WO2022224309A1 - モノマー組成物、成形体、ボンド磁石、及び圧粉磁心 - Google Patents
モノマー組成物、成形体、ボンド磁石、及び圧粉磁心 Download PDFInfo
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- WO2022224309A1 WO2022224309A1 PCT/JP2021/015883 JP2021015883W WO2022224309A1 WO 2022224309 A1 WO2022224309 A1 WO 2022224309A1 JP 2021015883 W JP2021015883 W JP 2021015883W WO 2022224309 A1 WO2022224309 A1 WO 2022224309A1
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- 125000001971 neopentyl group Chemical group [H]C([*])([H])C(C([H])([H])[H])(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
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Images
Classifications
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
- C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
- C08F220/10—Esters
- C08F220/12—Esters of monohydric alcohols or phenols
- C08F220/16—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms
- C08F220/18—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms with acrylic or methacrylic acids
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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
- C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
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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
- C08K3/02—Elements
- C08K3/08—Metals
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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
- C08K3/10—Metal compounds
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
- C08L33/04—Homopolymers or copolymers of esters
- C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
- C08L33/10—Homopolymers or copolymers of methacrylic acid esters
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
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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
- H01F1/032—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 hard-magnetic materials
- H01F1/04—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 hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
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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
- H01F1/032—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 hard-magnetic materials
- H01F1/04—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 hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/059—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and Va elements, e.g. Sm2Fe17N2
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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
- H01F1/14—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 metals or alloys
- H01F1/20—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 metals or alloys in the form of particles, e.g. powder
- H01F1/22—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 metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
- H01F1/24—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 metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
- H01F1/26—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 metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated by macromolecular organic substances
Definitions
- One aspect of the present invention relates to monomer compositions, compacts, bonded magnets, and dust cores.
- Magnetic members such as bonded magnets, dust cores and sintered magnetic cores, or structural members are manufactured as products of powder metallurgy.
- compacts are formed by compacting metal powders at high pressure. Since voids are likely to be formed in the metal powder that constitutes the molded body, the molded body that is composed of the metal powder is porous. Conventionally, voids in a molded body are impregnated with a resin in order to improve the mechanical strength of the molded body and to add functions to the molded body.
- the method for manufacturing a metal material described in Patent Document 1 below includes a step of impregnating the voids of a porous metal material (sintered body) with a resin. As a result, a metal material having excellent damping function is obtained.
- the method for manufacturing a bonded magnet described in Patent Document 2 includes a step of impregnating the voids of a molded body made of magnet powder with an epoxy resin, an acrylate compound, or the like. As a result, detachment and flaking of the magnet powder in the bonded magnet are suppressed.
- Molded bodies containing metal powder are required to have environmental resistance (for example, mechanical strength at high temperatures) depending on their use.
- environmental resistance for example, mechanical strength at high temperatures
- mechanical strength is imparted to the compact by mixing a binder such as a thermosetting resin or thermoplastic resin with the metal powder. Further, as described above, the resin is impregnated into the voids in the molded body in order to improve the mechanical strength of the molded body.
- the resin is efficiently impregnated into the minute voids in the bonded magnet or dust core. Moreover, it is desirable that the resin for impregnation imparts heat resistance (mechanical strength at high temperatures) to the bonded magnet or dust core. Conventionally, however, there has been no impregnating resin suitable for bonded magnets or dust cores. For example, when a sealing material such as acrylic resin or urethane resin is used for impregnation, it is difficult for the bonded magnet and dust core to have sufficient heat resistance (mechanical strength at high temperatures).
- An object of one aspect of the present invention is to provide a monomer composition, a molded body, a bonded magnet, and a dust core that increase the mechanical strength of a porous molded body containing metal powder at high temperatures.
- a monomer composition according to one aspect of the present invention is a monomer composition for impregnating voids in a porous compact.
- the compact contains metal powder and a thermosetting resin composition.
- the monomer composition contains at least one compound selected from the group consisting of acrylates having a dicyclopentane structure, acrylates having a dicyclopentene structure, methacrylates having a dicyclopentene structure, and methacrylates having a dicyclopentene structure.
- the monomer composition according to one aspect of the present invention may further contain at least one of an acrylate having a glycidyl group and a methacrylate having a glycidyl group.
- the monomer composition according to one aspect of the present invention may further contain at least one of an acrylate having a hydroxyl group and a methacrylate having a hydroxyl group.
- thermosetting resin composition may contain at least one functional group selected from the group consisting of glycidyl groups, hydroxyl groups, amide groups, and imide groups.
- a molded article according to one aspect of the present invention includes a metal powder, a thermosetting resin composition, and a resin having at least one of a dicyclopentane structure and a dicyclopentene structure.
- the molded article according to one aspect of the present invention may further contain an acrylic resin having a glycidyl group.
- the molded article according to one aspect of the present invention may further contain an acrylic resin having a hydroxyl group.
- the resin having at least one of a dicyclopentane structure and a dicyclopentene structure may be an acrylic resin.
- a resin having at least one of a dicyclopentane structure and a dicyclopentene structure may further have at least one of a glycidyl group and a hydroxyl group.
- a resin having at least one of a dicyclopentane structure and a dicyclopentene structure may have a crosslinked structure containing —CH(OH)—CH 2 —.
- a resin having at least one of a dicyclopentane structure and a dicyclopentene structure may be bonded to the thermosetting resin composition via a crosslinked structure.
- the metal powder may be a permanent magnet or a soft magnetic material.
- a bonded magnet according to one aspect of the present invention includes the compact described above, and the metal powder contained in the compact is at least one of a Sm--Fe--N magnet and an Nd--Fe--B magnet.
- a powder magnetic core according to one aspect of the present invention includes the compact described above, and the metal powder contained in the compact is at least one of pure iron and an alloy containing iron.
- a monomer composition a molded body, a bonded magnet, and a powder magnetic core that increase the mechanical strength of a porous molded body containing metal powder at high temperatures.
- FIG. 1 is a schematic diagram (cross-sectional view) of part of a porous molded body that is not impregnated with a monomer composition, and a schematic diagram (cross-sectional view) of a part of a molded body that is impregnated with a monomer composition.
- FIG. 2 is a schematic diagram of the thermosetting resin composition 2 (cured product) contained in the molded product.
- FIG. 3 is a schematic diagram of a resin (a polymer of a monomer composition) having a dicyclopentane structure, a dicyclopentene structure, a glycidyl group and a hydroxyl group.
- (Meth)acrylate described below means either one of acrylate and methacrylate, or both acrylate and methacrylate.
- a "(meth)acryl group” means either one of an acryl group and a methacryl group, or both an acryl group and a methacryl group.
- the monomer composition according to this embodiment is a monomer composition for impregnating voids in a porous molded body. That is, at least some or all of the many voids in the molded body are filled with the monomer composition.
- the monomer composition may be liquid at ambient temperature.
- a porous molded body contains a metal powder and a thermosetting resin composition.
- the thermosetting resin composition may be a cured product.
- a molded article that is not impregnated with a monomer composition may consist of only the metal powder and the thermosetting resin composition.
- a molded article 10A in FIG. 1 is a portion of a porous molded article that is not impregnated with the monomer composition 4A.
