WO2017191737A1 - フェライト粉、樹脂組成物および成形体 - Google Patents
フェライト粉、樹脂組成物および成形体 Download PDFInfo
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- WO2017191737A1 WO2017191737A1 PCT/JP2017/014857 JP2017014857W WO2017191737A1 WO 2017191737 A1 WO2017191737 A1 WO 2017191737A1 JP 2017014857 W JP2017014857 W JP 2017014857W WO 2017191737 A1 WO2017191737 A1 WO 2017191737A1
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- ferrite powder
- molded body
- resin composition
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- ferrite
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
- C01G49/00—Compounds of iron
- C01G49/02—Oxides; Hydroxides
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- C01—INORGANIC CHEMISTRY
- C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
- C01G49/00—Compounds of iron
- C01G49/0018—Mixed oxides or hydroxides
- C01G49/0072—Mixed oxides or hydroxides containing manganese
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47J—KITCHEN EQUIPMENT; COFFEE MILLS; SPICE MILLS; APPARATUS FOR MAKING BEVERAGES
- A47J36/00—Parts, details or accessories of cooking-vessels
- A47J36/02—Selection of specific materials, e.g. heavy bottoms with copper inlay or with insulating inlay
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
- C01G49/00—Compounds of iron
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/26—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on ferrites
- C04B35/2658—Other ferrites containing manganese or zinc, e.g. Mn-Zn ferrites
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/62695—Granulation or pelletising
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/64—Burning or sintering processes
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L101/00—Compositions of unspecified macromolecular compounds
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- 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
- H01F1/34—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 non-metallic substances, e.g. ferrites
- H01F1/36—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 non-metallic substances, e.g. ferrites in the form of particles
- H01F1/37—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 non-metallic substances, e.g. ferrites in the form of particles in a bonding agent
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B6/00—Heating by electric, magnetic or electromagnetic fields
- H05B6/64—Heating using microwaves
- H05B6/74—Mode transformers or mode stirrers
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- C01P2004/00—Particle morphology
- C01P2004/60—Particles characterised by their size
- C01P2004/61—Micrometer sized, i.e. from 1-100 micrometer
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- C01P2004/62—Submicrometer sized, i.e. from 0.1-1 micrometer
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3262—Manganese oxides, manganates, rhenium oxides or oxide-forming salts thereof, e.g. MnO
- C04B2235/3263—Mn3O4
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/42—Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium
- C04B2235/422—Carbon
- C04B2235/424—Carbon black
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
- C04B2235/6567—Treatment time
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
- C08K2003/2265—Oxides; Hydroxides of metals of iron
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
- C08K2003/2265—Oxides; Hydroxides of metals of iron
- C08K2003/2275—Ferroso-ferric oxide (Fe3O4)
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- C08K7/00—Use of ingredients characterised by shape
- C08K7/16—Solid spheres
Definitions
- the present invention relates to a ferrite powder, a resin composition, and a molded body.
- metal detectors cannot detect general plastic materials or the like, they cannot be detected even if foreign materials derived from tools such as packaging materials used at the time of manufacture are mixed.
- Patent Document 1 For the purpose of solving such a problem, a work glove including a metal detector composed of a metal such as iron has been proposed (see Patent Document 1).
- An object of the present invention is to provide a molded body that can be stably detected by a metal detector, and to provide a ferrite powder and a resin composition that can be suitably used for manufacturing the molded body. is there.
- the ferrite powder of the present invention is a ferrite powder that can be detected by a metal detector, Soft ferrite particles containing Mn in an amount of 3.5% to 20.0% by mass and Fe in an amount of 50.0% to 70.0% by mass are included.
- the volume average particle diameter of the constituent particles of the ferrite powder is 0.1 ⁇ m or more and 100 ⁇ m or less.
- the magnetization by VSM measurement when a magnetic field of 5K ⁇ 1000 / 4 ⁇ A / m is applied is preferably 85 A ⁇ m 2 / kg or more and 98 A ⁇ m 2 / kg or less.
- the resin composition of the present invention comprises the ferrite powder of the present invention, And a resin material.
- the ferrite powder is dispersed in the resin material.
- the ferrite powder content in the resin composition is preferably 5.0% by mass or more and 90% by mass or less.
- the resin material is polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol (PVA), fluororesin, silicone rubber, butadiene rubber, thermoplastic elastomer, epoxy resin, and silicone resin. It is preferable to include one or more selected from the group consisting of:
- the molded article of the present invention is characterized by having a portion formed using the resin composition of the present invention.
- the ferrite powder content is preferably 2.0% by mass or more and 20% by mass or less.
- the molded product of the present invention is preferably used in food production, processing and packaging sites.
- the molded body of the present invention is preferably used for some or all of cooking utensils, cooking utensils, and food packaging members.
- the molded body of the present invention preferably contains the ferrite powder in a region within 1.0 mm in the thickness direction from the surface.
- a molded body that can be stably detected by a metal detector, and to provide a ferrite powder and a resin composition that can be suitably used for manufacturing the molded body. it can.
- the ferrite powder of the present invention is characterized by comprising a plurality of soft ferrite particles containing 3.5% by mass or more and 20.0% by mass or less of Mn and 50.0% by mass or more and 70.0% by mass or less of Fe. To do.
- the ferrite powder and the molded body containing the ferrite powder can be easily detected by the metal detector. Therefore, for example, when the ferrite powder of the present invention or at least a part of a molded body containing the ferrite powder is mistakenly mixed in a product such as food, etc., it can be suitably detected by a metal detector, It is possible to effectively prevent the product from being distributed to the outside.
- the ferrite powder as described above has an oxide as a main component, is chemically stable, and has excellent corrosion resistance and chemical resistance. Therefore, the detection stability by the metal detector is excellent.
- the metal detector composed of a metal material
- the above ferrite powder is excellent also in the safety
- the content of Mn in the soft ferrite particles is less than 3.5% by mass, the amount of Fe becomes excessive, and the resin composition is produced (particularly during mixing and kneading by heating) or in the molded product.
- the oxidation reaction easily proceeds during production (particularly during molding by heating), and as a result, the magnetization of the finally obtained molded article is lowered. As a result, it becomes difficult to detect the ferrite powder and the molded body containing the ferrite powder with a metal detector.
- the oxidation proceeds and the magnetization becomes low when processing such as pulverization is performed after the main firing. As a result, it becomes difficult to detect the ferrite powder and the molded body containing the ferrite powder with a metal detector.
- the Fe content in the soft ferrite particles is less than 50.0% by mass, it means that the Mn content is increased, and oxidation is performed when processing such as pulverization is performed after the main firing. Advances and the magnetization becomes low. As a result, it becomes difficult to detect the ferrite powder and the molded body containing the ferrite powder with a metal detector.
- the Fe content in the soft ferrite particles exceeds 70.0% by mass, the amount of Fe becomes excessive, and the resin composition is produced (particularly during mixing and kneading by heating) or the molded article is produced.
