JP5790212B2 - 射出成形用組成物およびその製造方法 - Google Patents
射出成形用組成物およびその製造方法 Download PDFInfo
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- 238000001746 injection moulding Methods 0.000 title claims description 44
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- BJQHLKABXJIVAM-UHFFFAOYSA-N bis(2-ethylhexyl) phthalate Chemical compound CCCCC(CC)COC(=O)C1=CC=CC=C1C(=O)OCC(CC)CCCC BJQHLKABXJIVAM-UHFFFAOYSA-N 0.000 description 8
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Description
フェライト粒子の集合であるフェライト粉末と、第1バインダと、第2バインダと、を有する射出成形用組成物であって、
前記第2バインダの軟化点が、前記第1バインダの軟化点よりも低く、
前記フェライト粉末の重量をWp[g]、比表面積をS[m2/g]とし、前記第1バインダの重量をWb1[g]、密度をDb1[g/cm3]とし、前記第2バインダの重量をWb2[g]、密度をDb2[g/cm3]とし、
前記第1バインダの仮想厚みTb1[nm]を式(1)により算出し、前記第2バインダの仮想厚みTb2[nm]を式(2)により算出したときに、
前記Tb1が0.6〜3.0、前記Tb2が5.0〜16.0であることを特徴とする。
Tb1=(Wb1×103)/(Db1×Wp×S)…式(1)
Tb2=(Wb2×103)/(Db2×Wp×S)…式(2)
フェライト粉末と、第1バインダと、第2バインダと、を混練して混練物を得る工程を有し、
前記第2バインダの軟化点が、前記第1バインダの軟化点よりも低く、
前記フェライト粉末の重量をWp[g]、比表面積をS[m2/g]とし、前記第1バインダの重量をWb1[g]、密度をDb1[g/cm3]とし、前記第2バインダの重量をWb2[g]、密度をDb2[g/cm3]とし、
前記第1バインダの仮想厚みTb1[nm]を式(1)により算出し、前記第2バインダの仮想厚みTb2[nm]を式(2)により算出したときに、
前記Tb1が0.6〜3.0、前記Tb2が5.0〜16.0であることを特徴とする射出成形用組成物の製造方法。
Tb1=(Wb1×103)/(Db1×Wp×S)…式(1)
Tb2=(Wb2×103)/(Db2×Wp×S)…式(2)
本実施形態に係る射出成形用組成物は、フェライト粒子の集合であるフェライト粉末、第1バインダおよび第2バインダを有している。本実施形態では、組成物中において、該フェライト粒子は第1バインダおよび第2バインダに被覆されていることが好ましい。
被覆フェライト粒子としては、フェライト粒子の表面を第2バインダが覆い、第2バインダを第1バインダが覆う構成であってもよいが、本実施形態では、図1(A)に示すように、第1バインダは、フェライト粒子の外周を覆っており、第2バインダは、第1バインダの外周を覆っている構成を例示する。
Tb1=Wb1×103/(Db1×Wp×S)…式(1)
が求められる。同様にして、第2バインダの厚みTb2は、
Tb2=Wb2×103/(Db2×Wp×S)…式(2)
と求められる。
フェライト粉末の組成は、特に制限されず、所望の特性に応じて決定すればよい。また、フェライト粉末の比表面積S[m2/g]は、本実施形態では、6〜15であることが好ましい。
第1バインダは、後述する第2バインダの軟化点よりも高い軟化点を有していれば特に制限されない。本実施形態では、第1バインダは親水性であることが好ましい。
第2バインダは、第1バインダの軟化点よりも低い軟化点を有していれば特に制限されない。第2バインダは疎水性であることが好ましい。第1バインダおよび第2バインダ以外の材料(ワックスなど)が組成物に添加される場合、該材料は、一般的に、第2バインダの外側に存在することになる。そのため、第2バインダが親水性であると、該材料との混練状態が悪化する傾向にある。
