JP2024043492A - Magnetic wedge and rotating electric machine - Google Patents

Abstract

[Problem] To provide a magnetic wedge and a rotating electric machine having excellent magnetic properties and mechanical properties. [Solution] The magnetic wedge of the embodiment is a magnetic wedge for a rotating electric machine, the magnetic wedge comprises a plurality of flat magnetic metal particles and an intervening phase, the flat surfaces of the plurality of flat magnetic metal particles are oriented along the widthwise contour line at the center of the magnetic wedge in the width direction, and the flat surfaces are oriented along the thicknesswise contour line at the widthwise ends of the magnetic wedge, the average orientation angle of the plurality of flat magnetic metal particles with respect to the widthwise contour line at the widthwise center is 20 degrees or less, and the average orientation angle of the plurality of flat magnetic metal particles with respect to the thicknesswise contour line at the widthwise ends is 60 degrees or less. [Selected Figure] Figure 8

Description

Embodiments of the present invention relate to a magnetic wedge and a rotating electric machine.

Usually, the coil winding of a rotating electrical machine is housed in an iron core slot, and is supported and fixed by a wedge provided in the slot opening. Non-magnetic material is generally used as the material for this wedge, but since the magnetic resistance value in the gap between the stator core and rotor core becomes discontinuous, the surface of the core that faces the wedge with the gap in between becomes discontinuous. pulsations occur in the magnetic flux distribution, and harmonic loss increases. In order to reduce this harmonic loss, a wedge having appropriate magnetism (magnetic wedge) is also provided. By applying a magnetic wedge, harmonic loss is reduced and the efficiency of the rotating electrical machine is improved. FIG. 1 is a schematic diagram of the usage state of the magnetic wedge and the effect of the magnetic wedge. In FIG. 1, a radial gap type rotating electric machine is shown as an example. In FIG. 1, a magnetic wedge 100, a coil 230, a core tooth 250, and a core slot 260 are shown.

As for the magnetic wedge, it goes without saying that the higher the magnetic permeability of the magnetic wedge, the more harmonic loss can be reduced. However, as shown in Fig. 1, the magnetic wedge is arranged so as to bridge adjacent core teeth, so it has the disadvantage that leakage magnetic flux flowing between the core teeth via the magnetic wedge increases. . In addition, existing magnetic wedges have low saturation magnetization and are therefore prone to magnetic saturation, and furthermore, have low loss, which limits the scope for improving the efficiency of rotating electric machines. In addition, existing magnetic wedges have low magnetic permeability, which limits the scope for improving the efficiency of rotating electric machines, and they are insufficient in terms of thermal stability and mechanical properties (strength, toughness). Therefore, it is desirable to improve the characteristics of the magnetic wedge in terms of saturation magnetization, magnetic permeability, loss, strength, toughness, etc. In particular, it is desired to improve the properties of the magnetic wedge in terms of magnetic permeability, loss, strength, etc.

Utility Model Publication No. 58-6572

The problem to be solved by the present invention is to provide a magnetic wedge and a rotating electric machine having excellent magnetic properties and mechanical properties.

The magnetic wedge of the embodiment is a magnetic wedge for a rotating electric machine, and the magnetic wedge includes a plurality of flat magnetic metal particles and an intervening phase, and the flat magnetic wedge of the plurality of flat magnetic metal particles is formed at the center in the width direction of the magnetic wedge. The plane is oriented along the widthwise contour line, the flat plane is oriented along the widthwise contour line at the widthwise end, and the flat surface is oriented along the widthwise contour line at the widthwise center, and the flat surface is oriented along the widthwise contour line at the widthwise center. The average orientation angle of the flat magnetic metal particles is 20 degrees or less, and the average orientation angle of the plurality of flat magnetic metal particles with respect to the contour line in the thickness direction at the end portion in the width direction is 60 degrees or less.

The magnetic wedge of the embodiment is a magnetic wedge for a radial gap type rotating electric machine in which a stator is arranged to face a rotor at a predetermined radial distance, and the longitudinal direction is the axial direction, the thickness direction is the radial direction, and the width direction is the rotation direction. The magnetic wedge is a magnetic wedge for use in an axial gap type rotating electric machine in which a stator is arranged to face a rotor at a predetermined axial distance, and the longitudinal direction is the radial direction, the thickness direction is the axial direction, and the width direction is the rotation direction.

It is a schematic diagram of the use state of a magnetic wedge, and the effect of a magnetic wedge. FIG. 3 is a conceptual diagram showing an example of how to determine the thickness of flat magnetic metal particles in the magnetic wedge of the first embodiment. A conceptual diagram for explaining how to determine the maximum length and minimum length within the flat surface of a flat magnetic metal particle in the magnetic wedge of the first embodiment. A conceptual diagram for explaining another example of how to determine the maximum length and minimum length within the flat surface of a flat magnetic metal particle in the magnetic wedge of the first embodiment. A schematic diagram showing the direction when the coercive force is measured by changing the direction every 22.5 degrees with respect to the 360 degree angle within the flat plane of the flat magnetic metal particles in the magnetic wedge of the first embodiment. It is. FIG. 2 is a schematic diagram of flat magnetic metal particles in the magnetic wedge of the first embodiment. FIG. 3 is a schematic diagram of a magnetic wedge according to the first embodiment. FIG. 3 is a schematic diagram of a magnetic wedge according to the first embodiment. FIG. 3 is a schematic diagram of a magnetic wedge according to the first embodiment. FIG. 3 is a schematic diagram of a magnetic wedge according to the first embodiment. 4 is an example of the orientation angle of flat magnetic metal particles in the magnetic wedge of the first embodiment. It is an example of a cross-sectional photograph of the magnetic wedge of the first embodiment. It is an example of a cross-sectional photograph of the magnetic wedge of the first embodiment. FIG. 3 is a schematic diagram of the magnetic wedge of Example 1 of the first embodiment and the magnetic wedges of Comparative Examples 1, 2, 3, and 4. FIG. 3 is a schematic diagram of a magnetic wedge according to the first embodiment. FIG. 7 is a schematic diagram of a fifth step in the method for manufacturing a magnetic wedge according to the first embodiment. FIG. 13 is a schematic diagram illustrating an example of a radial gap type rotating electric machine according to a second embodiment. FIG. 2 is a schematic diagram showing an example of an axial gap type rotating electric machine according to a second embodiment. FIG. 13 is a schematic diagram illustrating an example of a generator according to a second embodiment. It is a schematic diagram showing an example of the linear motor of a 2nd embodiment.

Embodiments will be described below with reference to the drawings. In addition, in the drawings, the same or similar parts are given the same or similar symbols. In addition, in this specification, unless otherwise specified, measurements are performed at 25°C.

In this specification, each direction of "axial direction", "rotational direction", and "radial direction" shall be defined with the rotor of the rotating electric machine as a reference. That is, the "axial direction" means the direction along the rotation axis of the rotor, and the "rotation direction" means the direction of rotation around the rotation axis of the rotor (or the tangential direction thereof). The "radial direction" means a direction perpendicular to (perpendicularly intersects with) the rotation axis of the rotor.

(First embodiment)
The magnetic wedge of the embodiment is a magnetic wedge for a rotating electric machine, the magnetic wedge comprising a plurality of flat magnetic metal particles and an intervening phase, the flat surfaces of the plurality of flat magnetic metal particles at the widthwise center of the magnetic wedge being oriented along the widthwise contour line, and at the widthwise ends, the flat surfaces are oriented along the thicknesswise contour line of the magnetic wedge, the average orientation angle of the plurality of flat magnetic metal particles with respect to the widthwise contour line at the widthwise center is 20 degrees or less, and the average orientation angle of the plurality of flat magnetic metal particles with respect to the thicknesswise contour line at the widthwise ends is 60 degrees or less.

In addition, the magnetic wedge of the embodiment is a magnetic wedge for a rotating electric machine, and the magnetic wedge includes a plurality of flat magnetic metal particles and an intervening phase, and a plurality of flat magnetic metal particles at a center in the width direction of the magnetic wedge. The flat planes of the magnetic wedge are oriented in the width direction and the longitudinal direction, the flat planes are oriented in the thickness direction and the longitudinal direction at the ends of the magnetic wedge in the width direction, and the orientation angle of the plurality of flat magnetic metal particles at the center in the width direction is The average of the orientation angles of the plurality of flat magnetic metal particles at the ends in the width direction is 30 degrees or more and 90 degrees or less.

Further, the magnetic wedge of the embodiment is the magnetic wedge of a radial gap type rotating electric machine in which a stator is disposed facing a rotor at a predetermined interval in a radial direction, and the longitudinal direction is an axial direction. The thickness direction is the radial direction, and the width direction is the rotation direction. Further, the magnetic wedge of the embodiment is the magnetic wedge used in an axial gap type rotating electric machine in which a stator is disposed facing a rotor at a predetermined interval in the axial direction, and the longitudinal direction is The thickness direction is the axial direction, and the width direction is the rotation direction. The plurality of flat magnetic metal particles have an average thickness of 10 nm or more and 100 μm or less, and have flat surfaces and a magnetic metal phase containing at least one first element selected from the group consisting of Fe, Co, and Ni. However, the average value of the ratio of the average length in the flat plane to the thickness is 5 or more and 10,000 or less, and the intervening phase is present between the plurality of flat magnetic metal particles and includes oxygen (O), carbon (C), Contains at least one second element selected from the group consisting of nitrogen (N) and fluorine (F).

The flattened magnetic metal particles are flattened particles having a flaky shape.

Thickness refers to the average thickness of one flat magnetic metal particle. Any method may be used to determine the thickness as long as it can determine the average thickness of one flat magnetic metal particle. For example, a cross section perpendicular to the flat plane of flat magnetic metal particles is observed using a transmission electron microscope (TEM), a scanning electron microscope (SEM), or an optical microscope, and the observed flat magnetic metal particles are In the cross section, a method may be used in which ten or more arbitrary points are selected in the direction within the flat plane, the thickness at each selected point is measured, and the average value thereof is adopted. In addition, in the cross section of the observed flat magnetic metal particles, ten or more points were selected at equal intervals from one end to another in the direction within the flat plane (at this time, the end and the other end were (It is preferable not to select such a location because of the location), a method may be used in which the thickness at each selected location is measured and the average value thereof is adopted.

FIG. 2 is a conceptual diagram showing an example of how to determine the thickness of the flat magnetic metal particle in the magnetic wedge of the first embodiment. FIG. 2 specifically shows how to determine the thickness in this case. If 10 points are selected at equal intervals from one end to another end in the direction within the flat surface (excluding the ends) and the thicknesses at each point are t ₁ , t ₂ , ..., t ₁₀ , the thickness of the flat magnetic metal particle is (t ₁ + t ₂ + ... + t ₁₀ ) / 10. In addition, it is preferable to measure as many points as possible in the measurement because average information can be obtained. In addition, if the cross-sectional contour line is very uneven or has a rough surface contour line, and it is difficult to determine the average thickness in its current state, it is preferable to smooth the contour line with an average straight line or curve as appropriate depending on the situation, and then perform the above method.

