JP2017522711A - マンガンビスマスを含む異方性複合焼結磁石及びその常圧焼結方法 - Google Patents
マンガンビスマスを含む異方性複合焼結磁石及びその常圧焼結方法 Download PDFInfo
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- KYAZRUPZRJALEP-UHFFFAOYSA-N bismuth manganese Chemical compound [Mn].[Bi] KYAZRUPZRJALEP-UHFFFAOYSA-N 0.000 title 1
- 229910016629 MnBi Inorganic materials 0.000 claims abstract description 89
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- 229910001172 neodymium magnet Inorganic materials 0.000 claims description 5
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- UQDUPQYQJKYHQI-UHFFFAOYSA-N methyl laurate Chemical compound CCCCCCCCCCCC(=O)OC UQDUPQYQJKYHQI-UHFFFAOYSA-N 0.000 claims description 4
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- 229910052692 Dysprosium Inorganic materials 0.000 claims description 3
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- 229910052727 yttrium Inorganic materials 0.000 claims description 3
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- QGLWBTPVKHMVHM-KTKRTIGZSA-N (z)-octadec-9-en-1-amine Chemical compound CCCCCCCC\C=C/CCCCCCCCN QGLWBTPVKHMVHM-KTKRTIGZSA-N 0.000 claims description 2
- HNAGHMKIPMKKBB-UHFFFAOYSA-N 1-benzylpyrrolidine-3-carboxamide Chemical compound C1C(C(=O)N)CCN1CC1=CC=CC=C1 HNAGHMKIPMKKBB-UHFFFAOYSA-N 0.000 claims description 2
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- MMXKVMNBHPAILY-UHFFFAOYSA-N ethyl laurate Chemical compound CCCCCCCCCCCC(=O)OCC MMXKVMNBHPAILY-UHFFFAOYSA-N 0.000 description 4
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- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 2
- 235000021313 oleic acid Nutrition 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
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- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 1
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- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
- H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
- H01F1/0571—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes
- H01F1/0575—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together
- H01F1/0577—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together sintered
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- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/059—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and Va elements, e.g. Sm2Fe17N2
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Abstract
Description
急速凝固工程(RSP)は、1984年頃から広く用いられている工程であって、高温の液体状態から常温又は周辺温度の固体状態への転移期間における過熱及び潜熱を含む熱エネルギーの急速な抽出により、固体化したマイクロ構造(微細構造)を形成する過程を意味する。各種の急速凝固工程が開発されて用いられているが、真空誘導溶解法(Vacuum Induction Melting)、高圧鋳造法(squeeze casting)、スプラット急冷法(splat quenching)、溶融紡糸法(melt spinning)、プラナーフローキャスティング法(planar flow casting)、レーザ又は電子ビーム凝固法(laser or electron beam solidification)などが広く活用されており、これらの全てが熱の急速な抽出により固体化したマイクロ構造を形成することを特徴とする。