まず、原料粉末としてフェライト粉末と、第1バインダと、第2バインダと、を準備する。本実施形態では、ワックスを準備することが好ましく、必要に応じて、可塑剤を準備してもよい。
原料粉末として、BET比表面積(S)が5.5m2/gであるフェライト粉末1と、BET比表面積(S)が9.1m2/gであるフェライト粉末2とを準備した。第1バインダとしてアクリル樹脂を、第2バインダとしてポリエチレンを準備し、ワックスとしてパラフィンワックスを準備し、可塑剤としてジオクチルフタレート(DOP)を準備した。
まず、フェライト粉末2に対し、第1バインダを0.65重量%、第2バインダを4.95重量%、ワックスを1.47重量%、可塑剤を0.16重量%となる配合をニーダー内に投入し、混練を行い、回転数16rpm、混練時間2時間、混練温度195℃の条件で混練して、射出成形用組成物を得た。得られた射出成形用組成物について、流動性(MVR)を200℃、荷重10kgの条件で測定し、この組成物をさらにペレタイザを用いてペレットに成形した。結果を表1に示す。
次に、フェライト粉末1(試料3)およびフェライト粉末2(試料4)に対し、Tb1が1.2nm、Tb2が11.0nmとなるように、配合量を決定し、上記と同様にしてフェライト磁石の焼結体を作製し、特性を評価した。結果を表1に示す。
原料粉末として、BET比表面積(S)が10.3m2/gであるフェライト粉末を1000g(Wp)準備した。第1バインダとしてアクリル樹脂を、第2バインダとしてポリエチレンを準備し、ワックスとしてパラフィンワックスを準備し、可塑剤としてジオクチルフタレート(DOP)を準備した。
原料粉末として、BET比表面積(S)が9.0m2/gであるフェライト粉末を1000g(Wp)準備した。第1バインダとしてアクリル樹脂を、第2バインダとしてポリエチレンを準備し、ワックスとしてカルナバロウを準備し、可塑剤としてフタル酸ブチルラウリルを準備した。
10… フェライト粒子
1… 第1バインダ
2… 第2バインダ
3… ワックス
4… 可塑剤
Claims (4)
- フェライト粒子の集合であるフェライト粉末と、第1バインダと、第2バインダと、を有する射出成形用組成物であって、
前記第2バインダの軟化点が、前記第1バインダの軟化点よりも低く、
前記フェライト粉末の重量をWp[g]、比表面積をS[m2/g]とし、前記第1バインダの重量をWb1[g]、密度をDb1[g/cm3]とし、前記第2バインダの重量をWb2[g]、密度をDb2[g/cm3]とし、
前記第1バインダの仮想厚みTb1[nm]を式(1)により算出し、前記第2バインダの仮想厚みTb2[nm]を式(2)により算出したときに、
前記Tb1が0.8〜2.0、前記Tb2が8.0〜12.0であることを特徴とする射出成形用組成物。
Tb1=(Wb1×103)/(Db1×Wp×S)…式(1)
Tb2=(Wb2×103)/(Db2×Wp×S)…式(2) - 前記射出成形用組成物中には、前記フェライト粒子の外周を、前記第1バインダおよび前記第2バインダが覆っている被覆フェライト粒子が存在している請求項1に記載の射出成形用組成物。
- 前記Sが6〜15である請求項1または2に記載の射出成形用組成物。
- フェライト粉末と、第1バインダと、第2バインダと、を混練して混練物を得る工程を有し、
前記第2バインダの軟化点が、前記第1バインダの軟化点よりも低く、
前記フェライト粉末の重量をWp[g]、比表面積をS[m2/g]とし、前記第1バインダの重量をWb1[g]、密度をDb1[g/cm3]とし、前記第2バインダの重量をWb2[g]、密度をDb2[g/cm3]とし、
前記第1バインダの仮想厚みTb1[nm]を式(1)により算出し、前記第2バインダの仮想厚みTb2[nm]を式(2)により算出したときに、
前記Tb1が0.8〜2.0、前記Tb2が8.0〜12.0であることを特徴とする射出成形用組成物の製造方法。
Tb1=(Wb1×103)/(Db1×Wp×S)…式(1)
Tb2=(Wb2×103)/(Db2×Wp×S)…式(2)
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