JP7438900B2 - 圧粉材料及び回転電機 - Google Patents
圧粉材料及び回転電機 Download PDFInfo
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- JP7438900B2 JP7438900B2 JP2020148734A JP2020148734A JP7438900B2 JP 7438900 B2 JP7438900 B2 JP 7438900B2 JP 2020148734 A JP2020148734 A JP 2020148734A JP 2020148734 A JP2020148734 A JP 2020148734A JP 7438900 B2 JP7438900 B2 JP 7438900B2
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- magnetic metal
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/06—Metallic powder characterised by the shape of the particles
- B22F1/068—Flake-like particles
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/05—Metallic powder characterised by the size or surface area of the particles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/02—Compacting only
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- C—CHEMISTRY; METALLURGY
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Description
本実施の形態の圧粉材料は、複数の扁平磁性金属粒子と介在相とを備える圧粉材料であって、前記複数の扁平磁性金属粒子は、平均厚さが10nm以上100μm以下であり、扁平面と、Fe、Co及びNiからなる群から選ばれる少なくとも1つの第1の元素を含む磁性金属相と、を有し、前記厚さに対する前記扁平面内の平均長さの比の平均値が5以上10000以下であり、前記介在相は、前記複数の扁平磁性金属粒子間に存在し、酸素(O)、炭素(C)、窒素(N)及びフッ素(F)からなる群から選ばれる少なくとも1つの第2の元素を含み、前記圧粉材料において、前記扁平面が、前記圧粉材料が有する平面に対して平行に配向し、前記平面内における方向による保磁力差を有する圧粉材料であり、前記介在相が酸化物と樹脂を含み、前記酸化物の軟化温度が前記樹脂の軟化温度よりも高く、前記扁平磁性金属粒子の少なくとも一部に前記酸化物が固着している圧粉材料である。
化学式(1)中、Rはビフェニル、トリフェニル、テトラフェニルのいずれかの構造を含むことが好ましい。R’は構造内に少なくとも1つ以上の芳香環を有する構造を示すことが好ましい。
本実施の形態のシステム及びデバイス装置は、第1の実施の形態の圧粉材料を有するものである。したがって、第1の実施の形態と重複する内容については記載を省略する。このシステム、デバイス装置に含まれる圧粉材料の部品は、例えば、各種モータや発電機などの回転電機(例えば、モータ、発電機など)、変圧器、インダクタ、トランス、チョークコイル、フィルタ等のコアや、回転電機用の磁性楔(磁性くさび)等である。図12は、第2の実施の形態のモータシステムの概念図である。モータシステムは、回転電機システムの一例である。モータシステムとは、モータの回転数や電力(出力パワー)を制御する制御系を含めたシステムのことである。モータの回転数を制御する方式としては、ブリッジサーボ回路による制御、比例電流制御、電圧比較制御、周波数同期制御、PLL(Phase Locked Loop:位相同期ループ)制御、等による制御方法がある。一例として、PLLによる制御法について図12に示してある。