JP2021150619A - 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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- JP2021150619A JP2021150619A JP2020051876A JP2020051876A JP2021150619A JP 2021150619 A JP2021150619 A JP 2021150619A JP 2020051876 A JP2020051876 A JP 2020051876A JP 2020051876 A JP2020051876 A JP 2020051876A JP 2021150619 A JP2021150619 A JP 2021150619A
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- sintered magnet
- ferrite
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- ferrite sintered
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- 229910000859 α-Fe Inorganic materials 0.000 title claims abstract description 94
- 239000002245 particle Substances 0.000 claims abstract description 59
- 229910052788 barium Inorganic materials 0.000 claims description 8
- 229910052712 strontium Inorganic materials 0.000 claims description 8
- 230000005415 magnetization Effects 0.000 claims description 7
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 6
- 229910052742 iron Inorganic materials 0.000 claims description 5
- 238000000465 moulding Methods 0.000 description 37
- 238000000034 method Methods 0.000 description 22
- 239000002994 raw material Substances 0.000 description 16
- 238000001878 scanning electron micrograph Methods 0.000 description 16
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 15
- 239000000203 mixture Substances 0.000 description 15
- 238000010298 pulverizing process Methods 0.000 description 14
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- 238000001354 calcination Methods 0.000 description 11
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- 239000000843 powder Substances 0.000 description 9
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 description 8
- 239000011777 magnesium Substances 0.000 description 8
- 239000011575 calcium Substances 0.000 description 7
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 6
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- 150000001875 compounds Chemical class 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 5
- 239000000395 magnesium oxide Substances 0.000 description 5
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 5
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 5
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- 239000000463 material Substances 0.000 description 4
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- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 3
- 238000012935 Averaging Methods 0.000 description 3
- 229910004298 SiO 2 Inorganic materials 0.000 description 3
- 238000013329 compounding Methods 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
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- 238000007088 Archimedes method Methods 0.000 description 2
- -1 B 2 O 3 Inorganic materials 0.000 description 2
- 229910020599 Co 3 O 4 Inorganic materials 0.000 description 2
- RGHNJXZEOKUKBD-SQOUGZDYSA-N D-gluconic acid Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)[C@@H](O)C(O)=O RGHNJXZEOKUKBD-SQOUGZDYSA-N 0.000 description 2
