JP5418595B2 - 焼結磁石 - Google Patents
焼結磁石 Download PDFInfo
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- JP5418595B2 JP5418595B2 JP2011521903A JP2011521903A JP5418595B2 JP 5418595 B2 JP5418595 B2 JP 5418595B2 JP 2011521903 A JP2011521903 A JP 2011521903A JP 2011521903 A JP2011521903 A JP 2011521903A JP 5418595 B2 JP5418595 B2 JP 5418595B2
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- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
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- H01F1/10—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials non-metallic substances, e.g. ferrites, e.g. [(Ba,Sr)O(Fe2O3)6] ferrites with hexagonal structure
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Description
図1は、好適な実施形態のフェライト永久磁石を示す斜視図である。図1に示すフェライト永久磁石1(以下、単に「磁石1」と称する。)は、端面が円弧状となるように湾曲した形状を有しており、一般にアークセグメント形状、C形形状、瓦型形状、弓形形状等と呼ばれる形状を有している。この磁石1は、フェライト磁性材料の焼結体から構成された、フェライト焼結磁石である。
次に、上述したようなフェライト永久磁石の製造方法の好適な実施形態について説明する。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できる。各工程については以下に説明する。
配合工程では、フェライト磁性材料の原料を配合して、原料組成物を得る。まず、ハードフェライトの原料としては、ハードフェライト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、例えばSrCO3、La(OH)3、Pr6O11、Nd2O3、MnO、Fe2O3、BaCO3、CaCO3及びCo3O4等が例示できる。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できる。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、1100〜1250℃がさらに好ましい。仮焼の時間は1秒間〜10時間とすることができ、1秒間〜3時間であると好ましい。仮焼により得られる仮焼体は、上述したような主相(M相)を70%以上含む。主相の一次粒子径は、好ましくは10μm以下であり、より好ましくは2μm以下である。
粉砕工程では、仮焼工程により顆粒状や塊状とされた仮焼体を粉砕し、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、配合工程で配合しなかった原料を添加してもよい(原料の後添加)。粉砕工程は、例えば、仮焼体を粗い粉末となるように粉砕(粗粉砕)した後、これを更に微細に粉砕する(微粉砕)、2段階の工程で行ってもよい。
成形工程では、粉砕工程後に得られた粉砕材(好ましくは微粉砕材)を、磁場中で成形して、成形体を得る。成形は、乾式成形及び湿式成形のいずれの方法でも行うことができる。磁気的配向度を高くする観点からは、湿式成形で行うことが好ましい。
焼成工程では、成形工程で得られた成形体を焼成して焼結体とする。これにより、上述したような、フェライト磁性材料の焼結体からなる磁石1が得られる。アークセグメント形状の磁石を製造する場合、焼成では、所定の中心角を有するように成形された成形体が収縮し、この際、一定の縮率比が生じる。これにより、得られる焼結体は、成形体よりも更に小さな中心角を有するものとなる。円弧が深い焼結体を得るためには、焼成時の縮率比は、1.0〜2.5であると好ましく、1.5〜2.5であるとより好ましい。
まず、フェライト磁性材料の主成分の原料として、酸化鉄(Fe2O3)、炭酸カルシウム(CaCO3)、炭酸ストロンチウム(SrCO3)、酸化コバルト(Co3O4)及び水酸化ランタン(La(OH)3)を準備し、これらの原料を、焼成後のハードフェライトの組成(主組成)が以下の組成式となるようにそれぞれ秤量した。なお、酸化コバルトについては、微粉砕時にも添加を行うため、ここでは主組成が得られるために必要な量の半分を準備した。また、副成分の原料として、酸化ケイ素(SiO2)及び燐酸鉄(FePO4・nH2O)を準備した。SiO2は、フェライト磁性材料中、SiO2の含有量が0.69質量%となるように秤量した。また、FePO4・nH2Oの配合量は、フェライト磁性材料中、Pの含有量が、P2O5換算で表1に示す値となるようにそれぞれ変化させた。
