JP2020129579A - フェライト焼結磁石 - Google Patents
フェライト焼結磁石 Download PDFInfo
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- JP2020129579A JP2020129579A JP2019020763A JP2019020763A JP2020129579A JP 2020129579 A JP2020129579 A JP 2020129579A JP 2019020763 A JP2019020763 A JP 2019020763A JP 2019020763 A JP2019020763 A JP 2019020763A JP 2020129579 A JP2020129579 A JP 2020129579A
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- ferrite
- sintered magnet
- particles
- magnet
- ferrite sintered
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- H01—ELECTRIC ELEMENTS
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- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
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- C04B35/26—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on ferrites
- C04B35/2608—Compositions containing one or more ferrites of the group comprising manganese, zinc, nickel, copper or cobalt and one or more ferrites of the group comprising rare earth metals, alkali metals, alkaline earth metals or lead
- C04B35/2633—Compositions containing one or more ferrites of the group comprising manganese, zinc, nickel, copper or cobalt and one or more ferrites of the group comprising rare earth metals, alkali metals, alkaline earth metals or lead containing barium, strontium or calcium
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- C01G51/66—Cobaltates containing alkaline earth metals, e.g. SrCoO3
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Abstract
Description
式(1)中、Rは希土類元素及びBiからなる群より選ばれる少なくとも1種の元素であり、Rは少なくともLaを含み、
式(1)中、w、x、z及びmは、下記式(2)〜(5)を満たす。
0.110≦x≦0.173・・・(3)
8.51≦z≦9.71・・・(4)
0.208≦m≦0.269・・・(5)
さらに、磁化容易軸に平行な断面において、全フェライト粒子の数をN、積層欠陥を有するフェライト粒子の数をnとしたときに、0≦n/N≦0.20を満たす。
本実施形態に係るフェライト焼結磁石は、六方晶構造を有するフェライト粒子(結晶粒子)を含むものである。上記フェライトとしては、マグネトプランバイト型フェライト(M型フェライト)であることが好ましい。
式(1)中、Rは希土類元素(Yを含む)及びBiからなる群より選ばれる少なくとも1種の元素であり、Rは少なくともLaを含む。
0.110≦x≦0.173・・・(3)
8.51≦z≦9.71・・・(4)