- 229910021193 La 2 O 3 Inorganic materials 0.000 description 2
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- WRIDQFICGBMAFQ-UHFFFAOYSA-N (E)-8-Octadecenoic acid Natural products CCCCCCCCCC=CCCCCCCC(O)=O WRIDQFICGBMAFQ-UHFFFAOYSA-N 0.000 description 1
- LQJBNNIYVWPHFW-UHFFFAOYSA-N 20:1omega9c fatty acid Natural products CCCCCCCCCCC=CCCCCCCCC(O)=O LQJBNNIYVWPHFW-UHFFFAOYSA-N 0.000 description 1
- QSBYPNXLFMSGKH-UHFFFAOYSA-N 9-Heptadecensaeure Natural products CCCCCCCC=CCCCCCCCC(O)=O QSBYPNXLFMSGKH-UHFFFAOYSA-N 0.000 description 1
- 238000004438 BET method Methods 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
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- RGHNJXZEOKUKBD-SQOUGZDYSA-M D-gluconate Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)[C@@H](O)C([O-])=O RGHNJXZEOKUKBD-SQOUGZDYSA-M 0.000 description 1
- RGHNJXZEOKUKBD-UHFFFAOYSA-N D-gluconic acid Natural products OCC(O)C(O)C(O)C(O)C(O)=O RGHNJXZEOKUKBD-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- ZQPPMHVWECSIRJ-UHFFFAOYSA-N Oleic acid Natural products CCCCCCCCC=CCCCCCCCC(O)=O ZQPPMHVWECSIRJ-UHFFFAOYSA-N 0.000 description 1
- 239000005642 Oleic acid Substances 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 238000002441 X-ray diffraction Methods 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 238000013528 artificial neural network Methods 0.000 description 1
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 238000005119 centrifugation Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 229940050410 gluconate Drugs 0.000 description 1
- 239000000174 gluconic acid Substances 0.000 description 1
- 235000012208 gluconic acid Nutrition 0.000 description 1
- 150000004679 hydroxides Chemical class 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- QXJSBBXBKPUZAA-UHFFFAOYSA-N isooleic acid Natural products CCCCCCCC=CCCCCCCCCC(O)=O QXJSBBXBKPUZAA-UHFFFAOYSA-N 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 230000005381 magnetic domain Effects 0.000 description 1
- 239000000696 magnetic material Substances 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 150000002823 nitrates Chemical class 0.000 description 1
- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid Chemical compound CCCCCCCC\C=C/CCCCCCCC(O)=O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 239000011164 primary particle Substances 0.000 description 1
- 238000004445 quantitative analysis Methods 0.000 description 1
- 239000000700 radioactive tracer Substances 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000600 sorbitol Substances 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
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Abstract
Description
六方晶構造を有するフェライト粒子を含み、
磁化容易軸に平行な断面において、前記フェライト粒子の円形度の平均値をWとして、
0.56≦W≦0.68を満たす。
Rは希土類元素から選択される1種以上であり、Rとして少なくともLaを含んでもよく、
AはBaおよびSrから選択される1種以上であり、
0.364≦w≦0.495、
0.038≦x≦0.136、
8.280≦z≦10.45、
0.257≦m≦0.338を満たしてもよい。
Rは希土類元素から選択される1種以上であり、Rとして少なくともLaを含んでもよく、