- each molded body a plurality of metal particles 1 constituting metal powder are bound together by a thermosetting resin composition 2 . Part or the entire surface of each metal particle 1 may be covered with the thermosetting resin composition 2 .
- a plurality of voids 3 are formed in the molded body 10A that is not impregnated with the monomer composition 4A.
- the voids 3 may be rephrased as pores. For example, voids 3 may be formed between adjacent metal particles 1 .
- One void 3 may be a space surrounded by the thermosetting resin composition 2 covering each metal particle 1 .
- a plurality of voids 3 may communicate with each other.
- Each void 3 formed inside the molded body 10A may communicate with the outside of the molded body 10A via the voids 3 opened on the surface of the molded body 10B. Therefore, the monomer composition 4A may be impregnated into each void 3 formed inside the molded body 10A through the voids 3 opened on the surface of the molded body 10A.
- the dimensions (pore diameter) of the voids 3 in the compact 10A may be equal to or less than the particle diameter of the metal powder.
- the dimension (pore diameter) of the voids 3 in the compact 10A may be 0.1 ⁇ m or more and 100 ⁇ m or less.
- the dimensions (pore diameter) of the voids 3 in the compact 10A are not limited.
- Monomer composition 4A contains at least one compound selected from the group consisting of acrylates having a dicyclopentane structure, acrylates having a dicyclopentene structure, methacrylates having a dicyclopentene structure, and methacrylates having a dicyclopentene structure.
- a dicyclopentane structure is represented by the following chemical formula (1).
- a dicyclopentene structure is represented by the following chemical formula (2).
- the monomer composition 4A may contain a dicyclopentane structure or multiple types of (meth)acrylates having a dicyclopentane structure.
- the monomer composition 4A may contain all of an acrylate having a dicyclopentane structure, an acrylate having a dicyclopentene structure, a methacrylate having a dicyclopentene structure, and a methacrylate having a dicyclopentene structure.
- an acrylate having a dicyclopentane structure an acrylate having a dicyclopentene structure
- a methacrylate having a dicyclopentene structure a methacrylate having a dicyclopentene structure
- a methacrylate having a dicyclopentene structure referred to as a "cyclic cross linking structure”.
- the monomer composition 4A is polymerized (gelled) by heating. Polymerization of the monomer composition 4A containing the (meth)acrylate having a cyclic crosslinked structure produces a resin 4B (polymer) having a cyclic crosslinked structure. That is, by heating the compact 10B in which the voids 3 are impregnated with the monomer composition 4A, the resin 4B having the cyclic crosslinked structure is generated in the voids 3, and the voids 3 are filled with the resin 4B having the cyclic crosslinked structure.
- the resin 4B having a cyclic crosslinked structure may be an acrylic resin.
- the molded body 10B containing the resin 4B having a cyclic cross-linked structure has excellent heat resistance and can withstand high temperatures. It can have high mechanical strength.
- the mechanical strength of the molded article at high temperatures is, for example, the mechanical strength of the molded article at a temperature of 100° C. or higher and 200° C. or lower.
- the cyclic crosslinked structure itself may not react with other functional groups.
- the cyclic crosslinked structure in the molded body 10B may be detected by the following method.
- the powder obtained by pulverizing the compact 10B is added to a solvent having a smaller specific gravity (true specific gravity) than the metal powder in the compact 10B.
- a solvent having a smaller specific gravity (true specific gravity) than the metal powder in the compact 10B As a result, the metal powder settles in the solvent, and the component (resin component) of the compact 10B other than the metal powder floats in the solvent.
- a cyclic crosslinked structure is detected by analyzing the metal powder and the separated resin component by pyrolysis gas chromatography/mass spectrometry. That is, the resin component separated from the metal powder is decomposed into a plurality of types of components with small molecular weights by the decomposing device. A plurality of types of components are separated by gas chromatography, and the components (molecules) corresponding to the cyclic crosslinked structures are detected by mass spectrometry of each separated component.
- (Meth)acrylates having a cyclic crosslinked structure include dicyclopentenyl acrylate (FA-511AS), dicyclopentenyloxyethyl acrylate (FA-512AS), dicyclopentenyl acrylate (FA-513AS), dicyclopentenyl methacrylate (FA -511M), dicyclopentenyloxyethyl methacrylate (FA-512MT), and at least one (meth)acrylate selected from the group consisting of dicyclopentenyl methacrylate (FA-513M).
- the notation in parentheses above is a product name manufactured by Showa Denko Materials Co., Ltd.
- the monomer composition 4A may further contain at least one of an acrylate having a glycidyl group and a methacrylate having a glycidyl group.
- the monomer composition 4A may further contain at least one of an acrylate having a hydroxyl group and a methacrylate having a hydroxyl group.
- the monomer composition 4A may further contain both a (meth)acrylate having a glycidyl group and a (meth)acrylate having a hydroxyl group.
- the resin 4B having a cyclic crosslinked structure may be a copolymer formed from a (meth)acrylate having a cyclic crosslinked structure and a (meth)acrylate having a glycidyl group.
- the resin 4B having a cyclic crosslinked structure may be a copolymer formed from a (meth)acrylate having a cyclic crosslinked structure and a (meth)acrylate having a hydroxyl group.
- the resin 4B having a cyclic crosslinked structure may be a copolymer formed from a (meth)acrylate having a cyclic crosslinked structure, a (meth)acrylate having a glycidyl group, and a (meth)acrylate having a hydroxyl group.
- An acrylic resin (crosslinked body) having at least one of a glycidyl group and a hydroxyl group is produced by radical polymerization of the monomer composition 4A.
- radical polymerization produces an acrylic resin (crosslinked body) having at least one of a glycidyl group and a hydroxyl group.
- easy to do Further heating of the acrylic resin produced by radical polymerization may cause a cross-linking reaction between glycidyl groups of the acrylic resin.
- Further heating of the acrylic resin produced by the radical polymerization may cause a cross-linking reaction between the glycidyl groups of the acrylic resin and the hydroxyl groups of the acrylic resin. As shown in FIG.
- the above-described cross-linking reaction allows the resin 4B having a cyclic cross-linked structure to have a strong structure composed of the acrylic resin 6 cross-linked to each other in a network. That is, the resin 4B having a cyclic crosslinked structure can further have a crosslinked structure containing —CH(OH)—CH 2 — (a crosslinked structure derived from a glycidyl group). As a result, the heat resistance of the molded body 10B is likely to be improved, and the mechanical strength of the molded body 10B at high temperatures is likely to be increased.
- thermosetting resin composition By heating the acrylic resin produced by radical polymerization and the thermosetting resin composition, at least one of glycidyl groups and hydroxyl groups in the acrylic resin may react with functional groups in the thermosetting resin composition. As a result, a crosslinked structure may be formed between the acrylic resin and the thermosetting resin composition.
- a part of the glycidyl groups of the (meth)acrylate may remain in the molded body 10B without reacting with other functional groups. That is, the molded article 10B may further contain an acrylic resin having a glycidyl group. Part of the hydroxyl groups of the (meth)acrylate may remain in the molding 10B without reacting with other functional groups. That is, the molded body 10B may further contain an acrylic resin having a hydroxyl group.
- the resin 4B having a cyclic crosslinked structure may further have at least one functional group of a glycidyl group and a hydroxyl group.
