JP5120467B2 - フェライト磁性材料、フェライト磁石、フェライト焼結磁石 - Google Patents
フェライト磁性材料、フェライト磁石、フェライト焼結磁石 Download PDFInfo
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- JP5120467B2 JP5120467B2 JP2011002288A JP2011002288A JP5120467B2 JP 5120467 B2 JP5120467 B2 JP 5120467B2 JP 2011002288 A JP2011002288 A JP 2011002288A JP 2011002288 A JP2011002288 A JP 2011002288A JP 5120467 B2 JP5120467 B2 JP 5120467B2
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Description
Ca1−w−x−yRwSrxBayFezMm (1)
ただし、式(1)中、Rは希土類元素(Yを含む)及びBiからなる群より選ばれる少なくとも1種の元素であってLaを少なくとも含み、Mは、Co、Mn、Mg、Ni、Cu及びZnからなる群より選ばれる少なくとも1種の元素であってCoを少なくとも含み、
式(1)中、w、x、y、z及びmは、下記式(2)、(3)、(4)、(5)、(6)、(7)及び(8)を満たし、
0.25<w<0.5 (2)
0.01<x<0.35 (3)
0.0001<y<0.013 (4)
y<x (5)
8.7<z<9.9 (6)
1.0<w/m<2.1 (7)
0.017<m/z<0.055 (8)
副成分として少なくともSi成分を含み、
前記フェライト磁性材料中のこのSi成分のSiO2 換算での含有量y1をY軸に表わし、
前記zとmの合計量x1をX軸に表わしたときに、
x1とy1の関係が、前記X軸及びY軸を持つX−Y座標における4つの点a(8.9,1.2)、b(8.3,0.95)、c(10.0,0.35)及びd(10.6,0.6)で囲まれる範囲内にあることを特徴とする。
前記フェライト磁性材料中の前記Si成分のSiO2 換算での比率y1質量%をY軸に表わし、
前記zとmの合計量x1をX軸に表わしたときに、
x1とy1の関係が、前記X軸及びY軸を持つX−Y座標における4つの点a(8.9,1.2)、b(8.3,0.95)、c(10.0,0.35)及びd(10.6,0.6)で囲まれる範囲内にあることで、高いBr及びHcJを有するのみならず、高いHk/HcJを有するフェライト磁石又はフェライト焼結磁石となる。
前記各結晶粒子の断面の重心を通る粒径の最大値と最小値をそれぞれ求め、所定数以上の結晶粒子における前記粒径の最大値と最小値の平均をそれぞれL(μm)、S(μm)としたとき、
前記L及びSが、下記式(9)及び(10)を満たす。
L≦1.4 (9)
L/S≦2.4 (10)
本発明の一実施形態に係るフェライト焼結磁石を構成するフェライト磁性材料は、六方晶構造を有するフェライト相からなる主相を有するものである。前記フェライト相としてはマグネトプランバイト型(M型)フェライト(以下では、「M型フェライト」とする。)が好ましい。なお、マグネトプランバイト型(M型)フェライトからなる主相を特に「M相」という。ここで「フェライト相からなる主相」とは、通常、フェライト焼結磁石は「主相(結晶粒子)」と「粒界部分」とからなるところ、この「主相」がフェライト相であることを意味する。焼結体に占める主相の割合としては、好ましくは95体積%以上である。
Ca1−w−x−yRwSrxBayFezMm (1)
0.25<w<0.5 (2)
0.01<x<0.35 (3)
0.0001<y<0.013 (4)
y<x (5)
8.7<z<9.9 (6)
1.0<w/m<2.1 (7)
0.017<m/z<0.055 (8)
本実施形態に係るフェライト焼結磁石について、X線回折(XRD)測定により求めた結晶配向度Or(f)=Σ(00l)/Σ(hkl)は、0.9以上であることが好ましく、より好ましくは0.92以上である。
本実施形態に係るフェライト焼結磁石は、図2に示すように、断面が楕円状の結晶粒子から構成される。本実施形態では前記フェライト焼結磁石を構成する結晶粒子をc軸方向に平行な面で切断した切断面において、前記各結晶粒子の断面の重心を通る粒径の最大値と最小値をそれぞれ求め、所定数以上の結晶粒子の平均をそれぞれL(μm)、S(μm)としたとき、前記L及びSが、下記式(9)及び(10)を満たすことが好ましい。
