TWI769121B - 廢磁石再生方法 - Google Patents
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Abstract
一種廢磁石再生方法包含有下列步驟。首先,提供廢磁石與輔助合金,前處理廢磁石,氫破碎與過篩廢磁石與輔助合金,以形成主合金粉末與輔助合金粉末。依一預定比例混合主合金粉末與輔助合金粉末,以形成一混合物,然後再進行氣流粉碎、配向成形、燒結與時效處理後,進而獲得再生磁石。
Description
本發明係有關於一種廢磁石再生方法。特別是有關於一種釹鐵硼廢磁石再生方法。
隨著科技日益的進步,各類的電子與電設備常常需要使用到磁鐵等材料。其中,稀土磁石是硬磁材料界中的一顆新星,優異的特性使其在高性能的應用上迅速取代舊有磁石,並激發人們持續開拓新的運用。
釹鐵硼永磁材料是稀土金屬元素釹等和鐵元素形成的金屬間化合物,具有優異的磁性能,是最重要的稀土功能材料之一。近年來,釹鐵硼永磁材料應用領域日益廣泛,已由原來的航空、航太、航海、兵器等國防軍工領域,拓展至儀器、儀錶、能源、交通、醫療設備、電子電力、通訊等更為廣泛的民用高科技領域。
隨著釹鐵硼磁鐵的發展,釹鐵硼磁鐵的種類也更加豐富,規格也不斷增加,由於使用的稀土總量和稀土元素日益增加,如何能夠適當地進行釹鐵硼磁鐵的廢料回收,將有助於釹鐵硼磁鐵的永續發展,且減少資源消耗,進而降低對環境危害。
發明內容旨在提供本揭示內容的簡化摘要,以使閱讀者對本揭示內容具備基本的理解。此發明內容並非本揭示內容的完整概述,且其用意並非在指出本發明實施例的重要/關鍵元件或界定本發明的範圍。
本發明內容之一目的是在提供一種廢磁石再生方法,可以回收各種磁鐵廢料,以進一步加工為所需的磁鐵製品。
為達上述目的,本發明內容之一技術態樣係關於一種廢磁石再生方法包含有下列步驟。首先,提供廢磁石與輔助合金,前處理廢磁石,氫破碎與過篩廢磁石與輔助合金,以形成主合金粉末與輔助合金粉末。其中,主合金粉末與輔助合金粉末,依重量比90:10-99:1的區間,混合形成一混合物。另進一步地將混合物,進行氣流粉碎、配向成形、燒結與時效處理後,以獲得再生磁石,其中輔合金成分為R
a(Co,Fe)
b(Cu,Al,Ga)
c,R為稀土元素包含鑭(La)、鈰(Ce)、鐠(Pr)、釹(Nd)、釓(Gd)、鋱(Tb)、鏑(Dy)、鈥(Ho)或其混合物,其中70wt%≦a≦98wt%,0.1wt%≦b≦30wt%,0.1wt%≦c≦30wt%。
在一些實施例中,以風力發電機廢磁石為例,輔助合金的成分為(Nd
80Pr
20)
90(Co
25Fe
75)
7Cu
1Al
2,而主合金粉末與輔助合金粉末的重量比為97:3。
在一些實施例中,以車用發電機廢磁石為例,輔助合金成分為(Nd
40Pr
50Dy
10)
85(Co
40Fe
60)
9Ga
6,而主合金粉末與輔助合金粉末的重量比為98:2。
在一些實施例中,以硬碟驅動器的音圈電機廢磁石為例,輔助合金成分為(La
10Ce
15Nd
65Pr
10)
85(Co
10Fe
90)
8Al
7,而主合金粉末與輔助合金粉末的重量比為97.5:2.5。
在一些實施例中,前處理廢磁石更包含有下列步驟,篩選廢磁石、退磁廢磁石、去除廢磁石上的有機物、清潔廢磁石以及機械破碎廢磁石,以露出廢磁石的內部表面。
在一些實施例中,氫破碎與過篩廢磁石,更包含有分離廢磁石上的電鍍層,以得到主合金粉末。
在一些實施例中,去除廢磁石上的有機物以及清潔廢磁石,包含有浸泡剝漆劑、超音波水洗、超音波脫脂、酸洗以及乾燥製程。
因此,所述之廢磁石再生方法可以方便地進行廢磁石的回收,且當添加合適的輔助合金後,藉由氫破碎、過篩、氣流粉碎、磁場配向、冷均溫、燒結與時效處理,即可使再生的磁石達到原來磁石相同的磁特性,無需再次淬取稀有金屬,有助於各種釹鐵硼磁鐵的循環利用,且減少資源消耗,進而降低對環境危害。