- the (meth)acrylate having a glycidyl group may be, for example, at least one of glycidyl methacrylate and glycidyl acrylate (meth)acrylate.
- the (meth)acrylate having a hydroxyl group may be, for example, at least one (meth)acrylate of 2-hydroxyethyl acrylate and 2-hydroxymethyl acrylate.
- the thermosetting resin composition 2 in the molded article 10A contains an epoxy group, a glycidyl group, a hydroxyl group, an amino group, an amide group, an imide group, a carboxyl group and an acid anhydride.
- epoxy groups and glycidyl groups may be derived from epoxy resins.
- hydroxyl groups may be derived from epoxy resins and/or phenolic resins. As shown in FIG.
- the thermosetting resin composition 2 may be composed of an epoxy resin 5 crosslinked to each other in a network, and contains unreacted glycidyl groups and hydroxyl groups remaining after crosslinking (heat curing).
- the amide groups may be derived from polyamide resins and/or polyamideimide resins.
- the imide groups may be derived from polyimide resins, polyamideimide resins, and/or bismaleimide resins.
- hydroxyl groups contained in monomer composition 4A or its polymer react with glycidyl groups contained in thermosetting resin composition 2 to form —CH(OH)—CH 2 —.
- a crosslinked structure containing may be formed.
- the resin 4B having a cyclic crosslinked structure may be bonded (integrated) with the thermosetting resin composition 2 via a crosslinked structure containing —CH(OH)—CH 2 —.
- the monomer composition 4A may further contain a low-viscosity (meth)acrylate.
- low viscosity (meth)acrylates include stearyl acrylate, methoxytriethylene glycol acrylate, methoxypolyethylene glycol acrylate (methoxypolyethylene glycol #400 acrylate), methoxytripropylene glycol acrylate, phenoxydiethylene glycol acrylate, lauryl methacrylate, and benzyl methacrylate ( FA-BZM, trade name of Showa Denko Materials Co., Ltd.) may be at least one (meth)acrylate selected from the group consisting of.
- the monomer composition 4A may further contain a polyfunctional (meth)acrylate having two or more (meth)acrylic groups, since a crosslinked structure is likely to be formed with the polymerization of the monomer composition 4A.
- the polyfunctional (meth)acrylate is from the group consisting of pentaerythritol tetraacrylate, 1,4-butanediol dimethacrylate, neopentyl dimethacrylate, methoxydiethylene glycol dimethacrylate, methoxytetraethylene glycol dimethacrylate, and methoxydiethylene glycol dimethacrylate. It may be at least one selected (meth)acrylate.
- the monomer composition 4A may further contain a (meth)acrylate having a relatively long alkyl chain, since the molded article 10B is likely to have softness (flexibility).
- the (meth)acrylate having an alkyl chain may be at least one (meth)acrylate selected from the group consisting of lauryl methacrylate and dodecyl methacrylate.
- the monomer composition 4A may contain a thermal radical polymerization initiator.
- the thermal radical polymerization initiator may be at least one compound selected from the group consisting of azo compounds and peroxides.
- the thermal radical polymerization initiator may preferably be an organic peroxide because it does not generate gas when thermal radicals are generated.
- Organic peroxides that dissolve in (meth)acrylates (monomers) can be used.
- the organic peroxide may preferably be liquid at ambient temperature.
- the organic peroxide is at least one selected from the group consisting of benzoyl peroxide, t-butylperoxy-2-ethylhexanoate (PERBUTYL O, trade name manufactured by NOF CORPORATION) and lauryl peroxide. It may be a compound.
- the monomer composition 4A may be prepared by mixing a (meth)acrylate having a cyclic crosslinked structure, a low-viscosity (meth)acrylate, a polyfunctional (meth)acrylate, and a thermal radical polymerization initiator.
- the thermal radical polymerization initiator may be added to the monomer composition 4A immediately before the molded article 10A is impregnated with the monomer composition 4A.
- the total mass of all (meth)acrylates contained in monomer composition 4A may be expressed as 100 parts by mass, and the mass ratio of the thermal radical initiator to 100 parts by mass of (meth)acrylate is 0.1 It may be from 1 part by mass to 5 parts by mass, preferably from 1 part by mass to 2 parts by mass.
- the viscosity of the monomer composition 4A may be adjusted based on the composition and mixing ratio of each of the plurality of (meth)acrylates constituting the monomer composition 4A.
- the viscosity of the monomer composition 4A at 25° C. is preferably 1 mPa ⁇ s or more and 200 mPa ⁇ s or less, more preferably 10 mPa ⁇ s or more and 100 mPa ⁇ s or less, and most preferably 20 mPa ⁇ s or more and 90 mPa ⁇ s or less. . Since the monomer composition 4A has a relatively low viscosity as described above, the fine voids 3 in the molded body 10A can be easily impregnated with the monomer composition 4A.
- the monomer composition 4A may be impregnated into the voids 3 in the porous molded body 10A by the following method.
- the entire porous molded body 10A is immersed in the monomer composition 4A contained in a container capable of reducing the pressure inside. Due to the subsequent decompression in the container, the gas that fills the voids in the compact 10A is removed to the outside of the compact 10A. After removing the gas from the compact 10A, the pressure inside the container is returned to the atmospheric pressure.
- the monomer composition 4A is impregnated into the voids 3 of the porous compact 10A.
- the number of times of reducing the pressure in the container and releasing the pressure to the atmosphere may be one. A plurality of pressure reduction operations and atmospheric pressure release may be alternately repeated.
- thermosetting resin composition 2 By the first heat treatment of the molded body 10B impregnated with the monomer composition 4A, thermal polymerization of the monomer composition 4A (generation of the resin 4B having a cyclic cross-linking structure), a cross-linking reaction within the resin 4B having a cyclic cross-linking structure, And a cross-linking reaction between the resin 4B having a cyclic cross-linked structure and the thermosetting resin composition 2 may occur.
- the temperature of the first heat treatment of the molded article 10B may be substantially equal to the decomposition temperature of the thermal radical polymerization initiator in the monomer composition 4A.
- the temperature and required time for the first heat treatment of the molded article 10B differ depending on the composition of the thermal radical polymerization initiator.
- the temperature of the first heat treatment of the molded body 10B may be 40° C. or higher and 120° C. or lower, preferably 60° C. or higher and 110° C. or lower, more preferably 80° C. or higher and 100° C. or lower.
- the time required for the first heat treatment of the compact 10B may be 30 minutes or longer, preferably 1 hour or longer.
- the molded body 10B is subjected to the second heat treatment after the first heat treatment.
- the temperature of the second heat treatment of the molded body 10B may be 150° C. or higher and 210° C. or lower, preferably 180° C. or higher and 200° C. or lower.
- the time required for the second heat treatment of the molded body 10B may be 10 minutes or more and 60 minutes or less.
- the second heat treatment of the molded body 10B can further increase the mechanical strength of the molded body 10B.
- the impregnation amount Rm of the monomer composition 4A defined by the following formula 1 may be 0.1% by mass or more and 5.0% by mass or less, or 0.57% by mass or more and 1.3% by mass or less.
- M B in Equation 1 is the mass of molded article 10B impregnated with monomer composition 4A.