Moreover, the average thickness refers to the average value of the thickness of a plurality of flat magnetic metal particles, and is distinguished from the above-mentioned mere "thickness". When determining the average thickness, it is preferable to use a value averaged over 20 or more flat magnetic metal particles. Further, it is preferable to obtain average information for as many flat magnetic metal particles as possible. Furthermore, if it is not possible to observe 20 or more flat magnetic metal particles, it is preferable to observe as many flat magnetic metal particles as possible and use the average value for them. The average thickness of the flat magnetic metal particles is preferably 10 nm or more and 100 μm or less. The thickness is more preferably 10 nm or more and 1 μm or less, and even more preferably 10 nm or more and 100 nm or less. Further, the flat magnetic metal particles preferably have a thickness of 10 nm or more and 100 μm or less, more preferably 10 nm or more and 1 μm or less, and even more preferably 10 nm or more and 100 nm or less. This is preferable because eddy current loss can be sufficiently reduced when a magnetic field is applied in a direction parallel to the flat surface. Further, it is preferable that the thickness is small because the magnetic moment is confined in a direction parallel to the flat plane and magnetization progresses more easily due to rotational magnetization. When magnetization progresses by rotational magnetization, the magnetization tends to progress reversibly, so the coercive force becomes small, which reduces hysteresis loss, which is preferable.

The average length of the flat magnetic metal particles is defined as (a+b)/2 using the maximum length a and the minimum length b in the flat plane. The maximum length a and the minimum length b can be determined as follows. For example, consider a rectangle with the smallest area among the rectangles circumscribing a flat plane. The length of the long side of the rectangle is the maximum length a, and the length of the short side is the minimum length b. FIG. 3 is a conceptual diagram for explaining how to determine the maximum length and minimum length in the flat plane of flat magnetic metal particles in the magnetic wedge of the first embodiment. FIG. 3 is a schematic diagram showing the maximum length a and minimum length b determined by the above method using some flat magnetic metal particles as an example. Like the average thickness, the maximum length a and the minimum length b can be determined by observing the flat magnetic metal particles using a TEM, SEM, optical microscope, or the like. Furthermore, it is also possible to perform image analysis of the micrograph on a computer to determine the maximum length a and the minimum length b. In either case, it is preferable to use 20 or more flat magnetic metal particles as targets. Further, it is preferable to obtain the information for as many flat magnetic metal particles as possible because average information can be obtained. Furthermore, if it is not possible to observe 20 or more flat magnetic metal particles, it is preferable to observe as many flat magnetic metal particles as possible and use the average value for them. At this time, it is preferable to obtain the average value as much as possible, so the flat magnetic metal particles are uniformly dispersed (the flat magnetic metal particles with different maximum and minimum lengths are dispersed as randomly as possible). ), observation or image analysis is preferably performed. For example, a plurality of flat magnetic metal particles are sufficiently mixed and pasted on the tape, or a plurality of flat magnetic metal particles are dropped from above and then lowered and pasted on the tape. It is preferable to perform observation or image analysis by.

However, depending on the flat magnetic metal particles, when the maximum length a and the minimum length b are determined by the above method, the determination method may not capture the essence. FIG. 4 is a conceptual diagram for explaining another example of how to obtain the maximum length and minimum length in the flat plane of the flat magnetic metal particles in the magnetic wedge of the first embodiment. For example, in the case shown in FIG. 4, the flat magnetic metal particles are in an elongated and curved state, but in this case, essentially, the maximum and minimum lengths of the flat magnetic metal particles are as shown in FIG. These are the lengths of a and b shown in . In this way, the maximum lengths a and b cannot be determined completely uniquely, but basically, ``consider the rectangle with the smallest area among the rectangles circumscribing the flat plane, There is no problem with this method, where the length of the long side of the rectangle is the maximum length a, and the length of the short side is the minimum length b, but depending on the shape of the particle, if this method does not capture the essence, it may be necessary to Depending on the situation, determine the maximum length a and minimum length b that capture the essence. The thickness t is defined as the length in the direction perpendicular to the flat surface. The ratio A of the average length in the flat plane to the thickness is defined as A=((a+b)/2)/t using maximum length a, minimum length b, and thickness t.

The average value of the ratio of the average length in the flat plane to the thickness of the flat magnetic metal particles is preferably 5 or more and 10,000 or less. This is because the magnetic permeability increases. Furthermore, since the ferromagnetic resonance frequency can be increased, the ferromagnetic resonance loss can be reduced.

The average value is adopted as the ratio of the average length in the flat plane to the thickness. Preferably, the average value for 20 or more flat magnetic metal particles is used. Further, it is preferable to obtain the information for as many flat magnetic metal particles as possible because average information can be obtained. Furthermore, if it is not possible to observe 20 or more flat magnetic metal particles, it is preferable to observe as many flat magnetic metal particles as possible and use the average value for them. For example, if there are particles Pa, Pb, and Pc, and their thicknesses are Ta, Tb, and Tc, and their average lengths in the flat plane are La, Lb, and Lc, the average thickness is (Ta+Tb+Tc)/3. The average value of the ratio of the average length in the flat plane to the thickness is calculated as (La/Ta+Lb/Tb+Lc/Tc)/3.

It is preferable that the flat magnetic metal particles have a coercive force difference depending on the direction within the flat plane. The ratio of the coercive force difference depending on the direction is preferably as large as possible, and is preferably 1% or more. More preferably, the ratio of the coercive force difference is 10% or more, still more preferably the ratio of the coercive force difference is 50% or more, and still more preferably the ratio of the coercive force difference is 100% or more. The ratio of coercive force difference here means (Hc (max) - Hc (min)) using the maximum coercive force Hc (max) and the minimum coercive force Hc (min) in the flat plane. /Hc (min) x 100 (%). Note that the coercive force can be evaluated using a vibrating sample magnetometer (VSM) or the like. If the coercive force is low, by using a low magnetic field unit, it is possible to measure coercive forces of 0.1 Oe or less. Measurement is performed by changing the direction within the flat plane with respect to the direction of the measurement magnetic field.

Note that "having a coercive force difference" means the direction in which the coercive force is maximum and the direction in which the coercive force is minimum when measuring the coercive force by applying a magnetic field in 360 degrees in a flat plane. It means that there exists. For example, when measuring the coercive force by changing the direction every 22.5 degrees for a 360 degree angle in a flat plane, a difference in coercive force will appear, that is, the angle at which the coercive force is larger and the coercive force If an angle at which the is smaller appears, it is said that there is a coercive force difference. FIG. 5 shows the direction in which the coercive force was measured by changing the direction every 22.5 degrees with respect to the 360 degree angle within the flat plane of the flat magnetic metal particles in the magnetic wedge of the first embodiment. FIG. In addition, in FIG. 5, the flat surface of the flat magnetic metal particle is illustrated as seen from above. By having a coercive force difference within the flat plane, the minimum coercive force value is smaller than in an isotropic case where there is almost no coercive force difference, which is preferable. In a material that has magnetic anisotropy within the flat plane, the coercive force differs depending on the direction within the flat plane, and the minimum coercive force value is smaller than that of a magnetically isotropic material. This reduces hysteresis loss and improves magnetic permeability, which is preferable. In FIG. 5, flat magnetic metal particles 10 and flat surfaces 6 are shown.

Further, the flat magnetic metal particles have a magnetic metal phase containing at least one first element selected from the group consisting of Fe, Co, and Ni. The flat magnetic metal particles contain Fe and Co, and the amount of Co is preferably 10 at% or more and 60 at% or less, and 10 at% or more and 40 at% or less based on the total amount of Fe and Co. It is more preferable that the This is preferable because a suitably large magnetic anisotropy can easily be imparted and the above-mentioned magnetic properties can be improved. Further, Fe--Co based materials are preferable because they can easily achieve high saturation magnetization. Furthermore, it is preferable that the composition range of Fe and Co falls within the above range, since higher saturation magnetization can be achieved. Further, it is preferable that the flat magnetic metal particles and the deposited metal have the same composition because thermal stability and mechanical properties such as strength and hardness are easily improved.

The elements can be easily analyzed using EDX (Energy Dispersive X-ray spectroscopy) or ICP (Inductively Coupled Plasma) optical emission spectroscopy.

The flat magnetic metal particles include Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, Ba, Sr, Cr, Mo, Ag, Ga, Sc, V, Y, Nb, Pb, Cu, In, It is preferable that at least one nonmagnetic metal selected from the group consisting of Sn and rare earth elements is included. This makes it possible to improve the thermal stability and oxidation resistance of the flat magnetic metal particles. Among these, Al and Si are particularly preferable because they easily form a solid solution with Fe, Co, and Ni, which are the main components of the flat magnetic metal particles, and contribute to improving thermal stability and oxidation resistance.

In order to induce magnetic anisotropy, there is also a method of making the crystallinity of the flat magnetic metal particles as amorphous as possible and inducing magnetic anisotropy in one direction in the plane using a magnetic field or strain. In this case, it is desirable to have a composition that makes it easy to make the flat magnetic metal particles as amorphous as possible. From this point of view, the magnetic metals contained in the flat magnetic metal particles include B (boron), Si (silicon), Al (aluminum), C (carbon), Ti (titanium), Zr (zirconium), Hf ( hafnium), Nb (niobium), Ta (tantalum), Mo (molybdenum), Cr (chromium), Cu (copper), W (tungsten), P (phosphorus), N (nitrogen), Ga (gallium), Y ( It is preferable that at least one additional element selected from yttrium is included. Preferably, the additive element has a large difference in atomic radius from the atomic radius of at least one first element selected from the group consisting of Fe, Co, and Ni. Further, it is preferable that the additive element has a negative mixing enthalpy with at least one first element selected from the group consisting of Fe, Co, and Ni. Furthermore, it is preferable that the element be a multi-element system consisting of three or more types of elements in total, including the first element and additional elements. Further, semimetal additive elements such as B and Si have a slow crystallization rate and are likely to become amorphous, so it is advantageous to mix them into the system. From the above viewpoints, B, Si, P, Ti, Zr, Hf, Nb, Y, Cu, etc. are preferable, and among them, it is preferable that the additive element contains any one of B, Si, Zr, Hf, Y. More preferred. For example, it is preferable that the first element of the magnetic metal phase contains Fe and Co, and the additional elements contain Si and B. Further, it is preferable that the total amount of the additive element is 0.001 at% or more and 80 at% or less with respect to the total amount of the first element and the additive element. More preferably, it is 5 at% or more and 80 at% or less, and still more preferably 10 at% or more and 40 at% or less. Incidentally, it is preferable that the total amount of the above-mentioned additive elements is larger, since it becomes more amorphous and easier to impart magnetic anisotropy (i.e., it is preferable from the viewpoint of low loss and high magnetic permeability). However, on the other hand, since the proportion of the magnetic metal phase decreases, the saturation magnetization decreases, which is not preferable. From the above, it is important to select the composition and amount of added elements by comprehensively considering high saturation magnetization, low loss, high magnetic permeability, etc.

