ) Is different from the first embodiment in that it is covered with a coating layer containing at least one second element. Here, the description overlapping with the first embodiment is omitted.

  FIG. 7 is a schematic diagram of the flat magnetic metal particle 10 of the present embodiment.

  The coating layer 14 is made of Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, Ba, Sr, Cr, Mo, Ag, Ga, Sc, V, Y, Nb, Pb, Cu, In, Sn. Including at least one nonmagnetic metal selected from the group consisting of rare earth elements and including at least one second element of oxygen (O), carbon (C), nitrogen (N) and fluorine (F). Is more preferable. As the nonmagnetic metal, Al and Si are particularly preferable from the viewpoint of thermal stability. The flat magnetic metal particles 10 are Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, Ba, Sr, Cr, Mo, Ag, Ga, Sc, V, Y, Nb, Pb, Cu, In, When at least one nonmagnetic metal selected from the group consisting of Sn and rare earth elements is included, the coating layer 14 includes at least the same nonmagnetic metal as the nonmagnetic metal that is one of the constituent components of the flat magnetic metal particles 10. More preferably, one is included. Among oxygen (O), carbon (C), nitrogen (N) and fluorine (F), oxygen (O) is preferably contained, and oxides and composite oxides are preferred. The above is from the viewpoint of easy formation of the coating layer 14, oxidation resistance, and thermal stability. By the above, the adhesiveness of the flat magnetic metal particle 10 and the coating layer 14 can be improved, and it becomes possible to improve the thermal stability and oxidation resistance of the powder compact material mentioned later. The coating layer 14 can improve not only the thermal stability and oxidation resistance of the flat magnetic metal particles 10 but also the electrical resistance of the flat magnetic metal particles 10. By increasing the electrical resistance, it is possible to suppress eddy current loss and improve the frequency characteristics of the magnetic permeability. For this reason, it is preferable that the coating layer 14 is electrically high resistance, for example, it is preferable to have a resistance value of 1 mΩ · cm or more.

  The presence of the coating layer 14 is also preferable from a magnetic point of view. The flat magnetic metal particle 10 can be regarded as a pseudo thin film because the thickness of the flat magnetic metal particle 10 is smaller than the size of the flat surface 6. At this time, the integrated structure in which the coating layer 14 is formed on the surface of the flat magnetic metal particle 10 can be regarded as a pseudo laminated thin film structure, and the magnetic domain structure is stabilized in terms of energy. This makes it possible to reduce the coercive force (which reduces hysteresis loss), which is preferable. At this time, the magnetic permeability increases, which is preferable. From such a viewpoint, it is more preferable that the coating layer 14 is nonmagnetic (the magnetic domain structure is easily stabilized).

  The thickness of the coating layer 14 is preferably as thick as possible from the viewpoint of thermal stability, oxidation resistance, and electrical resistance. However, if the thickness of the coating layer is too large, the saturation magnetization becomes small and the magnetic permeability becomes small. Also, from the magnetic point of view, if the thickness is too thick, the “effect of stabilizing the magnetic domain structure and reducing the coercive force, reducing the loss, and increasing the magnetic permeability” is reduced. Considering the above, a preferable thickness of the coating layer is 0.1 nm or more and 1 μm or less, more preferably 0.1 nm or more and 100 m or less.

  The magnetic metal small particles 4 may be provided between the coating layers as shown in FIG. Further, the magnetic metal small particles 4 may be provided inside the coating layer 14 as shown in FIG. 7B, or a part thereof may be provided outside the coating layer 14.

  As described above, according to the present embodiment, it is possible to provide flat magnetic metal particles having high thermal stability and excellent mechanical properties.

(Third embodiment)
The dust material of the present embodiment includes a plurality of flat magnetic metal particles described in the first embodiment or the second embodiment and the flat magnetic metal particles, and includes at least one second element. An intervening phase. Here, the description overlapping with the first and second embodiments is omitted.

  FIG. 8 is a schematic diagram of the green compact material 100 of the present embodiment.

  The intervening phase 20 includes at least one second element of oxygen (O), carbon (C), nitrogen (N), and fluorine (F). This is because the resistance can be increased. The electrical resistivity of the intervening phase 20 is preferably higher than the electrical resistivity of the flat magnetic metal particle 10. This is because eddy current loss of the flat magnetic metal particles 10 can be reduced. Since the intervening phase 20 surrounds the flat magnetic metal particles 10, it can improve the oxidation resistance and thermal stability of the flat magnetic metal particles 10, which is preferable. Among these, those containing oxygen are more preferable from the viewpoints of high oxidation resistance and high thermal stability. Since the intervening phase 20 also plays a role of mechanically bonding the flat magnetic metal particles 10 to each other, it is preferable from the viewpoint of high strength.

  In addition, the intervening phase 20 includes an amount of 0.01 wt% or more and 80 wt% or less, more preferably 0.1 wt% or more and 60 wt% or less, and further preferably 0.1 wt% or more and 40 wt% or less with respect to the whole of the dust material 100. It is preferable. If the ratio of the intervening phase 20 is too large, the ratio of the flat magnetic metal particles 10 that are responsible for magnetism is decreased, which is not preferable because the saturation magnetization and the magnetic permeability of the dust material 100 are decreased. On the contrary, if the ratio of the intervening phase 20 is too small, the bonding between the flat magnetic metal particles 10 and the intervening phase 20 becomes weak, which is not preferable from the viewpoint of mechanical properties such as thermal stability, strength and toughness. The optimal ratio of the intervening phase 20 from the viewpoint of magnetic characteristics such as saturation magnetization and magnetic permeability, thermal stability, and mechanical characteristics is preferably 0.01 wt% or more and 80 wt% or less with respect to the whole dust material 100. Is 0.1 wt% or more and 60 wt% or less, more preferably 0.1 wt% or more and 40 wt% or less.

