JP6809371B2 - L10−FeNi磁粉及びボンド磁石 - Google Patents
L10−FeNi磁粉及びボンド磁石 Download PDFInfo
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- 239000006247 magnetic powder Substances 0.000 title claims description 122
- 229910002555 FeNi Inorganic materials 0.000 title claims description 72
- 239000002245 particle Substances 0.000 claims description 17
- 239000000463 material Substances 0.000 claims description 13
- 239000006249 magnetic particle Substances 0.000 claims description 10
- 238000001000 micrograph Methods 0.000 claims description 8
- 239000012798 spherical particle Substances 0.000 description 24
- 238000000034 method Methods 0.000 description 16
- BGPVFRJUHWVFKM-UHFFFAOYSA-N N1=C2C=CC=CC2=[N+]([O-])C1(CC1)CCC21N=C1C=CC=CC1=[N+]2[O-] Chemical compound N1=C2C=CC=CC2=[N+]([O-])C1(CC1)CCC21N=C1C=CC=CC1=[N+]2[O-] BGPVFRJUHWVFKM-UHFFFAOYSA-N 0.000 description 10
- 238000004519 manufacturing process Methods 0.000 description 9
- 238000005121 nitriding Methods 0.000 description 8
- 150000001875 compounds Chemical class 0.000 description 7
- 239000002994 raw material Substances 0.000 description 7
- 230000004907 flux Effects 0.000 description 6
- 239000011347 resin Substances 0.000 description 6
- 229920005989 resin Polymers 0.000 description 6
- 239000000203 mixture Substances 0.000 description 5
- 239000002131 composite material Substances 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 238000001746 injection moulding Methods 0.000 description 4
- 238000004898 kneading Methods 0.000 description 4
- 230000005415 magnetization Effects 0.000 description 3
- 239000002105 nanoparticle Substances 0.000 description 3
- 229910001172 neodymium magnet Inorganic materials 0.000 description 3
- 239000000725 suspension Substances 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 2
- 238000009689 gas atomisation Methods 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 239000004709 Chlorinated polyethylene Substances 0.000 description 1
- 239000004115 Sodium Silicate Substances 0.000 description 1
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 230000001678 irradiating effect Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000006902 nitrogenation reaction Methods 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
- 150000002910 rare earth metals Chemical class 0.000 description 1
- 229910000938 samarium–cobalt magnet Inorganic materials 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 229910052911 sodium silicate Inorganic materials 0.000 description 1
- 230000002194 synthesizing effect Effects 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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Description
式(1) P=Ls/Lr
前記式(1)においてLrは、顕微鏡の画像における前記L10−FeNi磁粉の周長である。前記式(1)においてLsは、前記Lrを算出した前記L10−FeNi磁粉の前記画像における面積と同じ面積を有する真円の周長である。
本開示の他の局面は、母材(7)と、前記母材中に分散した磁粉(9)と、を備えるボンド磁石(5)であって、前記磁粉は、本開示の一局面であるL10−FeNi磁粉(11)と、平均粒径が1〜500μmである大径磁粉(13)と、を含み、前記磁粉のうち、5質量%以上は、前記L10−FeNi磁粉であるボンド磁石である。本開示の他の局面であるボンド磁石は、磁石性能が高い。