It is preferable that at least a portion of the surface of the flat magnetic metal particles is covered with a coating layer having a thickness of 0.1 nm to 1 μm and containing at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N) and fluorine (F).

FIG. 6 is a schematic diagram of flat magnetic metal particles in the magnetic wedge of the first embodiment. A coating layer 9 and flat magnetic metal particles 10 are shown.

The coating layer includes 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 non-magnetic metal selected from the group consisting of rare earth elements, and at least one second selected from the group consisting of oxygen (O), carbon (C), nitrogen (N) and fluorine (F) It is more preferable to include an element. As the non-magnetic metal, Al and Si are particularly preferable from the viewpoint of thermal stability. Flat magnetic metal particles include Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, Ba, Sr, Cr, Mo, Ag, Ga, Sc, V, Y, Nb, Pb, Cu, In, Sn. , rare earth elements, the coating layer should include at least one nonmagnetic metal that is the same as the nonmagnetic metal that is one of the constituent components of the flat magnetic metal particles. is more preferable. Among oxygen (O), carbon (C), nitrogen (N), and fluorine (F), it is preferable that oxygen (O) is included, and oxides and composite oxides are preferable. The above is from the viewpoints of ease of forming the coating layer, oxidation resistance, and thermal stability. With the above, it is possible to improve the adhesion between the flat magnetic metal particles and the coating layer, and it becomes possible to improve the thermal stability and oxidation resistance of the magnetic wedge, which will be described later. The coating layer can not only improve the thermal stability and oxidation resistance of the flat magnetic metal particles, but also improve the electrical resistance of the flat magnetic metal particles. By increasing the electrical resistance, it becomes possible to suppress eddy current loss and improve the frequency characteristics of magnetic permeability. For this reason, it is preferable that the coating layer has high electrical resistance, for example, a resistance value of 1 mΩ·cm or more.

Further, the presence of the coating layer is also preferable from a magnetic viewpoint. Since the flat magnetic metal particles have a smaller thickness than the size of the flat surface, they can be regarded as a pseudo thin film. At this time, what is formed by forming a coating layer on the surface of the flat magnetic metal particles and integrating them can be regarded as a pseudo laminated thin film structure, and the magnetic domain structure becomes energetically stable. This makes it possible to reduce the coercive force (thereby reducing hysteresis loss), which is preferable. At this time, the magnetic permeability also increases, which is preferable. From this point of view, it is more preferable that the coating layer is nonmagnetic (the magnetic domain structure is more likely to be stabilized).

The thickness of the coating layer is preferably as thick as possible from the viewpoints of thermal stability, oxidation resistance, and electrical resistance. However, if the thickness of the coating layer becomes too thick, the saturation magnetization becomes small and the magnetic permeability also becomes small, which is not preferable. Also, from a magnetic point of view, if the thickness becomes too thick, the "effects of stabilizing the magnetic domain structure and lowering the coercive force, lowering the loss, and increasing the magnetic permeability" will be reduced. Considering the above, the thickness of the coating layer is preferably 0.1 nm or more and 1 μm or less, more preferably 0.1 nm or more and 100 m or less.

FIG. 7 is a schematic diagram of the magnetic wedge of this embodiment. As shown in FIG. 7, the magnetic wedge is not limited to a simple rectangular parallelepiped shape (with a rectangular cross section), but can also have various shapes such as a trapezoidal, hexagonal, or convex cross section. Here, regardless of the shape, three axial directions that are orthogonal or perpendicular to each other are defined as the width direction, the thickness direction, and the longitudinal direction. The longitudinal direction of the magnetic wedge is the direction in which the length of the magnetic wedge is longer. The thickness direction and the width direction of the magnetic wedge are directions perpendicular to the longitudinal direction of the magnetic wedge. Further, the thickness direction and the width direction of the magnetic wedge can be distinguished from the orientation state of the flat magnetic metal particles, which will be described later.

The closer the magnetic wedge is placed to the gap surface between the rotor and stator, the more effective it is (improving the efficiency of rotating electric machines). A hexagonal shape is preferable. Further, from the viewpoint of "a shape that makes it easy to draw magnetic flux into the magnetic wedge side (which makes it easy to improve the efficiency of the rotating electric machine)", trapezoidal and convex shapes are more preferable than hexagonal shapes. On the other hand, from the viewpoint of ease of manufacture and high reliability as a material (mechanical properties, thermal properties), a rectangular shape is most preferred, followed by a trapezoidal shape and a hexagonal shape. In this sense, the trapezoidal shape is easy to place close to the gap surface between the rotor and stator, and the trapezoidal shape makes it easy to draw magnetic flux into the magnetic wedge. It is very preferable because it is easy to increase the reliability (mechanical properties, thermal properties).

FIG. 8 is a schematic diagram of the magnetic wedge of this embodiment. 8(a) shows a rectangular cross section, FIG. 8(b) shows a trapezoidal cross section, FIG. 8(c) shows a hexagonal cross section, and FIG. 8(d) shows multiple flat shapes with a convex cross section. An example of orientation of magnetic metal particles is shown. In either case, the flat surfaces of the plurality of flat magnetic metal particles are oriented along the contour line in the width direction at the center in the width direction. At this time, the average orientation angle of the flat magnetic metal particles with respect to the rotation direction (width direction) at the center of the rotation direction is preferably 20 degrees or less, more preferably 1 degree or more and 20 degrees or less, and even more preferably is 1 degree or more and 10 degrees or less. Moreover, the flat surface is oriented along the contour line in the thickness direction at the end portion in the width direction. At this time, the average orientation angle of the plurality of flat magnetic metal particles with respect to the contour line in the thickness direction at the end in the width direction is preferably 60 degrees or less, more preferably 1 degree or more and 60 degrees or less. is preferable, more preferably 1 degree or more and 45 degrees or less, still more preferably 1 degree or more and 30 degrees or less, still more preferably 1 degree or more and 20 degrees or less, even more preferably 1 degree or more and 10 degrees or less. Note that the center refers to a region in the widthwise centerline of the magnetic wedge, including the centerline of the cross section including the width direction and the thickness direction, and within the range of "the average length of the flat magnetic metal particles." In addition, the end portion refers to the end in the width direction of the magnetic wedge, that is, the area within the range of "the average length of the flat magnetic metal particles" from the contour line in the thickness direction. In addition, more preferable definitions of the center portion and the end portions are as follows. The center refers to an area in the width direction of the magnetic wedge, including the center line of the cross section including the width direction and the thickness direction, and having a range of "half the average length of the flat magnetic metal particles". Point. Further, the end portion refers to the end in the width direction of the magnetic wedge, that is, a region within a range of "half the average length of the flat magnetic metal particles" from the contour line in the thickness direction.

Figure 9 is a schematic diagram of the magnetic wedge of this embodiment. Figure 9 (a) shows an example of the orientation of multiple flat magnetic metal particles when the cross section is trapezoidal, Figure 9 (b) shows a hexagonal cross section, and Figure 9 (c) shows a convex cross section. Figure 9 shows an example of an orientation different from that of Figure 8, but all of them are preferable. In Figure 9, the orientation at the center in the width direction is the same as that of Figure 8, but the orientation at the end in the width direction is different from that of Figure 8. In the embodiment shown in Figure 9, at the end in the width direction, the orientation angle of the flat magnetic metal particles with respect to the width direction is preferably 30 degrees or more and 90 degrees or less, more preferably 45 degrees or more and 90 degrees or less, and even more preferably 60 degrees or more and 90 degrees or less. When the flat magnetic metal particles have an orientation as shown in Figures 8 and 9, magnetic properties such as high magnetic permeability and low loss are improved, the efficiency of the rotating electric machine is greatly improved, and excellent mechanical properties such as improved strength of the magnetic wedge can be realized. In addition, in the center, the flat surfaces of the flat magnetic metal particles are oriented along the contour line in the width direction, and at the ends, the flat surfaces are oriented along the contour line in the thickness direction, making it possible to average the magnetic and mechanical properties three-dimensionally and achieve excellent magnetic and mechanical properties in all directions, the x, y, and z directions.

FIG. 10 is a schematic diagram of the magnetic wedge of this embodiment. Although FIG. 10 shows a schematic diagram of the arrangement of the magnetic wedges shown in FIG. 8(a), this is just an example, and FIGS. 8(b), (c), (d), FIG. Forms such as (b) and (c) may also be used. The magnetic wedge shown in FIG. 10 is a magnetic wedge used for a radial gap type rotating electrical machine in which a stator is disposed facing a rotor at a predetermined distance in the radial direction. In the case of a magnetic wedge for a radial gap type rotating electrical machine, the longitudinal direction of the magnetic wedge is the axial direction of the rotating electrical machine, the width direction of the magnetic wedge is the rotating direction of the rotating electrical machine, and the thickness direction of the magnetic wedge is the direction of the rotating electrical machine. It is radial. At the center of the magnetic wedge in the rotation direction, the flat surfaces of the flat magnetic metal particles are oriented in the rotation direction and the axial direction. At this time, the orientation angle of the flat magnetic metal particles with respect to the rotation direction (width direction) at the center of the rotation direction is preferably 20 degrees or less, more preferably 1 degree or more and 20 degrees or less, and more preferably 1 degree or less. The temperature is at least 10 degrees. Further, at the end portion in the rotational direction, the flat surface is oriented in the radial direction and the axial direction. At this time, the orientation angle of the flat magnetic metal particles with respect to the rotation direction (width direction) at the end in the rotation direction is preferably 30 degrees or more and 90 degrees or less, more preferably 45 degrees or more and 90 degrees or less, and even more preferably is 60 degrees or more and 90 degrees or less. The center includes the center line of the magnetic wedge in the rotation direction, including the center line of a cross section including the width direction and thickness direction, or the center line of a cross section perpendicular to the longitudinal direction, and refers to the "average length of the flat magnetic metal particles." Refers to the area within the range of . Further, the end portion refers to a region within a range of "the average length of the flat magnetic metal particles" from the end in the rotation direction of the magnetic wedge. The area ranging between the center and the edges is the "intermediate". In addition, more preferable definitions of the center portion and the end portions are as follows. The center refers to an area in the width direction of the magnetic wedge, including the center line of the cross section including the width direction and the thickness direction, and having a range of "half the average length of the flat magnetic metal particles". Point. Further, the end portion refers to the end in the width direction of the magnetic wedge, that is, a region within a range of "half the average length of the flat magnetic metal particles" from the contour line in the thickness direction.

The orientation angle of the flat magnetic metal particles is calculated as follows. First, if the target magnetic wedge is provided inside the rotating electrical machine, the target magnetic wedge is taken out from inside the rotating electrical machine. Here, the rotational direction of the rotating electrical machine is the width direction of the target magnetic wedge. Next, the outer dimensions of the target magnetic wedge are measured. This determines the longitudinal direction of the magnetic wedge (the direction in which the magnetic wedge is longest). For example, when the target magnetic wedge has a substantially rectangular parallelepiped shape, the direction along the longest side of the roughly rectangular parallelepiped shape is determined as the longitudinal direction of the target magnetic wedge. Next, a cross section perpendicular to the longitudinal direction of the magnetic wedge to be considered is determined. For such a cross-section, avoid using the end face of the target magnetic wedge. For such a cross section, the target magnetic wedge is cut perpendicular to the longitudinal direction of the target magnetic wedge so that the length is at least one-tenth of the length of the target magnetic wedge in the longitudinal direction. .