  The lattice mismatch ratio between the intervening phase 20 and the flat magnetic metal particles 10 is preferably 0.1% or more and 50% or less. This is preferable because the magnetic anisotropy is easily imparted to a reasonably large value and the magnetic characteristics are improved. In order to set the lattice mismatch within the above range, it can be realized by selecting a combination of the composition of the intervening phase and the composition of the flat magnetic metal particles 10. For example, Ni of fcc structure has a lattice constant of 3.52Å, MgO of NaCl type structure has a lattice constant of 4.21Å, and the lattice mismatch between them is (4.21−3.52) /3.52×100. = 20%. That is, the lattice mismatch can be set to 20% by setting the main composition of the flat magnetic metal particle 10 to Ni having an fcc structure and the intervening phase 20 to MgO. Thus, by selecting a combination of the main composition of the flat magnetic metal particles 10 and the main composition of the intervening phase 20, the lattice mismatch can be set in the above range.

  In addition, the intervening phase 20 includes an eutectic oxide, a resin, at least one magnetic metal selected from Fe, Co, and Ni, or at least one of these three. May be. These points will be described below.

  First, the case where the intervening phase 20 is an oxide having a eutectic system will be described. In this case, the intervening phase 20 includes B (boron), Si (silicon), Cr (chromium), Mo (molybdenum), Nb (niobium), Li (lithium), Ba (barium), Zn (zinc), La ( Lanthanum), P (phosphorus), Al (aluminum), Ge (germanium), W (tungsten), Na (sodium), Ti (titanium), As (arsenic), V (vanadium), Ca (calcium), Bi ( It includes an oxide having a eutectic system including at least two third elements from the group consisting of bismuth), Pb (lead), Te (tellurium), and Sn (tin). In particular, it is preferable to include a eutectic system including at least two elements of B, Bi, Si, Zn, and Pb. As a result, the adhesion between the flat magnetic metal particles and the intervening phase 20 is strengthened (bonding strength is increased), and mechanical properties such as thermal stability, strength, and toughness are easily improved.

  The oxide having the eutectic system preferably has a softening point of 200 ° C. or higher and 600 ° C. or lower, more preferably 400 ° C. or higher and 500 ° C. or lower. More preferably, it is an oxide having a eutectic system containing at least two elements of B, Bi, Si, Zn, and Pb, and has a softening point of 400 ° C. or higher and 500 ° C. or lower. As a result, the bonding between the flat magnetic metal particles 10 and the oxide having the eutectic system is strengthened, and mechanical properties such as thermal stability, strength, and toughness are easily improved. When integrating the flat magnetic metal particles 10 with the oxide having the eutectic system, heat treatment is performed at a temperature near the softening point of the oxide having the eutectic system, preferably at a temperature slightly higher than the softening point. By integrating, the adhesion between the flat magnetic metal particles 10 and the oxide having the eutectic system can be improved, and the mechanical characteristics can be improved. In general, the higher the temperature of the heat treatment, the better the adhesion between the flat magnetic metal particles 10 and the oxide having the eutectic system and the mechanical properties. However, if the temperature of the heat treatment becomes too high, the coefficient of thermal expansion becomes large, so that the adhesion between the flat magnetic metal particles 10 and the oxide having the eutectic system may be reduced (flat magnetic metal). If the difference between the thermal expansion coefficient of the particles 10 and the thermal expansion coefficient of the oxide having the eutectic system is increased, the adhesion may be further reduced). Moreover, when the crystallinity of the flat magnetic metal particles 10 is amorphous or amorphous, if the temperature of the heat treatment is high, crystallization proceeds and the coercive force increases, which is not preferable. Therefore, in order to achieve both mechanical properties and coercive force properties, the softening point of the oxide having the eutectic system is set to 200 ° C. or higher and 600 ° C. or lower, more preferably 400 ° C. or higher and 500 ° C. or lower. It is preferable that the oxides having the eutectic system be integrated with heat treatment at a temperature near the softening point, preferably slightly higher than the softening point. Moreover, it is preferable to use the integrated material at a temperature lower than the softening point when it is actually used in a device or system.

The oxide having the eutectic system preferably has a glass transition point. Further, the oxide having the eutectic system preferably has a thermal expansion coefficient of 0.5 × 10 ⁻⁶ / ° C. or higher and 40 × 10 ⁻⁶ / ° C. or lower. As a result, the bonding between the flat magnetic metal particles 10 and the oxide having the eutectic system is strengthened, and mechanical properties such as thermal stability, strength, and toughness are easily improved.

  It is more preferable that at least one eutectic particle 22 having a particle size of 10 nm or more and 10 μm or less (preferably spherical) is included. The eutectic particles 22 include the same material as the oxide having the eutectic system other than the particulate form. There may be some voids in the powdered material, and it is easy to observe that some of the above eutectic oxides are in the form of particles, preferably spherical. I can do it. Even when there are no voids, the particulate or spherical interface can be easily discriminated. The particle diameter of the eutectic particles 22 is more preferably 10 nm to 1 μm, and still more preferably 10 nm to 100 nm. As a result, the strain applied to the flat magnetic metal particles can be reduced and the coercive force can be reduced by moderately relaxing the stress while maintaining the adhesion between the flat magnetic metal particles during the heat treatment. . Thereby, the hysteresis loss is also reduced and the magnetic permeability is improved. The particle diameter of the eutectic particles 22 can be measured by TEM or SEM observation. FIG. 9 is a schematic view of the green compact material 110 at this time. In FIG. 9, the intervening phase 20 fills the space without a gap, but actually, the gap may partially exist.