L≦1.4 (9)
L/S≦2.4 (10)
以下の実施形態では、フェライト磁性材料からなるフェライト焼結磁石の製造方法の一例を示す。本実施形態では、フェライト焼結磁石は、配合工程、仮焼工程、粉砕工程、成形工程及び焼成工程を経て製造することが出来る。また、粉砕工程と成形工程の間に、微粉砕スラリーの乾燥工程、混練工程が含まれる場合があり、成形工程と焼成工程の間に、脱脂工程が含まれる場合がある。各工程について、以下に説明する。
配合工程では、フェライト磁性材料の原料を配合して、原料混合物を得る。まず、フェライト磁性材料の原料としては、これを構成する元素のうちの1種又は2種以上を含む化合物(原料化合物)が挙げられる。原料化合物は、例えば粉末状のものが好適である。原料化合物としては、各元素の酸化物、又は焼成により酸化物となる化合物(炭酸塩、水酸化物、硝酸塩等)が挙げられる。例えばSrCO3、La(OH)3、Fe2O3、BaCO3、CaCO3及びCo3O4等が例示出来る。原料化合物の粉末の平均粒径は、例えば、均質な配合を可能とする観点から、0.1〜2.0μm程度とすることが好ましい。
仮焼工程では、配合工程で得られた原料粉末を仮焼する。仮焼は、例えば、空気中等の酸化性雰囲気中で行うことが好ましい。仮焼の温度は、1100〜1400℃の温度範囲とすることが好ましく、1100〜1300℃がより好ましく、1150〜1300℃が更に好ましい。仮焼の時間は、1秒間〜10時間とすることができ、1秒間〜5時間であると好ましい。仮焼により得られる仮焼体は、前述したような主相(M相)を70%以上含む。仮焼体の一次粒子径は、好ましくは10μm以下であり、より好ましくは5μm以下であり、更に好ましくは2μm以下である。
粉砕工程では、仮焼工程で顆粒状や塊状となった仮焼体を粉砕し、再び粉末状にする。これにより、後述する成形工程での成形が容易となる。この粉砕工程では、前述したように、配合工程で配合しなかった原料を添加しても良い(原料の後添加)。粉砕工程は、例えば、仮焼体を粗い粉末となるように粉砕(粗粉砕)した後、これを更に微細に粉砕する(微粉砕)、2段階の工程で行っても良い。
すなわち、PIM(Powder Injection Molding)、粉末射出成形の一種)成形を用いる場合、前記のソルビトール等の多価アルコールの添加は、微粉砕スラリー乾燥時において粉末の凝集発生が顕著となったり、バインダ樹脂中への粉末の分散が悪くなる等の要因となり、好ましくない。その場合、分散剤を何も添加しないか、シランカップリング剤等の同一分子内に親水性基と疎水性(親油性)基を有する分散剤で、粉末を表面処理しても良い。その分散剤の添加量は、添加対象物(例えば粗粉砕材)に対して、0.3〜3.0質量%であれば良い。このような分散剤は、微粉砕終了後のスラリーに添加して混合するのが好ましいが、この例に制限されることなく、乾燥後の粉末に添加したり、バインダ樹脂との混練工程で添加されても良い。
成形・焼成工程では、粉砕工程後に得られた粉砕材(好ましくは微粉砕材)を成形して成形体を得た後、この成形体を焼成して焼結体を得る。成形は、乾式成形、湿式成形又はCIM成形のいずれの方法でも行うことが出来る。乾式成形法では、例えば、乾燥した磁性粉末を加圧成形しつつ磁場を印加して成形体を形成し、その後に、成形体を焼成する。湿式成形法では、例えば、磁性粉末を含むスラリーを磁場印加中で加圧成形しながら液体成分を除去して成形体を形成し、その後に、成形体を焼成する。
CIM成形法によってフェライト焼結磁石を得る場合には、湿式粉砕後、磁性粉末を含む微粉砕スラリーを乾燥させる。乾燥温度は、好ましくは80〜150°C、更に好ましくは100〜120°Cである。また、乾燥時間は、好ましくは1〜40時間、更に好ましくは5〜25時間である。乾燥後の磁性粉末の一次粒子の平均粒径は、好ましくは0.08〜2μmの範囲内、更に好ましくは0.1〜1μmの範囲内である。
湿式成形法によってフェライト焼結磁石を得る場合は、例えば、上述した微粉砕工程を湿式で行うことでスラリーを得た後、このスラリーを所定の濃度に濃縮して、湿式成形用スラリーを得、これを用いて成形を行うことが好ましい。スラリーの濃縮は、遠心分離やフィルタープレス等によって行うことが出来る。湿式成形用スラリーは、その全量中、微粉砕材が30〜80質量%程度を占めるものであると好ましい。スラリーにおいて、微粉砕材を分散する分散媒としては水が好ましい。この場合、スラリーには、グルコン酸、グルコン酸塩、ソルビトール等の界面活性剤を添加しても良い。また、分散媒としては非水系溶媒を使用しても良い。非水系溶媒としては、トルエンやキシレン等の有機溶媒を使用することが出来る。この場合には、オレイン酸等の界面活性剤を添加することが好ましい。なお、湿式成形用スラリーは、微粉砕後の乾燥状態の微粉砕材に、分散媒等を添加することによって調製しても良い。