- the oxidation reaction is likely to proceed at times (particularly during molding by heating), and as a result, the magnetization of the finally obtained molded article is lowered.
- Mn is not contained, the resistance of the ferrite powder becomes too low, and therefore, the resin molded product containing the ferrite powder may be deformed by being locally heated during heating by the microwave.
- the soft ferrite particles containing Mn and Fe instead of the soft ferrite particles containing Mn and Fe as described above, when particles composed of Ni-Zn-Cu ferrite are used, the Curie point of the ferrite powder is lowered, and it is used at a high temperature. Stable detection of ferrite powder by metal detectors in the environment becomes difficult.
- the content of Mn in the soft ferrite particles may be 3.5% by mass or more and 20.0% by mass or less, but is 5.0% by mass or more and 19.0% by mass or less. Preferably, it is 6.4 mass% or more and 18.0 mass% or less. Thereby, the effects as described above are more remarkably exhibited.
- the content of Fe in the soft ferrite particles may be 50.0% by mass or more and 70.0% by mass or less, preferably 51.0% by mass or more and 66.0% by mass or less, It is more preferable that it is 0.0 mass% or more and 65.0 mass% or less. As a result, the effects as described above are more remarkably exhibited.
- the content of metal elements (Fe, Mn, etc.) constituting the ferrite particles can be measured as follows.
- ferrite particles are weighed, and a mixture obtained by mixing the ferrite particles in a mixed solvent of pure water: 60 ml, 1N hydrochloric acid: 20 ml and 1N nitric acid: 20 ml is obtained. Thereafter, the mixture is heated to obtain a solution in which the ferrite particles are completely dissolved. Thereafter, the content of the metal element can be determined by measuring the solution using an ICP analyzer (for example, ICPS-1000IV, manufactured by Shimadzu Corporation).
- ICP analyzer for example, ICPS-1000IV, manufactured by Shimadzu Corporation.
- the soft ferrite constituting the soft ferrite particles may contain components (elements) other than Fe, Mn, and O.
- components (elements) other than Fe, Mn, and O include Mg, Ti, Si, Cl, Ca, Al, and the like.
- the content of components (elements) other than Fe, Mn, and O contained in the soft ferrite constituting the soft ferrite particles is preferably 1.0% by mass or less.
- the soft ferrite particles may contain components other than soft ferrite.
- the content of components other than soft ferrite contained in the soft ferrite particles is preferably 1.0% by mass or less.
- the volume average particle diameter of the constituent particles of the ferrite powder is not particularly limited, but is preferably 0.1 ⁇ m or more and 100 ⁇ m or less, and more preferably 0.2 ⁇ m or more and 80 ⁇ m or less.
- the dispersibility of the ferrite powder in the resin material can be further improved, and a resin composition containing the ferrite powder and the resin material can be more suitably manufactured.
- strength of the molded object manufactured using the said resin composition, surface property, and reliability can be improved more.
- the manufacture of the molded object using a resin composition can be performed more stably.
- the color tone of the molded product can be adjusted more suitably.
- the resin material may be used during the production of the resin composition described later. It is not preferable because it takes time to disperse the ferrite powder or the agglomerate is dispersed. Further, the smaller the particle size, the stronger the coloring power of ferrite, and it is not preferable because it tends to become dull when a color other than black, gray or brown is applied.
- the volume average particle diameter of the constituent particles of the ferrite powder exceeds the upper limit, depending on the amount of ferrite powder used for the production of the resin composition, the shape and size of the molded body produced using the resin composition Depending on the above, the strength and surface properties (finish) of the molded body when it is formed may be reduced, which is not preferable. Further, for example, when an injection molding method is employed as a method for producing a molded body, the resin composition may block the injection path, which is not preferable.
- the volume average particle diameter of the constituent particles of the ferrite powder is selected, for example, depending on the shape and size of the molded body produced using the ferrite powder, and more specifically, the production of the film / sheet shaped molded body.
- the volume average particle size of the constituent particles of the ferrite powder is preferably 10 ⁇ m or less.
- the volume average particle diameter of the ferrite powder is preferably 5 ⁇ m or more. Thereby, the influence of the color of ferrite powder at the time of coloring can be minimized.
- the volume average particle diameter can be determined, for example, by the following measurement. That is, first, 10 g of ferrite powder as a sample and 80 ml of water are placed in a 100 ml beaker, and 2 to 3 drops of a dispersant (sodium hexametaphosphate) are added. Next, dispersion is performed using an ultrasonic homogenizer (for example, UH-150 model manufactured by SMT Co. LTD.). As an ultrasonic homogenizer, SMT. Co. LTD. When using the UH-150 model, for example, the output level may be set to 4 and dispersion may be performed for 20 seconds. Thereafter, bubbles formed on the surface of the beaker can be removed and introduced into a Microtrac particle size analyzer (for example, Model 9320-X100 manufactured by Nikkiso Co., Ltd.) for measurement.
- a Microtrac particle size analyzer for example, Model 9320-X100 manufactured by Nikkiso Co., Ltd.
- the ferrite powder of the present invention may contain other particles in addition to the soft ferrite particles as described above.
- soft ferrite particles that do not satisfy the conditions as described above may be included, or hard ferrite particles may be included.
- the particles constituting the ferrite powder may be subjected to a surface treatment.
- the surface treatment agent used for the surface treatment of the particles include a silane coupling agent, a phosphoric acid compound, a carboxylic acid, and a fluorine compound.
- the aggregation of the particles can be more effectively prevented, and the flow of the ferrite powder and the resin composition containing the ferrite powder can be prevented.
- Property and ease of handling can be further improved.
- grains in a molded object can be improved more in a resin composition.
- the silane coupling agent for example, a silane compound having a silyl group and a hydrocarbon group can be used.
- the silane coupling agent has an alkyl group having 8 to 10 carbon atoms as the alkyl group. It is preferable.
- the aggregation of the soft ferrite particles can be more effectively prevented, and the fluidity and ease of handling of the ferrite powder and the resin composition containing the ferrite powder can be further improved. Moreover, the dispersibility of the soft ferrite particles in the molded body in the resin composition can be further improved.
- Examples of the phosphoric acid compound include lauryl phosphate, lauryl-2-phosphate, steareth-2 phosphate, phosphate ester of 2- (perfluorohexyl) ethylphosphonic acid, and the like.
- carboxylic acid for example, a compound having a hydrocarbon group and a carboxyl group (fatty acid) can be used. Specific examples of such compounds include decanoic acid, tetradecanoic acid, octadecanoic acid, cis-9-octadecenoic acid and the like.
- fluorine compound examples include a silane coupling agent as described above, a phosphoric acid compound, and a compound having a structure in which at least a part of hydrogen atoms of the carboxylic acid is substituted with a fluorine atom (fluorine silane compound, fluorine A phosphoric acid compound and a fluorine-substituted fatty acid).
- the magnetization of the ferrite powder by VSM measurement when a magnetic field of 5K ⁇ 1000 / 4 ⁇ A / m is applied is preferably 85 A ⁇ m 2 / kg or more and 98 A ⁇ m 2 / kg or less, and 87 A ⁇ m 2 / kg or more. More preferably, it is 97 A ⁇ m 2 / kg or less.