  The intervening phase 20 has a softening point higher than that of the oxide having the eutectic system, more preferably higher than 600 ° C., and O (oxygen), C (carbon), N It is preferable to further include intermediate intervening particles 24 containing at least one element of the group consisting of (nitrogen) and F (fluorine). The presence of the intermediate intervening particles 24 between the flat magnetic metal particles 10 prevents the flat magnetic metal particles 10 from being thermally fused and deteriorated when the dust material 150 is exposed to a high temperature. Can do. That is, it is desirable for the intermediate intervening particles 24 to exist mainly for thermal stability. Note that the softening point of the intermediate intervening particles 24 is higher than the softening point of the oxide having the eutectic system, and more preferably, the softening point is 600 ° C. or higher, thereby further improving the thermal stability. it can.

The intermediate intervening particles 24 are Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, Ba, Sr, Cr, Mo, Ag, Ga, Sc, V, Y, Nb, Pb, Cu, In, Sn, containing at least one nonmagnetic metal selected from the group consisting of rare earth elements, and at least one element selected from the group consisting of O (oxygen), C (carbon), N (nitrogen) and F (fluorine) It is preferable to contain. More preferably, from the viewpoint of high oxidation resistance and high thermal stability, an oxygen-containing oxide or composite oxide is more preferable. In particular, oxides such as aluminum oxide (Al ₂ O ₃ ), silicon dioxide (SiO ₂ ), titanium oxide (TiO ₂ ), zirconium oxide (Zr ₂ O ₃ ), composite oxides such as Al—Si—O, etc. Is preferable from the viewpoint of high oxidation resistance and high thermal stability.

  FIG. 10 is a schematic diagram of the dust material 120 and the dust material 130 including the intermediate intervening particles 24. In FIG. 10, the case where the intervening phase 20 does not contain the eutectic particles 22 (FIG. 10A) and the case where it contains (FIG. 10B) are shown. In FIG. 10A and FIG. 10B, the intervening phase 20 fills the space without a gap, but the gap may partially exist.

Examples of the method for producing the dust material 120 and the dust material 130 including the intermediate intervening particles 24 include flat magnetic metal particles and intermediate intervening particles (aluminum oxide (Al ₂ O ₃ ) particles, silicon dioxide (SiO ₂ ) particles). , Titanium oxide (TiO ₂ ) particles, zirconium oxide (Zr ₂ O ₃ ) particles, etc.) are mixed by a ball mill or the like to form a dispersed state, and then integrated by press molding or the like. The method of dispersing is not particularly limited as long as it can be appropriately dispersed.

  Next, the second “in the case where the intervening phase 20 contains a resin” will be described. In this case, the resin is not particularly limited, but polyester resin, polyethylene resin, polystyrene resin, polyvinyl chloride resin, polyvinyl butyral resin, polyvinyl alcohol resin, polybutadiene resin, Teflon (registered trademark) resin, polyurethane Resin, cellulose resin, ABS resin, nitrile-butadiene rubber, styrene-butadiene rubber, silicone resin, other synthetic rubber, natural rubber, epoxy resin, phenol resin, allyl resin, polybenzimidazole resin, amide resin, A polyimide resin, a polyamideimide resin, or a copolymer thereof is used. In particular, it is preferable to include a silicone resin and a polyimide resin having high heat resistance. As a result, the bonding between the flat magnetic metal particles and the intervening phase becomes strong, and mechanical properties such as thermal stability, strength, and toughness are easily improved.

  Next, the third “case where the intervening phase 20 contains at least one magnetic metal selected from Fe, Co, and Ni and has magnetism” will be described. In this case, it is preferable that the intervening phase has magnetism because the flat magnetic metal particles 10 are easily magnetically coupled to each other and the magnetic permeability is improved. Moreover, since the magnetic domain structure is stabilized, the frequency characteristic of the magnetic permeability is also improved, which is preferable. In addition, magnetism said here shows things, such as ferromagnetism, ferrimagnetism, weak magnetism, and antiferromagnetism. In particular, ferromagnetism and ferrimagnetism are preferred because the magnetic coupling force is increased. About the point in which the intervening phase 20 has magnetism, it can evaluate using VSM (Vibrating Sample Meterometer :). The point that the intervening phase 20 contains at least one magnetic metal selected from Fe, Co, and Ni and has magnetism can be easily examined using EDX or the like.

  Although three forms of the intervening phase 20 have been described above, it is preferable to satisfy at least one of these three, but two or more or even all three may be satisfied.

  FIG. 11 is a diagram for explaining the orientation of the flat magnetic metal particles 10 in the dust material of the present embodiment. Here, it is defined that the closer the angle formed between the plane parallel to the flat plane of the flat magnetic metal particles 10 and the plane 102 of the dust material 100 is closer to 0 degrees, the more oriented it is. Specifically, the above-mentioned angle is obtained for a large number of flat magnetic metal particles 10 of 10 or more, and the average value thereof is preferably 0 degree or more and 45 degrees or less, more preferably 0 degree or more and 30 degrees or less, and further preferably 0. It is desirable that the angle is not less than 10 degrees and not more than 10 degrees.

  As described above, according to the dust material of the present embodiment, a dust material having particularly excellent characteristics such as thermal stability and mechanical properties can be realized.