The cross section formed by cutting is a cross section including the width direction and the thickness direction, or a cross section perpendicular to the longitudinal direction. Next, the center line of the cross section formed by cutting is determined. As the center line of the cross section formed by cutting, for example, a straight line including the geometric center of the cross section is used. Next, a cross section of the target magnetic wedge formed by cutting is observed using an optical microscope, SEM, or TEM. Next, for each flat magnetic metal particle observed in the cross section formed by cutting, consider the rectangle with the smallest area among the rectangles circumscribing each flat magnetic metal particle, and the long side direction of the rectangle is The angle formed with reference to the rotational direction of the rotating electric machine in which the target magnetic wedge was provided is defined as the orientation angle of the flat magnetic metal particles. Note that the orientation angle is an angle formed between the rotation direction and the flat surface of the flat magnetic metal particles, and is not distinguished as positive or negative. FIG. 11 shows a few examples of orientation angles of flat magnetic metal particles determined by this method. Even if one flat magnetic metal particle is not completely contained within the observation range (even if it protrudes from the area and part of it is in the middle, it will be evaluated), the orientation angle of that particle will be evaluated. . However, flat magnetic metal particles may include particles whose contours are unclear during observation and are difficult to evaluate. In other words, there are cases where the outline of a particle cannot be clearly identified through image analysis, and in such cases it is removed from the observation target. In this way, the orientation angles of all the flat magnetic metal particles included in the observation range are determined, and the average value is adopted as the orientation angle of the flat magnetic metal particles in the center and the flat magnetic metal particles included in the edges. do. Further, the cross section to be observed is evaluated using a plurality of cross sections, for example, three or more cross sections, and the average value thereof is adopted. The center and end portions are shown in FIG. In FIG. 10, flat magnetic metal particles 10, intervening phases 20, and magnetic wedges 100 are shown. Regarding the orientation angle, FIG. 11 shows examples of 0 degrees, 45 degrees, and 90 degrees.
If the target magnetic wedge is not installed in the rotating electrical machine, find the center where the average orientation angle is the smallest in a cross section perpendicular to the longitudinal direction, and The direction is defined as the width direction (rotation direction). Specifically, the width direction (rotation direction) is temporarily determined in a plane perpendicular to the longitudinal direction. Next, the center is determined with respect to the tentatively determined width direction (rotation direction), and the orientation angle of the flat magnetic metal particles at the center is determined. At this time, the orientation angle is determined by considering the rectangle with the smallest area among the rectangles circumscribing the magnetic metal particles, and the angle that the long side of the rectangle makes with the "temporarily determined width direction (rotation direction)". Define. Next, in a cross section perpendicular to the longitudinal direction, the width direction (rotation direction) is changed and the orientation angle at the center is determined in the same manner. At this time, assuming that it will be installed inside a rotating electric machine, the arrangement will be changed so as to be realistic. Thereafter, the "temporarily determined width direction (rotation direction)" when the orientation angle at the center is the smallest is determined as the "official width direction (rotation direction)".

The orientation angle is expressed as an average value of the orientation angles of a plurality of flat magnetic metal particles included in each of the center and end regions. FIG. 12 shows an example of a cross-sectional photograph of the magnetic wedge of this embodiment. It was found that the magnetic wedge shown in FIG. 12 had a trapezoidal cross section, the orientation angle at the center was about 4 degrees, and the degree of orientation at the ends was about 37 degrees with respect to the contour line in the thickness direction. Further, FIG. 13 shows an example of a cross-sectional photograph of the magnetic wedge of this embodiment. The magnetic wedge shown in FIG. 13 had a rectangular cross section, and it was found that the orientation angle at the center was about 5 degrees and the degree of orientation at the ends was about 33 degrees. When flat magnetic metal particles have such orientation, magnetic properties such as high magnetic permeability and low loss are improved, and the efficiency of rotating electric machines is greatly improved. At the same time, it has excellent properties such as improving the strength of magnetic wedges. Mechanical properties can be achieved.
Note that the orientation of flat magnetic metal particles can also be discussed in terms of number ratio. In this case, the number of oriented flat magnetic metal particles is preferably 10% or more, more preferably 50% of the total number of flat magnetic metal particles included in each of the center and end regions. or more, and more preferably 80% or more. When flat magnetic metal particles have such orientation, magnetic properties such as high magnetic permeability and low loss are improved, and the efficiency of rotating electric machines is greatly improved. At the same time, it has excellent properties such as improving the strength of magnetic wedges. Mechanical properties can be achieved.

FIG. 14 shows a schematic diagram comparing the magnetic wedge of this embodiment (Example 1) with existing magnetic wedges (Comparative Examples 1 to 4). Comparative Example 1 is a magnetic wedge in which spherical magnetic metal particles are dispersed, Comparative Example 2 is a magnetic wedge in which flat magnetic metal particles are stacked and oriented in the y direction, and Comparative Example 3 is a magnetic wedge in which flat magnetic metal particles are stacked and oriented in the z direction. , Comparative Example 4 is a magnetic wedge in which flat magnetic metal particles are stacked and oriented in the x direction. A detailed comparison will be given later, but in Example 1, the magnetic properties and mechanical It is possible to average the characteristics three-dimensionally and achieve excellent characteristics in all directions, including the x direction, y direction, and z direction. This is a characteristic that cannot be achieved in any of Comparative Examples 1 to 4. In addition, in Comparative Examples 2 to 4, the magnetic particles are stacked only in one direction, so the magnetic properties and mechanical properties are specialized so that they are excellent in a specific direction. It is not possible to provide excellent characteristics in all directions including the x direction, y direction, and z direction. Note that a schematic diagram of an example of a radial gap type rotating electric machine is shown in FIG. 17.

In this specification, "the flat magnetic metal particles are stacked and oriented in the y direction" means that a plurality of flat magnetic metal particles are stacked in the y direction, and the flat surface of the flat magnetic metal particles is in the x direction. and oriented in the z direction. "The flat magnetic metal particles are stacked and oriented in the x direction" means that a plurality of flat magnetic metal particles are stacked in the x direction, and the flat surfaces of the flat magnetic metal particles are oriented in the y and z directions. It means what you are doing. "The flat magnetic metal particles are stacked and oriented in the z direction" means that a plurality of flat magnetic metal particles are stacked in the z direction, and the flat surfaces of the flat magnetic metal particles are oriented in the x and y directions. It means what you are doing.

FIG. 15 is a schematic diagram of a magnetic wedge in the case of an axial gap type rotating electric machine. The magnetic wedge shown in FIG. 15 is a magnetic wedge used in an axial gap type rotating electric machine in which a stator is disposed facing a rotor at a predetermined distance in the axial direction. In the case of a magnetic wedge used in an axial gap type rotating electric machine, the longitudinal direction of the magnetic wedge is the radial direction of the rotating electric machine, the width direction of the magnetic wedge is the rotation direction of the rotating electric machine, and the thickness direction of the magnetic wedge is the rotation direction. This is the axial direction of the electric machine. The flat surface is oriented in the rotation direction and the radial direction at the center in the rotation direction, and the flat surface is oriented in the axial direction and the radial direction at the end in the rotation direction. At this time, the orientation angle of the flat magnetic metal particles with respect to the rotation direction (width direction) at the center of the rotation direction is preferably 20 degrees or less, preferably 1 degree or more and 20 degrees or less, more preferably 1 degree or less. The temperature is at least 10 degrees. Further, at the end portion in the rotational direction, the flat surface is oriented in the axial direction and the radial direction. At this time, the orientation angle of the flat magnetic metal particles with respect to the rotation direction (width direction) at the end in the rotation direction is preferably 30 degrees or more and 90 degrees or less, more preferably 45 degrees or more and 90 degrees or less, and even more preferably is 60 degrees or more and 90 degrees or less. The obtained excellent magnetic properties, excellent mechanical properties, and improved efficiency of the rotating electric machine are the same as in the case of the radial gap type rotating electric machine described above, so a description thereof will be omitted here. Note that a schematic diagram of an example of an axial gap type rotating electric machine is shown in FIG.

The manufacturing method of the magnetic wedge of this embodiment will be described. Note that the manufacturing method is not particularly limited and will be described only as an example.

The first step is a step of manufacturing a magnetic metal ribbon containing at least one first element selected from the group consisting of Fe, Co, and Ni. This process is a process of producing a ribbon or a thin film using a film forming apparatus such as a roll quenching apparatus or a sputtering apparatus. At this time, in a film forming method using a film forming apparatus, it is desirable to form a film with uniaxial anisotropy in the film plane by film formation in a magnetic field, rotational film formation, or the like. In addition, when using a film-forming device, the thickness can be made thinner, the structure tends to be more sophisticated, and rotational magnetization is more likely to occur, so the film-forming method is used when creating a rotary magnetization type. is desirable. Roll quenchers are desirable when synthesizing bulk materials because they are suitable for large-scale synthesis. In the case of a roll quenching device, a single roll quenching device is preferred because it is simple.

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 to facilitate insertion into an electric furnace for heat treatment. For example, it may be cut into appropriate sizes using a mixer device or the like. By carrying out this step, it is desirable that the pulverization property is easily improved in the next third step of pulverization. The atmosphere for the heat treatment is preferably a vacuum atmosphere with a low oxygen concentration, an inert atmosphere, or a reducing atmosphere, and more preferably H ₂ (hydrogen), CO (carbon monoxide), CH ₄ (methane), etc. It is preferable to use a reducing atmosphere. The reason for this is that even if the magnetic metal ribbon is oxidized, by performing heat treatment in a reducing atmosphere, the oxidized metal can be reduced and returned to metal. In this way, the magnetic metal ribbon whose saturation magnetization has decreased due to oxidation can be reduced and the saturation magnetization can be restored. Note that if the crystallization of the magnetic metal ribbon significantly progresses due to heat treatment, the coercive force will increase and the magnetic permeability will decrease, so conditions should be selected to suppress excessive crystallization. is preferred. Further, it is more preferable to perform the heat treatment in a magnetic field. The larger the applied magnetic field, the more preferable it is, but it is preferable to apply 1 kOe or more, more preferably 10 kOe or more. This is preferable because magnetic anisotropy can be developed within the plane of the magnetic metal ribbon and excellent magnetic properties can be achieved.

