JP7367581B2 - フェライト焼結磁石 - Google Patents
フェライト焼結磁石 Download PDFInfo
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- JP7367581B2 JP7367581B2 JP2020051876A JP2020051876A JP7367581B2 JP 7367581 B2 JP7367581 B2 JP 7367581B2 JP 2020051876 A JP2020051876 A JP 2020051876A JP 2020051876 A JP2020051876 A JP 2020051876A JP 7367581 B2 JP7367581 B2 JP 7367581B2
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Description
六方晶構造を有するフェライト粒子を含み、
磁化容易軸に平行な断面において、前記フェライト粒子の円形度の平均値をWとして、
0.56≦W≦0.68を満たす。
Rは希土類元素から選択される1種以上であり、Rとして少なくともLaを含んでもよく、
AはBaおよびSrから選択される1種以上であり、
0.364≦w≦0.495、
0.038≦x≦0.136、
8.280≦z≦10.45、
0.257≦m≦0.338を満たしてもよい。
Rは希土類元素から選択される1種以上であり、Rとして少なくともLaを含んでもよく、
AはBaおよびSrから選択される1種以上であり、
CaをCaO換算で2.505質量%以上2.951質量%以下、
RをR2O3換算で8.028質量%以上8.239質量%以下、
AをAO換算で0.666質量%以上1.666質量%以下、
FeをFe2O3換算で84.564質量%以上84.937質量%以下、
CoをCoO換算で2.341質量%以上2.521質量%以下、含んでもよい。
Ca1-w-xRwAxFezCom(原子数比)として、カルシウム(Ca)、R、A、鉄(Fe)およびコバルト(Co)を含んでよい。
Rは希土類元素から選択される1種以上であり、Rとして少なくともランタン(La)を含んでよい。
Aはバリウム(Ba)およびストロンチウム(Sr)から選択される1種以上である。
上記組成式のw、x、z、mは、次の範囲を満たす組成であってよい。
0.364≦w≦0.495、
0.038≦x≦0.136、
8.280≦z≦10.45、
0.257≦m≦0.338
Rは希土類元素から選択される1種以上であり、Rとして少なくともLaを含み、
AはBaおよびSrから選択される1種以上であり、
CaをCaO換算で2.505質量%以上2.951質量%以下、
RをR2O3換算で8.028質量%以上8.239質量%以下、
AをAO換算で0.666質量%以上1.666質量%以下、
FeをFe2O3換算で84.564質量%以上84.937質量%以下、
CoをCoO換算で2.341質量%以上2.521質量%以下、含む組成であってよい。
配合工程では、フェライト焼結磁石の原料を配合して、原料混合物を得る。フェライト焼結磁石の原料としては、これを構成する元素のうちの1種または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。
仮焼工程では、配合工程で得られた原料混合物を仮焼する。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°C~1300°Cの温度範囲とすることができる。仮焼の時間は、1秒~10時間とすることができる。
粉砕工程では、仮焼工程で顆粒状や塊状となった仮焼体を粉砕し、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。粉砕工程では、前述したように、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、これをさらに微細に粉砕(微粉砕)する2段階の工程で行ってもよい。
成形・焼成工程では、粉砕工程後に得られた粉砕材(好ましくは微粉砕材)を成形して成形体を得た後、この成形体を焼成して焼結体を得る。成形は、乾式成形、湿式成形またはCeramic Injection Molding(CIM)のいずれの方法でも行うことができる。
湿式成形法によってフェライト焼結磁石を得る場合は、上述した微粉砕工程を湿式で行うことでスラリーを得る。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。これを用いて成形を行うことができる。
出発原料として、CaCO3、La2O3、SrCO3、BaCO3、Fe2O3、Co3O4、MgO、B2O3、Al2O3、SiO2およびMnOを準備し、表1、表2に記載の各試料の組成になるように秤量した。なお、表1にはCa1-w-xRwAxFezComの原子数比を記載した。表2には各元素の酸化物換算での含有量を質量%単位で、それぞれ記載した。