(Fourth embodiment)
The system and device device of the present embodiment have the dust material of the first to third embodiments. Therefore, the description overlapping with the first to third embodiments is omitted. The components of the dust material included in this system and device device include, for example, rotating electric machines such as various motors and generators (for example, motors and generators), cores such as transformers, inductors, transformers, choke coils, and filters. And a magnetic wedge (magnetic wedge) for a rotating electrical machine. FIG. 12 shows a conceptual diagram of a motor system 1000 as an example of a rotating electrical machine system. The motor system is a system including a control system that controls the rotation speed and electric power (output power) of the motor. As a method for controlling the rotational speed of the motor, there are control methods such as control by a bridge servo circuit, proportional current control, voltage comparison control, frequency synchronization control, PLL (Phase Locked Loop) control, and the like. As an example, a control method using a PLL is shown in FIG. A motor system 1000 that controls the number of rotations of a motor using a PLL includes a motor, a rotary encoder that detects the number of rotations of the motor by converting a mechanical displacement amount of the rotation of the motor into an electric signal, and a motor given by a command A phase comparator that compares the rotational speed of the motor and the rotational speed of the motor detected by the rotary encoder and outputs a difference between the rotational speeds, and a controller that controls the motor to reduce the rotational speed difference. On the other hand, methods for controlling the motor power include PWM (Pulse Width Modulation) control, PAM (Pulse Amplitude Modulation) control, vector control, pulse control, bipolar drive, pedestal control, resistance There are control methods such as control. Other control methods include control methods such as microstep drive control, multiphase drive control, inverter control, and switching control. As an example, an inverter control method is shown in FIG. A motor system 1000 that controls electric power of a motor by an inverter is controlled by an AC power source, a rectifier that converts an output of the AC power source into a DC current, an inverter circuit that converts the DC current into an AC at an arbitrary frequency, and the AC A motor to be provided.

  FIG. 13 shows a conceptual diagram of a motor 200 as an example of a rotating electrical machine. In the motor 200, a first stator (stator) 210 and a second rotor (rotor) 220 are disposed. In the figure, an inner rotor type in which the rotor is arranged inside the stator is shown, but an outer rotor type in which the rotor is arranged outside the stator may be used.

  FIG. 14 shows a conceptual diagram of the motor core. As the motor core, a stator core and a rotor core are applicable. This point will be described below with reference to FIG. FIG. 14A is a conceptual cross-sectional view of the first stator 210. The first stator 210 has a core and a winding. The winding is wound around a part of the protrusion provided on the inner side of the core. The dust material of the first to third embodiments can be arranged in this core. FIG. 14B is a conceptual cross-sectional view of the first rotor 220. The first rotor 220 has a core and a winding. The winding is wound around a part of the protrusion provided on the outer side of the core. The dust material of the first to third embodiments can be arranged in this core.

  13 and 14 merely show an example of the motor, and the application destination of the dust material is not limited to this. It can be applied to all types of motors as a core to make it easier to guide magnetic flux.

  FIG. 15 shows a transformer / transformer 300, and FIG. 16 shows a conceptual diagram of an inductor. These are shown only as examples. In transformers, transformers, and inductors, in the same way as motor cores, powder materials can be applied to all types of transformers, transformers, and inductors to make it easier to guide magnetic flux or to use high permeability. .

  FIG. 17 shows a conceptual diagram of a generator 500 as an example of a rotating electrical machine. The generator 500 includes a second stator (stator) 530 that uses the dust material of the first and third embodiments, and a second rotor that uses the dust material of the first to third embodiments. One (or both) of (rotor) 540 is provided. In the figure, the second rotor (rotor) 540 is disposed inside the second stator 530, but may be disposed outside. The second rotor 540 is connected to a turbine 510 provided at one end of the generator 500 via a shaft 520. The turbine 510 is rotated by, for example, a fluid supplied from outside (not shown). Note that the shaft 520 can be rotated by transmitting dynamic rotation such as regenerative energy of an automobile in place of the turbine 510 rotated by a fluid. Various known configurations can be adopted for the second stator 530 and the second rotor 540.

  The shaft 520 is in contact with a commutator (not shown) disposed on the side opposite to the turbine 510 with respect to the second rotor 540. The electromotive force generated by the rotation of the second rotor 540 is boosted to the system voltage and transmitted as electric power of the generator 500 via a phase separation bus (not shown) and a main transformer (not shown). The second rotor 540 is charged by static electricity from the turbine 510 or an axial current accompanying power generation. For this reason, the generator 500 includes a brush 550 for discharging the charge of the second rotor 540.

  Moreover, in FIG. 18, a preferable example is described about the relationship between the direction of magnetic flux and the arrangement direction of the dust material. First, in both the domain wall motion type and the rotary magnetization type, the flat surfaces 10a of the flat magnetic metal particles 10 included in the dust material are aligned in parallel with each other as much as possible in a layered manner with respect to the direction of the magnetic flux. It is preferable to arrange. This is because eddy current loss can be reduced by making the cross-sectional area of the flat magnetic metal particles 10 penetrating the magnetic flux as small as possible. In addition, in the domain wall motion type, it is preferable to arrange the easy magnetization axis (arrow direction) in the flat surface 10a of the flat magnetic metal particle 10 in parallel with the magnetic flux direction. As a result, it can be used in a direction in which the coercive force is further reduced, which is preferable because hysteresis loss can be reduced. Moreover, the magnetic permeability can be increased, which is preferable. On the contrary, in the rotary magnetization type, it is preferable to arrange the easy magnetization axis (arrow direction) in the flat surface 10a of the flat magnetic metal particle 10 perpendicularly to the direction of the magnetic flux. As a result, it can be used in a direction in which the coercive force is further reduced, which is preferable because hysteresis loss can be reduced. That is, it is preferable to arrange as shown in FIG. 18 after grasping the magnetization characteristics of the dust material and determining whether it is a domain wall motion type or a rotary magnetization type (the determination method is as described above). If the direction of the magnetic flux is complicated, it may be difficult to completely arrange as shown in FIG. 18, but it is preferable to arrange as shown in FIG. 18 as much as possible. The arrangement method described above includes all the systems and device devices of the present embodiment (for example, rotating electric machines such as various motors and generators (for example, motors and generators)), transformers, inductors, transformers, choke coils, and filters. It is desirable to be applied to a core such as a magnetic wedge or a wedge for a rotating electrical machine.