下文係舉實施例配合所附圖式進行詳細說明,但所提供之實施例並非用以限制本揭露所涵蓋的範圍,而結構運作之描述非用以限制其執行之順序,任何由元件重新組合之結構,所產生具有均等功效的裝置,皆為本揭露所涵蓋的範圍。另外,圖式僅以說明為目的,並未依照原尺寸作圖。為使便於理解,下述說明中相同元件或相似元件將以相同之符號標示來說明。
另外,在全篇說明書與申請專利範圍所使用之用詞(terms),除有特別註明外,通常具有每個用詞使用在此領域中、在此揭露之內容中與特殊內容中的平常意義。某些用以描述本揭露之用詞將於下或在此說明書的別處討論,以提供本領域技術人員在有關本揭露之描述上額外的引導。
於實施方式與申請專利範圍中,除非內文中對於冠詞有所特別限定,否則『一』與『該』可泛指單一個或複數個。而步驟中所使用之編號僅係用來標示步驟以便於說明,而非用來限制前後順序及實施方式。
其次,在本文中所使用的用詞『包含』、『包括』、『具有』、『含有』等等,均為開放性的用語,即意指包含但不限於。
第1圖係依照本發明一實施例所繪示的一種廢磁石再生方法之流程示意圖。如圖中所示,廢磁石再生方法100包含有下列步骤,首先,步驟110,提供廢磁石,與步驟112提供輔助合金。接著,步驟120前處理廢磁石,其中,前處理廢磁石,更包含有篩選廢磁石,剔除非屬磁石的材料,然後將廢磁石進行退磁,接著去除廢磁石上的有機物,並清潔廢磁石的表面,而後再以機械破碎方式將廢磁石破碎成小顆粒,以露出廢磁石的內部的新鮮表面。
在一些實施例中,去除廢磁石上的有機物以及清潔廢磁石則可以利用浸泡剝漆劑、超音波水洗、超音波脫脂、酸洗以及乾燥等製程進行,以去除廢磁石上的有機物,並進一步地清潔廢磁石,然本發明並不限定於此。
接著,步驟130,利用氫破碎爐混合廢磁石與輔助合金的顆粒。在一些實施例中,氫破碎製程利用常溫吸氫2小時,並利用570度高溫脫氫約7小時,以同時破碎廢磁石與輔助合金,然本發明並不限定於此。
然後,步驟140,鍍層分離過篩,以將廢磁石表面剝離的鍍層篩除,以去除鍍層等雜質。
步驟150,混合潤滑劑,例如是混合0.1%的潤滑劑。
步驟160,利用氣流粉碎上述之分離過篩後之廢磁石與輔助合金的顆粒,例如是在氮氣保護下進行氣流粉碎,以使廢磁石與輔助合金的顆粒進一步粉碎成為主合金粉末與輔助合金粉末。其中,主合金粉末與輔助合金粉末,進一步混合成一混合物,其重量比約在90:10-99:1的區間。
步驟170,利用橡膠模具充填混合物於其中,例如是在氮氣室中進行填料。
然後,步驟180進行磁場配向,例如是脈衝磁場配向並進行真空包裝。
步驟190,利用冷均壓(Cold Isostatic Pressing;CIP)成型,其將混合物以可塑之橡膠模具包覆後,置入裝滿介質液體之腔體內,藉由高壓液體使粉末壓縮成型。在一些實施例中,成型後的混合物生胚可以利用脈衝磁場進行脫磁。
步驟200,燒結製程,將成型後的混合物生胚在氮氣室中進行拆模,以進一步進行燒結。在一些實施例中,燒結條件為真空狀態下,以1060攝氏度至1080攝氏度進行高溫真空燒結約5小時。
然後,步驟210,同樣在真空狀態下,對燒結後之磁石,進行時效處理,例如是在470攝氏度,維持4小時,以進行時效處理,然本發明並不限定於此。此外,在一些實施例中,步驟130至步驟190較佳地採用隔氧製程,然本發明並不限定於此。
在一些實施例中,輔合金的成分為:
R
a(Co,Fe)
b(Cu,Al,Ga)
c其中,R為稀土元素包含鑭(La)、鈰(Ce)、鐠(Pr)、釹(Nd)、釓(Gd)、鋱(Tb)、鏑(Dy)、鈥(Ho)或其混合物,而70wt%≦a≦98wt%,0.1wt%≦b≦30wt%,以及0.1wt%≦c≦30wt%。
以下將分別以風力發電機之回收釹鐵硼磁石、車用發電機之回收釹鐵硼磁石以及硬碟驅動器(Hard disk drive;HDD)的音圈電機(Voice coil motor;VCM) 之回收釹鐵硼磁石為例,說明本發明之廢磁石再生方法所製備的釹鐵硼磁鐵的磁特性。