- MB can be rephrased as the mass of the molded body 10B containing the resin 4B having a cyclic crosslinked structure.
- M A in Equation 1 is the mass of the porous compact 10A before being impregnated with the monomer composition 4A.
- the metal powder may be a permanent magnet.
- permanent magnets include samarium-cobalt (Sm-Co) alloy magnets, neodymium-iron-boron (Nd-Fe-B) alloy magnets, samarium-iron-nitrogen (Sm-Fe-N) alloy magnets, It may be an iron-cobalt (Fe--Co) alloy magnet or an Al--Ni--Co alloy magnet (alnico magnet).
- the particle size of the metal powder may be, for example, 20 ⁇ m or more and 300 ⁇ m or less, or 40 ⁇ m or more and 250 ⁇ m or less.
- the bonded magnet according to the present embodiment includes permanent magnet powder (for example, at least one of Sm--Fe--N magnets and Nd--Fe--B magnets), thermosetting resin composition 2, and a cyclic crosslinked structure.
- permanent magnet powder for example, at least one of Sm--Fe--N magnets and Nd--Fe--B magnets
- thermosetting resin composition 2 for example, thermosetting resin composition 2, and a cyclic crosslinked structure.
- the metal powder may be a soft magnetic material.
- the metal powder which is a soft magnetic material, may be, for example, at least one kind of metal selected from the group consisting of pure iron and alloys containing iron.
- Alloys containing iron include, for example, Fe—Cr alloys (stainless steel), Fe—Ni—Cr alloys (stainless steel), Fe—Si alloys, Fe—Si—Al alloys (sendust), Fe—Ni system alloy (permalloy), Fe--Cu--Ni-based alloy (permalloy), Fe--Co-based alloy (permendur), Fe--Cr--Si-based alloy (electromagnetic stainless steel), and Fe--Ni--Mn--C system It may be at least one metal selected from the group consisting of alloys (invar).
- the metal powder which is a soft magnetic material
- the metal powder which is a soft magnetic material
- the metal powder, which is a soft magnetic material may be Fe amorphous alloy.
- the metal powder, which is a soft magnetic material may be at least one of amorphous iron powder and carbonyl iron powder.
- the particle size of the metal powder may be, for example, 60 ⁇ m or more and 150 ⁇ m or less.
- the dust core according to the present embodiment includes the above soft magnetic powder (for example, at least one of pure iron and an alloy containing iron), a thermosetting resin composition 2, and a resin having a cyclic crosslinked structure It may be a molded body 10B containing 4B.
- Dust cores are used, for example, in inductors, transformers, reactors, thyristor valves, noise filters (EMI filters), choke coils, iron cores for motors, rotors and yokes of motors for general home appliances and industrial equipment, diesel engines and gasoline engines. It may be used in a solenoid core (stationary iron core) for an electromagnetic valve incorporated in an electronically controlled fuel injection device, a position sensor, and a magnetostrictive sensor.
- EMI filters noise filters
- the metal powder may contain multiple types of metal elements.
- the metal powder may further contain at least one element selected from the group consisting of base metal elements, noble metal elements, transition metal elements, and rare earth elements, in addition to the above elements.
- metal powders such as copper (Cu), titanium (Ti), manganese (Mn), cobalt (Co), nickel (Ni), zinc (Zn), aluminum (Al), tin (Sn), chromium ( Cr), barium (Ba), strontium (Sr), lead (Pb) and silver (Ag), oxygen (O), beryllium (Be), phosphorus (P), boron (B), and silicon (Si) It may further contain at least one element selected from the group.
- the molded body 10A may contain one type of metal powder, or may contain a plurality of types of metal powder.
- the molded body 10A (the molded body 10B) may contain multiple types of metal powders that differ in average particle diameter or median diameter (D50).
- the shape of each metal particle 1 that constitutes the metal powder is not particularly limited.
- the individual metal particles 1 can be spherical, flattened or acicular, for example.
- the particle size of the metal powder may be calculated based on weight measurement of the metal particles by sieving. The particle size of the metal powder may be measured with a laser diffraction particle size distribution analyzer.
- the molded body 10A (molded body 10B) may further contain an inorganic filler (for example, silica (SiO 2 ) particles) in addition to the metal powder.
- the thermosetting resin composition 2 may contain at least one thermosetting resin selected from the group consisting of epoxy resins, phenolic resins, bismaleimide resins, polyimide resins, and polyamideimide resins.
- the thermosetting resin composition 2 may further contain a polyamide resin (thermoplastic resin) in addition to the above thermosetting resins.
- a functional group contained in the thermosetting resin may react with either a glycidyl group or a hydroxyl group of the resin 4B having a cyclic crosslinked structure to form a crosslinked structure (--CH ( OH)--CH.sub.2--).
- thermosetting resin selected from the group consisting of epoxy resins, phenolic resins, bismaleimide resins, polyimide resins, and polyamideimide resins has at least one functional group selected from glycidyl groups and hydroxyl groups.
- a glycidyl group of the thermosetting resin may react with either a glycidyl group or a hydroxyl group of the resin 4B having a cyclic crosslinked structure to form a crosslinked structure (--CH ( OH)--CH.sub.2--).
- a hydroxyl group of the thermosetting resin may react with a glycidyl group of the resin 4B having a cyclic crosslinked structure to form a crosslinked structure (--CH ( OH)--CH.sub.2--). Due to the crosslinked structure between the resin 4B having a cyclic crosslinked structure and the thermosetting resin, the mechanical strength of the molded body 10B at high temperatures is likely to be further increased. For the same reason, the functional group (eg, amide group) of the polyamide resin in the thermosetting resin composition 2 reacts with the glycidyl group of the resin 4B having a cyclic crosslinked structure to form a crosslinked structure (—CH(OH) —CH 2 —) may be formed.
- the functional group eg, amide group
- epoxy resins include biphenyl-type epoxy resins, stilbene-type epoxy resins, diphenylmethane-type epoxy resins, sulfur atom-containing epoxy resins, novolak-type epoxy resins, dicyclopentadiene-type epoxy resins, salicylaldehyde-type epoxy resins, naphthols and phenols.
- Copolymerized epoxy resins epoxidized aralkyl-type phenolic resins, bisphenol-type epoxy resins, glycidyl ether-type epoxy resins of alcohols, glycidyl ether-type epoxy resins of para-xylylene and/or meta-xylylene-modified phenolic resins, terpene-modified phenolic resins glycidyl ether type epoxy resin, cyclopentadiene type epoxy resin, glycidyl ether type epoxy resin of polycyclic aromatic ring-modified phenol resin, glycidyl ether type epoxy resin of naphthalene ring-containing phenol resin, glycidyl ester type epoxy resin, glycidyl type or methyl glycidyl type epoxy resins, alicyclic type epoxy resins, halogenated phenol novolac type epoxy resins, ortho-cresol novolak type epoxy resins, hydroquinone type epoxy resins, thi
- phenolic resins include aralkyl-type phenolic resins, dicyclopentadiene-type phenolic resins, salicylaldehyde-type phenolic resins, novolak-type phenolic resins, copolymer-type phenolic resins of benzaldehyde-type phenol and aralkyl-type phenol, para-xylylene and/or meta-xylylene-modified from the group consisting of phenolic resins, melamine-modified phenolic resins, terpene-modified phenolic resins, dicyclopentadiene-type naphthol resins, cyclopentadiene-modified phenolic resins, polycyclic aromatic ring-modified phenolic resins, biphenyl-type phenolic resins, and triphenylmethane-type phenolic resins It may be at least one resin selected.