1.L10−FeNi磁粉の構成
L10−FeNiは、L10構造を有するFeNiを意味する。本開示のL10−FeNi磁粉は、L10−FeNiから成る磁粉である。
式(1) P=Ls/Lr
図1に示すように、前記式(1)におけるLrは、顕微鏡画像におけるL10−FeNi磁粉1の周長である。前記式(1)においてLsは、Lrを算出したL10−FeNi磁粉1の顕微鏡画像における面積Sと同じ面積Sを有する真円3の周長である。
前記式(2)においてLsは、粒径Dを算出するべきL10−FeNi磁粉の顕微鏡画像における面積と同じ面積を有する真円の周長である。顕微鏡画像中の100個のL10−FeNi磁粉における粒径Dの平均値を、L10−FeNi磁粉の平均粒径Davgとする。
本開示のL10−FeNi磁粉の平均粒径Davgは、400nm〜1μmであることが好ましい。この場合、ボンド磁石の残留磁束密度が一層大きくなり、ボンド磁石における磁粉の配向度が一層高くなる。
図2に示すように、本開示のボンド磁石5は、母材7と、母材7中に分散した磁粉9と、を備える。磁粉9は、本開示のL10−FeNi磁粉11と、平均粒径が1〜500μmである大径磁粉13と、を含む。磁粉9のうち、5質量%以上は、L10−FeNi磁粉11である。
大径磁粉13は特に限定されず、適宜選択した磁石粉を大径磁粉13として用いることができる。大径磁粉13として、例えば、希土類磁粉等が挙げられる。大径磁粉13の材質として、例えば、SmFeN、NdFeB、SmCo等が挙げられる。大径磁粉13における球状度Pの平均値Pavgは、1.0〜0.4の範囲が好ましい。
本開示のボンド磁石は、例えば、以下のようにして製造することができる。まず、本開示のL10−FeNi磁粉と、母材とを所定の質量比で混合し、真空混練して、プレコンパウンドを作成する。母材は、例えば樹脂である。真空混練における温度は例えば140℃である。真空混練の時間は例えば10時間である。
(4−1)磁粉C1、C2の製造
原料として、FeNi球状粒子Aを用意した。FeNi球状粒子Aは日清エンジニアリング株式会社製の特注品である。FeNi球状粒子Aは、公知の熱プラズマ法により製造されたものである。FeNi球状粒子Aにおける組成比は、Fe:Ni=50:50である。組成比の単位はat.%である。
レーザー照射法:ケイ酸ナトリウム系増粘剤水溶液にFeNi球状粒子Aのナノ粒子を1質量%以下加え、超音波ホモジナイザーを用いて分散させることで、懸濁液を調製した。この懸濁液では、FeNi球状粒子Aのナノ粒子が水中に分散している。超音波ホモジナイザーの出力は150Wである。
粒径が異なる3種類のFeNi球状粒子Aを用意した。3種類のFeNi球状粒子Aに対し、それぞれ、窒化脱窒素処理を行った。この窒化脱窒素処理は、磁粉Cの製造に用いた処理と同様である。その結果、L10構造のFeNi球状粒子から成る磁粉D1〜D3が得られた。磁粉D1〜D3における、Pavg、Davg、Ms、及びHcを測定した。その結果を上記表1に示す。
原料として、粒径が異なる2種類のFeNi球状粒子Eを用意した。FeNi球状粒子Eは日清エンジニアリング株式会社製の特注品である。FeNi球状粒子Eは、公知のガスアトマイズ法により製造されたものである。FeNi球状粒子Eにおける組成比は、Fe:Ni=50:50のである。組成比の単位はat.%である。
NdFeB焼結磁石を、ジェットミルを用いて粉砕することにより、NdFeBから成る磁粉Gを製造した。磁粉Gにおける、Pavg、Davg、Ms、及びHcを測定した。その結果を上記表1に示す。
大径磁粉Lを用意した。大径磁粉LはSmFeNから成る磁粉であり、市販品である。大径磁粉LにおけるPavg、Davg、Ms、及びHcを測定した。その結果を上記表1に示す。
以下のようにしてボンド磁石M1〜M8を製造した。小径磁粉と、樹脂とを所定の質量比で混合し、140℃で10時間真空混練して、プレコンパウンドを作成した。小径磁粉とは、磁粉C1、C2、D1〜D3、F1、F2、Gのうちのいずれかである。ボンド磁石と、それが含有する小径磁粉との対応関係は以下の表2に示すとおりである。また、表2に、ボンド磁石M1〜M8に含まれる小径磁粉の内容を示す。ボンド磁石M1〜M8のそれぞれにおいて、樹脂はポリアミドである。
ボンド磁石M1〜M9のそれぞれについて、Ms、Mrを測定した。また、Mr/Msを算出した。それらを上記表2に示す。MrはVSMを用いて測定した残留磁化である。3Tの外部磁場を印加後、外部磁場を0としたときの磁化の値をMrとする。ボンド磁石M1〜M4では、Ms、Mr、Mr/Msの値が特に大きかった。
<他の実施形態>
以上、本開示の実施形態について説明したが、本開示は上述の実施形態に限定されることなく、種々変形して実施することができる。
(2)上記実施形態における1つの構成要素が有する複数の機能を、複数の構成要素によって実現したり、1つの構成要素が有する1つの機能を、複数の構成要素によって実現したりしてもよい。また、複数の構成要素が有する複数の機能を、1つの構成要素によって実現したり、複数の構成要素によって実現される1つの機能を、1つの構成要素によって実現したりしてもよい。また、上記実施形態の構成の一部を省略してもよい。また、上記実施形態の構成の少なくとも一部を、他の上記実施形態の構成に対して付加又は置換してもよい。なお、特許請求の範囲に記載した文言から特定される技術思想に含まれるあらゆる態様が本開示の実施形態である。
Claims (4)
- 平均粒径が400nm〜1μmであり、以下の式(1)で定義する球状度Pの平均値が0.9以上であるL10−FeNi磁粉(11)。
式(1) P=Ls/Lr
前記式(1)においてLrは、顕微鏡の画像における前記L10−FeNi磁粉の周長である。前記式(1)においてLsは、前記Lrを算出した前記L10−FeNi磁粉の前記画像における面積と同じ面積を有する真円の周長である。 - 母材(7)と、
前記母材中に分散した磁粉(9)と、
を備えるボンド磁石(5)であって、
前記磁粉は、請求項1に記載のL10−FeNi磁粉(11)と、平均粒径が1〜500μmである大径磁粉(13)と、を含み、
前記磁粉のうち、5質量%以上は、前記L10−FeNi磁粉であるボンド磁石。 - 請求項2に記載のボンド磁石であって、
前記磁粉の充填率が80質量%以上であるボンド磁石。 - 請求項2又は3に記載のボンド磁石であって、
前記磁粉のうち、10質量%以上は、前記L10−FeNi磁粉であるボンド磁石。
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