JP6863374B2 - フェライト磁石 - Google Patents
フェライト磁石 Download PDFInfo
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- JP6863374B2 JP6863374B2 JP2018518389A JP2018518389A JP6863374B2 JP 6863374 B2 JP6863374 B2 JP 6863374B2 JP 2018518389 A JP2018518389 A JP 2018518389A JP 2018518389 A JP2018518389 A JP 2018518389A JP 6863374 B2 JP6863374 B2 JP 6863374B2
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- ferrite
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- orthoferrite
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Description
マグネトプランバイト構造を有するフェライト相とオルソフェライト相とを有するフェライト磁石であって、A、R、Fe及びMeそれぞれの金属元素の総計の構成比率を
A1−xRx(Fe12−yMey)zの式(1)で表したとき、
(式(1)中、AはSr、Ba、Ca及びPbから選択される少なくとも1種の元素であり、Rは希土類元素(Yを含む)及びBiから選択される少なくとも1種の元素であってLaを少なくとも含み、Meは、Co、または、CoおよびZnである。)
式(1)中、x、y、およびzは、下記式(2)、(3)、(4)および(5)を満たし、
0.71≦x≦0.84 (2)
0.30≦y≦0.60 (3)
0.80≦z<1.10 (4)
1.60<x/yz<4.00 (5)
前記オルソフェライト相の含有量(m)がモル%で、
0<m<28.0
であることを特徴とする。
A1−xRx(Fe12−yMey)z (1)
(組成式(1)中、AはSr、Ba、Ca及びPbから選択される少なくとも1種の元素であり、Rは希土類元素(Yを含む)及びBiから選択される少なくとも1種の元素であってLaを少なくとも含み、Meは、Co、または、CoおよびZnである。)
組成式(1)中、x、y、およびzは、下記式(2)、(3)、(4)および(5)を満たし、
0.71≦x≦0.84 (2)
0.30≦y≦0.60 (3)
0.80≦z<1.10 (4)
1.60<x/yz<4.00 (5)
前記オルソフェライト相の含有量(m)がモル%で、
0<m<28.0
である。
Aは、Sr、Ba、Ca及びPbから選択される少なくとも1種の元素である。Aとして、少なくともSrを用いることが保磁カ(HcJ)向上の観点から最も好ましい。
上記組成式(1)におけるxは、RがAを置換している割合を示している。上記組成式(1)においてxが0.71未満になると、すなわちRの量が少なすぎると、フェライト磁石におけるRの固溶量が不十分となり、Br及びHcJが低下する。しかし、xが0.84を超えると、BrおよびHcJが低下する。そこで本発明はxの範囲を0.71≦x≦0.84とする。好ましいxの値は0.74≦x≦0.84、より好ましいxの値は0.76≦x≦0.84、さらに好ましいxの値は0.76≦x0.81である。
上記組成式(1)におけるyは、MeがFeを置換している割合、すなわち、Co量またはCo+Zn量を示している。yもxと同様、本発明においては高い残留磁束密度(Br)を得る観点から設定される。yが0.30未満ではフェライト磁石におけるMeの固溶量が不十分となり、Br及びHcJが低下する。一方、yが0.60を超えると六方晶M型フェライト中に置換固溶できない過剰な元素Meが存在する。そこで本発明はyの範囲を0.30≦y≦0.60とする。好ましいyの値は0.30≦y≦0.55、より好ましいyの値は0.30≦y≦0.51、さらに好ましいyの値は0.34≦y≦0.51である。
上記組成式(1)におけるzは、A及びRの合計に対するFe及びMeの合計の比を示している。zが小さすぎると、A及びRを含む非磁性相が増えるため、飽和磁化が低くなってくる。一方、zが大きすぎると、α−Fe2O3相又は、Meを含むスピネルフェライト相が増えるため、飽和磁化が低くなってくる。そこで本発明はzの範囲を0.80≦z<1.10とする。好ましいzの値は0.80≦z≦1.04、より好ましいzの値は0.84≦z≦1.04、さらに好ましいzの値は0.84≦z≦1.00である。
上記組成式(1)におけるx/yzは、Rの置換量とMeの置換量との比率を示している。本実施形態では、x/yzは1.60<x/yz<4.00とする。x、yおよびzがこの関係を満たすことで、良好なBrとHcJが得られる。この比率が高すぎる場合と低すぎる場合とでは、Br及びHcJがむしろ低下してしまう傾向にある。好ましいx/yzの値は1.62≦x/yz≦2.97、より好ましいx/yzの値は1.75≦x/yz≦2.97、さらに好ましいx/yzの値は1.75≦x/yz≦2.62である。
本実施形態のフェライト磁石は、M相(マグネトプランバイト構造を有するフェライト相)を主相として含み、M相以外の相として、オルソフェライト相を少なくとも含む。本実施形態では、オルソフェライト相の含有量(m)がモル%で、0<m<28.0である。オルソフェライト相の含有量がこのような条件を満たすことで、高いBrを有するフェライト磁石が得られる。