- the magnetization is less than the lower limit value, it is difficult to detect the formed body by a metal detector unless the ferrite powder content in the formed body is increased. It will be enough. Moreover, when the content rate of the ferrite powder in a molded object is raised in order to improve the ease of detection by a metal detector, the toughness and strength of the molded object are likely to decrease.
- the magnetization exceeds the upper limit value, the adjustment of the composition of the ferrite powder is complicated in order to realize the magnetic characteristics, and it becomes difficult to stably obtain excellent characteristics. Further, even if the magnetization exceeds the upper limit, practically, it is not possible to further improve the easiness of detection of the ferrite powder or a molded body containing the ferrite powder by a metal detector.
- the residual magnetization of the ferrite powder by VSM measurement when a magnetic field of 5 K ⁇ 1000 / 4 ⁇ A / m is applied is 4.5 A ⁇ m 2 / kg or more and 40 A ⁇ m 2 / kg or less. It is more preferably 0 A ⁇ m 2 / kg or more and 37 A ⁇ m 2 / kg or less.
- the residual magnetization is less than the lower limit value, the content of the ferrite powder in the molded body produced using the ferrite powder is not increased, and the detection by the metal detector is insufficient. Become. Moreover, when the content rate of the ferrite powder in a molded object is raised in order to improve the ease of detection by a metal detector, the toughness and strength of the molded object are likely to decrease.
- the remanent magnetization exceeds the above upper limit value, the adjustment of the composition of the ferrite powder becomes complicated in order to realize the magnetic characteristics, and it becomes difficult to stably obtain excellent characteristics. Moreover, even if the remanent magnetization exceeds the upper limit, practically, it is not possible to further improve the ease of detection of the ferrite powder or a molded body containing the ferrite powder by a metal detector.
- the coercive force of the ferrite powder by VSM measurement when a magnetic field of 5K ⁇ 1000 / 4 ⁇ A / m is applied is preferably 550 A / m or more and 6500 A / m or less, and 600 A / m or more and 5300 A / m or less. More preferred.
- the coercive force is less than the lower limit value, when the molded body manufactured using the ferrite powder of the present invention is magnetized, sufficient magnetization cannot be performed, and the molded body is detected by a metal detector. This is not preferable because the ease of detection may be reduced.
- the adjustment of the composition of the ferrite powder becomes complicated in order to realize the magnetic characteristics, and it becomes difficult to stably obtain excellent characteristics. Further, even if the coercive force exceeds the upper limit, practically, it is not possible to further improve the ease of detection of the ferrite powder or a molded body containing the ferrite powder by a metal detector.
- the said magnetic characteristic can be calculated
- the Curie temperature (Curie point) of the ferrite powder is preferably 400 ° C. or higher, and more preferably 450 ° C. or higher.
- the Curie temperature can be obtained by measurement based on JIS C 2560-1.
- the ferrite powder of the present invention may be produced by any method, but can be suitably produced, for example, by the method described below.
- At least one of MnCO 3 and Mn 3 O 4 is mixed as a raw material with Fe 2 O 3 .
- the raw materials may be mixed by either wet mixing or dry mixing.
- the raw materials can be mixed using, for example, a Henschel mixer or a ball mill.
- the obtained mixture is temporarily fired to obtain a temporarily sintered product.
- the firing conditions for the temporary firing are not particularly limited, but can be suitably performed in the air at a temperature of 800 ° C. or higher and 1200 ° C. or lower, for example.
- the temporary sintered product is pulverized.
- the temporary sintered product can be pulverized using, for example, a rod mill, a ball mill, or the like.
- a composition containing water, a binder such as polyvinyl alcohol (PVA), and a dispersing agent in addition to the pulverized product of the pre-sintered body is prepared, and the composition is sprayed and dried to obtain granulated powder.
- a binder such as polyvinyl alcohol (PVA)
- a dispersing agent in addition to the pulverized product of the pre-sintered body
- the composition is prepared, for example, by adding a binder such as water, polyvinyl alcohol (PVA), and a dispersing agent to the coarsely pulverized product of the pre-sintered product and subjecting it to a fine pulverization (wet pulverization) treatment. May be. Then, ferrite powder is obtained by carrying out main baking of the granulated powder.
- a binder such as water, polyvinyl alcohol (PVA), and a dispersing agent to the coarsely pulverized product of the pre-sintered product and subjecting it to a fine pulverization (wet pulverization) treatment. May be.
- ferrite powder is obtained by carrying out main baking of the granulated powder.
- the firing conditions for the main firing are not particularly limited, for example, the firing can be suitably performed in the air at a temperature of 1000 ° C. or higher and 1300 ° C. or lower.
- the ferrite powder contains other particles in addition to the soft ferrite particles as described above, the powder containing a plurality of soft ferrite particles obtained as described above and other particles are mixed. By doing so, the target ferrite powder can be obtained.
- the resin composition of the present invention contains the ferrite powder of the present invention as described above and a resin material.
- the ferrite powder may be contained in any form, but is preferably present dispersed in the resin material.
- the ease of handling of the resin composition is further improved, and the molded body to be described in detail later can be more suitably molded.
- the content rate of the ferrite powder in a resin composition is not specifically limited, It is preferable that it is 5.0 mass% or more and 90 mass% or less, and it is more preferable that it is 7.0 mass% or more and 88 mass% or less.
- the moldability of the molded body can be further improved, the toughness, strength, reliability, etc. of the molded body can be further improved, and the ease of detection by the metal detector of the molded body can be improved. Stability can be further improved.
- the detection stability may be It may be insufficient.
- the ferrite powder content in the resin composition exceeds the upper limit, the moldability of the molded body is lowered, and the toughness, strength, reliability, and the like of the molded body may be lowered.
- resin material contained in the resin composition for example, various thermoplastic resins, various curable resins, and the like can be used.
- polyolefin such as polyethylene, polypropylene, poly- (4-methylpentene-1), ethylene-propylene copolymer, cyclic polyolefin; modified polyolefin; polystyrene; butadiene-styrene copolymer; acrylonitrile— Butadiene-styrene copolymer (ABS resin); acrylonitrile-styrene copolymer (AS resin); polyvinyl chloride; polyvinylidene chloride; ethylene-vinyl acetate copolymer (EVA); polyamide (eg, nylon 6, nylon 46) , Nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, nylon 6-12, nylon 6-66); polyimide; polyamideimide; acrylic resin such as polymethyl methacrylate; polycarbonate (PC); eye Polymer alcohol (PVA); ethylene-vinyl alcohol copolymer (EVOH); polyethylene terephthalate (PET),
- Polyether Polyacetal (POM); Polyphenylene oxide; Modified polyphenylene oxide; Polyetherketone (PEK); Polyetheretherketone (PEEK); Polyetherimide; Polysulfone; Polyethersulfone; Polyphenylenesulfide; Polytetrafluoro Fluorine resins such as ethylene and polyvinylidene fluoride; silicone rubber, isoprene rubber, butadiene rubber, nitrile rubber, natural rubber, etc.