主組成の組成式:Ca1−w−xRwAxFezMmO19
式中、A=Sr、R=La、M=Coである。また、w=0.40、x=0.15、z=9.53、m=0.24である。
まず、実験例1の各フェライト焼結磁石の製造における、焼成時における成形体の収縮の割合を、厚み(shh(%)=100−(焼結体の厚み/成形体の厚み)×100)、及び直径(shΦ(%)=100−(焼結体の直径/成形体の直径)×100)をそれぞれ求め、これに基づいて焼結前後の縮率比(shh/shΦ:c軸方向/a軸方向)を算出した。
まず、フェライト磁性材料の主成分の原料として、酸化鉄(Fe2O3)、炭酸カルシウム(CaCO3)、炭酸ストロンチウム(SrCO3)を準備し、これらの原料を、焼成後のハードフェライトの組成(主組成)が以下の組成式となるようにそれぞれ秤量した。また、副成分の原料として、酸化ケイ素(SiO2)及び燐酸鉄(FePO4・nH2O)を準備した。SiO2は、フェライト磁性材料中、SiO2の含有量が0.21質量%となるように秤量した。また、FePO4・nH2Oの配合量は、フェライト磁性材料中、Pの含有量が、P2O5換算で表2に示す値となるようにそれぞれ変化させた。
式中、A=Sr、R=La、M=Coである。また、w=0.127、x=0.116、z=10.36、m=0.11である。
実験例2の各フェライト焼結磁石について、実験例1と同様に、shh(%)、shΦ(%)、shh/shΦ、P含有量、Br、HcJ、及びHk/HcJをそれぞれ求めた。得られた結果を表2に示す。
まず、フェライト磁性材料の主成分の原料として、酸化鉄(Fe2O3)、炭酸カルシウム(CaCO3)、炭酸ストロンチウム(SrCO3)を準備し、これらの原料を、焼成後のハードフェライトの組成(主組成)が以下の組成式となるようにそれぞれ秤量した。また、副成分の原料として、燐酸鉄(FePO4・nH2O)を準備した。FePO4・nH2Oの配合量は、フェライト磁性材料中、Pの含有量が、P2O5換算で表3に示す値となるようにそれぞれ変化させた。
式中、A=Srである。また、x=0.105、z=10.20である。
実験例3の各フェライト焼結磁石について、実験例1と同様に、shh(%)、shΦ(%)、shh/shΦ、P含有量、Br、HcJ、及びHk/HcJをそれぞれ求めた。得られた結果を表3に示す。
まず、フェライト磁性材料の主成分の原料として、酸化鉄(Fe2O3)、炭酸カルシウム(CaCO3)、炭酸ストロンチウム(SrCO3)及び硫酸ストロンチウム(SrSO4)を準備した。Fe2O3、CaCO3及びSrCO3については、焼成後のハードフェライトの組成(主組成)が以下の組成式となるようにそれぞれ秤量した。また、SrSO4については、フェライト焼結磁石におけるSの含有量が、表4に示す値となるようにそれぞれ変化させた。
式中、A=Sr、R=La、M=Coである。また、w=0.127、x=0.116、z=10.36、m=0.11である。
実験例4の各フェライト焼結磁石について、実験例1と同様に、shh(%)、shΦ(%)、shh/shΦ、Br、HcJ、及びHk/HcJをそれぞれ求めた。また、各フェライト焼結磁石のS含有量を、誘導結合プラズマ発光分光分析装置で測定した。これらの結果を表4に示す。
実験例1における、Pの含有量を0.0008質量%としたフェライト磁性材料、及び、0.0802質量%としたフェライト磁性材料をそれぞれ用いて、図1に示すアークセグメント型のフェライト焼結磁石を作製した。具体的には、各湿式成形用スラリーを得た後、アークセグメント形状が得られるように成形工程を行ったこと以外は、実験例1と同様にして、フェライト焼結磁石を得た。そして、実験例5では、どちらのフェライト磁性材料を用いる場合でも、表5に示す同じ焼結体寸法が得られるように、成形体寸法をそれぞれ調整した。それぞれのフェライト磁性材料を用いて同じ焼結体寸法を得るために必要であった各成形体寸法について、表5に示す。表5中のOR、IR、幅及び長さの各寸法は、それぞれ図2に示した部分の寸法である。
目的とする焼結体の寸法を表6に示すように変えたこと以外は、実験例5と同様の2種類のフェライト磁性材料を用い、同じ焼結体寸法を得るために必要であったそれぞれの成形体寸法を求めた。得られた結果を表6に示す。
目的とする焼結体の寸法を表7に示すように変えたこと以外は、実験例5と同様の2種類のフェライト磁性材料を用い、同じ焼結体寸法を得るために必要であったそれぞれの成形体寸法を求めた。また、各フェライト磁性材料を用いた焼結体の製造をそれぞれ10000回行い、そのうち焼結体にクラックが生じた回数を数えるとともに、成形工程において、湿式成形用スラリーを金型に充填するのに要した平均時間を求めた。得られた結果を表7に示す。
Claims (4)
- ハードフェライトを含む焼結磁石であって、
Pの含有量が、P2O5換算で、0.001〜0.1質量%である、ことを特徴とする焼結磁石。 - Pの含有量が、P2O5換算で、0.005〜0.08質量%である、ことを特徴とする請求項1記載の焼結磁石。
- アークセグメント形状を有する請求項1又は2に記載の焼結磁石。
- 前記アークセグメント形状の中心角が60〜132°である請求項3に記載の焼結磁石。
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