この原料混合物を乾燥後、大気中、1200°Cで2時間保持する仮焼処理を行い、仮焼体を得た。
得られた仮焼体をロッドミルにて粗粉砕し、粗粉砕材を得た。次に、湿式ボールミルにて微粉砕を28時間行い、スラリーを得た。得られたスラリーを固形分濃度が70~75質量%となるように調整して湿式成形用スラリーとした。
次に、湿式磁場成形機を使用して予備成形体を得た。成形圧力は、50MPa、印加磁場は800kA/mとした。また、成形時の加圧方向と磁場印加方向は、同一方向に設定した。湿式成形で得られた予備成形体は円板状であり、直径30mm、高さ15mmであった。
実施例1~3、比較例1~3の各フェライト焼結磁石の上下面を加工した後、25°Cの大気雰囲気中にて、最大印加磁場1989kA/mのB-Hトレーサを使用して磁気特性を測定した。結果を表1に示す。なお、Brは450mT以上を良好とし、460mT以上をさらに良好とした。Hcjは320kA/m以上を良好とし、350kA/m以上をさらに良好とした。
実施例1~3、比較例1~3の各フェライト焼結磁石の密度は、アルキメデス法により測定した。結果を表1に示す。
まず、各フェライト焼結磁石の磁化容易軸に平行な断面において、図1A、図2Aに示すようなSEM画像を撮影した。なお、図1Aが実施例3、図2Aが比較例1である。倍率を5000倍とし、26μm×19μmのSEM画像を撮影した。なお、各SEM画像には、少なくとも100個のフェライト粒子が含まれていることを確認した。
Claims (5)
- 六方晶構造を有するフェライト粒子を含み、
磁化容易軸に平行な断面において、
前記フェライト粒子の円形度の平均値をWとして、
0.56≦W≦0.68を満たし、
Ca 1-w-x R w A x Fe z Co m (原子数比)として、Ca、R、A、FeおよびCoを含み、
Rは希土類元素から選択される1種以上であり、Rとして少なくともLaを含み、
AはBaおよびSrから選択される1種以上であり、
0.364≦w≦0.495、
0.038≦x≦0.136、
8.280≦z≦10.45、
0.257≦m≦0.338を満たすフェライト焼結磁石。 - 前記断面において、前記フェライト粒子のHeywood径の平均値が1.00μm以上1.23μm以下である請求項1に記載のフェライト焼結磁石。
- MgO換算で0.010質量%以上0.090質量%以下のMgを含む請求項1または2に記載のフェライト焼結磁石。
- Ca、R、A、FeおよびCoを含み、
Rは希土類元素から選択される1種以上であり、Rとして少なくともLaを含み、
AはBaおよびSrから選択される1種以上であり、
CaをCaO換算で2.505質量%以上2.951質量%以下、
RをR2O3換算で8.028質量%以上8.239質量%以下、
AをAO換算で0.666質量%以上1.666質量%以下、
FeをFe2O3換算で84.564質量%以上84.937質量%以下、
CoをCoO換算で2.341質量%以上2.521質量%以下、含む請求項1~3のいずれかに記載のフェライト焼結磁石。 - B2O3換算で0.005質量%以上0.058質量%以下のBを含む請求項1~4のいずれかに記載のフェライト焼結磁石。
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JP2005032745A (ja) | 2003-07-07 | 2005-02-03 | Hitachi Metals Ltd | 焼結フェライト磁石およびその製造方法 |
JP2009001476A (ja) | 2007-03-28 | 2009-01-08 | Hitachi Metals Ltd | フェライト焼結磁石及びその製造方法、並びにそれを用いたマグネットロール及び非可逆回路素子 |
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JP2019172507A (ja) | 2018-03-28 | 2019-10-10 | Tdk株式会社 | フェライト焼結磁石及びフェライト焼結磁石の製造方法 |
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JP2005032745A (ja) | 2003-07-07 | 2005-02-03 | Hitachi Metals Ltd | 焼結フェライト磁石およびその製造方法 |
JP2009001476A (ja) | 2007-03-28 | 2009-01-08 | Hitachi Metals Ltd | フェライト焼結磁石及びその製造方法、並びにそれを用いたマグネットロール及び非可逆回路素子 |
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