The third step is to crush the heat-treated magnetic metal ribbon to produce flat magnetic metal particles. In this step, before the main pulverization, the magnetic metal ribbon or thin film may be cut into appropriate sizes using a mixer device or the like. In this step, pulverization is performed using a pulverizer such as a bead mill or a planetary mill. Note that the type of crushing device is not particularly limited. Examples include a planetary mill, a bead mill, a rotary ball mill, a vibrating ball mill, an agitated ball mill (attritor), a jet mill, a centrifugal separator, or a method combining a mill and centrifugation. During pulverization, it is preferable to perform the pulverization while cooling at a temperature of 0° C. or lower, as this facilitates the progress of the pulverization. In particular, it is preferable to cool to liquid nitrogen temperature (77K), dry ice temperature (194K), etc. Among these, cooling to liquid nitrogen temperature is more preferable. As a result, the magnetic metal ribbon is susceptible to low-temperature brittleness and is easily pulverized. In other words, it is preferable because it allows efficient pulverization without applying excessive stress or strain to the magnetic metal ribbon. However, in many cases, the powder can be sufficiently pulverized even without cooling, and in that case, cooling is not necessary.

In addition, in the third step, the thickness of the flat magnetic metal particles can be reduced by not only simply pulverizing but also rolling. Incidentally, if the predetermined thickness is reached by the second step, the rolling process can be omitted. Here, rolling may be performed simultaneously, rolling after pulverization, or pulverization after rolling. In this case, it is preferable to use a device that can apply strong gravitational acceleration. It can be done using methods. For example, a high-power planetary mill device is preferable because it can easily apply gravitational acceleration of several tens of Gs. In the case of a high-power planetary mill device, it is more preferable to use an inclined planetary mill device in which the direction of rotational gravitational acceleration and the direction of orbital gravitational acceleration are not on the same straight line but at an angle. In normal planetary mill equipment, the direction of rotational gravitational acceleration and the direction of orbital gravitational acceleration are on the same straight line, but in tilted planetary mill equipment, the container performs rotational motion in an inclined state, so the rotational gravitational acceleration is The direction and the direction of the orbital gravitational acceleration are not on the same straight line but at an angle. This is preferable because power is efficiently transmitted to the sample and crushing and rolling proceed efficiently. Furthermore, in consideration of mass productivity, a bead mill device that can easily handle large quantities is preferred.

The above cutting, crushing and rolling are carried out (rolling is carried out as necessary. If unnecessary, it is not carried out), and in some cases, the cutting, crushing and rolling are repeated to obtain a flat magnetic metal with a predetermined thickness and aspect ratio. It is desirable to process it so that it becomes particles. At this time, it is preferable to crush and roll the particles to have a thickness of 10 nm or more and 100 μm or less, more preferably 10 nm or more and 1 μm or less, and still more preferably 10 nm or more and 100 nm or less, because the particles are likely to undergo rotational magnetization.
In order to achieve the degree of orientation of the flat magnetic metal particles as in this embodiment, it is effective to improve the slippage of the flat magnetic metal particles and increase their fluidity. Therefore, it is preferable that the average thickness of the flat magnetic metal particles is 10 μm or more and 30 μm or less, more preferably 10 μm or more and 20 μm or less, and the average value of the ratio of the average length to the thickness of the flat magnetic metal particles is 10 or more. It is preferably 100 or less, more preferably 10 or more and 50 or less.

Further, it is desirable that the obtained oblate magnetic metal particles be subjected to heat treatment to appropriately remove lattice distortion. 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, and the heat treatment atmosphere is a vacuum atmosphere with a low oxygen concentration, an inert atmosphere, or a reducing atmosphere. A reducing atmosphere such as H ₂ , CO, CH ₄ or the like is more preferable. Further, it is more preferable to perform the heat treatment in a magnetic field. The reasons and details are the same as in the second step, so explanations are omitted here.

Next, as a fourth step, the above-mentioned intervening phase and magnetic metal particles are mixed to form a mixed powder of the intervening phase and flat magnetic metal particles. Next, as a fifth step, the mixed powder of the intervening phase and magnetic metal particles is molded. Further, heat treatment may be performed before or after the above steps as appropriate. In other words, heat treatment may be performed before or at the same time as molding. Further, heat treatment may be performed before and after processing. The heat treatment conditions are as described above. Further, it is more preferable to perform the heat treatment in a magnetic field. The reasons and details are the same as in the second step, so explanations are omitted here.

Note that this fifth step is very important in order to obtain the magnetic wedge of this embodiment. In this fifth step, it is preferable to use a method of applying press pressure in a uniaxial direction, such as uniaxial press molding or hot press molding. FIG. 16 shows a schematic diagram of the fifth step in the method for manufacturing a magnetic wedge according to this embodiment. When press pressure is applied in a uniaxial direction, the flat magnetic metal particles tend to be stacked and oriented in the direction in which the press pressure is applied. Therefore, if simple uniaxial press molding is used, the flat magnetic metal particles will be stacked and oriented in one direction in the direction of application of press pressure, and the magnetic wedge of this embodiment cannot be obtained. Therefore, when applying press pressure in a uniaxial direction, a molding die that is magnetized in a direction parallel to the direction in which the press pressure is applied is used. Note that, generally, the distance (gap) between the mold die and the mold punch is very narrow, for example, about 5 μm. In this case, the flat magnetic metal particles become difficult to move inside the mold, and the structure of this embodiment cannot be obtained. Therefore, the distance between the mold die and the mold punch is adjusted appropriately. For example, in the case of flat magnetic metal particles having an average thickness of 10 to 20 μm and an average ratio of the average length in the flat plane to the thickness of about 10 to 50, a gap of about 50 μm is provided. By providing such a gap, the fluidity of the intervening phase increases and flows out from the gap appropriately, discharging the voids contained in the magnetic material. Further, at this time, the flat magnetic metal particles are oriented while moving inside the mold, and the flat magnetic metal particles are attracted to the magnetized mold punch, causing local segregation. On the other hand, if the gap between the mold die and the mold punch of the hot press is too large, the intervening phase will flow out too much and the amount of the intervening phase contained in the magnetic material will decrease, which is not preferable. Therefore, it is important to appropriately set the distance (gap) between the mold die and the mold punch. In the case of flat magnetic metal particles with an average thickness of 10 to 20 μm and an average ratio of the average length in the flat plane to the thickness of about 10 to 50, it is preferable that the gap is greater than 5 and 100 μm or less. More preferably, the thickness is 10 or more and 80 μm or less (more preferably around 50 μm). However, if the size of the flat magnetic metal particles (average thickness, average ratio of the average length in the flat plane to the thickness) changes, the optimal gap range may change, and the type of intervening phase, The optimal gap range may change depending on the molding conditions such as temperature, pressure, time, etc., so this is only a guideline, and the actual size of flat magnetic metal particles, type of intervening phase, temperature, pressure, time, etc. of molding Appropriate settings are made depending on the conditions.

Further, a magnetic field is applied in a direction parallel to the direction in which the press pressure is applied. As a result, in the center of the magnetic wedge after molding, the flat magnetic metal particles are stacked and oriented in the direction of application of press pressure, while at the ends, the flat magnetic metal particles are stacked in a direction perpendicular to the direction of application of press pressure. It becomes easier to orient. Note that in order to easily achieve such orientation, hot press molding or the like is performed while applying a magnetic field. In other words, it is molded while applying heat, magnetic field, and press pressure simultaneously. The hot pressing temperature is preferably 50°C or higher and 1000°C or lower, more preferably 50°C or higher and 800°C or lower. The larger the applied magnetic field is, the more preferable it is, but it is preferable to apply 1 kOe or more, more preferably 10 kOe or more. The press pressure is preferably 1 MPa or more and 100 MPa or less, more preferably 1 MPa or more and 10 MPa or less. Furthermore, after molding, heat treatment is performed while applying a magnetic field in a direction perpendicular to the direction of application of press pressure. These make it easier to achieve the above-mentioned orientation.

When measuring the coercive force depending on the direction in a plane parallel to the flat plane of the flat magnetic metal particles that the magnetic wedge has, for example, the direction is changed every 22.5 degrees for a 360 degree angle in the plane. and measure the coercive force.

By having a coercive force difference within the plane of the magnetic wedge, the minimum coercive force value is smaller than in an isotropic case where there is almost no coercive force difference, which is preferable. In a material that has magnetic anisotropy within a plane, the coercive force differs depending on the direction within the plane, and the minimum coercive force value is smaller than that of a magnetically isotropic material. This reduces hysteresis loss and improves magnetic permeability, which is preferable.

In a plane parallel to the flat surface of the flat magnetic metal particle that the magnetic wedge has, the greater the percentage of the coercive force difference due to direction, the more preferable, and it is preferably 1% or more. More preferably, the percentage of the coercive force difference is 10% or more, even more preferably, the percentage of the coercive force difference is 50% or more, and even more preferably, the percentage of the coercive force difference is 100% or more. The percentage of the coercive force difference here is defined as (Hc(max)-Hc(min))/Hc(min)x100(%), using the maximum coercive force Hc(max) and the minimum coercive force Hc(min) in the flat surface.

Note that the coercive force can be easily evaluated using a vibrating sample magnetometer (VSM) or the like. If the coercive force is low, by using a low magnetic field unit, it is possible to measure coercive forces of 0.1 Oe or less. Measurement is performed by changing the direction in the plane of the magnetic wedge (in a plane parallel to the flat plane of the flat magnetic metal particles) with respect to the direction of the measurement magnetic field.

When calculating the coercive force, the value obtained by dividing the difference between the magnetic fields at two points intersecting the horizontal axis (the magnetic fields H1 and H2 where magnetization becomes zero) by 2 (that is, the coercive force = | H2 - It can be calculated as H1|/2).

The intervening phase contains at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N) and fluorine (F). This is because it is possible to increase the resistance. The electrical resistivity of the intervening phase is preferably higher than the electrical resistivity of the flat magnetic metal particles. This is because it is possible to reduce the eddy current loss of the flat magnetic metal particles. Since the intervening phase exists surrounding the flat magnetic metal particles, it is preferable that it can improve the oxidation resistance and thermal stability of the flat magnetic metal particles. Among these, those containing oxygen are more preferable from the viewpoint of high oxidation resistance and high thermal stability. Since the intervening phase also plays a role in mechanically bonding the flat magnetic metal particles to each other, it is also preferable from the viewpoint of high strength.

Preferably, the intervening phase contains a resin. Examples of resins include thermoplastic resins, thermosetting resins, polyester resins, vinyl ester resins, polyethylene resins, polystyrene resins, polyvinyl chloride resins, polyvinyl butyral resins, polyvinyl alcohol resins, polybutadiene resins, and 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, phenolic resin, allyl resin, polybenzo resin Imidazole resin, amide resin, polyimide resin, polyamideimide resin, bismaleimide resin, or copolymers thereof are used. In particular, in order to achieve high thermal stability, it is preferable to include a silicone resin, polyimide resin, imide resin, or bismaleimide resin with high heat resistance. Epoxy resins, phenol resins, and polyester resins are preferable because they are relatively high heat resistant, high strength, and versatile resins. In addition, to increase strength, FRP (Fiber-Reinforced Plastics) is a mixture of fibers such as glass fiber, aramid fiber (Kevlar (registered trademark) fiber), carbon fiber, Zylon fiber, polyethylene fiber (Dyneema), and boron fiber. Materials such as fiber-reinforced plastics are also preferred. As a result, the bond 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. Furthermore, since the intervening phase surrounds the flat magnetic particles, the oxidation resistance is excellent, and deterioration of magnetic properties due to oxidation of the flat magnetic metal particles is less likely to occur, which is preferable. The type of resin can be identified by IR (Infrared Spectroscopy), NMR (Nuclear Magnetic Resonance), or the like.

