JP6927404B1 - フェライト仮焼体、フェライト焼結磁石及びその製造方法 - Google Patents
フェライト仮焼体、フェライト焼結磁石及びその製造方法 Download PDFInfo
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- JP6927404B1 JP6927404B1 JP2020215957A JP2020215957A JP6927404B1 JP 6927404 B1 JP6927404 B1 JP 6927404B1 JP 2020215957 A JP2020215957 A JP 2020215957A JP 2020215957 A JP2020215957 A JP 2020215957A JP 6927404 B1 JP6927404 B1 JP 6927404B1
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/74—Physical characteristics
- C04B2235/76—Crystal structural characteristics, e.g. symmetry
- C04B2235/767—Hexagonal symmetry, e.g. beta-Si3N4, beta-Sialon, alpha-SiC or hexa-ferrites
Abstract
Description
Ca、R、A、Fe及びCoの金属元素(ただし、Rは希土類元素の少なくとも1種であってLaを必須に含む元素、AはSrおよび/またはBa)の原子比を示す一般式:Ca1-x-yRxAyFe2n-zCozにおいて、
前記x、y及びz、並びにn(ただし、2nはモル比であって、2n=(Fe+Co)/(Ca+R+A)で表される)が、
0.30≦1-x-y≦0.55、
0.25≦x≦0.35、
0.15≦y≦0.40、
1-x-y>y、
0<z≦0.18、及び
9.0≦2n-z<11.0、
を満足する。
Ca、R、A、Fe及びCoの金属元素(ただし、Rは希土類元素の少なくとも1種であってLaを必須に含む元素、AはSrおよび/またはBa)の原子比を示す一般式:Ca1-x-yRxAyFe2n-zCozにおいて、
前記x、y及びz、並びにn(ただし、2nはモル比であって、2n=(Fe+Co)/(Ca+R+A)で表される)が、
0.15≦x≦0.35、
0.05≦y≦0.40、
1-x-y>y、
0<z≦0.18、及び
7.5≦2n-z<11.0、
を満足する。
Ca、R、A、Fe及びCoの金属元素(ただし、Rは希土類元素の少なくとも1種であってLaを必須に含む元素、AはSrおよび/またはBa)の原子比を示す一般式:Ca1-x-yRxAyFe2n-zCozにおいて、
前記x、y及びz、並びにn(ただし、2nはモル比であって、2n=(Fe+Co)/(Ca+R+A)で表される)が、
0.30≦1-x-y≦0.55、
0.25≦x≦0.35、
0.15≦y≦0.40、
1-x-y>y、
0<z≦0.18、及び
9.0≦2n-z<11.0、
を満足する原料粉末を混合し、混合原料粉末を得る原料粉末混合工程、
前記混合原料粉末を仮焼し、仮焼体を得る仮焼工程、
前記仮焼体を粉砕し、仮焼体の粉末を得る粉砕工程、
前記仮焼体の粉末を成形し、成形体を得る成形工程、及び
前記成形体を焼成し、焼結体を得る焼成工程、
を含む。
具体的には、従来のSrLaCo系磁石よりも少ないCo含有量(原子比で0.15未満)で従来のSrLaCo系磁石と同等の磁石特性を有するフェライト焼結磁石の提供が可能となる。また、従来のSrLaCo系磁石と同等のCo含有量(原子比で0.15以上0.18以下)で従来のSrLaCo系磁石を超える磁石特性、好ましい形態では従来のCaLaCo磁石に匹敵する磁石特性を有するフェライト焼結磁石の提供が可能となる。
本発明のフェライト仮焼体は、
Ca、R、A、Fe及びCoの金属元素(ただし、Rは希土類元素の少なくとも1種であってLaを必須に含む元素、AはSrおよび/またはBa)の原子比を示す一般式:Ca1-x-yRxAyFe2n-zCozにおいて、
前記x、y及びz、並びにn(ただし、2nはモル比であって、2n=(Fe+Co)/(Ca+R+A)で表される)が、
0.30≦1-x-y≦0.55、
0.25≦x≦0.35、
0.15≦y≦0.40、
1-x-y>y、
0<z≦0.18、及び