- Rubber materials Various thermoplastic elastomers such as styrene, polyolefin, polyvinyl chloride, polyurethane, polyester, polyamide, polybutadiene, trans polyisoprene, fluororubber, chlorinated polyethylene; epoxy resin; phenol Resins; Urea resins; Melamine resins; Unsaturated polyesters; Silicone resins; Polyurethanes, etc., and copolymers, blends, polymer alloys, etc. mainly composed of these, etc. Can be used.
- the resin materials contained in the resin composition are polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol (PVA), fluororesin, silicone rubber, butadiene rubber, thermoplastic elastomer, epoxy resin, and silicone resin. It is preferable to include one or more selected from the group consisting of:
- the dispersion stability of the ferrite powder in the resin composition is further improved, and the moldability of the molded body can be further improved.
- the toughness, strength, reliability and the like of the molded body can be further improved.
- the adhesion to various resins is improved, further improving the dispersion stability of the ferrite powder in the resin composition.
- the moldability of the molded body can be further improved.
- the resin material contained in the resin composition may have a composition different from that of the resin material contained in the molded body produced using the resin composition.
- the resin material contained in the resin composition may be a precursor (for example, a monomer, dimer, trimer, oligomer, prepolymer, etc.) of the resin material contained in the final molded body.
- the content of the resin material in the resin composition is not particularly limited, but is preferably 8.0% by mass to 95% by mass, and more preferably 10% by mass to 90% by mass.
- the moldability of the molded body can be further improved, the toughness, strength, reliability, etc. of the molded body can be further improved, and the ease of detection by the metal detector of the molded body can be improved. Stability can be further improved.
- the content of the resin material in the resin composition is less than the lower limit, the moldability of the molded body is lowered, and the toughness, strength, reliability, etc. of the molded body may be lowered. .
- the content of the resin material in the resin composition exceeds the upper limit, the content of the ferrite powder is relatively lowered, and depending on the composition of the soft ferrite particles, the metal detector of the molded product can be detected.
- the stability of detection may be insufficient.
- the resin composition of the present invention only needs to contain ferrite powder and a resin material, and may further contain other components (other components).
- Such components include various colorants such as pigments and dyes, various fluorescent materials, various phosphorescent materials, various phosphorescent materials, solvents, infrared absorbing materials, ultraviolet absorbers, dispersants, and surfactants.
- the resin composition of the present invention may be in any form, and examples of the resin composition include powders, pellets, dispersions, slurries, gels, etc., but pellets are preferred.
- the ease of handling of the resin composition is further improved, and a molded article using the resin composition can be more suitably produced.
- the storage stability of the resin composition can be further improved, and deterioration of the constituent components of the resin composition during storage can be more effectively prevented.
- the volume average particle size is preferably 1 mm or more and 10 mm or less, and more preferably 2 mm or more and 7 mm or less.
- the resin composition of the present invention can be produced, for example, by mixing the ferrite powder and the resin material described above.
- Mixing of ferrite powder and resin material is, for example, a mixing device (kneading device) such as a planetary mixer, a twin screw mixer, a kneader, a Banbury mixer, a stirring kneader such as an oven roll, a single screw extruder, a twin screw extruder, etc. It can carry out suitably by using.
- a mixing device such as a planetary mixer, a twin screw mixer, a kneader, a Banbury mixer, a stirring kneader such as an oven roll, a single screw extruder, a twin screw extruder, etc. It can carry out suitably by using.
- the molded product of the present invention has a portion formed using the resin composition of the present invention as described above.
- the strength, durability, etc. of the molded body can be further improved.
- an external force such as tension or bending is applied, particularly when a large external force is applied. Even when an external force is repeatedly applied, it is more effectively prevented that a part of the molded body is detached due to cutting or the like. Therefore, it is possible to more effectively prevent a part of the molded body from being mixed into the product or the like as a foreign substance.
- the molded body of the present invention only needs to have at least a part formed using the resin composition of the present invention, and the whole may be formed using the resin composition of the present invention. And in addition to the site
- it has a base portion made of a material other than the resin composition of the present invention, and a surface layer provided on the surface of the base portion and formed using the resin composition of the present invention. It may be.
- the molded article of the present invention may be molded by mixing, for example, the resin composition of the present invention and another resin composition (a composition not containing the ferrite powder of the present invention).
- the molded body preferably contains at least the ferrite powder near the surface thereof.
- the molded body preferably contains ferrite powder in a region within 1.0 mm in the thickness direction from the surface, and ferrite powder in a region within 0.5 mm in the thickness direction from the surface. It is more preferable that it contains.
- the vicinity of the surface of the molded body is a part that is particularly easily detached from the molded body. Therefore, the effect of the present invention is more remarkably exhibited by including ferrite powder in such a region.
- Such a molded body is suitable, for example, by applying a magnetic field from the direction that should be the surface of the molded body when the molded body is molded (the resin material constituting the resin composition is softened or melted). Can be manufactured.
- the above-described ferrite can be unevenly distributed in the vicinity of the surface of the molded body, and the effects as described above can be exhibited more remarkably.
- the content of the ferrite powder in the molded body of the present invention varies depending on the usage of the molded body, but is preferably 2.0% by mass or more and 20% by mass or less, and 2.5% by mass or more and 18% by mass or less. It is more preferable that
- the toughness, strength, reliability and the like of the molded body can be further improved, and the ease of detection of the molded body by a metal detector and the stability of detection can be further improved.
- the molded body does not contain the ferrite powder (that is, other than the resin composition of the present invention).
- the above-described conditions for the content of ferrite powder are satisfied in the portion containing the ferrite powder.
- the molded body of the present invention may be used for the purpose of detection by a metal detector, in other words, all or part of the molded body (for example, a section of the molded body) may be applied to inspection by a metal detector.
- the molded article of the present invention can be used for, for example, food production, processing, and packaging (including packaging, the same applies hereinafter), cosmetics, and quasi-drugs. Manufacturing, processing, packaging site, pharmaceutical manufacturing, processing, packaging site, products other than the above, processing, packaging site, medical site, cell culture, tissue culture, organ culture, genetic recombination And the like for use in the field of performing biological treatment such as, and for use in the field of performing chemical treatment such as synthesis of compounds.
- the molded article of the present invention is preferably used in the field of food production, processing, and packaging.
- Foods are required to have high safety, but are generally manufactured, processed, and packaged in an environment where foreign substances are easily mixed. Therefore, by applying the present invention to articles used in the production, processing, and packaging of food, the effects of the present invention are more remarkably exhibited.
- articles used in food manufacturing and processing sites include many articles that are applied to microwave ovens (for example, various cooking utensils, various containers, trays, wrap films, etc.). Since ferrite, which is a metal material, is used, it can be suitably adapted to the use of a microwave oven.