Bismaleimide-based resins are preferable because they can be molded at a relatively low temperature (for example, 180° C. or lower) and can be molded using a general-purpose low-temperature hot press machine. In addition, it is preferable in terms of properties after molding because it can achieve high thermal stability and excellent mechanical properties. Furthermore, it is easy to combine (join) with flat magnetic metal particles, and it is easy to achieve excellent mechanical properties such as thermal stability, strength, and toughness as a composite material, which is preferable. Further, the intervening phase easily surrounds the flat magnetic particles, and deterioration of magnetic properties due to oxidation of the flat magnetic metal particles is less likely to occur, which is preferable.

It is preferable that the bismaleimide resin has a glass transition temperature of 250° C. or higher. This increases thermal stability and strength, which is preferable.

Specific examples of bismaleimide resins include 4,4'-diphenylmethane bismaleimide, phenylmethane maleimide, m-phenylene bismaleimide, bisphenol A diphenyl ether bismaleimide, 3,3'-dimethyl-5,5'-diethyl-4,4'-diphenylmethane bismaleimide, 4-methyl-1,3-phenylene bismaleimide, 1,6'-bismaleimide-(2,2,4-trimethyl)hexane, 2,2'-diallyl bisphenol A, 4, It is preferable to include 4'-diphenylether bismaleimide, 4,4'-diphenylsulfone bismaleimide, 1,3-bis(3-maleimidophenoxy)benzene, 1,3-bis(4-maleimidophenoxy)benzene, bis(3-ethyl-5-methyl-4-maleimidophenyl)methane, 2,2'-bis[4-(4-maleimidophenoxy)phenyl]propane, etc. (The resin is made by polymerizing monomers, and it is preferable to include the above as monomers.) This increases the thermal stability and strength, making it preferable.

Further, as a curing agent for curing the monomer, 4,4'-diaminodiphenylmethane, diaminodiphenyl ether, diaminodiphenylsulfone, 2,2-bis[4-(4-aminophenoxy)phenyl]propane, o,o' - It is preferable to contain diallylbisphenol A or the like. However, the curing agent may be of any other type as long as it is used to appropriately cure the monomer.

Preferred combinations of monomers and curing agents include, for example, 4,4'-diphenylmethane bismaleimide and 4,4'-diaminodiphenylmethane. In addition, when 4,4'-diphenylmethane bismaleimide and 4,4'-diaminodiphenylmethane are included, the ratio of 4,4'-diphenylmethane bismaleimide to 4,4'-diaminodiphenylmethane is 1 or more and 3 or less. is preferable, and more preferably about 2. The above ratio is preferable because thermal stability, strength, etc. are high.

The molecular weight of the intervening phase (resin) is preferably 100 or more and 1000 or less. This increases thermal stability and strength, which is preferable.

（２）

（３） The polyimide resin preferably contains a repeating unit represented by the following chemical formula (1).
(1)
In chemical formula (1), R preferably includes a biphenyl, triphenyl, or tetraphenyl structure. R' preferably represents a structure having at least one aromatic ring within the structure.
Moreover, it is more preferable that the polyimide resin has the following structural formula (2) or (3).

(2)

(3)

As described above, according to the present embodiment, the magnetic wedge is a magnetic wedge of a rotating electric machine, and the magnetic wedge includes a plurality of flat magnetic metal particles and an intervening phase, and the magnetic wedge is provided with a plurality of flat magnetic metal particles and an intervening phase, and the The flat surfaces of the plurality of flat magnetic metal particles are oriented in the width direction and the longitudinal direction, the flat surfaces are oriented in the thickness direction and the longitudinal direction at the ends in the width direction, and the flat surfaces are oriented in the thickness direction and the longitudinal direction at the ends in the width direction, and The average orientation angle of the plurality of flat magnetic metal particles is 20 degrees or less, and the average orientation angle of the plurality of flat magnetic metal particles at the ends in the width direction is 30 degrees or more and 90 degrees or less. Further, the magnetic wedge is the magnetic wedge of a radial gap type rotating electric machine in which a stator is disposed facing a rotor at a predetermined interval in a radial direction, and the longitudinal direction is an axial direction, and The thickness direction is the radial direction, and the width direction is the rotation direction. Further, the magnetic wedge is the magnetic wedge used in an axial gap type rotating electric machine in which a stator is disposed facing a rotor at a predetermined interval in the axial direction, and the longitudinal direction is the radial direction. , the thickness direction is the axial direction, and the width direction is the rotation direction. The orientation angle at the center is 20 degrees or less, and the orientation angle at the ends is 30 degrees or more and 90 degrees or less, so the magnetic property has excellent magnetic properties such as low magnetic loss and excellent mechanical properties such as high strength. It becomes possible to provide wedges.

(Second embodiment)
The rotating electrical machine of this embodiment includes the magnetic wedge of the first embodiment. Therefore, description of content that overlaps with the first embodiment will be omitted. In this specification, the term "rotating electric machine" refers to a concept that includes any of an electric motor, a generator, and, if necessary, a motor/generator that functions as both a motor and a generator.

FIG. 17 is an example of the radial gap type motor of this embodiment. A radial gap type motor has a rotor and a stator that is arranged to face the rotor with a predetermined gap in the radial direction. In FIG. 17, the rotor is placed inside the stator, but it may be placed outside. The rotor includes a rotor core and a shaft, and is rotatably supported. On the other hand, the stator includes a stator core, a field coil inserted into a slot in the stator core, and a magnetic wedge held in a wedge groove in a slot opening.

Figure 17 shows an example in which the magnetic wedges of the first embodiment are arranged, but is not limited to this. In the case of a radial gap type rotating electric machine, the stator is arranged facing the rotor at a predetermined radial distance, so the "gap surface" is a surface parallel to a cylindrical surface centered on the rotation axis of the rotor. Therefore, the radial direction is perpendicular to the gap surface, and the axial direction and rotation direction are parallel to the gap surface. Figure 17 shows flat magnetic metal particles 10, intervening phase 20, magnetic wedge 100, rotating electric machine 200, rotor 210, stator 220, coil 230, gap surface 240, and iron core teeth 250.

By arranging the magnetic wedges of the first embodiment, it is possible to reduce harmonic losses occurring on the rotor surface while suppressing leakage flux. In addition, the magnetic flux passing through the air gap increases, so the torque of the radial gap motor is increased. High efficiency can be achieved by either or both of the above loss reduction effect and torque increase effect.

Note that radial gap motors include those with a conductor in the rotor (induction motor), permanent magnets (permanent magnet motor), and magnetic materials (reluctance motor). I do not care.

Figure 18 shows an example of an axial gap motor according to this embodiment. The axial gap motor has a rotor and a stator arranged facing the rotor across a predetermined gap in the axial direction. The stator includes a stator core, a field coil inserted into the slot of the stator core, and a magnetic wedge held in the wedge groove at the slot opening. By arranging the magnetic wedge according to this embodiment, it is possible to reduce harmonic loss occurring on the rotor surface while suppressing an increase in leakage flux. Furthermore, because the magnetic flux passing through the gap increases, the torque of the axial gap motor is increased. As a result, high efficiency can be achieved.

In FIG. 18, the rotor is arranged between two stators, but it may be arranged on one side or both sides of one stator. In the case of an axial gap type rotating electric machine, the stator is disposed facing the rotor at a predetermined distance in the axial direction, so the "gap surface" is a surface perpendicular to the rotation axis of the rotor. Therefore, the axial direction is perpendicular to the gap surface, and the rotational direction and the radial direction are parallel to the gap surface. In FIG. 18, flat magnetic metal particles 10, an intervening phase 20, a magnetic wedge 100, a rotating electric machine 200, a rotor 210, a coil 230, a gap surface 240, an iron core tooth 250, a stator 270, and a shaft 280 are shown.

Figure 19 is a schematic diagram showing an example of a generator of this embodiment. A generator usually has a rotor that houses an excitation coil in the slots of the rotor core (otherwise, a rotor with a permanent magnet as an excitation source may be adopted) and a stator that houses an armature coil in the slots of the stator core, and generates power in the armature coil by rotating the rotor and passing an excitation current through the excitation coil. The rotor has a rotor core, a field coil inserted in the slots of the rotor core, and a magnetic wedge held in the wedge groove at the slot opening, and is supported by bearings so that it can rotate. By arranging the magnetic wedge of this embodiment, it is possible to reduce harmonic loss generated on the stator surface while suppressing an increase in leakage magnetic flux. In addition, since the magnetic flux that passes through the air gap and interlinks with the armature coil increases, the generated voltage induced in the armature coil increases. As a result, high efficiency can be achieved.

In FIG. 19, the magnetic wedge is placed at the slot opening of the rotor core, but it may be placed at the slot opening of the stator core. Also, the figure shows a winding type generator with an excitation coil in the rotor, but it may be a permanent magnet type generator with a permanent magnet in the rotor. In this case, the magnetic wedge is placed at the slot opening of the stator core. In FIG. 19, flat magnetic metal particles 10, intervening phase 20, magnetic wedge 100, rotating electric machine 200, rotor 210, stator core 222, excitation coil 232, armature coil 234, gap surface 240, and core teeth 250 are shown.

Since a linear motor is a radial gap type motor developed into a flat plate-like structure, the magnetic wedge of the present invention can also be applied to a linear motor. That is, the stator may include a stator core and a field coil inserted into a slot of the stator core, and a magnetic wedge may be provided in the slot opening. FIG. 20 is a schematic diagram showing an example of the linear motor of this embodiment. In a linear motor, the moving direction of the mover, the direction perpendicular to the moving direction of the mover, and the direction perpendicular to the stator correspond to the rotational direction, axial direction, and radial direction of the radial gap type motor, respectively. By arranging the magnetic wedge of this embodiment, it is possible to reduce harmonic loss occurring on the surface of the movable element while suppressing an increase in leakage magnetic flux. Furthermore, since the magnetic flux passing through the air gap increases, the thrust of the linear motor is improved. With the above, high efficiency can be achieved. In FIG. 20, the flat magnetic metal particles 10, the intervening phase 20, the magnetic wedge 100, the stator 220, the coil 230, the gap surface 240, the iron core teeth 250, and the mover 290 are shown.

As described above, according to the rotating electrical machine of this embodiment, it is possible to suppress the increase in leakage magnetic flux due to the use of magnetic wedges and effectively alleviate the pulsation of the magnetic flux distribution on the surface of the iron core, thereby achieving high efficiency. . Note that the slot shape of the rotating electrical machine of this embodiment may be a semi-closed slot (or semi-closed slot), but is preferably an open slot (or an open slot, an open slot). At this time, harmonic loss can be significantly reduced, which is preferable.