  In order to apply to this system and device apparatus, the compacted material allows various processing. For example, in the case of a sintered body, machining such as polishing or cutting is performed, and in the case of powder, mixing with an epoxy resin or a resin such as polybutadiene is performed. Further surface treatment is performed if necessary. Further, a winding process is performed as necessary.

  According to the system and device device of the present embodiment, a motor system, motor, transformer, transformer, inductor, and generator having excellent characteristics (high efficiency, low loss) can be realized.

(Example)
Hereinafter, Examples 1 to 15 of the present invention will be described in more detail while comparing with Comparative Examples 1 to 11. About the flat magnetic metal particles obtained by the following examples and comparative examples, the thickness of the flat magnetic metal particles, the aspect ratio, the ratio of the maximum length to the minimum length in the flat plane, the particle size distribution of the flat magnetic metal particles Coefficient of variation (CV value), average size of small magnetic metal particles, average number of small magnetic metal particles (number of small magnetic metal particles integrated into one flat magnetic metal particle), lattice distortion of flat magnetic metal particles Are shown in Table 1. The thickness of the flat magnetic metal particles, the aspect ratio, the ratio of the maximum length to the minimum length in the flat plane, the average size of the magnetic metal small particles, and the average number of the magnetic metal small particles are measured by TEM observation / SEM. Based on the observation, the average value of many particles is calculated. The variation coefficient (CV value) of the particle size distribution of the flat magnetic metal particles is calculated by a measured value by a particle size distribution meter. Lattice distortion is performed by XRD analysis.

Example 1
First, a ribbon of Fe—Co—Si—B (Fe: Co = 70: 30 atomic%) is prepared using a single roll quenching apparatus. Next, the ribbon is cut into an appropriate size using a mixer device. Thereafter, the cut ribbon piece is collected and pulverized and rolled at about 1000 rpm in an Ar atmosphere by a bead mill using a ZrO ₂ ball and a ZrO ₂ container to form a flat powder. Next, the obtained powder is heat-treated at 300 ° C. in an H ₂ atmosphere. Thereafter, the obtained powder is pulverized by a bead mill using liquid nitrogen. Thereafter, heat treatment is performed at 400 ° C. in an H ₂ atmosphere to obtain flat magnetic metal particles. By repeating the above-described operations of pulverization / rolling, heat treatment, liquid nitrogen pulverization, and heat treatment, processing is performed so as to obtain a predetermined size and structure. The crystal structure of the magnetic phase of the flat magnetic metal particles is a body-centered cubic structure. The surface of the obtained flat magnetic metal particles was coated with a nonmagnetic SiO ₂ layer with a thickness of 20 nm by a sol-gel method, and then an inorganic oxide binder phase (B ₂ O ₃ —Bi ₂ O ₃ —ZnO: The mixture is mixed with a softening point (425 ° C.), molded in a magnetic field (orienting the flat particles), and subjected to heat treatment to obtain a powdered material. The heat treatment is performed at a temperature slightly higher than the softening point.

(Example 2)
Except for the thickness of the flat magnetic metal particles being 1 μm, it is almost the same as in Example 1.

(Example 3)
Except for the thickness of the flat magnetic metal particles being 10 μm, it is almost the same as in Example 1.

Example 4
Except for the thickness of the flat magnetic metal particles being 100 μm, it is almost the same as in Example 1.

(Example 5)
Except that the aspect ratio of the flat magnetic metal particles is 100, it is almost the same as Example 1.

(Example 6)
Except that the aspect ratio of the flat magnetic metal particles is 10,000, it is almost the same as Example 1.

(Example 7)
Example 3 is substantially the same as Example 3 except that the ratio of the maximum length to the minimum length in the flat plane of the flat magnetic metal particles is 5.

(Example 8)
Example 3 is substantially the same as Example 3 except that the coefficient of variation (CV value) in the particle size distribution of the flat magnetic metal particles is 60%.

Example 9
It is almost the same as Example 3 except that the average particle diameter of the magnetic metal small particles is 10 nm.

(Example 10)
Example 3 is substantially the same as Example 3 except that the average particle size of the magnetic metal small particles is 1 μm.

(Example 11)
Example 3 is substantially the same as Example 3 except that the average number of small magnetic metal particles is 5.

(Example 12)
Except for the fact that the lattice strain of the flat magnetic metal particles is 0.01%, it is almost the same as Example 3.

(Example 13)
Except that the lattice strain of the flat magnetic metal particles is 9.6%, it is almost the same as in Example 3.

(Example 14)
The third embodiment is almost the same as the third embodiment except that the flat magnetic metal particles are (110) oriented.

(Example 15)
Except for imparting uniaxial anisotropy in the flat surface of the flat magnetic metal particles by heat treatment in a magnetic field, that is, providing magnetic anisotropy in one direction, it is almost the same as Example 3.

(Comparative Example 1)
Example 3 is substantially the same as Example 3 except that the average number of magnetic metal small particles is four.

(Comparative Example 2)
Except for the thickness of the flat magnetic metal particles being 8 nm, it is almost the same as in Example 1.

(Comparative Example 3)
Example 4 is substantially the same as Example 4 except that the thickness of the flat magnetic metal particles is 120 μm.

(Comparative Example 4)
Except that the aspect ratio of the flat magnetic metal particles is 4, it is almost the same as Example 1.

(Comparative Example 5)
Except for the aspect ratio of the flat magnetic metal particles being 12000, it is almost the same as in Example 1.

(Comparative Example 6)
Except that the ratio of the maximum length to the minimum length in the flat surface of the flat magnetic metal particle is 6, it is almost the same as Example 3.

(Comparative Example 7)
Example 3 is substantially the same as Example 3 except that the coefficient of variation (CV value) in the particle size distribution of the flat magnetic metal particles is 65%.