AはBaおよびSrから選択される1種以上であり、
CaをCaO換算で2.505質量%以上2.951質量%以下、
RをR2O3換算で8.028質量%以上8.239質量%以下、
AをAO換算で0.666質量%以上1.666質量%以下、
FeをFe2O3換算で84.564質量%以上84.937質量%以下、
CoをCoO換算で2.341質量%以上2.521質量%以下、含んでもよい。
Ca1−w−xRwAxFezCom(原子数比)として、カルシウム(Ca)、R、A、鉄(Fe)およびコバルト(Co)を含んでよい。
Rは希土類元素から選択される1種以上であり、Rとして少なくともランタン(La)を含んでよい。
Aはバリウム(Ba)およびストロンチウム(Sr)から選択される1種以上である。
上記組成式のw、x、z、mは、次の範囲を満たす組成であってよい。
0.364≦w≦0.495、
0.038≦x≦0.136、
8.280≦z≦10.45、
0.257≦m≦0.338
Rは希土類元素から選択される1種以上であり、Rとして少なくともLaを含み、
AはBaおよびSrから選択される1種以上であり、
CaをCaO換算で2.505質量%以上2.951質量%以下、
RをR2O3換算で8.028質量%以上8.239質量%以下、
AをAO換算で0.666質量%以上1.666質量%以下、
FeをFe2O3換算で84.564質量%以上84.937質量%以下、
CoをCoO換算で2.341質量%以上2.521質量%以下、含む組成であってよい。
配合工程では、フェライト焼結磁石の原料を配合して、原料混合物を得る。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種または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。
仮焼工程では、配合工程で得られた原料混合物を仮焼する。仮焼は、例えば、空気中等の酸化性雰囲気中で行うことができる。仮焼の温度は、1100°C〜1300°Cの温度範囲とすることができる。仮焼の時間は、1秒〜10時間とすることができる。
粉砕工程では、仮焼工程で顆粒状や塊状となった仮焼体を粉砕し、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。粉砕工程では、前述したように、配合工程で配合しなかった原料を添加してもよい(原料の後添加)。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(微粉砕)する2段階の工程で行ってもよい。
成形・焼成工程では、粉砕工程後に得られた粉砕材(好ましくは微粉砕材)を成形して成形体を得た後、この成形体を焼成して焼結体を得る。成形は、乾式成形、湿式成形またはCeramic Injection Molding(CIM)のいずれの方法でも行うことができる。
湿式成形法によってフェライト焼結磁石を得る場合は、上述した微粉砕工程を湿式で行うことでスラリーを得る。このスラリーを所定の濃度に濃縮して湿式成形用スラリーを得る。これを用いて成形を行うことができる。
出発原料として、CaCO3、La2O3、SrCO3、BaCO3、Fe2O3、Co3O4、MgO、B2O3、Al2O3、SiO2およびMnOを準備し、表1、表2に記載の各試料の組成になるように秤量した。なお、表1にはCa1−w−xRwAxFezComの原子数比を記載した。表2には各元素の酸化物換算での含有量を質量%単位で、それぞれ記載した。
この原料混合物を乾燥後、大気中、1200°Cで2時間保持する仮焼処理を行い、仮焼体を得た。
得られた仮焼体をロッドミルにて粗粉砕し、粗粉砕材を得た。次に、湿式ボールミルにて微粉砕を28時間行い、スラリーを得た。得られたスラリーを固形分濃度が70〜75質量%となるように調整して湿式成形用スラリーとした。
次に、湿式磁場成形機を使用して予備成形体を得た。成形圧力は、50MPa、印加磁場は800kA/mとした。また、成形時の加圧方向と磁場印加方向は、同一方向に設定した。湿式成形で得られた予備成形体は円板状であり、直径30mm、高さ15mmであった。
実施例1〜3、比較例1〜3の各フェライト焼結磁石の上下面を加工した後、25°Cの大気雰囲気中にて、最大印加磁場1989kA/mのB−Hトレーサを使用して磁気特性を測定した。結果を表1に示す。なお、Brは450mT以上を良好とし、460mT以上をさらに良好とした。Hcjは320kA/m以上を良好とし、350kA/m以上をさらに良好とした。
実施例1〜3、比較例1〜3の各フェライト焼結磁石の密度は、アルキメデス法により測定した。結果を表1に示す。
まず、各フェライト焼結磁石の磁化容易軸に平行な断面において、図1A、図2Aに示すようなSEM画像を撮影した。なお、図1Aが実施例3、図2Aが比較例1である。倍率を5000倍とし、26μm×19μmのSEM画像を撮影した。なお、各SEM画像には、少なくとも100個のフェライト粒子が含まれていることを確認した。
Claims (6)
- 六方晶構造を有するフェライト粒子を含み、
磁化容易軸に平行な断面において、前記フェライト粒子の円形度の平均値をWとして、
0.56≦W≦0.68を満たすフェライト焼結磁石。 - 前記断面において、前記フェライト粒子のHeywood径の平均値が1.00μm以上1.23μm以下である請求項1に記載のフェライト焼結磁石。
- MgO換算で0.010質量%以上0.090質量%以下のMgを含む請求項1または2に記載のフェライト焼結磁石。
- Ca1−w−xRwAxFezCom(原子数比)として、Ca、R、A、FeおよびCoを含み、
Rは希土類元素から選択される1種以上であり、Rとして少なくともLaを含み、
AはBaおよびSrから選択される1種以上であり、
0.364≦w≦0.495、
0.038≦x≦0.136、
8.280≦z≦10.45、
0.257≦m≦0.338を満たす請求項1〜3のいずれかに記載のフェライト焼結磁石。 - Ca、R、A、FeおよびCoを含み、
Rは希土類元素から選択される1種以上であり、Rとして少なくともLaを含み、
AはBaおよびSrから選択される1種以上であり、
CaをCaO換算で2.505質量%以上2.951質量%以下、
RをR2O3換算で8.028質量%以上8.239質量%以下、
AをAO換算で0.666質量%以上1.666質量%以下、
FeをFe2O3換算で84.564質量%以上84.937質量%以下、
CoをCoO換算で2.341質量%以上2.521質量%以下、含む請求項1〜4のいずれかに記載のフェライト焼結磁石。 - B2O3換算で0.005質量%以上0.058質量%以下のBを含む請求項1〜5のいずれかに記載のフェライト焼結磁石。
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