- the phenolic resin may be a copolymer composed of two or more of
- a phenolic novolac resin may be, for example, a resin obtained by condensation or co-condensation of phenols and/or naphthols and aldehydes in the presence of an acidic catalyst.
- Phenols constituting the phenolic novolac resin may be, for example, at least one selected from the group consisting of phenol, cresol, xylenol, resorcinol, catechol, bisphenol A, bisphenol F, biphenol, phenylphenol and aminophenol.
- Naphthols constituting the phenol novolak resin may be, for example, at least one selected from the group consisting of ⁇ -naphthol, ⁇ -naphthol and dihydroxynaphthalene.
- the aldehydes constituting the phenol novolac resin may be, for example, at least one selected from the group consisting of formaldehyde, acetaldehyde, propionaldehyde, benzaldehyde and salicylaldehyde.
- the phenols constituting the phenolic novolac resin may be compounds having two phenolic hydroxyl groups in one molecule.
- the compound having two phenolic hydroxyl groups in one molecule may be, for example, at least one selected from the group consisting of resorcin, catechol, bisphenol A, bisphenol F, and substituted or unsubstituted biphenol.
- the ratio of the hydroxyl group equivalent of the phenol resin to the epoxy equivalent of the epoxy resin is 0.5 or more and 1.5 or less, 0.9 or more and 1.4 or less, 1.0 or more and 1.4 or less, or 1.0 or more and 1.2.
- the bismaleimide resin may contain an addition reaction product of polymaleimides (a) and aminophenols (b), and an epoxy compound (c).
- An addition reaction product is obtained by reacting the polymaleimides (a) and the aminophenols (b), and the bismaleimide resin may be obtained by adding the epoxy compound (c) to the addition reaction product.
- the polymaleimide (a) constituting the bismaleimide resin is represented by the following chemical formula (A).
- R 1 in chemical formula (A) is an n-valent organic group.
- Each of X 1 and X 2 is a monovalent atom selected from hydrogen or halogen, or a monovalent organic group.
- X 1 and X 2 may be the same, or X 1 and X 2 may be different from each other.
- n in the chemical formula (A) is an integer of 2 or more.
- Polymaleimides (a) include, for example, ethylenebismaleimide, hexamethylenebismaleimide, m-phenylenebismaleimide, p-phenylenebismaleimide, 4,4′-diphenylmethanebismaleimide, 4,4′-diphenyletherbismaleimide, 4 ,4'-diphenylsulfonebismaleimide, 4,4'-dicyclohexylmethanebismaleimide, m-xylylenebismaleimide, p-xylylenebismaleimide, and 4,4'-phenylenebismaleimide.
- Monomaleimides can be, for example, N-3-chlorophenylmaleimide or N-4-nitrophenylmaleimide.
- the aminophenol (b) constituting the bismaleimide resin is represented by the following chemical formula (B).
- R2 in the formula (B) is a monovalent atom selected from hydrogen or halogen, or a monovalent organic group.
- m in the chemical formula (B) is an integer of 1-5.
- Aminophenols (b) include o-aminophenol, m-aminophenol, p-aminophenol, o-aminocresol, m-aminocresol, p-aminocresol, aminoxylenol, aminochlorophenol, aminobromophenol, amino It may be at least one compound selected from the group consisting of catechol, aminoresorcin, aminobis(hydroxyphenol)propane and aminooxybenzoic acid.
- the epoxy compound (c) constituting the bismaleimide resin has two or more epoxy groups in the molecule.
- the epoxy compound (c) includes, for example, bisphenol A type epoxy resin, bisphenol F type epoxy resin, novolac type epoxy resin, glycidyl ester resin of polycarboxylic acid, polyglycidyl ether of polyol, urethane-modified epoxy resin, unsaturated compound as epoxy at least selected from the group consisting of fatty acid-type polyepoxides obtained by epoxidizing unsaturated compounds, alicyclic polyepoxides obtained by epoxidizing unsaturated compounds, epoxy resins having heterocyclic rings, epoxy resins having heterocyclic rings, and epoxy resins obtained by glycidylating amines. It may be a single compound.
- An addition reaction product is obtained by the reaction of the above-mentioned polymaleimides (a) and aminophenols (b).
- the weight ratio of aminophenols (b) may be 5 to 40 parts by weight, preferably 10 to 30 parts by weight, per 100 parts by weight of polymaleimides (a).
- the reaction temperature of polymaleimides (a) and aminophenols (b) may be, for example, 50 to 200°C, preferably 80 to 180°C.
- the reaction time of polymaleimides (a) and aminophenols (b) may be appropriately adjusted within the range of several minutes to several tens of hours.
- the content of the addition reaction product in the bismaleimide resin may be 30-80% by mass.
- the bismaleimide resin may be, for example, at least one resin selected from KIR-30, KIR-50 and KIR-100 (these are trade names manufactured by Kyocera Corporation).
- the polyimide resin may be a dehydration polycondensate of tetracarboxylic anhydride and 4,4'-bis(3-aminophenoxy)biphenyl.
- Polyimide resins are Aurum PL450C, Aurum PL500A, Aurum PL6200, Aurum PD450L (products manufactured by Mitsui Chemicals, Inc.), SolverPI-5600 (products manufactured by Solver) and Serprim (products manufactured by Mitsubishi Gas Chemical Co., Ltd.). It may be at least one resin selected.
- the polyamide resin may be particles of nylon 6 obtained from ⁇ -caprolactam and/or particles of nylon 12 obtained from lauryllactam.
- the polyamide resin is selected from the group consisting of particles made of nylon 6 (TR-1 and TR-2 manufactured by Toray Industries, Inc.) and particles made of nylon 12 (SP-500 and SP-10 manufactured by Toray Industries, Inc.). It may be at least one resin selected.
- the polyamideimide resin may be a polyamideimide resin having a siloxane structure.
- the polyamideimide resin may have two or more carboxyl groups at at least one of both ends of the polyamideimide molecular chain.
- a carboxy group of the polyamideimide resin may react with a glycidyl group contained in the monomer composition 4A or its polymer to form a crosslinked structure containing —CH(OH)—CH 2 —.
- the polyamideimide resin may be the polyamideimide resin described in JP-A-2019-48948.
- the thermosetting resin composition 2 may contain a plurality of types of thermosetting resins described above.
- the thermosetting resin composition 2 may further contain other resins (for example, thermoplastic resins) in addition to the above thermosetting resins.
- the thermosetting resin composition 2 may further contain at least one other resin selected from the group consisting of polyphenylene sulfide resin, acrylic resin, polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyethylene terephthalate and silicone resin. .
- thermosetting resin composition 2 further contains at least one compound selected from the group consisting of a curing agent, a coupling agent (e.g., a silane coupling agent), and an additive, in addition to the above thermosetting resin.
- a coupling agent e.g., a silane coupling agent
- the additive may be, for example, at least one compound selected from the group consisting of curing accelerators (curing catalysts), flame retardants, waxes (lubricants) and organic solvents.