PLLによるモータの回転数を制御するモータシステムは、モータと、モータの回転の機械的変位量を電気信号に変換してモータの回転数を検出するロータリーエンコーダと、ある命令により与えられたモータの回転数とロータリーエンコーダにより検出されたモータの回転数を比較しそれらの回転数差を出力する位相比較器と、当該回転数差を小さくするようにモータを制御するコントローラと、を備える。一方、モータの電力を制御する方法としては、PWM(Pulse Width Modulation:パルス幅変調)制御、PAM(Pulse Amplitude Modulation:パルス電圧振幅波形)制御、ベクトル制御、パルス制御、バイポーラ駆動、ペデスタル制御、抵抗制御、等による制御方法がある。またその他の制御方法として、マイクロステップ駆動制御、多相駆動制御、インバータ制御、スイッチング制御、等の制御方法がある。一例として、インバータによる制御法について図12に示してある。インバータによるモータの電力を制御するモータシステムは、交流電源と、交流電源の出力を直流電流に変換する整流器と、当該直流電流を任意の周波数による交流に変換するインバータ回路と、当該交流により制御されるモータと、を備える。
以下に、実施例1~11を、比較例1~6と対比しながらより詳細に説明する。以下に示す実施例及び比較例によって得られる圧粉材料について、扁平磁性金属粒子の平均厚さ、厚さに対する扁平面内の平均長さの比の平均値、樹脂の軟化温度、酸化物の軟化温度、磁性金属相の結晶化温度、酸化物の樹脂に対する比をまとめたものを表1に示す。
まず、単ロール急冷装置を用いて、Fe-Co-Si-B(Fe70Co30B25(at%)-4wt%Si)のリボンを作製する。次に得られたリボンをH2雰囲気中300℃で熱処理を行う。次に、このリボンを、ミキサー装置を用いて所定のサイズに粉砕し、扁平磁性金属粒子を得る。なお、得られた扁平磁性金属粒子の結晶化温度は555℃である。その後、得られた扁平磁性金属粒子を酸化物(Bi2O3-ZnO-B2O3:軟化温度455℃)とともに混合し、軟化温度で熱処理を行ないプレスすることによって、扁平磁性金属粒子に酸化物をしっかりと固着させる。その後、軽く粉砕し、樹脂(ポリイミド樹脂:軟化温度450℃)とともに混合し、磁場中成型を行い(扁平粒子を配向化させる)、ホットプレス装置によって、ホットプレス成型を行う。その後、磁場中熱処理を施すことによって圧粉材料を得る。磁場中熱処理では、磁化容易軸方向に磁場を印加して熱処理を行う。なお、上記の通り、介在相としては酸化物と樹脂を含み、酸化物の樹脂に対する比は1である。また、酸化物の軟化温度は樹脂の軟化温度よりも高く、前記扁平磁性金属粒子の少なくとも一部に前記酸化物が固着していた。得られた圧粉材料は、平面内の方向によって1%以上の保磁力差を有していた。
酸化物を軟化温度460℃の酸化ホウ素にすること以外は実施例1とほぼ同じである。
樹脂を軟化温度370℃のポリイミド樹脂にすること以外は実施例2とほぼ同じである。
Fe-Co-Si-Bの組成をB量で調整し、扁平磁性金属粒子の結晶化温度を510℃にすること以外は実施例2とほぼ同じである。
酸化物の樹脂に対する比を0.1にすること以外は実施例2とほぼ同じである。
酸化物の樹脂に対する比を10にすること以外は実施例2とほぼ同じである。
実施例2において、リボンを、ミキサー装置を用いて適当な大きさに切断し、その後切断したリボン片を回収し、ZrO2ボールとZrO2容器を用いたビーズミルによってAr雰囲気下において約1000rpmの粉砕・圧延化を行い扁平粉末化し、扁平磁性金属粒子を得る。上記の、粉砕・圧延化、熱処理、の作業を繰り返すことによって、扁平磁性金属粒子の平均厚さが10nm、厚さに対する扁平面内の平均長さの比の平均値が200であること以外は実施例2とほぼ同じである。
扁平磁性金属粒子の平均厚さが1μm、厚さに対する扁平面内の平均長さの比の平均値が100であること以外は実施例7とほぼ同じである。
扁平磁性金属粒子の平均厚さが100μm、厚さに対する扁平面内の平均長さの比の平均値が5であること以外は実施例7とほぼ同じである。
扁平磁性金属粒子の平均厚さが10nm、厚さに対する扁平面内の平均長さの比の平均値が1000であること以外は実施例7とほぼ同じである。
扁平磁性金属粒子の平均厚さが10nm、厚さに対する扁平面内の平均長さの比の平均値が10000であること以外は実施例7とほぼ同じである。