實施例一:風力發電機之回收釹鐵硼磁石
使用風力發電機廢磁石18000公克(原N40H等級廢磁石;亦即BHmax=37-41MGOe/ iHc>17kOe),以及輔助合金556公克,其中,輔助合金之成分為:
(Nd
80Pr
20)
90(Co
25Fe
75)
7Cu
1Al
2
主合金粉末與輔助合金粉末的重量比約為97:3,經本發明之廢磁石再生方法100處理後可得再生磁石,其磁特性如表一所示。
表一
其中,Br:殘留磁化量
iHc:本質矯頑磁力
BHmax:最大磁能積
Density(g/cm3) | Br(kG) | iHc(kOe) | BHmax(MGOe) | |
風力發電機 廢磁石 | 7.45 | 12.45 | 18.25 | 39.64 |
再生磁石 | 7.47 | 12.68 | 17.55 | 40.12 |
其中,利用本發明之廢磁石再生方法100處理後所得之再生磁石之BHmax=40.12MGOe,而iHc=17.55kOe , iHc已達H等級,因此,特性已回復至原N40H等級之磁石,換言之,原18000公克的風力發電機廢磁石,可獲得17271公克(已扣除輔合金556 公克)的再生磁石,且其磁特性,亦可達原N40H等級。經由本發明之廢磁石再生方法,可以再生96%的風力發電機廢磁石,藉由添加適當的輔助合金成分以及相應的製程處理,有效地增加廢磁石的再利用比例,且再生的廢磁石亦能達到所需的磁特性,有助於風力發電機之釹鐵硼磁鐵的循環利用,且減少資源消耗,進而降低對環境危害。
實施例二:車用發電機之回收釹鐵硼磁石
使用車用發電機廢磁石23250公克(原EH等級廢磁石,亦即耐高溫極高矯頑磁力廢磁石),以及輔助合金475公克,其中,輔助合金之成分為:
(Nd
40Pr
50Dy
10)
85(Co
40Fe
60)
9Ga
6
主合金粉末與輔助合金粉末的重量比約為98:2,經本發明之廢磁石再生方法100處理後可得再生磁石,其磁特性如表二所示。
表二
其中,Br:殘留磁化量
iHc:本質矯頑磁力
BHmax:最大磁能積
Density(g/cm3) | Br(kG) | iHc(kOe) | BHmax(MGOe) | |
車用發電機 廢磁石 | 7.62 | 11.34 | 31.3 | 32.15 |
再生磁石 | 7.58 | 11.76 | 30.8 | 31.66 |
其中,利用本發明之廢磁石再生方法100處理後所得之再生磁石之BHmax=31.66MGOe,而iHc=30.8kOe , iHc已達EH等級,因此,特性已回復至原耐高溫EH等級之磁石,換言之,原23250公克的車用發電機廢磁石,可獲得20237公克(已扣除輔合金475公克)的再生磁石,且其磁特性,亦可達原EH等級。經由本發明之廢磁石再生方法,可以再生87%的車用發電機廢磁石,本發明藉由添加適當的輔助合金成分以及相應的製程處理,有效地增加廢磁石的再利用比例,且再生的廢磁石亦能達到所需的磁特性,有助於車用發電機之釹鐵硼磁鐵的循環利用,且減少資源消耗,進而降低對環境危害。
實施例三:硬碟驅動器的音圈電機之回收釹鐵硼磁石
使用硬碟驅動器的音圈電機廢磁石34450公克(原N50M(BHmax=47-51MGOe/iHc>14kOe)及N45H(BHmax=42-46MGOe/ iHc> 17kOe))廢磁石,以及輔助合金883公克,其中,輔助合金之成分為:
(La
10Ce
15Nd
65Pr
10)
85(Co
10Fe
90)
8Al
7
主合金粉末與輔助合金粉末的重量比約為97.5:2.5,經本發明之廢磁石再生方法100處理後可得再生磁石,其磁特性如表三所示。
表三
其中,Br:殘留磁化量
iHc:本質矯頑磁力
BHmax:最大磁能積
Density(g/cm3) | Br(kG) | iHc(kOe) | BHmax(MGOe) | |
硬碟驅動器的音圈電機 廢磁石 | 7.5-7.51 | 13.44-14.00 | 14.93-17.89 | 45.10-49.00 |