(Comparative Example 8)
It is almost the same as Example 3 except that the average size of the magnetic metal small particles is 8 nm.

(Comparative Example 9)
It is almost the same as Example 3 except that the average size of the magnetic metal small particles is 2 μm.

(Comparative Example 10)
Except for the fact that the lattice distortion of the flat magnetic metal particles is 0.008%, it is almost the same as Example 3.

(Comparative Example 11)
Except for the fact that the lattice strain of the flat magnetic metal particles is 10.5%, it is almost the same as Example 3.

  Next, with respect to the evaluation materials of Examples 1 to 15 and Comparative Examples 1 to 11, saturation magnetization, magnetic permeability real part (μ ′), magnetic permeability loss (tan δ), and magnetic permeability after 100 hours are as follows. The change with time of the real part (μ ′), iron loss, and strength ratio are evaluated. The evaluation results are shown in Table 2.

  (1) Saturation magnetization: Measure saturation magnetization at room temperature using VSM.

  (2) Permeability real part μ ′, permeability loss (tan δ = μ ″ / μ ′ × 100 (%)): The permeability of the ring-shaped sample is measured using an impedance analyzer at a frequency of 1 kHz. The magnetic permeability real part μ ′ and the magnetic permeability imaginary part μ ″ are measured. Further, the permeability loss or loss coefficient tan δ is calculated by μ ″ / μ ′ × 100 (%).

  (3) Temporal change in permeability real part μ ′ after 100 hours: The sample for evaluation was heated in the atmosphere at 60 ° C. for 100 hours, and then measured again for real part μ ′. Permeability real part μ ′ after standing / permeability real part μ ′ before standing) is obtained.

  (4) Iron loss: Measure iron loss under operating conditions of 1 kHz and 1 T using a BH analyzer.

  (5) Strength ratio: The bending strength of the evaluation sample was measured, and the ratio to the bending strength of the comparative sample (= the bending strength of the evaluation sample / the bending strength of the comparative sample) was indicated. In addition, an Example was shown by the ratio with the comparative example 1.

  As is apparent from Table 1, the flat magnetic metal particles according to Examples 1 to 15 have a thickness of 10 nm to 100 μm, an aspect ratio of 5 to 10,000, and a ratio of the maximum length to the minimum length in the flat plane. The average size of the magnetic metal small particles is 10 nm or more and 1 μm or less, the average number of the magnetic metal small particles is 5 or more, and the lattice strain is 0.01% or more and 10% or less. In Example 14, the flat surfaces of the flat magnetic metal particles are (110) oriented. Example 15 has uniaxial anisotropy in the flat plane of the flat magnetic metal particles.

  As is apparent from Table 2, the dust material using the flat magnetic metal particles of Examples 1 to 15 is excellent in the temporal change ratio and strength ratio of the magnetic permeability as compared with the dust material of the comparative example. I understand that That is, it is understood that the thermal stability and mechanical strength are excellent. Moreover, it turns out that the dust material of Examples 1-15 also has the outstanding magnetic characteristic of high saturation magnetization, high magnetic permeability, and low loss. And since it is a compacting material, application to a complicated shape is possible.

(Example 16)
Example 3 is substantially the same as Example 3 except that the surface of the flat magnetic metal particles is coated with a nonmagnetic SiO ₂ layer with a thickness of about 1 nm by a sol-gel method.
(Example 17)
Example 3 is substantially the same as Example 3 except that the surface of the flat magnetic metal particles is coated with a nonmagnetic SiO ₂ layer with a thickness of about 10 nm by a sol-gel method.
(Example 18)
Example 3 is substantially the same as Example 3 except that the surface of the flat magnetic metal particles is coated with a nonmagnetic SiO ₂ layer with a thickness of about 100 nm by a sol-gel method.
(Example 19)
Example 3 is substantially the same as Example 3 except that the surface of the flat magnetic metal particle is coated with a nonmagnetic SiO ₂ layer with a thickness of about 900 nm by a sol-gel method.
(Example 20)
The dust material of the present example is substantially the same as Example 1 except that it has a eutectic system with a softening point of 200 ° C. The eutectic composition is PV-Ag-O.
(Example 21)
The dust material of this example is substantially the same as Example 3 except that it has a binder phase with a softening point of about 300 ° C. The composition of the binder phase is Pb—B—O.
(Example 22)
The dust material of the present example is substantially the same as Example 3 except that it has a binder phase with a softening point of about 400 ° C. The composition of the binder phase is Bi—B—O.
(Example 23)
The dust material of this example is substantially the same as Example 3 except that it has a binder phase with a softening point of about 500 ° C. The composition of the binder phase is B-Bi-Zn-O.
(Example 24)
The dust material of this example is substantially the same as Example 3 except that it has a binder phase with a softening point of about 600 ° C. The composition of the binder phase is B-Bi-Si-O.
(Example 25)
The powdered material of the present example is the same as that of Example 1 except that the heat treatment time after molding in a magnetic field is doubled so that a binder phase having a spherical shape and a particle size of 50 nm is generated on the surface of the flat magnetic metal particles. 3 is almost the same. The composition of the binder phase is B-Bi-Zn-O.
(Comparative Example 12)
Example 3 is substantially the same as Example 3 except that the surface of the flat magnetic metal particle is not coated with a nonmagnetic SiO ₂ layer.
(Comparative Example 13)
Example 3 is substantially the same as Example 3 except that the surface of the flat magnetic metal particles is coated with a nonmagnetic SiO ₂ layer with a thickness of about 2 μm by a sol-gel method.
(Comparative Example 14)
Except for having a binder phase with a softening point of about 100 ° C., it is almost the same as Example 3. As the binder phase, an organic epoxy resin is used.
(Comparative Example 15)
Except for having a binder phase with a softening point of about 700 ° C., it is almost the same as Example 3. The composition of the binder phase is Si—B—Al—O.