- the content of the metal powder in the molded body 10A (molded body 10B) is 95% by mass or more and 99.5% by mass or less with respect to the total mass (100% by mass) of the metal powder and the thermosetting resin composition 2, More preferably, it may be 96% by mass or more and 99% by mass or less.
- the content of the metal powder is within the above range, the magnetic or soft magnetic properties of the molded body 10B and the mechanical strength of the molded body 10B at high temperatures are likely to be compatible.
- the porous molded body 10A (the molded body 10A before being impregnated with the monomer composition 4A) may be produced by the following method.
- thermosetting resin composition is obtained by dissolving the raw materials of the thermosetting resin composition described above in an organic solvent.
- the organic solvent may be, for example, at least one solvent selected from the group consisting of acetone, methyl ethyl ketone, methyl isobutyl ketone, benzene, toluene and xylene.
- the metal powder is added to the thermosetting resin composition solution to disperse the metal powder in the thermosetting resin composition solution.
- the organic solvent is removed from the solution containing the metal powder and the thermosetting resin composition by vacuum distillation and drying of the solution containing the metal powder and the thermosetting resin composition.
- the surfaces of individual metal particles constituting the metal powder are coated with the thermosetting resin composition, and a compound (powder) containing the metal powder and the thermosetting resin composition is obtained.
- the inorganic fillers may be added to the solution of the thermosetting resin composition along with the metal powder.
- a surface treatment of each of the metal powder and the inorganic filler with a coupling agent may be performed in advance.
- Lubricants such as saturated fatty acid salts may be added to the compound.
- the step of removing the organic solvent from the solution containing the metal powder and the thermosetting resin composition it is preferable to use an evaporator to distill off the organic solvent under reduced pressure at room temperature while stirring the solution.
- a compound may be obtained by further drying the solid matter obtained by distillation under reduced pressure using a vacuum dryer or the like, and then appropriately pulverizing the solid matter.
- distillation under reduced pressure distillation under normal pressure may be carried out while stirring the above solution with a kneader or the like. Heating is not preferable as a drying method for the solid obtained by distillation.
- the solid may be dried by heating the solid at 80° C. or lower, preferably 60° C. or lower.
- a solvent is used in the above-described method of making a compound, but the compound may be made without using a solvent. That is, the compound may be made by dry mixing without using a solvent.
- a metal powder and a thermosetting resin composition may be mixed in a closed container at normal temperature and pressure.
- a compact is obtained by compression molding the above compound filled in the mold.
- the molding pressure may be, for example, 500 MPa or more and 2500 MPa or less, or 700 MPa or more and 2000 MPa or less.
- the density of the compact may be preferably 75% or more and 90% or less, more preferably 80% or more and 90% or less, relative to the true density of the metal powder.
- the heat treatment of the molded body may cure the thermosetting resin composition in the molded body. Since the metal particles in the molded article are bound together by the cured product of the thermosetting resin composition, a molded article having high mechanical strength can be easily obtained.
- the heat treatment temperature of the molded body may be a temperature at which the thermosetting resin composition is sufficiently cured.
- the heat treatment temperature of the compact may be, for example, 150° C. or higher and 450° C. or lower, preferably 200° C. or higher and 350° C. or lower.
- the heat treatment atmosphere may be air (preferably dry air) or an inert atmosphere (eg nitrogen). In order to suppress oxidation of the metal powder in the compact, it is preferable to heat-treat the compact in an inert atmosphere.
- the time for which the heat treatment temperature is maintained may be several minutes to 4 hours, preferably 15 minutes to 3 hours. .
- Example 1 Dicyclopentanyl methacrylate ("FA-513M” manufactured by Showa Denko Materials Co., Ltd.), glycidyl methacrylate ("Light Ester G” manufactured by Kyoei Chemical Co., Ltd.), 2-hydroxyethyl methacrylate (manufactured by Fujifilm Wako Co., Ltd.) product), dodecyl methacrylate (manufactured by Fujifilm Wako Co., Ltd.), pentaerythritol tetraacrylate (“EBECRYL 40” manufactured by Daicel Corporation), and t-butyl peroxy-2-ethylhexanoate (NOF Corporation)
- the monomer composition of Example 1 was made by mixing "PERBUTYL O” manufactured by the Company at room temperature in a Plastic bottle. The monomer composition was liquid at room temperature. The mass of each component constituting the monomer composition is shown in Table 1 below. The volume of the poly bottle was 250 ml.
- the viscosity of the monomer composition of Example 1 was measured at 25°C. Anton Paar Rheometer MCR301 was used to measure the viscosity. The viscosities of the monomer compositions are shown in Table 1 below.
- a porous molded body of Example 1 was produced by compression molding a compound containing metal powder and a thermosetting resin composition and heating (curing the thermosetting resin composition).
- Nd--Fe--B alloy powder was used as the metal powder.
- the Nd--Fe--B alloy powder was MQP-B manufactured by Magnequench International, LLC.
- the average particle size of the Nd--Fe--B alloy powder was 100 ⁇ m.
- the thermosetting resin composition included an epoxy resin and a phenolic resin.
- the compact was ring-shaped (cylindrical). The dimensions of the compact were 25 mm outer diameter x 21 mm inner diameter x 3 mm thickness.
- the content of metal powder in the compact is shown in Table 1 below.
- the content of the metal powder in the compact means the ratio of the mass of the metal powder to the total mass of the metal powder and the thermosetting resin composition.
- the volume of the molded body was calculated from the dimensions of the porous molded body.
- the mass of the porous compact was measured with an electronic balance.
- the density of the porous compact was calculated by dividing the mass of the compact by the volume of the compact.
- the density of the porous compact of Example 1 is shown in Table 1 below.
- the voids of the porous molding were impregnated with the monomer composition by the following method.
- the mass M A of the porous shaped bodies was measured before impregnation with the monomer composition.
- the porous molded body and the monomer composition were placed in a square container made of stainless steel, and the entire porous molded body was immersed in the monomer composition.
- a rectangular container containing the molded article and the monomer composition was placed in a vacuum desiccator.
- the inside of the vacuum desiccator was gradually decompressed with a vacuum pump. After the inside of the vacuum desiccator was decompressed until no air bubbles were generated from the compact due to decompression, the vacuum desiccator was allowed to stand for 30 minutes.
- the inside of the vacuum desiccator was gradually opened to the atmosphere, and the internal pressure of the vacuum desiccator was returned to normal pressure in about 30 minutes.
- the molded article was removed from the monomer composition, the monomer composition adhering to the surface of the molded article was wiped off, and the molded article was placed on a polytetrafluoroethylene sheet.
- the monomer composition impregnated in the molded article was polymerized. After that, the compact was further heated at 180° C. for 30 minutes.
- a product of ESPEC Corp. was used as the explosion-proof constant temperature bath.