- the soft ferrite as described above can generate heat (especially suitable heat generation up to a predetermined temperature in which excessive temperature rise is prevented) when applied to a microwave oven by adjusting the composition. For this reason, for example, the cooking time can be shortened and the baking color of the food can be adjusted suitably.
- the form of food in addition to solid form and semi-solid form (gel form of jelly, pudding, etc.), the form of food includes liquid, and the concept of food includes drinks and the like.
- Food additives and supplements are also included in the concept of food.
- natural products such as animal-derived meat, seafood, plant-derived vegetables, fruits, seeds, grains, beans, seaweed, and processed products thereof, artificial sweeteners, artificial seasonings such as artificial seasonings, etc.
- New synthetic products are also included in the concept of food.
- Examples of molded products used in the production and processing of food include cooking appliances, cooking utensils, cooking utensils, tableware, clothing (articles worn on the human body), and packaging members used for food packaging And articles used in association therewith, as well as articles used for maintenance and repair of these.
- hot plate such as: pans, pans, kettles and their lids, knives, scissors, ladle, spatula, peeler, slicer, mixer, chopper, masher, rolling pin, mudler, whisk, pestle, bowl, drainer , Cutting board, mat, rice paddle, mold, die cutting, lye removal, grater (food grader), frying (turner), pick, drainer, sieve, mill, drop lid, ice tray, grill, tongs, egg cutter , Cooking utensils such as measuring cups and measuring spoons; towels, kitchen paper, towels, towels, paper towels, Cutting utensils, wrap film, oven paper, squeezed bags, virtues, pans and other cooking utensils; dishes, cups, bowls, chopsticks (including chopsticks), spoons, fork
- the molded article of the present invention is preferably used for some or all of cooking utensils, cooking utensils, and food packaging members.
- such a molded body has a high possibility that at least a part of the molded body will be mixed into the food, particularly in the production, processing, and packaging sites of the food. Therefore, when the present invention is applied to the molded body as described above, the effects of the present invention are more remarkably exhibited.
- Various molding methods can be used as a method for producing a molded body, such as an injection molding method (insert molding method, multicolor molding method, sandwich molding method, injection molding method, etc.), extrusion molding method, inflation molding method, Examples include a T-die film molding method, a laminate molding method, a blow molding method, a hollow molding method, a compression molding method, a calendar molding method and the like, an optical molding method, a three-dimensional layered molding method, and the like.
- an injection molding method insert molding method, multicolor molding method, sandwich molding method, injection molding method, etc.
- extrusion molding method inflation molding method
- Examples include a T-die film molding method, a laminate molding method, a blow molding method, a hollow molding method, a compression molding method, a calendar molding method and the like, an optical molding method, a three-dimensional layered molding method, and the like.
- the resin composition contains a curable resin
- a curing reaction of the curable resin is performed.
- the curing reaction varies depending on the type of the curable resin and the like, but can be performed by heating or irradiation with energy rays such as ultraviolet rays.
- a resin material for dilution may be used in addition to the resin composition of the present invention.
- the molded body has a base formed using a material other than the resin composition described above, and a surface layer provided on the base and formed using the resin composition of the present invention, the above Such as casting, forging, powder injection molding method (PIM (Powder Injection Molding)), etc. You may use and form a surface layer.
- PIM Powder injection molding method
- it may be magnetized when the molded body is molded. Thereby, it is possible to further improve the ease of detection of the formed body by the metal detector and the stability of the detection.
- the molded body may be manufactured by subjecting the molded body obtained by the above-described molding method to post-treatment such as grinding and polishing.
- the resin composition of the present invention in the resin composition, the case where the ferrite powder is dispersed and present in the resin material has been mainly described, but in the resin composition of the present invention, for example, the ferrite powder is It settles in the liquid and may be used after being dispersed by stirring or the like, if necessary.
- the resin composition of the present invention may be a dispersion in which ferrite powder and resin particles are dispersed in a volatile liquid.
- the resin composition of the present invention may have a configuration in which, for example, ferrite powder and resin powder are simply mixed.
- Example A1 Fe 2 O 3 and Mn 3 O 4 were prepared, and these were put into a Henschel mixer at a molar ratio of 8.0: 0.67, followed by dry mixing for 10 minutes. Was pelletized with a roller compactor. Thereafter, calcination temperature (calcination temperature): 1000 ° C., and calcination was performed in an air atmosphere rotary kiln.
- the obtained slurry was spray-dried with a spray dryer to obtain a granulated product. Then, the particle size adjustment of the obtained granulated material was performed, and further, it heated at 650 degreeC for 2 hours with the rotary electric furnace, and the binder was removed.
- the obtained granulated product was fired (peak firing) at 1280 ° C. for 4 hours in a nitrogen atmosphere, and further pulverized and classified to obtain ferrite powder. .
- the Mn content was 7.88% by mass
- the Fe content was 64.13% by mass.
- the content of metal elements (Fe, Mn, etc.) in the particles constituting the ferrite powder was determined as follows. Specifically, 0.2 g of ferrite particles were weighed, a mixture of pure water: 60 ml with 1N hydrochloric acid: 20 ml and 1N nitric acid: 20 ml was heated to prepare an aqueous solution in which ferrite particles were completely dissolved, and ICP analysis was performed. The content of each metal element was determined by performing measurement using an apparatus (manufactured by Shimadzu Corporation, ICPS-1000IV). In addition, it calculated
- the volume average particle diameter of the constituent particles of the ferrite powder was 45 ⁇ m.
- the volume average particle diameter was determined by the following measurement. That is, first, ferrite powder as a sample: 10 g and water: 80 ml were placed in a 100 ml beaker, and two drops of a dispersant (sodium hexametaphosphate) were added. Subsequently, dispersion was performed using an ultrasonic homogenizer (UH-150 type manufactured by SMT Co Ltd). At this time, the output level of the ultrasonic homogenizer was set to 4, and dispersion was performed for 20 seconds.
- UH-150 type manufactured by SMT Co Ltd ultrasonic homogenizer
- the magnetization was 92 A ⁇ m 2 / kg
- the residual magnetization was 6.2 A ⁇ m 2 / kg
- the coercive force was 1225 A / m. It was.
- the above magnetic properties were obtained as follows. That is, first, ferrite powder was packed in a cell having an inner diameter of 5 mm and a height of 2 mm, and set in a vibration sample type magnetic measuring device (VSM-C7-10A manufactured by Toei Kogyo Co., Ltd.). Next, an applied magnetic field was applied, sweeping was performed to 5K ⁇ 1000 / 4 ⁇ ⁇ A / m, and then the applied magnetic field was decreased to prepare a hysteresis curve. Thereafter, magnetization, residual magnetization, and coercive force were obtained from the data of this curve.
- VSM-C7-10A vibration sample type magnetic measuring device
- the Curie temperature was measured about the ferrite powder, it was 450 degreeC.