<配合工程>
まず、出発原料としてフェライト焼結磁石を構成する金属元素の化合物の粉末を準備した。出発原料は、酸化鉄(Fe2 O3 ;不純物として、Mn、Cr、Al、Si、Clを含む)、水酸化ランタン(La(OH)3 )、炭酸カルシウム(CaCO3 )、炭酸ストロンチウム(SrCO3 )、炭酸バリウム(BaCO3 )、酸化コバルト(Co3 O4 )を準備し、表1〜6に記載の各試料の組成になるように秤量した。また、Si成分原料として、酸化ケイ素(SiO2 、含水率:約20%前後、以後も同一原料使用)を出発原料の総量に対して、表1〜6に記載の各試料の組成になるように秤量した。
前記出発原料及びSiO2、それぞれの粉末を湿式アトライタにて混合、粉砕し、スラリー状の原料混合物を得た。この原料混合物を乾燥後、大気中、1225℃で2時間保持する仮焼処理を行い、仮焼体を得た。
得られた仮焼体を小型ロット振動ミルにて粗粉砕し、粗粉砕材を得た。焼成後のフェライト焼結磁石を構成する金属元素の比率が、表1〜6に記載の各試料に示す値となるように、得られた粗粉砕材に対して、酸化鉄(Fe2 O3 ;不純物として、Mn、Cr、Al、Si、Clを含む)、炭酸カルシウム(CaCO3 )、炭酸ストロンチウム(SrCO3 )、酸化コバルト(Co3 O4 )、及び副成分として酸化ケイ素(SiO2 )を、それぞれ適宜添加するとともにソルビトールを0.45wt%添加した。次いで、湿式ボールミルにて、BET法により求められる比表面積(SSA)が、8.0〜9.0m2/gとなるように微粉砕し、スラリーを得た。得られたスラリーを乾燥、整粒し、フェライト材料粉末を得た。
成形は、CIM成形により行った。まず、前述の実施工程で得られたフェライト材料粉末、PP(ポリプロピレン、バインダ樹脂として使用)、パラフィンワックス、アクリル樹脂、及びDOP(フタル酸ジオクチル、可塑剤として添加)を準備し、これらを、フェライト材料粉末=87質量%、PP=5.1質量%、パラフィンワックス=5.1質量%、アクリル樹脂=1質量%、DOP=2質量%となるように秤量した。次いでこれらを加圧加熱ニーダーを用いて、165℃で2.5hr混練し、混練物(コンパウンド)をペレタイザでペレット状に成形し、図4に示すペレット10を得た。
実施例7では、成形工程において、成形体中の有機成分の体積百分率を表7に示す値になるように変えた以外は、実施例1〜6と同様にしてフェライト焼結体を得た。なお、前記有機成分とは、PP(ポリプロピレン)、パラフィンワックス、アクリル樹脂、及びDOP(フタル酸ジオクチル)の合計であり、PP、パラフィンワックス、アクリル樹脂、DOPの混合比率は、成形体中の有機成分比率が変化しても、実施例1に示す比率となるように一定とした。
実施例7では、成形体中の有機成分の体積割合を変えることにより、焼結磁石の結晶配向度、結晶粒子径、アスペクト比を変化させた。
実施例8では、粉砕工程においてソルビトールを添加せず、フェライト材料粉末(フィラー)をシランカップリング剤処理した以外は実施例1〜6と同様にしてフェライト焼結磁石を作製し、評価を行った。具体的には、実施例8では粗粉砕材にソルビトールを添加せずに微粉砕を実施し、微粉砕終了後、シランカップリング剤(信越シリコーン(株)製KBM−503、KBM−1003)を粗粉砕材に対して1wt%、微粉砕スラリー中に添加し、更に湿式ボールミルにて0.5hr混合、分散処理を行った以外、実施例1〜6と同様にフェライト焼結磁石を得た。
実施例9は、CIM成形を湿式成形に変えた以外は実施例1〜6と同様にしてフェライト焼結磁石を得て、評価を行った。すなわち、実施例9では成形・焼成工程を以下の通り行った。
まず、トルエンを分散媒として微粉砕を実施し、微粉砕スラリーを得た。この微粉砕時にオレイン酸を、粗粉砕材に対して1.3wt%添加した。得られたスラリーを、固形分濃度が74〜76質量%となるように溶媒量を調整し、このスラリーを湿式磁場成形機を用いて印加磁場を1.2Tとして磁場中成形し、直径30mm、高さ15mmの円柱状成形体を作製した。次に、得られた成形体を大気中、室温にて十分に乾燥した後、大気中、1200〜1230℃で1時間保持する焼成を行い、焼結体であるフェライト焼結磁石を得た。