- the radial crushing strength of a molded article containing an acrylic resin having a cyclic crosslinked structure was measured by the following method. Using a universal compression tester, compression pressure was applied to the sides of the ring-shaped compact in a direction perpendicular to the center axis of the compact. By increasing the compression pressure, the compression pressure at which the compact broke was measured. The compression pressure at which the molded body is destroyed means radial crushing strength (unit: MPa). AG-10TBR manufactured by Shimadzu Corporation was used as a universal compression tester. The crosshead speed in the crush strength measurement was 1 mm/min. The radial crushing strength in air at room temperature (25° C.) and the radial crushing strength in air at 150° C. were measured. The radial crushing strength of Example 1 is shown in Table 1 below.
- Example 5 (Examples 2 to 9 and Comparative Examples 1 to 5)
- dicyclopentenyl acrylate (“FA-511A” manufactured by Showa Denko Materials Co., Ltd.) was used instead of dicyclopentanyl methacrylate (FA-513M).
- dicyclopentenyloxyethyl methacrylate (“FA-512MT” manufactured by Showa Denko Materials Co., Ltd.) was used instead of dicyclopentanyl methacrylate (FA-513M).
- F-512MT dicyclopentenyloxyethyl methacrylate
- Comparative Examples 1-3 the respective monomer compositions were not made.
- the monomer composition of Comparative Example 4 was a mixture consisting of 2-hydroxyethyl methacrylate, methyl methacrylate, dodecyl methacrylate, pentaerythritol tetraacrylate, and t-butyl peroxy-2-ethylhexanoate.
- the monomer composition of Comparative Example 5 was a mixture consisting of methyl methacrylate, dodecyl methacrylate, pentaerythritol tetraacrylate, and t-butyl peroxy-2-ethylhexanoate.
- the mass of each component constituting the monomer compositions of Examples 2 to 9 and Comparative Examples 4 and 5 are shown in Table 1 below.
- Monomer compositions of Examples 2 to 9 and Comparative Examples 4 and 5 were prepared in the same manner as in Example 1 except for the above items. In the same manner as in Example 1, the viscosities of the monomer compositions of Examples 2 to 9 and Comparative Examples 4 and 5 were measured. The viscosities of each of the monomer compositions of Examples 2-9 and Comparative Examples 4 and 5 are shown in Table 1 below.
- Molded bodies of Examples 2 to 9 and Comparative Examples 4 and 5 containing the polymer of the monomer composition were obtained in the same manner as in Example 1 except for the above items.
- the impregnation amounts Rm of the monomer compositions of Examples 2 to 9 and Comparative Examples 4 and 5 were calculated.
- the impregnation amounts Rm of the monomer compositions of Examples 2 to 9 and Comparative Examples 4 and 5 are shown in Table 1 below.
- the radial crushing strength of each molded product of Examples 2 to 9 and Comparative Examples 1 to 5 was measured.
- each molded article of Comparative Examples 1 to 3 means the radial crushing strength of a porous molded article not impregnated with the monomer composition.
- the radial crushing strength of the moldings of Examples 2 to 9 and Comparative Examples 1 to 5 are shown in Table 1 below.
- the radial crushing strength at 25°C of each of Examples 1 to 6 was higher than the radial crushing strength of each of Comparative Examples 1, 2 and 4 at 25°C.
- the radial crushing strength at 150° C. of each of Examples 1 to 6 was higher than that of each of Comparative Examples 1, 2 and 4 at 150° C.
- the radial crushing strength at 25°C of each of Examples 7 to 9 was higher than the radial crushing strength of each of Comparative Examples 3 and 5 at 25°C.
- the radial crushing strength at 150° C. of each of Examples 7 to 9 was higher than the radial crushing strength of each of Comparative Examples 3 and 5 at 150° C.
- the monomer composition according to one aspect of the present invention is used as a raw material for bonded magnets or powder magnetic cores.
- SYMBOLS 1 Metal particle which comprises metal powder, 2... Thermosetting resin composition, 3... Void, 4A... Monomer composition, 4B... Resin having cyclic crosslinked structure (polymer of monomer composition), 10A... Porous 10B ... A molded article impregnated with a monomer composition (a molded article containing a resin having a cyclic crosslinked structure).