連続定格:3kW
管電圧:45kV
管電流:40mA
サンプリング幅:0.02deg
走査速度:4.00deg/min
発散スリット:1.00deg
散乱スリット:1.00deg
受光スリット:0.30mm
次に、上述したようなフェライト磁石のうち、フェライト焼結磁石について、その製造方法の一例を示す。本実施形態のフェライト焼結磁石の製造方法では、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、フェライト磁石の原料を配合して、原料組成物を得る。まず、フェライト磁石の原料としては、フェライト磁石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、ZnO、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、1000〜1340℃の温度範囲とすることが好ましく、1100〜1340℃がより好ましく、1250〜1340℃がさらに好ましい。好ましい温度範囲とすることで、オルソフェライト相をフェライト磁石中に含ませることができる。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、主相(M相)およびオルソフェライト相を合計で98.7モル%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段階の工程から構成されていてもよい。
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。湿式成形により成形する場合は、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ることが好ましい。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できる。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よい。また、分散媒としては非水系溶媒を使用してもよい。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できる。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よい。
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、フェライト磁石の焼結体からなる永久磁石(フェライト焼結磁石)が得られる。焼成は、大気中等の酸化性雰囲気中で行うことができる。焼成温度は、1050〜1340℃であると好ましく、1250〜1340℃であるとより好ましい。また、焼成時間(焼成温度に保持する時間)は、0.5〜3時間程度であると好ましい。
まず、フェライト磁石の主組成の原料として、酸化鉄(Fe2O3)、炭酸ストロンチウム(SrCO3)、酸化コバルト(Co3O4)および水酸化ランタン(La(OH)3)を準備し、これらの原料を、仮焼後の組成が以下の組成式となるように秤量した。
組成式:
A1−xRx(Fe12−yMey)z
式中、A=Sr、R=La、Me=Coである。また、x=0.80、y=0.35、z=1.10である。
組成式:
A1−xRx(Fe12−yMey)z
式中、A=Sr、R=La、Me=Coである。
実験例2では、焼成後の焼結体の組成が表2の組成式となるようにしたことと、焼成後の焼結体に対してSiの含有量がSiO2換算で0.05質量%となるように、粗粉砕材に対してSiO2を添加したことと、焼成温度を1290℃にしたこと以外は、実験例1と同様にしてフェライト焼結磁石の製造を行った。
実験例3では、焼成後の焼結体の組成が表3の組成式となるようにしたことと、焼成後の焼結体に対してSiの含有量がSiO2換算で0.05質量%となるように、粗粉砕材に対してSiO2を添加したこと以外は、実験例1と同様にしてフェライト焼結磁石の製造を行った。
実験例4では、フェライト磁石の主組成の原料として、酸化鉄(Fe2O3)、炭酸ストロンチウム(SrCO3)、酸化コバルト(Co3O4)および水酸化ランタン(La(OH)3)を準備し、これらの原料を、仮焼後の組成が以下の組成式となるように秤量した。
組成式:
A1−xRx(Fe12−yMey)z
式中、A=Sr、R=La、Me=Coである。また、x=0.80、y=0.35、z=0.94である。
Claims (1)
- マグネトプランバイト構造を有するフェライト相とオルソフェライト相とを有するフェライト磁石であって、A、R、Fe及びMeそれぞれの金属元素の総計の構成比率を
A1−xRx(Fe12−yMey)zの式(1)で表したとき、
(式(1)中、AはSr、Ba、Ca及びPbから選択される少なくとも1種の元素、Rは希土類元素(Yを含む)及びBiから選択される少なくとも1種の元素であってLaを少なくとも含み、Meは、Co、または、CoおよびZnである。)
式(1)中、x、y、およびzは、下記式(2)、(3)、(4)および(5)を満たし、
0.71≦x≦0.84 (2)
0.30≦y≦0.60 (3)
0.80≦z<1.10 (4)
1.60<x/yz<4.00 (5)
前記オルソフェライト相の含有量(m)がモル%で、
0<m<28.0
であり、
前記フェライト磁石が、Siを含み、前記Siの含有量がSiO 2 換算で0.002質量%を超え0.15質量%未満であることを特徴とするフェライト磁石。
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