9.0≦2n-z<11.0、
を満足する。
原料粉末としては、価数にかかわらず、それぞれの金属の酸化物、炭酸塩、水酸化物、硝酸塩、塩化物等の化合物を使用することができる。原料粉末を溶解した溶液であってもよい。Caの化合物としては、Caの炭酸塩、酸化物、塩化物等が挙げられる。Laの化合物としては、La2O3等の酸化物、La(OH)3等の水酸化物、La2(CO3)3・8H2O等の炭酸塩等が挙げられる。A元素の化合物としては、Srおよび/またはBaの炭酸塩、酸化物、塩化物等が挙げられる。Feの化合物としては、酸化鉄、水酸化鉄、塩化鉄、ミルスケール等が挙げられる。Coの化合物としては、CoO、Co3O4等の酸化物、CoOOH、Co(OH)2等の水酸化物、CoCO3等の炭酸塩、及びm2CoCO3・m3Co(OH)2・m4H2O等の塩基性炭酸塩(m2、m3、m4は正の数である)が挙げられる。
式:(CaCO3の分子量×CaO換算での添加量)/CaOの分子量
によって求めることができる。例えば、CaO換算で0.5質量%のCaCO3を添加する場合、
{(40.08[Caの原子量]+12.01[Cの原子量]+48.00[Oの原子量×3]=100.09[CaCO3の分子量])×0.5質量%[CaO換算での添加量]}/(40.08[Caの原子量]+16.00[Oの原子量]=56.08[CaOの分子量])=0.892質量%[CaCO3の添加量]、となる。
前記の通り、本発明のフェライト仮焼体は、SiO2やCaCO3などの焼結助剤を添加しなくても、液相が生成し、焼結することができ、本発明のフェライト焼結磁石を得ることができる。この時、フェライト仮焼体の成分、組成と、フェライト焼結磁石の成分、組成は、基本的に同じとなる(製造工程における不純物の混入などは考慮しない)。
Ca、R、A、Fe及びCoの金属元素(ただし、Rは希土類元素の少なくとも1種であってLaを必須に含む元素、AはSrおよび/またはBa)の原子比を示す一般式:Ca1-x-yRxAyFe2n-zCozにおいて、
前記x、y及びz、並びにn(ただし、2nはモル比であって、2n=(Fe+Co)/(Ca+R+A)で表される)が、
0.15≦x≦0.35、
0.05≦y≦0.40、
1-x-y>y、
0<z≦0.18、及び
7.5≦2n-z<11.0、
を満足するものとなる。
本発明に基づく実験例として、一般式Ca1-x-yLaxSryFe2n-zCozにおいて、原子比が表1の試料No.1〜30に示す1-x-y、x、y、z及び2n-zになるようにCaCO3粉末、La(OH)3粉末、SrCO3粉末、Fe2O3粉末及びCo3O4粉末を所定の割合で秤量し、秤量後の粉末の合計100質量%に対してH3BO3粉末を0.1質量%添加後、それぞれ湿式ボールミルで4時間混合した後、乾燥、整粒して30種類の混合原料粉末を得た。
本発明に基づく実験例として、一般式Ca1-x-yLaxAyFe2n-zCozにおいて、A元素をSr(試料No.31、32、34〜37)またはBa(試料No.33)とする以外は、実験例1と同様にして7種類のフェライト焼結磁石を得た。各試料の原料粉末混合工程時の秤量組成、仮焼温度、CaCO3(CaO換算)及びSiO2の添加量、ボールミル後の平均粒度、焼成条件、焼成温度、並びに得られたフェライト焼結磁石のBr、HcJ及びHk/HcJの測定結果を表2に示す。
Claims (21)
- Ca、R、A、Fe及びCoの金属元素(ただし、Rは希土類元素の少なくとも1種であってLaを必須に含む元素、AはSrおよび/またはBa)の原子比を示す一般式:Ca1-x-yRxAyFe2n-zCozにおいて、
前記x、y及びz、並びにn(ただし、2nはモル比であって、2n=(Fe+Co)/(Ca+R+A)で表される)が、
0.30≦1-x-y≦0.55、
0.25≦x≦0.35、
0.15≦y≦0.40、
1-x-y>y、
0<z≦0.18、及び
9.0≦2n-z<11.0、
を満足するフェライト仮焼体。 - 請求項1に記載のフェライト仮焼体において、
前記1-x-yは、0.40≦1-x-y≦0.50を満足することを特徴とするフェライト仮焼体。 - 請求項1に記載のフェライト仮焼体において、
前記yは、0.20≦y≦0.35を満足することを特徴とするフェライト仮焼体。 - 請求項1に記載のフェライト仮焼体において、
前記zは、0<z≦0.17を満足することを特徴とするフェライト仮焼体。 - 請求項1に記載のフェライト仮焼体において、