The rotating electric machine of this embodiment can be applied to transportation systems such as railways, electric vehicles, and hybrid cars, social systems such as elevators and air conditioners, industrial systems such as robots, pumps, compressors, and blowers, energy systems such as thermal power generators, hydroelectric generators, wind power generators, nuclear power generators, and geothermal generators, and home appliances such as washing machines, and can improve the efficiency of the system. In particular, in large-capacity industrial machines, open slots are generally used as the slot shape, so it is preferable to have the magnetic wedge of the first embodiment. In addition, main motors for railways use form-wound coils because they need to withstand high voltages and vibrations, and open slots are used as the slot shape, so it is preferable to have the magnetic wedge of the first embodiment.

In railways, the loss in rotating electric machines accounts for about half of the power consumed when the train is running, so reducing the loss in rotating electric machines has a significant effect on improving efficiency. Also, in electric vehicles and hybrid cars, the efficiency of the main motor can be improved by using the magnetic wedge of the first embodiment, thereby extending the cruising distance.

As for generators, great effects are expected for hydroelectric generators, especially variable speed pumped storage generators. It is also expected to have great effects on wind power generators.

(Example)
Below, Examples 1 to 7 will be explained in more detail while comparing them with Comparative Examples 1 to 6. Incidentally, a schematic diagram of the arrangement of the flat magnetic metal particles in the magnetic wedges of Example 1 and Comparative Examples 1 to 4 is shown in FIG.

(Example 1)
First, a ribbon of Fe-Co-Si-B (Fe70Co30B25(at%)-4wt%Si) is produced using a single roll quenching device. Next, the obtained ribbon is heat-treated at 300° C. in an H ₂ atmosphere. Next, this ribbon was crushed using a mixer device to obtain flat magnetic metal particles (the average thickness was about 15 μm, and the average ratio of the average length in the flat plane to the thickness was about 30). ). Thereafter, the obtained flat magnetic metal particles are mixed with an imide resin (polyimide resin) and molded. Molding is performed according to FIG. That is, the mold used for molding is one that is magnetized in a direction parallel to the direction in which press pressure is applied. The gap between the mold die and the mold punch was approximately 50 μm. Furthermore, when applying press pressure in a uniaxial direction, a magnetic field is applied in a direction parallel to the direction in which the press pressure is applied. Thereafter, hot press molding was performed, and after the molding, heat treatment was performed while applying a magnetic field in a direction perpendicular to the direction of application of press pressure to produce a magnetic wedge. Note that the cross-sectional shape of the magnetic wedge was made to be rectangular. The width direction of the magnetic wedge is the x direction, the length direction is the y direction, and the thickness direction is the z direction. In the produced magnetic wedge, the orientation angle of the above-mentioned flat magnetic metal particles was measured. In the measurement, the orientation angles of all the flat magnetic metal particles included in the center and edges of the observation range were determined, and the average value was used. In addition, evaluation was performed on three cross sections to be observed, and the average value was adopted. As a result, it was confirmed that the orientation angle was 5 degrees (satisfied 20 degrees or less) at the center, and 33 degrees (satisfied 30 degrees or more and 90 degrees or less) at the ends. Incidentally, it was confirmed that the orientation angle at the end is 33 degrees, which is the same as the orientation angle with respect to the contour line in the thickness direction.

(Example 2)
It is almost the same as Example 1 except that the resin used for molding is bismaleimide resin. The ratio of 4,4'-diphenylmethane bismaleimide to 4,4'-diaminodiphenylmethane was 2. It was confirmed that the orientation angle was 5 degrees (satisfied 20 degrees or less) at the center and 34 degrees (satisfied 30 degrees or more and 90 degrees or less) at the ends. Incidentally, it was confirmed that the orientation angle at the end is 34 degrees, which is the same as the orientation angle with respect to the contour line in the thickness direction.

(Example 3)
This example is almost the same as Example 2 except that the cross-sectional shape (cross-section in the xz plane) of the magnetic wedge is trapezoidal. The orientation angle at the center should be approximately 4 degrees (20 degrees or less), and the degree of orientation at the edges should be approximately 37 degrees (60 degrees or less) with respect to the contour line in the thickness direction. confirmed.

Example 4
Other than making the cross-sectional shape of the magnetic wedge (cross-section in the xz plane) convex, it is almost the same as Example 2. It was confirmed that the orientation angle at the center was about 5 degrees (satisfying 20 degrees or less), and the orientation degree at the end was about 38 degrees (satisfying 60 degrees or less) with respect to the contour line in the thickness direction.

(Example 5)
This example is almost the same as Example 2 except that the cross-sectional shape (cross-section in the xz plane) of the magnetic wedge is hexagonal. The orientation angle at the center should be approximately 4 degrees (20 degrees or less), and the degree of orientation at the edges should be approximately 30 degrees (60 degrees or less) with respect to the contour line in the thickness direction. confirmed.

(Example 6)
It is almost the same as Example 2 except that the ratio of 4,4'-diphenylmethane bismaleimide to 4,4'-diaminodiphenylmethane is 1. It was confirmed that the orientation angle was 5 degrees (satisfied 20 degrees or less) at the center and 34 degrees (satisfied 30 degrees or more and 90 degrees or less) at the ends. Incidentally, it was confirmed that the orientation angle at the end is 34 degrees, which is the same as the orientation angle with respect to the contour line in the thickness direction.

(Example 7)
It is almost the same as Example 2 except that the ratio of 4,4'-diphenylmethane bismaleimide to 4,4'-diaminodiphenylmethane is 3. It was confirmed that the orientation angle was 5 degrees (satisfied 20 degrees or less) at the center and 34 degrees (satisfied 30 degrees or more and 90 degrees or less) at the ends. Incidentally, it was confirmed that the orientation angle at the end is 34 degrees, which is the same as the orientation angle with respect to the contour line in the thickness direction.

(Comparative Example 1)
A commercially available magnetic wedge was used as the magnetic wedge in which spherical magnetic metal particles were dispersed. This material is a material in which Fe powder is isotropically dispersed three-dimensionally.

(Comparative example 2)
The molding method was simple hot press molding (using a non-magnetized mold, no magnetic field applied), and cutting was performed to create a magnetic wedge in which the flat magnetic metal particles were stacked and oriented in the y direction. Same as Example 1.

(Comparative example 3)
The molding method is simple hot press molding (using a non-magnetized mold, no magnetic field applied), and cutting is performed to create a magnetic wedge in which flat magnetic metal particles are laminated and oriented in the z direction. Same as Example 1.

(Comparative example 4)
The molding method is simple hot press molding (using a non-magnetized mold, no magnetic field applied), and cutting is performed to create a magnetic wedge in which the flat magnetic metal particles are laminated and oriented in the x direction. Same as Example 1.

(Comparative example 5)
It is almost the same as Example 2 except that the ratio of 4,4'-diphenylmethane bismaleimide to 4,4'-diaminodiphenylmethane is 0.7. It was confirmed that the orientation angle was 5 degrees (satisfied 20 degrees or less) at the center and 34 degrees (satisfied 30 degrees or more and 90 degrees or less) at the ends. Incidentally, it was confirmed that the orientation angle at the end is 34 degrees, which is the same as the orientation angle with respect to the contour line in the thickness direction.

(Comparative Example 6)
The ratio of 4,4'-diphenylmethane bismaleimide to 4,4'-diaminodiphenylmethane was 3.3, which was almost the same as Example 2. It was confirmed that the orientation angle at the center was 5 degrees (satisfying 20 degrees or less), and the orientation angle at the end was 34 degrees (satisfying 30 degrees or more and 90 degrees or less). Incidentally, it was confirmed that the orientation angle at the end with respect to the contour line in the thickness direction was also the same 34 degrees.

Table 1 shows the cross-sectional shape of the magnetic wedge in this embodiment, the type of resin, and the ratio of 4,4'-diphenylmethane bismaleimide to 4,4'-diaminodiphenylmethane, along with Comparative Examples 1 to 6.

Table 2 shows the magnetic properties of the magnetic wedge of this embodiment, the flexural strength as a mechanical property, the flexural strength after heat resistance testing as a thermomechanical property, and the degree of efficiency improvement as a rotating electric machine, along with comparative examples 1 to 6.

(1) Iron loss: Using a BH analyzer, measure the iron loss under operating conditions of 100 Hz and 1 T. If direct measurement under conditions of 100 Hz and 1 T is not possible, measure the frequency dependence and magnetic flux density dependence of iron loss, and estimate the iron loss at 100 Hz and 1 T from that data (and use this estimated value). Iron loss is shown as a ratio based on the iron loss of Comparative Example 1.

(2) Magnetic permeability: Measure the magnetic permeability at 100 Hz. The magnetic permeability is shown as a ratio based on the iron loss of Comparative Example 1.

(3) Degree of efficiency improvement as a rotating electric machine: Using a standard radial gap type motor as a motif, the efficiency improvement range is calculated based on the efficiency when using a non-magnetic wedge. The degree of efficiency improvement is shown as a ratio based on the width of efficiency improvement in Comparative Example 1.

(4) Strength: Measure the bending strength of the evaluation sample at 25°C, and compare it to the bending strength of the sample of Comparative Example 1 at 25°C (= bending strength of the evaluation sample at 25°C/ The bending strength of the sample of Comparative Example 1 at 25°C) is shown.

(5) Strength after heat resistance test: After heating the evaluation sample at 220°C in the air for 100 hours (heat resistance test), the bending strength was measured at 25°C, and the sample of Comparative Example 1 was heated at 220°C in the air for 100 hours. Ratio to the bending strength at 25°C after heating (= bending strength at 25°C after heating at 220°C in the air for 100 hours of the evaluation sample / after heating at 220°C in the air for 100 hours in Comparative Example 1) It is expressed as the bending strength at 25°C).