- the Curie temperature of the ferrite powder was determined by measurement based on JIS C 2560-1. In addition, it calculated
- Examples A2 to A4 The ratio of Fe 2 O 3 and Mn 3 O 4 used as raw materials is shown in Table 1, and the conditions for pulverization treatment for the temporary sintered body, the conditions for spray drying with a spray dryer, and the conditions for particle size adjustment for the granulated product are as follows.
- a ferrite powder was produced in the same manner as in Example A1 except that the adjustment was performed.
- Example A5 Fe 2 O 3 , Mn 3 O 4 and carbon black (C) were prepared, and these were charged into a Henschel mixer at a molar ratio of 8.0: 0.67: 1.1, Dry mixing and granulation for 10 minutes.
- the obtained granulated material was fired at 1000 ° C. for 4 hours (peak) in a nitrogen atmosphere using a stationary electric furnace.
- the fired product obtained by the above firing was wet-ground using a bead mill at a solid content of 60% by mass for 30 minutes, washed, dehydrated and dried to obtain a ferrite powder.
- Table 1 summarizes the manufacturing conditions of the ferrite powders of the above-described Examples and Comparative Examples, and Table 2 summarizes the characteristics of the ferrite powders.
- Example B1 Using a kneader and a pelletizer, the ferrite powder produced in Example A3 and polypropylene as a resin material were mixed, kneaded, and granulated at a mass ratio of 5.0: 95.0. This obtained the resin composition as a pellet whose volume average particle diameter is 3 mm.
- Examples B2 to B5 A resin composition as a pellet was obtained in the same manner as in Example B1, except that the blending ratio of ferrite powder and polypropylene was changed as shown in Table 3.
- Example B6 Using a kneader and a pelletizer, the ferrite powder produced in Example A3, polypropylene as a resin material, and silica as a white pigment (Nippon Aerosil Co., Ltd., AEROSIL 200) in a mass ratio of 2.0: 93 Mixing, kneading and granulation at 0.0: 5.0. This obtained the resin composition as a pellet whose volume average particle diameter is 3 mm.
- Example B7 and B8 A resin composition as a pellet was obtained in the same manner as in Example B6 except that the blending ratio of ferrite powder, polypropylene, and silica was changed as shown in Table 3.
- Example B9 to B13 Except having made the kind of resin material as shown in Table 3, the resin composition as a pellet was obtained like Example B8.
- Examples B14 to B17 The resin composition as a pellet was obtained in the same manner as in Example B1 except that the type of ferrite powder and the type of resin material were as shown in Table 3 and the amounts of each component were as shown in Table 3. .
- Example B18 Using a ball mill, the ferrite powder produced in Example A3, nylon resin powder, and silica particles as a white pigment were mixed at the same mass ratio as in Example B12 to obtain a powdery resin composition. Obtained.
- Example B19 A powdery resin composition was obtained in the same manner as in Example B18 except that the types of resin materials were as shown in Table 3.
- Example B4 A resin composition as a pellet was obtained in the same manner as in Example B6 except that iron powder (average particle diameter: 60 ⁇ m) was used instead of ferrite powder and the blending amount of each component was changed.
- Table 3 summarizes the conditions of the resin compositions of the respective examples and comparative examples described above.
- the column of MFR in Table 3 shows the value of the melt flow rate (MFR) when measured under the conditions of temperature: 190 ° C. and load: 2.16 kg based on JIS K 7210.
- ⁇ 3 Manufacture of molded body (Example C1) Using a kneader and a T-die, the resin composition (pellet) produced in Example B1 was melted and molded to obtain a sheet-like molded body having a thickness of 100 ⁇ m.
- Examples C2, C3 A sheet-like molded body was produced in the same manner as in Example C1, except that the pellets produced in Examples B2 and B3 were used instead of the pellets produced in Example B1. did.
- Example C4 Using a kneader, the resin composition (pellet) produced in Example B4 was melted and injection molded into a molding die to obtain a plate-like molded body having a thickness of 2 mm.
- Example C5 Using a kneader, the resin composition (pellet) produced in Example B5 was melted and injection molded into a molding die to obtain a plate-like molded body having a thickness of 2 mm.
- Examples C6 to C13 A sheet-like molded body was produced in the same manner as in Example C1, except that the pellets produced in Examples B6 to B13 were used instead of the pellets produced in Example B1. did.
- Example C14 The ferrite powder produced in Example A3 and silica as a white pigment (AEROSIL200, manufactured by Nippon Aerosil Co., Ltd.) were dispersed in an aqueous PVA solution having a solid content of 10% by mass, and coated and dried using an applicator. Thickness: 100 ⁇ m A sheet-like molded product was obtained. At this time, the mass ratio of the solid content of PVA, ferrite powder, and SiO 2 was 75.0 wt%, 20.0 wt%, and 5.0 wt%, respectively.
- AEROSIL200 silica as a white pigment
- Example C15 Ferrite powder produced in Example A3, liquid epoxy resin, polymerization initiator, boron trifluoride monoethylamine complex as a curing agent, and silica as a white pigment (manufactured by Nippon Aerosil Co., Ltd., AEROSIL 200) After mixing, the mixture was poured into a mold made of silicone resin. Then, it heated at 120 degreeC, the epoxy resin was hardened, and the disk-shaped molded object of diameter: 13mm and thickness: 2.0mm was manufactured.
- the content of the ferrite powder in the obtained molded body was 20.0% by mass, the content of the resin material was 75.0% by mass, and the content of the colorant was 5.0% by mass.
- Example C16 The ferrite powder produced in Example A3, the olefin-based thermoplastic elastomer, and titanium dioxide particles as a white pigment were mixed, and this mixture was poured into a silicone resin mold. Then, it heated at 120 degreeC and manufactured the disk-shaped molded object of diameter: 13mm and thickness: 2.0mm.
- Example C17 and C18 A disc-shaped molded body was produced in the same manner as in Example C16 except that the type of the resin material was changed as shown in Table 5.
- Example C19 The ferrite powder produced in Example A3, the silicone resin, and the titanium dioxide particles as the white pigment, the ferrite powder content in the molded body is 20.0 mass%, and the resin material content is 75.0.
- the mixture was mixed so that the content of the colorant (pigment) was 5.0% by mass, and this mixture was poured into a mold made of silicone resin.
- a silicone resin diluted with an organic solvent to a solid content of 20% by weight was used.
- the organic solvent was evaporated by heating the entire mold at 65 ° C. and then heated to 120 ° C. to cure the silicone resin to produce a disk-shaped molded body having a diameter of 13 mm and a thickness of 2.0 mm.
- Example C20 A disc-shaped molded body was produced in the same manner as in Example C19 except that the type of the resin material was changed as shown in Table 5.
- Examples C21 to C24 A sheet-like molded body was produced in the same manner as in Example C1, except that the pellets produced in Examples B14 to B17 were used instead of the pellets produced in Example B1. did.
- Example C25 The resin composition (powder) produced in Example B18 was charged into a mold and then pressed, then removed from the mold, heated at 180 ° C. for 4 hours to be melted and cured, diameter: 13 mm, thickness: 2 A disc-shaped molded body of 0.0 mm was manufactured.