次の段階は、作製された非磁性相のMnBi系リボンに磁性を付与する段階である。一実施例によれば、磁性付与のために低温熱処理を行うが、例えば、280〜340℃の温度、並びに真空及び不活性ガス雰囲気の条件で低温熱処理を行い、3時間及び24時間熱処理を行うことにより、前記非磁性相のMnBi系リボンに含まれるMnの拡散を誘導して磁性相のMnBi系リボンを形成し、それによりMnBi系磁性体を作製することができる。MnBi低温相(Low Temperature Phase, LTP)を形成するための熱処理により、磁性相が90%以上、より好ましくは95%以上含まれるようにすることができる。MnBi低温相が約90%以上含まれれば、MnBi系磁性体は優れた磁気特性を有することになる。
次の段階として、MnBi低温相のMnBi合金を粉砕してMnBi硬磁性相粉末を準備する。
MnBi硬磁性相と希土類硬磁性相との混合では潤滑剤を用いて磁場成形体を作製することが重要である。後続の焼結段階の前の磁場成形段階において外部圧力を印加して成形するためには、潤滑剤を用いて粉末を混合しなければならない。
本段階においては、外部磁場及び圧力を印加する磁場成形工程を行うことにより、磁場の方向と粉末のC軸方向とを平行に配向させて異方性を確保する。このように磁場成形により一軸方向に異方性を確保した異方性磁石は、等方性磁石と比較して優れた磁気特性を有する。
従来は、ホットプレスなどを用いた急速焼結で高特性の焼結磁石を製造することができたが、本発明において提案した方法を用いれば、常圧焼結で高特性の焼結磁石を製造することができ、従来の焼結磁石工程の熱処理炉を用いることができるという利点がある。
図1の概要図に示すように異方性複合焼結磁石を製造したが、具体的には、まず、MnBiリボンを作製する急速凝固工程(RSP)でホイール速度を60〜70m/sにすることにより、MnBi、Bi相の結晶の大きさが50〜100nmとなるようにMnBiリボンを作製した。
前記製造されたMnBi/SmFeN(30重量%)常圧焼結磁石におけるXPS(X-ray photoelectron spectroscopy)の結果を図5に示した。図5から、残留炭素(C1s)の含有量が37.8at%であり、表面から10nmの厚さで検出されたことが確認された。
MnBi/SmFeN(30重量%)常圧焼結磁石における固有保磁力(HCi)、残留磁束密度(Br)、誘導保磁力(HCB)、密度(Density)及び最大磁気エネルギー積[(BH)max]を示すものとして、磁気特性は、VSM(vibrating sample magnetometer)(Lake Shore #7300 USA、最大25kOe)を用いて常温(25℃)で測定し、その値を下記表1と図3及び図4に示した。
Claims (15)
- MnBi相粒子及び希土類硬磁性相粒子を含む異方性複合焼結磁石であって、粒子間の界面に残留炭素を含むことを特徴とする焼結磁石。
- 前記MnBi相粒子の組成は、MnBiをMnxBi100-xと表すとXが50〜55であることを特徴とする請求項1に記載の焼結磁石。
- 前記希土類硬磁性相は、R−CO、R−Fe−B又はR−Fe−N(ここで、Rは、Sc、Y、La、Ce、Pr、Nd、Pm、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm、Yb及びLuからなる群から選択される希土類元素)で表されることを特徴とする請求項1に記載の焼結磁石。
- 前記希土類硬磁性相は、SmFeN、NdFeB又はSmCoであることを特徴とする請求項1に記載の焼結磁石。
- 前記焼結磁石は、MnBi相を55〜99重量%、希土類硬磁性相を1〜45重量%含むことを特徴とする請求項1に記載の焼結磁石。
- 請求項1に記載の焼結磁石を含む製品であって、冷蔵庫又はエアコンのコンプレッサ用モータ、洗濯機の駆動モータ、モバイルハンドセットの振動モータ、スピーカ、ボイスコイルモータ、リニアモータ、カメラのズーム、絞り、シャッタ、微細加工機のアクチュエータ、デュアルクラッチトランスミッション(Dual Clutch Transmission, DCT)、アンチロックブレーキシステム(Anti-lock Brake System, ABS)、電動パワーステアリング(Electric Power Steering, EPS)モータ及び燃料ポンプからなる群から選択されるものである製品。
- (a)急速凝固工程(Rapid Solidification Process, RSP)でMnBi系リボンを作製する段階と、
(b)作製された非磁性相のMnBi系リボンを熱処理して磁性相のMnBi系リボンに転移させる段階と、
(c)前記作製された磁性相のリボンを粉砕してMnBi硬磁性相粉末を準備する段階と、
(d)前記MnBi硬磁性相粉末を希土類硬磁性相粉末と潤滑剤の存在下で混合する段階と、
(e)外部磁場及び圧力を印加して前記混合物を磁場成形する段階と、
(f)前記成形物を常圧焼結する段階とを含むことを特徴とするMnBiを含む異方性複合焼結磁石の常圧焼結製造方法。 - 前記潤滑剤は、エチルブチレート、メチルカプリレート、メチルラウレート及びステアレートからなる群から選択されることを特徴とする請求項7に記載の方法。
- 前記段階(e)で印加される圧力は、300〜1000Mpaであることを特徴とする請求項7に記載の方法。
- 前記常圧焼結は、200〜500℃で1分〜5時間、常圧焼結炉で行われることを特徴とする請求項7に記載の方法。
- 前記段階(a)で作製されたMnBi系リボンは、結晶粒の大きさが50〜100nmであることを特徴とする請求項7に記載の方法。
- 前記急速凝固工程でのホイール速度は、60〜70m/sであることを特徴とする請求項7に記載の方法。
- 前記段階(b)でのMnBi合金リボンの熱処理は、280〜340℃の温度で行われることを特徴とする請求項7に記載の方法。
- MnBi硬磁性相粉末の大きさは0.5〜5μmであり、希土類硬磁性相粉末の大きさは1〜5μmであることを特徴とする請求項7に記載の方法。
- MnBiリボンの粉砕工程(c)中に、オレイン酸(C18H34O2)、オレイルアミン(C18H37N)、ポリビニルピロリドン及びポリソルベートからなる群から選択される分散剤を用いることを特徴とする請求項7に記載の方法。
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