From Table 2, compared to Comparative Example 1, in Comparative Examples 2, 3, and 4, the loss is reduced in all x, y, and z directions, and the magnetic permeability is improved, but the improvement width is different depending on the direction. There are fewer directions. Comparative Example 2 has a small improvement in the y direction, Comparative Example 3 has a small improvement in the z direction, and Comparative Example 4 has a small improvement in the x direction. Further, the degree of efficiency improvement as a rotating electric machine is large in Comparative Example 2, but small in Comparative Examples 3 and 4. The main causes of this are that in Comparative Example 3, the amount of magnetic flux leaking between the teeth increases, and in Comparative Example 4, the amount of magnetic flux leaking in the axial direction increases. Further, regarding the strength, Comparative Example 2 has a low strength in the y direction, Comparative Example 3 has a low strength in the z direction, and Comparative Example 4 has a low strength in the x direction. Furthermore, the strength after the heat resistance test also has a generally similar tendency. In contrast, in Example 1, by changing the orientation angle of the flat magnetic metal particles between the center and the edges, excellent magnetic properties (low loss, high magnetic permeability) and excellent magnetic properties were obtained regardless of the direction. It can be seen that mechanical properties (such as high strength) can be achieved. In other words, the flat magnetic metal particles are stacked and oriented in the z-direction at the center, and the flat magnetic metal particles are stacked and oriented in the x-direction at the ends, thereby averaging the magnetic properties and mechanical properties three-dimensionally. , y-direction, and z-direction. Similarly, in Example 2, although the strength and the strength after the heat resistance test are slightly inferior to those in Example 1, it can be seen that it has generally the same excellent properties. Furthermore, in Examples 3 to 5, the cross-sectional shape (cross-section in the xz plane) of the magnetic wedge was changed to a trapezoidal shape, a convex shape, and a hexagonal shape, but compared to the rectangular shape of Example 2, It can be seen that they have almost the same excellent characteristics. In Examples 6 and 7, the ratio of 4,4'-diphenylmethane bismaleimide to 4,4'-diaminodiphenylmethane was changed to 1 or 3, but the ratio was slightly lower than that of Example 2 with a ratio of 2. It can be seen that although the strength and the strength after the heat resistance test are inferior, they have generally the same excellent characteristics. On the other hand, in Comparative Examples 5 and 6, the ratio of 4,4'-diphenylmethane bismaleimide to 4,4'-diaminodiphenylmethane was changed to 0.7 and 3.3. It can also be seen that the strength after the heat resistance test is significantly inferior. That is, it can be seen that the ratio of 4,4'-diphenylmethane bismaleimide to 4,4'-diaminodiphenylmethane is preferably 1 to 3, with 2 being the most preferred.

Although several embodiments and examples of the invention have been described, these embodiments and examples are presented by way of example and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and changes can be made without departing from the gist of the invention. These embodiments and their modifications are included within the scope and gist of the invention, as well as within the scope of the invention described in the claims and its equivalents.

The above-described embodiments can be summarized as the following technical solutions.
(Technical proposal 1)
A magnetic wedge for a rotating electric machine,
The magnetic wedge comprises a plurality of flat magnetic metal particles and an intervening phase;
A magnetic wedge, wherein the flat surfaces of the multiple flat magnetic metal particles at the widthwise center of the magnetic wedge are oriented along the widthwise contour line, and the flat surfaces at the widthwise ends are oriented along the thicknesswise contour line of the magnetic wedge, the average orientation angle of the multiple flat magnetic metal particles with respect to the widthwise contour line at the widthwise center is 20 degrees or less, and the average orientation angle of the multiple flat magnetic metal particles with respect to the thicknesswise contour line at the widthwise ends is 60 degrees or less.
(Technical proposal 2)
A magnetic wedge for a rotating electric machine,
The magnetic wedge comprises a plurality of flat magnetic metal particles and an intervening phase;
A magnetic wedge in which the flat surfaces of the multiple flat magnetic metal particles are oriented in the width direction and the longitudinal direction at the center of the magnetic wedge in the width direction, and the flat surfaces are oriented in the thickness direction and the longitudinal direction at the ends of the magnetic wedge in the width direction, the average orientation angle of the multiple flat magnetic metal particles at the center in the width direction is 20 degrees or less, and the average orientation angle of the multiple flat magnetic metal particles at the ends in the width direction is 30 degrees or more and 90 degrees or less.
(Technical proposal 3)
A magnetic wedge according to Technical Scheme 1 or 2, wherein a cross section perpendicular to the length direction of the magnetic wedge is at least one selected from the group consisting of a trapezoidal shape, a convex shape, a hexagonal shape, and a rectangular shape.
(Technical proposal 4)
The magnetic wedge is for a radial gap type rotating electric machine in which a stator is disposed facing a rotor at a predetermined radial distance,
The longitudinal direction is an axial direction,
The thickness direction is the radial direction,
The width direction is a rotation direction.
A magnetic wedge according to any one of technical proposals 1 to 3.
(Technical proposal 5)
The magnetic wedge is used in an axial gap type rotating electric machine in which a stator is disposed facing a rotor with a predetermined axial gap therebetween,
The longitudinal direction is a radial direction,
The thickness direction is the axial direction,
The width direction is a rotation direction.
A magnetic wedge according to any one of technical proposals 1 to 3.
(Technical proposal 6)
The flat magnetic metal particles have an average thickness of 10 nm or more and 100 μm or less, the flat surfaces and a magnetic metal phase containing at least one first element selected from the group consisting of Fe, Co and Ni, and the average ratio of the average length within the flat surfaces to the thickness is 5 or more and 10,000 or less,
The intervening phase is present between the flat magnetic metal particles and contains at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N) and fluorine (F);
A magnetic wedge according to any one of technical proposals 1 to 5.
(Technical proposal 7)
A magnetic wedge as described in technical proposal 6, wherein the average thickness of the plurality of flat magnetic metal particles is 10 μm or more and 30 μm or less, and the average value of the ratio of the average length to the thickness of the flat magnetic metal particles is 10 or more and 100 or less.
(Technical proposal 8)
A magnetic wedge according to technical proposal 1 or 2, wherein the intervening phase contains a resin.
(Technical proposal 9)
The magnetic wedge according to technical proposal 8, wherein the resin is a bismaleimide resin.
(Technical proposal 10)
The magnetic wedge according to Technical Solution 9, wherein the bismaleimide resin comprises 4,4'-diphenylmethane bismaleimide.
(Technical proposal 11)
The magnetic wedge according to technical proposal 10, wherein the bismaleimide resin comprises 4,4'-diphenylmethane bismaleimide and 4,4'-diaminodiphenylmethane, and the ratio of 4,4'-diphenylmethane bismaleimide to 4,4'-diaminodiphenylmethane is 1 to 3.
(Technical proposal 12)
A magnetic wedge according to any one of Technical Schemes 9 to 11, wherein the glass transition temperature of the bismaleimide resin is 250° C. or higher.
(Technical proposal 13)
A magnetic wedge according to any one of technical proposals 8 to 12, wherein the molecular weight of the resin is 100 or more and 1,000 or less.
(Technical proposal 14)
A magnetic wedge described in any one of Technical Proposals 1 to 13, wherein at least a portion of the surface of the flat magnetic metal particle is covered with a coating layer having a thickness of 0.1 nm or more and 1 μm or less and containing at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N) and fluorine (F).
(Technical proposal 15)
A magnetic wedge according to any one of technical solutions 1 to 14, having a difference in coercive force depending on the direction within a plane parallel to the flat surface.
(Technical proposal 16)
A rotating electric machine equipped with the magnetic wedge described in any one of technical proposals 1 to 15.

6: Flat surface 9: Coating layer 10: Flat magnetic metal particles 20: Intervening phase 100: Magnetic wedge 200: Rotating electric machine 210: Rotor 220: Stator 222: Stator core 230: Coil 232: Excitation coil 234: Armature Coil 240: Gap surface 250: Core teeth 260: Core slot 270: Stator 280: Shaft 290: Mover

Claims (16)

A magnetic wedge for a rotating electric machine,
The magnetic wedge includes a plurality of flat magnetic metal particles and an intervening phase,
At the widthwise center of the magnetic wedge, the flat surfaces of the plurality of flat magnetic metal particles are oriented along the widthwise contour line, and at the widthwise ends, the flat surfaces are aligned with the thickness of the magnetic wedge. the plurality of flat magnetic metal particles are oriented along a contour line in the width direction, and the average orientation angle of the plurality of flat magnetic metal particles with respect to the contour line in the width direction at the center portion in the width direction is 20 degrees or less; A magnetic wedge, wherein the average orientation angle of the plurality of flat magnetic metal particles with respect to the contour line in the thickness direction in the section is 60 degrees or less. A magnetic wedge for a rotating electric machine,
The magnetic wedge includes a plurality of flat magnetic metal particles and an intervening phase,
At the widthwise center of the magnetic wedge, the flat surfaces of the plurality of flat magnetic metal particles are oriented in the width direction and the longitudinal direction, and at the widthwise ends of the magnetic wedge, the flat surfaces are oriented in the thickness direction and the longitudinal direction. The plurality of flat magnetic metal particles are oriented in the longitudinal direction, the average orientation angle of the plurality of flat magnetic metal particles at the center portion in the width direction is 20 degrees or less, and the plurality of flat magnetic metal particles at the end portions in the width direction are oriented in the width direction. A magnetic wedge whose average orientation angle is 30 degrees or more and 90 degrees or less. 3. The magnetic wedge according to claim 1, wherein the cross section perpendicular to the longitudinal direction of the magnetic wedge is at least one selected from the group consisting of a trapezoidal shape, a convex shape, a hexagonal shape, and a rectangular shape. The magnetic wedge is for a radial gap type rotating electric machine in which a stator is disposed facing a rotor at a predetermined radial distance,
The longitudinal direction is an axial direction,
The thickness direction is the radial direction,
The width direction is a rotation direction.
3. The magnetic wedge according to claim 1 or 2. The magnetic wedge is used in an axial gap type rotating electric machine in which a stator is disposed facing a rotor with a predetermined axial gap therebetween,
The longitudinal direction is a radial direction,
The thickness direction is the axial direction,
The width direction is a rotation direction.
3. The magnetic wedge according to claim 1 or 2. The plurality of flat magnetic metal particles have an average thickness of 10 nm or more and 100 μm or less, and a magnetic metal phase containing the flat plane and at least one first element selected from the group consisting of Fe, Co, and Ni; and the average value of the ratio of the average length in the flat plane to the thickness is 5 or more and 10,000 or less,
The intervening phase exists between the plurality of flat magnetic metal particles and contains at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F). include,
The magnetic wedge according to claim 1 or claim 2. The magnetic material according to claim 6, wherein the average thickness of the plurality of flat magnetic metal particles is 10 μm or more and 30 μm or less, and the average value of the ratio of the average length to the thickness of the flat magnetic metal particles is 10 or more and 100 or less. wedge. The magnetic wedge according to claim 1 or claim 2, wherein the intervening phase contains a resin. The magnetic wedge according to claim 8, wherein the resin is a bismaleimide resin. The magnetic wedge according to claim 9, wherein the bismaleimide resin comprises 4,4'-diphenylmethane bismaleimide. The bismaleimide resin contains 4,4'-diphenylmethane bismaleimide and 4,4'-diaminodiphenylmethane, and the ratio of 4,4'-diphenylmethane bismaleimide to 4,4'-diaminodiphenylmethane is 1 or more and 3 or less. The magnetic wedge according to claim 10. The magnetic wedge according to claim 9, wherein the bismaleimide resin has a glass transition temperature of 250°C or higher. The magnetic wedge according to claim 8, wherein the resin has a molecular weight of 100 or more and 1000 or less. At least a part of the surface of the flat magnetic metal particles has a thickness of 0.1 nm or more and 1 μm or less, and contains at least one member selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F). 3. The magnetic wedge according to claim 1, wherein the magnetic wedge is covered with a coating layer containing two second elements. 3. The magnetic wedge according to claim 1, wherein the magnetic wedge has a coercive force difference depending on the direction in a plane parallel to the flat surface. A rotating electric machine comprising the magnetic wedge according to claim 1 or 2.