酸化物を使用せずに、樹脂のみを使用すること以外は実施例2とほぼ同じである(介在相はポリイミド樹脂のみ)。
樹脂を使用せずに、酸化物のみを使用すること以外は実施例2とほぼ同じである(介在相は酸化物のみ)。
酸化物を軟化温度440℃のBi2O3-ZnO-B2O3にすること以外は実施例2とほぼ同じである。
酸化物の樹脂に対する比を0.08にすること以外は実施例2とほぼ同じである。
酸化物の樹脂に対する比を12にすること以外は実施例2とほぼ同じである。
Fe-Co-Si-Bの組成をB量で調整し、扁平磁性金属粒子の結晶化温度を500℃にすること以外は実施例2とほぼ同じである。
2b 凸部
6 扁平面
9 被覆層
10 扁平磁性金属粒子
20 介在相
22 所定の断面
100 圧粉材料
102 平面
200 モータ
300 モータコア
400 変圧器・トランス
500 インダクタ
Claims (14)
- 複数の扁平磁性金属粒子と介在相とを備える圧粉材料であって、
前記複数の扁平磁性金属粒子は、平均厚さが10nm以上100μm以下であり、扁平面と、Fe、Co及びNiからなる群から選ばれる少なくとも1つの第1の元素を含む磁性金属相と、を有し、前記厚さに対する前記扁平面内の平均長さの比の平均値が5以上10000以下であり、
前記介在相は、前記複数の扁平磁性金属粒子間に存在し、酸素(O)、炭素(C)、窒素(N)及びフッ素(F)からなる群から選ばれる少なくとも1つの第2の元素を含み、前記圧粉材料において、前記扁平面が、前記圧粉材料が有する平面に対して平行に配向し、前記平面内における方向による保磁力差を有する圧粉材料であり、
前記介在相が酸化物と樹脂を含み、前記酸化物の軟化温度が前記樹脂の軟化温度よりも高く、前記扁平磁性金属粒子の少なくとも一部に前記酸化物が固着し、前記樹脂が前記酸化物と前記扁平磁性金属粒子の周囲に配置している圧粉材料。 - 前記酸化物の軟化温度が前記樹脂の軟化温度よりも10℃以上高い請求項1に記載の圧粉材料。
- 前記樹脂の軟化温度が300℃以上400℃以下である請求項1又は請求項2に記載の圧粉材料。
- 前記酸化物の軟化温度が前記磁性金属相の結晶化温度よりも50℃以上低い請求項1ないし請求項3いずれか一項記載の圧粉材料。
- 前記酸化物の前記樹脂に対する比が、面積比として0.1以上10以下である請求項1ないし請求項4いずれか一項記載の圧粉材料。
- 前記磁性金属相が、B、Si、Al、C、Ti、Zr、Hf、Nb、Ta、Mo、Cr、Cu、W、P、N、Ga、Yからなる群から選ばれる少なくとも1つの添加元素を含む請求項1ないし5いずれか一項記載の圧粉材料。
- 前記磁性金属相の第1の元素としてFeとCoを含み、前記添加元素としてSiとBを含む請求項6に記載の圧粉材料。
- 前記酸化物が酸化ホウ素を含む請求項1ないし請求項7いずれか一項記載の圧粉材料。
- 前記樹脂がポリイミド樹脂を含む請求項1ないし請求項8いずれか一項記載の圧粉材料。
- 前記ポリイミド樹脂が下記化学式(1)で表される繰り返し単位を含む請求項9に記載の圧粉材料。
(1) - 前記磁性金属相の平均結晶粒径が10nm以下である請求項1ないし請求項10いずれか一項記載の圧粉材料。
- 前記扁平磁性金属粒子の表面の少なくとも一部が、厚さ0.1nm以上1μm以下で、酸素(O)、炭素(C)、窒素(N)及びフッ素(F)からなる群から選ばれる少なくとも1つの第2の元素を含む被覆層で覆われている請求項1ないし請求項11いずれか一項記載の圧粉材料。
- 前記圧粉材料が有する前記平面内において、方向による保磁力差の割合が1%以上である請求項1ないし請求項12いずれか一項記載の圧粉材料。
- 請求項1ないし請求項13いずれか一項記載の圧粉材料を備える回転電機。
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2020148734A JP7438900B2 (ja) | 2020-09-04 | 2020-09-04 | 圧粉材料及び回転電機 |
CN202110183551.6A CN114141463A (zh) | 2020-09-04 | 2021-02-08 | 压粉材料及旋转电机 |
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