- Example C26 The resin composition (powder) produced in Example B19 was charged into a mold and then pressed, then removed from the mold, heated at 180 ° C. for 4 hours to be melted and cured, diameter: 13 mm, thickness: 2 A disc-shaped molded body of 0.0 mm was manufactured.
- Table 4 and Table 5 collectively show the conditions of the molded bodies of the respective examples and comparative examples described above.
- ⁇ 4 Evaluation of Molded Body ⁇ 4-1 >> Detection by Metal Detector
- a belt conveyor type metal detector (META-HAWKII, manufactured by System Square Co., Ltd.) was used for the molded body manufactured in each of the above-described Examples and Comparative Examples. ) was passed, and the sensitivity (level meter, iron ball sensitivity) capable of detecting the molded body was determined.
- ⁇ 4-2 Heating at the time of microwave irradiation
- the molded bodies produced in each of the above Examples and Comparative Examples were heated at 600 W for 5 minutes using a commercially available microwave oven, and the state of each molded body at this time was determined. The evaluation was made according to the following criteria.
- Examples C1 to C14, C21 to C24, and Comparative Examples C1 to C4 in which the molded body was formed into a sheet were cut into a size of 80 mm ⁇ 60 mm, and the sections were evaluated.
- Examples C15 to C20, C25, and C26 the obtained molded bodies were used as they were for evaluation. These results are shown in Table 6.
- the ferrite powder of the present invention is a ferrite powder that can be detected by a metal detector, and Mn is 3.5% by mass or more and 20.0% by mass or less, Fe is 50.0% by mass or more and 70.0% by mass or less, Contains soft ferrite particles. Therefore, it is possible to provide a ferrite powder that can be suitably used for manufacturing a molded body that can be stably detected by a metal detector. Therefore, the ferrite powder of the present invention has industrial applicability.
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Abstract
Description
本発明のフェライト粉は、金属探知機で検出可能なフェライト粉であって、
Mnを3.5質量%以上20.0質量%以下、Feを50.0質量%以上70.0質量%以下、含有するソフトフェライト粒子を含むことを特徴とする。
樹脂材料とを含むことを特徴とする。
《フェライト粉》
まず、本発明のフェライト粉について説明する。
これにより、前述したような効果がより顕著に発揮される。
これにより、着色時にフェライト粉の色味の影響を最小限に抑えることができる。
粒子の表面処理に用いる表面処理剤としては、例えば、シランカップリング剤、リン酸系化合物、カルボン酸、フッ素系化合物等が挙げられる。
得られた混合物を、仮焼成し仮焼結物とする。
その後、造粒粉を本焼成することにより、フェライト粉が得られる。
次に、本発明の樹脂組成物について説明する。
次に、本発明の成形体について説明する。
各実施例および各比較例のフェライト粉を以下のようにして製造した。
まず、Fe2O3とMn3O4とを用意し、これらを、モル比で、8.0:0.67の割合で、ヘンシェルミキサーに投入し、10分間乾式混合を行った後、混合物をローラーコンパクターでペレット化した。その後、焼成温度(仮焼温度):1000℃、大気雰囲気のロータリーキルンにて仮焼成を行った。
その後、得られた造粒物の粒度調整を行い、さらに、ロータリー式電気炉で、650℃で2時間加熱し、バインダーの除去を行った。
体積平均粒径は、以下のような測定により求めた。すなわち、まず、試料としてのフェライト粉:10gと水:80mlとを100mlのビーカーに入れ、分散剤(ヘキサメタリン酸ナトリウム)を2滴添加した。次いで、超音波ホモジナイザー(SMT.Co.LTD.製UH-150型)を用い分散を行った。このとき、超音波ホモジナイザーの出力レベルを4に設定し、20秒間分散を行った。その後、ビーカー表面にできた泡を取り除き、マイクロトラック粒度分析計(例えば、日機装株式会社製、Model9320-X100等)に導入し、測定を行った。なお、後に述べる各実施例および各比較例についても同様にして求めた。
なお、後に述べる各実施例および各比較例についても同様にして求めた。
原料として用いるFe2O3とMn3O4との比率を表1に示すようにし、仮焼結体に対する粉砕処理の条件、スプレードライヤーによる噴霧乾燥の条件、造粒物に対する粒度調整の条件を調整した以外は、前記実施例A1と同様にしてフェライト粉を製造した。
まず、Fe2O3とMn3O4とカーボンブラック(C)とを用意し、これらを、モル比で、8.0:0.67:1.1の割合で、ヘンシェルミキサーに投入し、10分間乾式混合、造粒した。
原料の使用量および造粒物の焼結温度を表1に示すようにした以外は、前記実施例A5と同様にしてフェライト粉を製造した。
原料としてFe2O3とNiOとZnOとCuOとを用い、これらの比率を、モル比で、49.0:15.5:29.0:6.5とし、造粒物に対する本焼成を、大気中、1250℃で行った以外は、前記実施例A1と同様にしてフェライト粉を製造した。
前述したような各実施例および各比較例のフェライト粉を用いて、以下のようにして、樹脂組成物を製造した。
ニーダー、ペレタイザーを用いて、前記実施例A3で製造したフェライト粉と、樹脂材料としてのポリプロピレンとを、質量比で、5.0:95.0で混合・混練、造粒した。
これにより、体積平均粒径が3mmのペレットとしての樹脂組成物を得た。