0.208≦m≦0.269・・・(5)
以下に、本実施形態に係るフェライト焼結磁石の製造方法の一例を示す。上記製造方法は、原料粉末調製工程、仮焼工程、粉砕工程、成形工程及び焼成工程を備える。また、上記製造方法は、上記粉砕工程と上記成形工程の間に、微粉砕スラリーの乾燥工程、及び混練工程を備えていてもよく、上記成形工程と上記焼成工程との間に、脱脂工程を備えていてもよい。各工程について、以下に説明する。
原料粉末調製工程では、フェライト焼結磁石の原料を混合して、原料混合物を得て、必要に応じて、これを粉砕することにより原料粉末を得る。まず、フェライト焼結磁石の原料としては、これを構成する元素のうちの1種又は2種以上を含む化合物(原料化合物)が挙げられる。原料化合物は、例えば、粉末状のものが好適である。原料化合物としては、各元素の酸化物、又は焼成により酸化物となる化合物(炭酸塩、水酸化物、硝酸塩等)が挙げられる。例えば、SrCO3、La2O3、Fe2O3、BaCO3、CaCO3、Co3O4、H3BO3、Al2O3、及びSiO2等が例示できる。
仮焼工程では、原料粉末調製工程で得られた原料粉末を仮焼する。仮焼は、例えば、空気(大気)中等の酸化性雰囲気中で行うことが好ましい。仮焼の温度は、1100〜1400℃の温度範囲であることが好ましく、1100〜1300℃であることがより好ましく、1150〜1300℃であることがさらに好ましい。本実施形態に係るフェライト焼結磁石の製造方法では上記仮焼温度のいずれにおいても安定した磁気特性を得ることができる。仮焼の時間(仮焼の温度で保持する時間)は、1秒間〜10時間であることができ、1秒間〜5時間であることが好ましい。仮焼により得られる仮焼体は、上述したような主相(M相)を70%以上含む。仮焼体の一次粒子径は、好ましくは5μm以下であり、より好ましくは2μm以下であり、さらに好ましくは1μm以下である。仮焼における粒成長を抑制し、仮焼体の一次粒子径を(例えば1μm以下に)小さくすることにより、得られるフェライト焼結磁石のHcJを一層向上させることができる。
粉砕工程では、仮焼工程で顆粒状又は塊状となった仮焼体を粉砕し、再び粉末状にする。これにより、後述する成形工程での成形が容易となる。この粉砕工程において、原料粉末調製工程で混合しなかった原料をさらに添加してもよい。ただし、仮焼温度依存性の効果、又は、仮焼における粒成長の抑制効果を得る観点からは、原料は原料粉末調製工程においてすべて混合されていることが好ましい。粉砕工程は、例えば、仮焼体を粗い粉末となるように粉砕(粗粉砕)した後、これをさらに微細に粉砕する(微粉砕)、2段階の工程からなるものであってもよい。
成形工程では、粉砕工程後に得られた粉砕材(好ましくは微粉砕材)を、磁場中で成形して、成形体を得る。成形は、乾式成形及び湿式成形のいずれの方法によっても行うことができる。磁気的配向度を高くする観点からは、湿式成形によって行うことが好ましい。
焼成工程では、成形工程で得られた成形体を焼成して焼結体とする。これにより、上述したようなフェライト磁石の焼結体、すなわちフェライト焼結磁石が得られる。焼成は、大気中等の酸化性雰囲気中で行うことができる。焼成温度は、1120〜1270℃であることが好ましく、1150〜1240℃であることがより好ましい。また、焼成時間(焼成温度での保持時間)は、0.5〜3時間程度であることが好ましい。
[実施例1]
<原料粉末調製工程>
フェライト焼結磁石を構成する金属元素の原料として、平均一次粒子径0.3μmの炭酸カルシウム(CaCO3)粒子、酸化ランタン(La2O3)粒子、平均一次粒子径0.5μmの炭酸ストロンチウム(SrCO3)粒子、平均一次粒子径0.3μmの酸化鉄(Fe2O3:不純物として、Mn、Cr、Al、Si及びClを含む)、及び、酸化コバルト(Co3O4)粒子を準備した。これらの原料を、金属元素を下記式(1a)で表わされる原子比で含むフェライト焼結磁石において、概ねw=0.388、x=0.133、z=8.721、m=0.247となるように秤量し、混合した。次いで、フェライト焼結磁石の原料として、さらに、ホウ酸(H3BO3)粒子及びアルミナ(Al2O2)粒子を準備した。得られるフェライト焼結磁石全体に対してホウ素の含有量がH3BO3換算で0.144質量%となり、アルミニウムの含有量がAl2O2換算で0.060質量%となるように、ホウ酸粒子及びアルミナ粒子をそれぞれ秤量し、上記混合物に加えた。得られた原料混合物を湿式アトライタにて混合、粉砕し、乾燥して、原料粉末を得た。