まず、実施例1〜9の各試料について、アルキメデス法により密度測定を行った。
次いで、実施例1〜9の各フェライト焼結磁石の上下面を加工した後、25℃の大気雰囲気中にて、最大印加磁場1989kA/mのB−Hトレーサを使用して磁気特性(残留磁束密度Br、保磁力HcJ、角形比Hk/HcJ)を測定した。結果を表1〜9に示す。ここで、Hkは磁気ヒステリシスループの第2象限において、磁束密度が残留磁束密度の90%になるときの外部磁界強度である。
実施例1の試料番号1−4、実施例5の試料番号5−5、実施例6〜9の各試料について円板状のフェライト焼結磁石の片面を平滑に研磨し、この平滑研磨面に対してXRD(X線回折)測定を行い(X線源:CuKα)、フェライト焼結磁石に由来する回折ピークを同定した。同定した回折ピークの面指数とピーク強度から、焼結磁石の結晶配向度Or(f)を求めた。なお、表1の試料番号1−4、表5の試料番号5−4は同一試料であるため、表5の試料番号5−4の欄にも同様に結晶配向度を示す。
各フェライト焼結磁石について、次のようにして結晶粒子径及びアスペクト比を求めた。
まず、フェライト焼結磁石のc軸(磁化容易軸)方向に並行な断面を切り出し、その断面に鏡面研磨し、フッ酸(濃度36%)によるエッチング処理を行った。次いで、エッチング処理面を走査型電子顕微鏡(SEM)で観察し、結晶粒子の断面像を得た。試料番号1−4(もしくは3−3、4−4、5−4、7−8)のSEMによる断面像を図3(a)、試料番号7−1のSEMによる断面像を図3(b)にそれぞれ示す。
表2中、試料番号2−1a、2−2、2−3、2−4、2−4a、2−5は実施例であり、試料番号2−1、2−6、2−7、2−8は比較例である。
表3中、試料番号3−1、3−1a、3−2、3−3、3−4、3−5、3−6、3−7、3−8、3−8a、3−9は実施例であり、試料番号3−10、3−11は比較例である。
表4中、試料番号4−2a、4−3、4−4、4−4a、4−5は実施例であり、試料番号4−1、4−2、4−6、4−7は比較例である。
表5中、試料番号5−2s、5−2a、5−3、5−4、5−5、5−5a、5−6、5−7aは実施例であり、試料番号5−1、5−2、5−7、5−8、5−9、5−10は比較例である。
表6中、試料番号6−1、6−2、6−3、6−4、6−6、6−7、6−8は実施例であり、試料番号6−5は比較例である。
表7中、試料7−1、7−2、7−3、7−4、7−5、7−6、7−7、7−8、7−9、7−10は実施例である。
表8中、試料番号8−1、8−2は実施例である。
表9中、試料番号9−1、9−2は実施例である。
表1より、Srの比率(x)が、0.0003を超え0.373未満であり、Caの比率(1−w−x−y)が、0.229を超え、0.601未満であると、Br及びHcJを良好に維持しつつ、高いHk/HcJが得られることが判明した。表1より、さらに、Srの比率(x)が、0.05〜0.25であり、Caの比率(1−w−x−y)が、0.354〜0.551であると、Br及びHcJをより良好に維持しつつ、より高いHk/HcJが得られることが判明した。
また、表7より、前記フェライト磁性材料において、平均最大粒径Lが1.47未満又はL/Sが2.46未満だと、高いHcJが得られることが確認できた。
8… 金型
10… ペレット
12… キャビティ
20… 結晶粒子
Claims (7)
- 六方晶構造を有するフェライト相からなる主相を有するフェライト磁性材料であって、
前記フェライト磁性材料を構成する金属元素の組成は下記式(1)で表され、
Ca1−w−x−yRwSrxBayFezMm ・・・(1)
ただし、式(1)中、Rは希土類元素(Yを含む)及びBiからなる群より選ばれる少なくとも1種の元素であってLaを少なくとも含み、Mは、Co、Mn、Mg、Ni、Cu及びZnからなる群より選ばれる少なくとも1種の元素であってCoを少なくとも含み、
前記式(1)中、w、x、y、z及びmは、下記式(2)、(3)、(4)、(5)、
(6)、(7)及び(8)を満たし、
0.25<w<0.5 ・・・(2)
0.01<x<0.35 ・・・(3)
0.0001<y<0.013 ・・・(4)
y<x ・・・(5)
8.7<z<9.9 ・・・(6)
1.0<w/m<2.1 ・・・(7)
0.017<m/z<0.055 ・・・(8)
副成分として少なくともSi成分を含み、
前記フェライト磁性材料中の前記Si成分のSiO2 換算での含有量y1質量%をY軸に表わし、