再生磁石 | 7.51 | 13.73 | 16.33 | 47.21 |
其中,利用本發明之廢磁石再生方法100處理後所得之再生磁石之BHmax=47.21MGOe,而iHc=16.33kOe , 已達N48M等級磁石,因此,特性已回復至原等級之磁石的中間值,換言之,原34450公克的硬碟驅動器的音圈電機廢磁石,可獲得22097公克(已扣除輔合金883公克)的再生磁石,且其磁特性,亦可達原等級的中間值。經由本發明之廢磁石再生方法,可以再生64.1%的硬碟驅動器的音圈電機廢磁石,本發明藉由添加適當的輔助合金成分以及相應的製程處理,有效地增加廢磁石的再利用比例,且再生的廢磁石亦能達到所需的磁特性,有助於硬碟驅動器的音圈電機之釹鐵硼磁鐵的循環利用,且減少資源消耗,進而降低對環境危害。
有鑑於此,本案之廢磁石再生方法可以方便地進行廢磁石的回收,且當添加合適的輔助合金後,藉由氫破碎、過篩、氣流粉碎、磁場配向、冷均溫、燒結與時效處理,即可使再生的磁石達到原來磁石相同的磁特性,無需再次淬取稀有金屬,有助於各種釹鐵硼磁鐵的循環利用,且減少資源消耗,進而降低對環境危害。
雖然本揭露已以實施方式揭露如上,然其並非用以限定本揭露,任何本領域具通常知識者,在不脫離本揭露之精神和範圍內,當可作各種之更動與潤飾,因此本揭露之保護範圍當視後附之申請專利範圍所界定者為準。
100:廢磁石再生方法
110~210:步驟
為讓本揭露之上述和其他目的、特徵、優點與實施例能更明顯易懂,所附圖式之說明如下:
第1圖是依照本發明一實施例所繪示的一種廢磁石再生方法之流程示意圖。
100:廢磁石再生方法
110~210:步驟
Claims (10)
- 一種廢磁石再生方法,包含: 提供廢磁石與輔助合金; 前處理該些廢磁石; 氫破碎與過篩該些廢磁石與該些輔助合金,以形成主合金粉末與輔助合金粉末,其中,該些主合金粉末與該些輔助合金粉末,依重量比90:10-99:1的區間,混合形成一混合物;以及 將該混合物,進行氣流粉碎、配向成形、燒結與時效處理後,以獲得再生磁石,其中該些輔合金成分為R a(Co,Fe) b(Cu,Al,Ga) c,R為稀土元素包含鑭(La)、鈰(Ce)、鐠(Pr)、釹(Nd)、釓(Gd)、鋱(Tb)、鏑(Dy)、鈥(Ho)或其混合物,其中70wt%≦a≦98wt%,0.1wt%≦b≦30wt%,0.1wt%≦c≦30wt%。
- 如請求項1所述之廢磁石再生方法,其中該些輔助合金成分為(Nd 80Pr 20) 90(Co 25Fe 75) 7Cu 1Al 2。
- 如請求項2所述之廢磁石再生方法,其中該些主合金粉末與該些輔助合金粉末的重量比為97:3。
- 如請求項1所述之廢磁石再生方法,其中該些輔助合金成分為(Nd 40Pr 50Dy 10) 85(Co 40Fe 60) 9Ga 6。
- 如請求項4所述之廢磁石再生方法,其中該些主合金粉末與該些輔助合金粉末的重量比為98:2。
- 如請求項1所述之廢磁石再生方法,其中該些輔助合金成分為(La 10Ce 15Nd 65Pr 10) 85(Co 10Fe 90) 8Al 7。
- 如請求項6所述之廢磁石再生方法,其中該些主合金粉末與該些輔助合金粉末的重量比為97.5:2.5。
- 如請求項1所述之廢磁石再生方法,其中該前處理該些廢磁石,包含: 篩選該些廢磁石; 退磁該些廢磁石; 去除該些廢磁石上的有機物; 清潔該些廢磁石;以及 機械破碎該些廢磁石,以露出該些廢磁石的內部表面。
- 如請求項8所述之廢磁石再生方法,其中,該氫破碎與過篩該些廢磁石,更包含分離該些廢磁石上的電鍍層,並得到該些主合金粉末。
- 如請求項9所述之廢磁石再生方法,其中該去除該些廢磁石上的有機物以及該清潔該些廢磁石,包含,浸泡剝漆劑、超音波水洗、超音波脫脂、酸洗以及乾燥製程。
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