前記2n-z は、9.0≦2n-z≦10.5を満足することを特徴とするフェライト仮焼体。 - 請求項5に記載のフェライト仮焼体において、
前記2n-z は、9.0≦2n-z≦10.0を満足することを特徴とするフェライト仮焼体。 - Ca、R、A、Fe及びCoの金属元素(ただし、Rは希土類元素の少なくとも1種であってLaを必須に含む元素、AはSrおよび/またはBa)の原子比を示す一般式:Ca1-x-yRxAyFe2n-zCozにおいて、
前記x、y及びz、並びにn(ただし、2nはモル比であって、2n=(Fe+Co)/(Ca+R+A)で表される)が、
0.15≦x≦0.35、
0.05≦y≦0.40、
1-x-y>y、
0<z≦0.18、及び
7.5≦2n-z<11.0、
を満足するフェライト焼結磁石。 - 請求項7に記載のフェライト焼結磁石において、
前記1-x-yは、0.40≦1-x-y≦0.50を満足することを特徴とするフェライト焼結磁石。 - 請求項7に記載のフェライト焼結磁石において、
前記yは、0.20≦y≦0.35を満足することを特徴とするフェライト焼結磁石。 - 請求項7に記載のフェライト焼結磁石において、
前記zは、0<z≦0.17を満足することを特徴とするフェライト焼結磁石。 - 請求項7に記載のフェライト焼結磁石において、
前記2n-z は、7.5≦2n-z≦10.5を満足することを特徴とするフェライト焼結磁石。 - 請求項11に記載のフェライト焼結磁石において、
前記2n-z は、7.5≦2n-z≦10.0を満足することを特徴とするフェライト焼結磁石。 - 請求項7〜12のいずれかに記載のフェライト焼結磁石において、
SiO2換算で0質量%を超え1.5質量%以下のSiをさらに含有することを特徴とするフェライト焼結磁石。 - Ca、R、A、Fe及びCoの金属元素(ただし、Rは希土類元素の少なくとも1種であってLaを必須に含む元素、AはSrおよび/またはBa)の原子比を示す一般式:Ca1-x-yRxAyFe2n-zCozにおいて、
前記x、y及びz、並びにn(ただし、2nはモル比であって、2n=(Fe+Co)/(Ca+R+A)で表される)が、
0.30≦1-x-y≦0.55、
0.25≦x≦0.35、
0.15≦y≦0.40、
1-x-y>y、
0<z≦0.18、及び
9.0≦2n-z<11.0、
を満足する原料粉末を混合し、混合原料粉末を得る原料粉末混合工程、
前記混合原料粉末を仮焼し、仮焼体を得る仮焼工程、
前記仮焼体を粉砕し、仮焼体の粉末を得る粉砕工程、
前記仮焼体の粉末を成形し、成形体を得る成形工程、及び
前記成形体を焼成し、焼結体を得る焼成工程、
を含むフェライト焼結磁石の製造方法。 - 請求項14に記載のフェライト焼結磁石の製造方法において、
前記1-x-yは、0.40≦1-x-y≦0.50を満足することを特徴とするフェライト焼結磁石の製造方法。 - 請求項14に記載のフェライト焼結磁石の製造方法において、
前記yは、0.20≦y≦0.35を満足することを特徴とするフェライト焼結磁石の製造方法。 - 請求項14に記載のフェライト焼結磁石の製造方法において、
前記zは、0<z≦0.17を満足することを特徴とするフェライト焼結磁石の製造方法。 - 請求項14に記載のフェライト焼結磁石の製造方法において、
前記2n-z は、9.0≦2n-z≦10.5を満足することを特徴とするフェライト焼結磁石の製造方法。 - 請求項18に記載のフェライト焼結磁石の製造方法において、
前記2n-z は、9.0≦2n-z≦10.0を満足することを特徴とするフェライト焼結磁石の製造方法。 - 請求項14〜19のいずれかに記載のフェライト焼結磁石の製造方法において、
前記仮焼工程後、前記成形工程前に、前記仮焼体又は仮焼体の粉末100質量%に対して0質量%を超え1.5質量%以下のSiO2を添加する工程をさらに含むことを特徴とするフェライト焼結磁石の製造方法。 - 請求項14〜19のいずれかに記載のフェライト焼結磁石の製造方法において、
前記仮焼工程後、前記成形工程前に、前記仮焼体又は仮焼体の粉末100質量%に対して0質量%を超え1.5質量%以下のSiO2を添加する工程と前記仮焼体又は仮焼体の粉末100質量%に対してCaO換算で0質量%を超え1.5質量%以下のCaCO3を添加する工程とをさらに含むことを特徴とするフェライト焼結磁石の製造方法。
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