前記zとmの合計量x1をX軸に表わしたときに、
x1とy1の関係が、前記X軸及びY軸を持つX−Y座標における4つの点a(8.9,1.2)、b(8.3,0.95)、c(10.0,0.35)及びd(10.6,0.6)で囲まれる範囲内にあり、
前記y1は、0.50以上であり、
Brは392.0mT以上であり、
HcJは301.0kA/m以上であり、
Hk/HcJは78.5%以上であることを特徴とするフェライト磁性材料。 - 請求項1に記載のフェライト磁性材料からなるフェライト磁石。
- 前記フェライト磁石において、X線回折測定により求めた結晶配向度Or(f)=Σ(001)/Σ(hkl)が0.9以上であることを特徴とする、請求項2に記載のフェライト磁石。
- 前記フェライト磁石を構成する結晶粒子をc軸方向に平行な面で切断した切断面において、
前記各結晶粒子の断面の重心を通る粒径の最大値と最小値をそれぞれ求め、所定数以上の結晶粒子における前記粒径の最大値と最小値の平均をそれぞれL(μm)、S(μm)としたとき、
前記L及びSが、下記式(9)及び(10)を満たす、請求項2又は3に記載のフェライト磁石。
L≦1.4 ・・・(9)
L/S≦2.4 ・・・(10) - 請求項1に記載のフェライト磁性材料からなるフェライト焼結磁石。
- 前記フェライト焼結磁石において、X線回折測定により求めた結晶配向度Or(f)=Σ(001)/Σ(hkl)が0.9以上であることを特徴とする、請求項5に記載のフェライト焼結磁石。
- 前記フェライト焼結磁石を構成する結晶粒子をc軸方向に平行な面で切断した切断面において、
前記各結晶粒子の断面の重心を通る粒径の最大値と最小値をそれぞれ求め、所定数以上の結晶粒子における前記粒径の最大値と最小値の平均をそれぞれL(μm)、S(μm)としたとき、
前記L及びSが、下記式(9)及び(10)を満たす、請求項5又は6に記載のフェライト焼結磁石。
L≦1.4 ・・・(9)
L/S≦2.4 ・・・(10)
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JP2011002288A JP5120467B2 (ja) | 2010-03-17 | 2011-01-07 | フェライト磁性材料、フェライト磁石、フェライト焼結磁石 |
CN201180004147.2A CN102666431B (zh) | 2010-03-17 | 2011-03-15 | 铁素体磁性材料、铁素体磁铁、铁素体烧结磁铁 |
US13/520,270 US8591760B2 (en) | 2010-03-17 | 2011-03-15 | Ferrite magnetic material, ferrite magnet, and ferrite sintered magnet |
PCT/JP2011/056091 WO2011115129A1 (ja) | 2010-03-17 | 2011-03-15 | フェライト磁性材料、フェライト磁石、フェライト焼結磁石 |
KR1020127034230A KR101613649B1 (ko) | 2010-03-17 | 2011-03-15 | 페라이트 자성 재료, 페라이트 자석, 페라이트 소결 자석 |
EP11756314.8A EP2511249B9 (en) | 2010-03-17 | 2011-03-15 | Ferrite magnetic material, ferrite magnet, ferrite sintered magnet |
KR1020127016460A KR101245265B1 (ko) | 2010-03-17 | 2011-03-15 | 페라이트 자성 재료, 페라이트 자석, 페라이트 소결 자석 |
US14/070,842 US9202613B2 (en) | 2010-03-17 | 2013-11-04 | Ferrite magnetic material, ferrite magnet, and ferrite sintered magnet |
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EP2905790B1 (en) | 2012-09-28 | 2024-02-07 | Proterial, Ltd. | Ferrite sintered magnet and method for producing same |
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