As is clear from Table 3, the flat magnetic metal particles according to Examples 16 to 25 have a thickness of 10 nm to 100 μm, an aspect ratio of 5 to 10,000, and a ratio of the maximum length to the minimum length in the flat plane. The average size of the magnetic metal small particles is 10 nm or more and 1 μm or less, the average number of the magnetic metal small particles is 5 or more, and the lattice strain is 0.01% or more and 10% or less. The surfaces of the flat magnetic metal particles are covered with a nonmagnetic oxide layer having a thickness of 0.1 nm to 1 μm. The softening point of the binder phase is 200 ° C. or more and 600 ° C. or less.
On the other hand, Comparative Example 12 has no coating layer, and Comparative Example 13 has a coating layer thickness as large as about 2 μm. In Comparative Example 14, the softening point of the binder phase is about 100 ° C., and in Comparative Example 15, the softening point of the binder phase is about 700 ° C. That is, Comparative Examples 12 to 15 are outside the scope of the claims.

  As is apparent from Table 4, the dust material using the flat magnetic metal particles of Examples 16 to 25 is superior in the temporal change rate and strength ratio of the magnetic permeability, in particular, as compared with the dust material of the comparative example. I understand that That is, it is understood that the thermal stability and mechanical strength are excellent. Moreover, it turns out that the dust material of Examples 16-25 has the outstanding magnetic characteristic of high saturation magnetization, high magnetic permeability, and low loss. And since it is a compacting material, application to a complicated shape is possible.

  That is, the dust material according to Example 16 to Example 25 satisfies high saturation magnetization, high magnetic permeability, low loss, high thermal stability, high oxidation resistance, and high strength, and has a complicated shape. It can be seen that this is a soft magnetic powder material that can be applied.

  Although several embodiments and examples of the present invention have been described, these embodiments and examples are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

2 Magnetic metal particle 4 Magnetic metal small particle 6 Flat surface 10 Flat magnetic metal particle 14 Covering layer 20 Intervening phase 22 Eutectic particle 24 Intermediate intervening particle 80 Flat magnetic metal particle 100 Powder material 110 Powder material 120 Powder material 130 Pressure Powder material 102 Plane 200 Motor 210 First stator 220 First rotor 300 Transformer / transformer 400 Inductor 500 Generator 510 Turbine 520 Shaft 530 Second stator 540 Second rotor 1000 Motor system

First, the case where the intervening phase 20 is an oxide having a eutectic system will be described. In this case, the intervening phase 20 includes B (boron), Si (silicon), Cr (chromium), Mo (molybdenum), Nb (niobium), Li (lithium), Ba (barium), Zn (zinc), La ( Lanthanum), P (phosphorus), Al (aluminum), Ge (germanium), W (tungsten), Na (sodium), Ti (titanium), As (arsenic), V (vanadium), Ca (calcium), Bi ( It includes an oxide having a eutectic system including at least two third elements from the group consisting of bismuth), Pb (lead), Te (tellurium), and Sn (tin). In particular, it is preferable to include a eutectic system including at least two fourth elements of B, Bi, Si, Zn, and Pb. As a result, the adhesion between the flat magnetic metal particles and the intervening phase 20 is strengthened (bonding strength is increased), and mechanical properties such as thermal stability, strength, and toughness are easily improved.

The oxide having the eutectic system preferably has a softening point of 200 ° C. or higher and 600 ° C. or lower, more preferably 400 ° C. or higher and 500 ° C. or lower. More preferably, it is an oxide having a eutectic system containing at least two fourth elements of B, Bi, Si, Zn, and Pb and has a softening point of 400 ° C. or higher and 500 ° C. or lower. . As a result, the bonding between the flat magnetic metal particles 10 and the oxide having the eutectic system is strengthened, and mechanical properties such as thermal stability, strength, and toughness are easily improved. When integrating the flat magnetic metal particles 10 with the oxide having the eutectic system, heat treatment is performed at a temperature near the softening point of the oxide having the eutectic system, preferably at a temperature slightly higher than the softening point. By integrating, the adhesion between the flat magnetic metal particles 10 and the oxide having the eutectic system can be improved, and the mechanical characteristics can be improved. In general, the higher the temperature of the heat treatment, the better the adhesion between the flat magnetic metal particles 10 and the oxide having the eutectic system and the mechanical properties. However, if the temperature of the heat treatment becomes too high, the coefficient of thermal expansion becomes large, so that the adhesion between the flat magnetic metal particles 10 and the oxide having the eutectic system may be reduced (flat magnetic metal). If the difference between the thermal expansion coefficient of the particles 10 and the thermal expansion coefficient of the oxide having the eutectic system is increased, the adhesion may be further reduced). Moreover, when the crystallinity of the flat magnetic metal particles 10 is amorphous or amorphous, if the temperature of the heat treatment is high, crystallization proceeds and the coercive force increases, which is not preferable. Therefore, in order to achieve both mechanical properties and coercive force properties, the softening point of the oxide having the eutectic system is set to 200 ° C. or higher and 600 ° C. or lower, more preferably 400 ° C. or higher and 500 ° C. or lower. It is preferable that the oxides having the eutectic system be integrated with heat treatment at a temperature near the softening point, preferably slightly higher than the softening point. Moreover, it is preferable to use the integrated material at a temperature lower than the softening point when it is actually used in a device or system.