フェライト粉とポリプロピレンとの配合比率を表3に示すように変更した以外は、前記実施例B1と同様にしてペレットとしての樹脂組成物を得た。
ニーダー、ペレタイザーを用いて、前記実施例A3で製造したフェライト粉と、樹脂材料としてのポリプロピレンと、白色顔料としてのシリカ(日本エアロジル社製、AEROSIL200)とを、質量比で、2.0:93.0:5.0で混合・混練、造粒した。
これにより、体積平均粒径が3mmのペレットとしての樹脂組成物を得た。
フェライト粉とポリプロピレンとシリカとの配合比率を表3に示すように変更した以外は、前記実施例B6と同様にしてペレットとしての樹脂組成物を得た。
樹脂材料の種類を表3に示すようにした以外は、前記実施例B8と同様にしてペレットとしての樹脂組成物を得た。
フェライト粉の種類および樹脂材料の種類を表3に示すようにし、各成分の配合量を表3に示すようにした以外は、前記実施例B1と同様にしてペレットとしての樹脂組成物を得た。
ボールミルを用いて、前記実施例A3で製造したフェライト粉と、ナイロン樹脂粉末と、白色顔料としてのシリカ粒子とを、前記実施例B12と同様の質量比で混合し、粉状の樹脂組成物を得た。
樹脂材料の種類を表3に示すようにした以外は、前記実施例B18と同様にして粉状の樹脂組成物を得た。
フェライト粉の種類を、それぞれ、前記比較例A1~A3で製造したフェライト粉に変更し、各成分の配合量を変更した以外は、前記実施例B6と同様にしてペレットとしての樹脂組成物を得た。
フェライト粉の代わりに鉄粉(平均粒径:60μm)を用い、各成分の配合量を変更した以外は、前記実施例B6と同様にしてペレットとしての樹脂組成物を得た。
(実施例C1)
ニーダー、Tダイを用いて、前記実施例B1で製造した樹脂組成物(ペレット)を溶融、成形し、厚さ:100μmのシート状の成形体を得た。
樹脂組成物として、前記実施例B1で製造したペレットの代わりに、それぞれ、前記実施例B2、B3で製造したペレットを用いた以外は、前記実施例C1と同様にしてシート状の成形体を製造した。
ニーダーを用いて、前記実施例B4で製造した樹脂組成物(ペレット)を溶融、成形金型に射出成形し、厚さ:2mmの板状の成形体を得た。
ニーダーを用いて、前記実施例B5で製造した樹脂組成物(ペレット)を溶融、成形金型に射出成形し、厚さ:2mmの板状の成形体を得た。
樹脂組成物として、前記実施例B1で製造したペレットの代わりに、それぞれ、前記実施例B6~B13で製造したペレットを用いた以外は、前記実施例C1と同様にしてシート状の成形体を製造した。
固形分10質量%のPVA水溶液に実施例A3で製造したフェライト粉および白色顔料としてのシリカ(日本エアロジル社製、AEROSIL200)を分散し、アプリケーターを用いて、塗工・乾燥し、厚さ:100μmのシート状の成形体を得た。この時、PVAの固形分、フェライト粉、および、SiO2の質量比が、それぞれ、75.0重量%、20.0重量%、5.0重量%となるようにした。
前記実施例A3で製造したフェライト粉と、液状のエポキシ樹脂と、重合開始剤と、硬化剤としての三フッ化ホウ素モノエチルアミンコンプレックスと、白色顔料としてのシリカ(日本エアロジル社製、AEROSIL200)とを混合し、この混合物をシリコーン樹脂製の成形型に流し込んだ。その後、120℃に加熱し、エポキシ樹脂を硬化させ、直径:13mm、厚さ:2.0mmの円盤状の成形体を製造した。
前記実施例A3で製造したフェライト粉と、オレフィン系熱可塑性エラストマーと、白色顔料としての二酸化チタン粒子とを混合し、この混合物をシリコーン樹脂製の成形型に流し込んだ。その後、120℃に加熱し、直径:13mm、厚さ:2.0mmの円盤状の成形体を製造した。
樹脂材料の種類を表5に示すように変更した以外は、前記実施例C16と同様にして円盤状の成形体を製造した。
前記実施例A3で製造したフェライト粉と、シリコーン樹脂と、白色顔料としての二酸化チタン粒子とを、成形体中におけるフェライト粉の含有率が20.0質量%、樹脂材料の含有率が75.0質量%、着色剤(顔料)の含有率が5.0質量%になるように混合し、この混合物をシリコーン樹脂製の成形型に流し込んだ。このとき、シリコーン樹脂は固形分20重量%に有機溶媒で希釈したものを用いた。65℃で成形型ごと加熱することで有機溶媒を蒸発させた後、120℃に加熱し、シリコーン樹脂を硬化させ、直径:13mm、厚さ:2.0mmの円盤状の成形体を製造した。
樹脂材料の種類を表5に示すように変更した以外は、前記実施例C19と同様にして円盤状の成形体を製造した。
樹脂組成物として、前記実施例B1で製造したペレットの代わりに、それぞれ、前記実施例B14~B17で製造したペレットを用いた以外は、前記実施例C1と同様にしてシート状の成形体を製造した。
前記実施例B18で製造した樹脂組成物(粉状)を金型に投入後加圧した後、金型から取り出し、180℃で4時間加熱し溶融・硬化させ、直径:13mm、厚さ:2.0mmの円盤状の成形体を製造した。
前記実施例B19で製造した樹脂組成物(粉状)を金型に投入後加圧した後、金型から取り出し、180℃で4時間加熱し溶融・硬化させ、直径:13mm、厚さ:2.0mmの円盤状の成形体を製造した。
樹脂組成物として、前記実施例B1で製造したペレットの代わりに、それぞれ、前記比較例B1~B4で製造したペレットを用いた以外は、前記実施例C1と同様にしてシート状の成形体を製造した。
《4-1》金属探知機による検出
前述した各実施例および各比較例で製造した成形体について、ベルトコンベア式の金属探知機(システムスクエア社製、META-HAWKII)を通過させ、成形体を検出することができる感度(レベルメーター、鉄球感度)を求めた。
前述した各実施例および各比較例で製造した成形体について、市販の電子レンジを用いて600W、5分間加熱し、このときの各成形体の状態を、以下の基準に従い評価した。
△:温度上昇が不十分であった(20℃以上30℃未満)。
×:成形体の異常加熱が認められ、成形体の焦げ等が確認された。または、電子レンジ内に火花が発生する等の異常が認められ、評価を中止した。または、ほとんど加熱されなかった(20℃未満)。
これらの結果を表6に示す。
Claims (12)
- 金属探知機で検出可能なフェライト粉であって、
Mnを3.5質量%以上20.0質量%以下、Feを50.0質量%以上70.0質量%以下、含有するソフトフェライト粒子を含むことを特徴とするフェライト粉。 - 前記フェライト粉の構成粒子の体積平均粒径が0.1μm以上100μm以下である請求項1に記載のフェライト粉。
- 5K・1000/4πA/mの磁場をかけたときのVSM測定による磁化が85A・m2/kg以上98A・m2/kg以下である請求項1または2に記載のフェライト粉。
- 請求項1ないし3のいずれか1項に記載のフェライト粉と、
樹脂材料とを含むことを特徴とする樹脂組成物。 - 前記樹脂材料中に、前記フェライト粉が分散して存在している請求項4に記載の樹脂組成物。
- 前記樹脂組成物中における前記フェライト粉の含有率が5.0質量%以上90質量%以下である請求項4または5に記載の樹脂組成物。
- 前記樹脂材料は、ポリエチレン、ポリプロピレン、ポリ塩化ビニル、ポリ塩化ビニリデン、ポリビニルアルコール(PVA)、フッ素系樹脂、シリコーンゴム、ブタジエンゴム、熱可塑性エラストマー、エポキシ樹脂およびシリコーン樹脂よりなる群から選択される1種または2種以上を含む請求項4ないし6のいずれか1項に記載の樹脂組成物。
- 請求項4ないし7のいずれか1項に記載の樹脂組成物を用いて形成された部位を有することを特徴とする成形体。
- 前記フェライト粉の含有率が2.0質量%以上20質量%以下である請求項8に記載の成形体。
- 前記成形体は、食品の製造、加工、包装現場で用いられる請求項8または9に記載の成形体。
- 前記成形体は、調理器具類、調理用具類、食品包装部材の一部もしくは全部に使用される請求項10に記載の成形体。
- 前記成形体は、表面から厚さ方向に1.0mm以内の領域に前記フェライト粉を含む請求項8ないし11のいずれか1項に記載の成形体。
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