Ca1−w−xLawSrxFezCom・・・(1a)
原料粉末に対し、大気中、1200℃で2時間保持する仮焼を行い、仮焼体を得た。得られた仮焼体を、BET法により求められる比表面積が0.5〜2.5m2/gとなるように、小型ロッド振動ミルにて粗粉砕した。得られた粗粉砕材を、湿式ボールミルを用いて32時間微粉砕し、BET法により求められる比表面積が7.0〜10m2/gである微粉砕粒子を有する湿式成形用スラリーを得た。微粉砕後のスラリーを遠心分離機で脱水して固形分濃度を70〜80質量%に調整することにより、湿式成形用スラリーを得た。
湿式成形用スラリーを、湿式磁場成形機を使用して、10kOeの印加磁場中で成形し、直径30mm×厚さ15mmの円柱状の成形体を得た。得られた成形体を、大気中、室温にて十分に乾燥した。次いで、大気中で昇温し、特に1100℃以上では1.0℃/分で昇温し、1205℃で1時間保持し、その後1100℃まで10.0℃/分で降温し、その後室温まで降温する焼成を行い、実施例1のフェライト焼結磁石を得た。
原料粉末調整工程において、平均一時粒子径が0.3μmのFe2O3粒子に代えて平均一次粒子径が0.4μmのFe2O3粒子、及び、平均一時粒子径が0.5μmのSrCO3粒子に代えて、平均一次粒子径が1.0μmのSrCO3粒子に代える以外は、実施例1と同様にして、実施例2のフェライト焼結磁石を得た。
原料粉末調整工程において、平均一時粒子径が0.3μmのFe2O3粒子に代えて、平均一次粒子径が0.5μmのFe2O3粒子、平均一時粒子径が0.5μmのSrCO3粒子に代えて、平均一次粒子径が2.0μmのSrCO3粒子、及び、平均一時粒子径が0.3μmのCaCO3粒子に代えて、平均一次粒子径が1.0μmのCaCO3粒子を用いる以外は、実施例2と同様にして、実施例3のフェライト焼結磁石を得た。
焼成工程において、1100℃以上での昇温速度5.0℃/分とし、焼成温度を1220℃とし、1100℃までの降温速度を5.0℃/分とする以外は、実施例3と同様として、比較例1のフェライト焼結磁石を得た。
[積層欠陥割合]
各実施例の磁石の磁化容易軸に平行な断面のTEM写真を撮影した。画像の範囲は、縦が4μmで横が7.4μmとし、縦方向を磁化容易軸とした。画像の範囲内にすべての領域が現れているフェライト粒子の数Nを求めた後、Nのうち、粒子内に線状領域を有する粒子の数nを求め、積層欠陥割合であるn/Nを求めた。実施例2におけるSEM写真の例を図2に示す。白矢印は、線状領域SFの一例を示す。
実施例及び比較例で得られた円柱状の各フェライト焼結磁石の上下面を加工した後、最大印加磁場25kOeのB−Hトレーサを用い、これらの残留磁束密度Br(mT)及び保磁力HcJ(kA/m)を求めるとともに、磁束密度がBrの90%になるときの外部磁界強度(Hk)を測定した。Hk及びHcJの測定結果から、角形比Hk/HcJを求めた。
Claims (3)
- 六方晶構造を有するフェライト粒子を含むフェライト焼結磁石であって、
前記フェライト焼結磁石は金属元素を下記式(1)で表される原子比で含み、
Ca1−w−xRwSrxFezCom・・・(1)
式(1)中、Rは希土類元素及びBiからなる群より選ばれる少なくとも1種の元素であり、Rは少なくともLaを含み、
式(1)中、w、x、z及びmは、下記式(2)〜(5)を満たし、
0.360≦w≦0.420・・・(2)
0.110≦x≦0.173・・・(3)
8.51≦z≦9.71・・・(4)
0.208≦m≦0.269・・・(5)
磁化容易軸に平行な断面において、全フェライト粒子の数をN、積層欠陥を有するフェライト粒子の数をnとしたときに、0≦n/N≦0.20を満たす、フェライト焼結磁石。 - さらに、AlをAl2O3換算で0.03〜0.3質量%含む、請求項1に記載のフェライト焼結磁石。
- さらに、BをH3BO3換算で0.037〜0.181質量%含む、請求項1又は2に記載のフェライト焼結磁石。
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WO2011001831A1 (ja) * | 2009-06-30 | 2011-01-06 | 日立金属株式会社 | フェライト焼結磁石の製造方法及びフェライト焼結磁石 |
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