The intervening phase 20 has a softening point higher than that of the oxide having the eutectic system, more preferably higher than 600 ° C., and O (oxygen), C (carbon), N It is preferable to further include intermediate intervening particles 24 containing at least one second element in the group consisting of (nitrogen) and F (fluorine). The presence of the intermediate intervening particles 24 between the flat magnetic metal particles 10 prevents the flat magnetic metal particles 10 from being thermally fused and deteriorated when the dust material 150 is exposed to a high temperature. Can do. That is, it is desirable for the intermediate intervening particles 24 to exist mainly for thermal stability. Note that the softening point of the intermediate intervening particles 24 is higher than the softening point of the oxide having the eutectic system, and more preferably, the softening point is 600 ° C. or higher, thereby further improving the thermal stability. it can.

The intermediate intervening particles 24 are Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, Ba, Sr, Cr, Mo, Ag, Ga, Sc, V, Y, Nb, Pb, Cu, In, sn, it includes at least one non-magnetic metal selected from the group consisting of rare earth elements, and, O (oxygen), the C (carbon), N (nitrogen) and F of at least one of the group consisting of (fluorine) It is preferable to contain 2 elements. More preferably, from the viewpoint of high oxidation resistance and high thermal stability, an oxygen-containing oxide or composite oxide is more preferable. In particular, oxides such as aluminum oxide (Al ₂ O ₃ ), silicon dioxide (SiO ₂ ), titanium oxide (TiO ₂ ), and zirconium oxide ( ZrO ₂ ), and complex oxides such as Al—Si—O are high. It is preferable from the viewpoint of oxidation resistance and high thermal stability.

Examples of the method for producing the dust material 120 and the dust material 130 including the intermediate intervening particles 24 include flat magnetic metal particles and intermediate intervening particles (aluminum oxide (Al ₂ O ₃ ) particles, silicon dioxide (SiO ₂ ) particles). , Titanium oxide (TiO ₂ ) particles, zirconium oxide ( ZrO ₂ ) particles, etc.) are mixed by a ball mill or the like to form a dispersed state, and then integrated by press molding or the like. The method of dispersing is not particularly limited as long as it can be appropriately dispersed.

Claims (20)

A flat plane and at least one first element selected from the group consisting of Fe, Co, and Ni, and a ratio of a maximum length to a minimum length in the flat plane is 1 or more and 5 or less on average A plurality of magnetic metal particles having an average thickness of 10 nm to 100 μm and an average aspect ratio of 5 to 10,000;
A plurality of small magnetic metal particles that are arranged on the flat surface in an average of 5 or more and contain at least one of the first elements of the group consisting of Fe, Co, and Ni, and have an average particle size of 10 nm to 1 μm When,
A plurality of flat magnetic metal particles.   The plurality of flat magnetic metal particles according to claim 1, wherein a CV value of the plurality of flat magnetic metal particles is 0.1% or more and 60% or less.   The flat magnetic metal particle has a portion having a body-centered cubic crystal structure, contains Fe and Co, and the amount of Co is 10 atomic percent or more and 60 atomic percent or less with respect to the total amount of Fe and Co. A plurality of flat magnetic metal particles according to claim 1 or 2.   The plurality of flat magnetic metal particles according to any one of claims 1 to 3, wherein the flat magnetic metal particles have a lattice strain of 0.01% or more and 10% or less.   5. The plurality of flat magnetic metal particles according to claim 1, wherein the flat surface is oriented in a (110) plane.   The plurality of flat magnetic metal particles according to any one of claims 1 to 5, wherein the flat magnetic metal particles have magnetic anisotropy in one direction within the flat surface.   The plurality of flat magnetic metal particles according to claim 1, wherein the magnetization behavior of the flat magnetic metal particles proceeds by domain wall movement.   The plurality of flat magnetic metal particles according to any one of claims 1 to 6, wherein the magnetization behavior of the flat magnetic metal particles proceeds by rotational magnetization.   At least a part of the surface of the flat magnetic metal particle has a thickness of 0.1 nm or more and 1 μm or less, and at least one second of oxygen (O), carbon (C), nitrogen (N), and fluorine (F). The plurality of flat magnetic metal particles according to any one of claims 1 to 8, which are covered with a coating layer containing any element. The plurality of flat magnetic metal particles according to any one of claims 1 to 9,
An intervening phase present between the flat magnetic metal particles and containing at least one second element;
A compacted material comprising.   The dusting material according to claim 10, wherein the flat surfaces of the plurality of flat magnetic metal particles are oriented in layers so as to be parallel to each other. The intervening phase is composed of B, Si, Cr, Mo, Nb, Li, Ba, Zn, La, P, Al, Ge, W, Na, Ti, As, V, Ca, Bi, Pb, Te, and Sn. has a eutectic system comprising at least two third elements of the group, it has a softening point at 200 ° C. or higher 600 ° C. or less, the thermal expansion coefficient of 0.5 × 10- ^{6 /} ℃ than 40 × powder material according to claim 10 or claim 11 wherein comprises an oxide is 10- ^{6 /} ° C. or less.   The intervening phase includes the oxide having the eutectic system containing at least two fourth elements of B, Bi, Si, Zn, and Pb and having a softening point of 400 ° C. or more and 500 ° C. or less. The green compact material according to claim 12 comprising.   The dust material according to claim 12 or 13, wherein the eutectic system has eutectic particles having a particle size of 10 nm or more and 10 µm or less.   The powder material according to any one of claims 12 to 14, wherein the intervening phase further includes intermediate intervening particles having a softening point higher than that of the eutectic system and including at least one of the second elements.   The green compact material according to any one of claims 10 to 15, wherein the intervening phase includes a resin.   The powdered material according to any one of claims 10 to 16, wherein the intervening phase contains at least one magnetic metal selected from Fe, Co, and Ni.   A rotating electrical machine having a plurality of flat magnetic metal particles according to any one of claims 1 to 9.   A motor having a plurality of flat magnetic metal particles according to any one of claims 1 to 9. The generator which has the some flat magnetic metal particle as described in any one of Claims 1 thru | or 9.