Abstract
Description
環状架橋構造を有する樹脂4Bは、他のアクリル樹脂に比べて高いガラス転移点(Tg)を有し易いので、環状架橋構造を有する樹脂4Bを含む成形体10Bは、耐熱性に優れ、高温において高い機械的強度を有することができる。高温での成形体の機械的強度とは、例えば、100℃以上200℃以下である温度での成形体の機械的強度である。環状架橋構造自体は、他の官能基と反応しなくてよい。
成形体10B中の環状架橋構造は以下の方法により検出されてよい。
成形体10Bの粉砕により得られた粉末が、成形体10B中の金属粉末よりも比重(真比重)が小さい溶媒へ添加される。その結果、金属粉末は溶媒中で沈降し、金属粉末以外の成形体10Bの成分(樹脂成分)は、溶媒中に浮遊する。金属粉末と分離された樹脂成分を熱分解ガスクロマトグラフィー/質量分析で分析することにより、環状架橋構造が検出される。つまり、金属粉末と分離された樹脂成分は、分解装置により、分子量が小さい複数種の成分へ分解される。複数種の成分はガスクロマトグラフィーにより分離され、互いに分離された各成分の質量分析により、環状架橋構造に相当する成分(分子)が検出される。
モノマー組成物4Aのラジカル重合により、グリシジル基及び水酸基のうち少なくともいずれかを有するアクリル樹脂(架橋体)が生成する。モノマー組成物4Aが、2個以上の(メタ)アクリル基を有する多官能(メタ)アクリレートを含む場合、ラジカル重合により、グリシジル基及び水酸基のうち少なくともいずれかを有するアクリル樹脂(架橋体)が生成し易い。ラジカル重合によって生成したアクリル樹脂の更なる加熱により、アクリル樹脂が有するグリシジル基同士の架橋反応が起きてよい。ラジカル重合によって生成したアクリル樹脂の更なる加熱により、アクリル樹脂が有するグリシジル基とアクリル樹脂が有する水酸基との架橋反応が起きてもよい。図3に示されるように、上記の架橋反応により、環状架橋構造を有する樹脂4Bは、網目状に互いに架橋されたアクリル樹脂6から構成される強固な構造を有することができる。つまり、環状架橋構造を有する樹脂4Bは、-CH(OH)-CH2-を含む架橋構造(グリシジル基に由来する架橋構造)を更に有することができる。その結果、成形体10Bの耐熱性が向上し易く、高温での成形体10Bの機械的強度が増加し易い。
ラジカル重合によって生成したアクリル樹脂及び熱硬化性樹脂組成物の加熱により、アクリル樹脂中のグリシジル基及び水酸基のうち少なくともいずれかが、熱硬化性樹脂組成物中の官能基と反応してよい。その結果、架橋構造がアクリル樹脂と熱硬化性樹脂組成物との間に形成されてよい。
水酸基を有する(メタ)アクリレートは、例えば、2-ヒドロキシエチルアクリレート及び2-ヒドロキシメチルアクリレートのうち少なくともいずれかの(メタ)アクリレートであってよい。
モノマー組成物4Aの重合に伴って、モノマー組成物4A又はその重合体に含まれるグリシジル基は、熱硬化性樹脂組成物2に含まれる上記官能基と反応して、-CH(OH)-CH2-を含む架橋構造が形成されてよい。モノマー組成物4Aの重合に伴って、モノマー組成物4A又はその重合体含まれる水酸基が、熱硬化性樹脂組成物2に含まれるグリシジル基と反応して、-CH(OH)-CH2-を含む架橋構造が形成されてよい。つまり、環状架橋構造を有する樹脂4Bは、-CH(OH)-CH2-を含む架橋構造を介して熱硬化性樹脂組成物2と結合(一体化)されてよい。その結果、成形体10Bの耐熱性が向上し易く、高温での成形体10Bの機械的強度が増加し易い。
Rm=(MB-MA)÷MB×100 (1)
本実施形態に係るボンド磁石は、永久磁石の粉末(例えば、Sm‐Fe‐N系磁石及びNd-Fe‐B系磁石のうち少なくともいずれか)、熱硬化性樹脂組成物2、及び環状架橋構造を有する樹脂4Bを含む成形体10Bであってよい。
本実施形態に係る圧粉磁心は、上記の軟磁性体の粉末(例えば、純鉄、及び鉄を含む合金のうち少なくともいずれか)、熱硬化性樹脂組成物2、及び環状架橋構造を有する樹脂4Bを含む成形体10Bであってよい。圧粉磁心は、例えば、インダクタ、変圧器、リアクトル、サイリスタバルブ、ノイズフィルタ(EMIフィルタ)、チョークコイル、モータ用鉄心、一般家電機器及び産業機器用モータのロータ及びヨーク、ディーゼルエンジン及びガソリンエンジンの電子制御式燃料噴射装置に組み込まれる電磁弁用のソレノイドコア(固定鉄心)、位置センサ、並びに、磁歪式センサに用いられてもよい。
例えば、ポリアミド樹脂は、εカプロラクタムから得られるナイロン6の粒子、及びラウリルラクタムから得られるナイロン12の粒子のうち少なくともいずれかであってよい。例えば、ポリアミド樹脂は、ナイロン6からなる粒子(東レ株式会社製のTR-1及びTR-2)、並びにナイロン12からなる粒子(東レ株式会社製のSP-500及びSP-10)からなる群より選ばれる少なくとも一種の樹脂であってよい。
例えば、ポリアミドイミド樹脂は、シロキサン構造を有するポリアミドイミド樹脂であってよい。ポリアミドイミド樹脂は、当該ポリアミドイミドの分子鎖の両末端のうち少なくとも一方の末端に2個以上のカルボキシ基を有してよい。ポリアミドイミド樹脂のカルボキシ基が、モノマー組成物4A又はその重合体に含まれるグリシジル基と反応して、-CH(OH)-CH2-を含む架橋構造が形成されてよい。ポリアミドイミド樹脂は、特開2019-48948号公報に記載のポリアミドイミド樹脂であってよい。
ジシクロペンタニルメタクリレート(昭和電工マテリアルズ株式会社製の「FA-513M」)、グリシジルメタクリレート(共栄化学株式会社製の「ライトエステルG」)、2-ヒドロキシエチルメタクリレート(富士フィルム和光株式会社製の商品)、ドデシルメタクリレート(富士フィルム和光株式会社製の商品)、ペンタエリスリトールテトラアクリレート(ダイセル株式会社製の「EBECRYL 40」)、及びt-ブチルパーオキシ-2-エチルヘキサノエイト(日油株式会社製の「パーブチルO」)をポリ瓶(Plastic bottle)中において室温で混合することにより、実施例1のモノマー組成物が作製された。モノマー組成物は室温で液体であった。モノマー組成物を構成する各成分の質量は、下記表1に示される。ポリ瓶の容積は、250mlであった。
モノマー組成物の含浸前に、多孔質の成形体の質量MAが測定された。多孔質の成形体及びモノマー組成物がステンレス製の角型容器に収容され、多孔質の成形体の全体がモノマー組成物中に浸漬された。成形体及びモノマー組成物が収容された角型容器が、真空デシケータ内に配置された。真空デシケータの内部が真空ポンプで徐々に減圧された。減圧に伴う成形体からの気泡の発生が見られなくなるまで真空デシケータの内部を減圧した後、真空デシケータが30分間放置された。30分の経過後、真空デシケータの内部を徐々に大気開放し、真空デシケータの内部の気圧が約30分間で常圧に戻された。成形体がモノマー組成物から取り出され、成形体の表面に付着したモノマー組成物がふき取られ、成形体がポリテトラフルオロエチレン製のシート上に設置された。防爆型恒温槽内で成形体を90℃で1時間加熱することにより、成形体中に含浸されたモノマー組成物を重合させた。その後、成形体が180℃で30分間更に加熱された。防爆型恒温槽としては、ESPEC Corp.の製品が用いられた。
以上の方法により、モノマー組成物の重合体(環状架橋構造を有するアクリル樹脂)を含む成形体が得られた。環状架橋構造を有するアクリル樹脂を含む成形体の質量MBが測定された。下記数式1で定義されるモノマー組成物の含浸量Rmが算出された。実施例1のモノマー組成物の含浸量Rmは、下記表1に示される。
Rm=(MB-MA)÷MB×100 (1)
万能圧縮試験機を用いて、リング状の成形体の中心軸線に垂直な方向において、圧縮圧力が成形体の側面に印加された。圧縮圧力を増加させて、成形体が破壊された時の圧縮圧力が測定された。成形体が破壊された時の圧縮圧力は、圧環強度(単位:MPa)を意味する。万能圧縮試験機としては、株式会社島津製作所製のAG-10TBRが用いられた。圧壊強度の測定におけるクロスヘッドの速度は、1mm/分であった。室温(25℃)の大気中での圧環強度、及び150℃の大気中での圧環強度が測定された。実施例1の圧環強度は、下記表1に示される。
実施例4のモノマー組成物の作製では、ジシクロペンタニルメタクリレート(FA-513M)の代わりに、ジシクロペンテニルアクリレート(昭和電工マテリアルズ株式会社製の「FA-511A」)が用いられた。
実施例5のモノマー組成物の作製では、ジシクロペンタニルメタクリレート(FA-513M)の代わりに、ジシクロペンテニルオキシエチルメタクリレート(昭和電工マテリアルズ株式会社製の「FA-512MT」)が用いられた。
比較例1~3では、其々のモノマー組成物は作製されなかった。
比較例4及び5其々のモノマー組成物の作製では、FA-513M、FA-511A、FA-512MTのいずれも用いられなかった。つまり、比較例4及び5其々のモノマー組成物は、環状架橋構造を有する(メタ)アクリレートを含んでいなかった。
比較例4のモノマー組成物は、2-ヒドロキシエチルメタクリレート、メチルメタクリレート、ドデシルメタクリレート、ペンタエリスリトールテトラアクリレート、及びt-ブチルパーオキシ-2-エチルヘキサノエイトからなる混合物であった。
比較例5のモノマー組成物は、メチルメタクリレート、ドデシルメタクリレート、ペンタエリスリトールテトラアクリレート、及びt-ブチルパーオキシ-2-エチルヘキサノエイトからなる混合物であった。
実施例2~9、比較例4及び5其々のモノマー組成物を構成する各成分の質量は、下記表1に示される。
上記の事項を除いて実施例1と同様の方法で、実施例2~9、比較例4及び5其々のモノマー組成物が作製された。実施例1と同様の方法で、実施例2~9、比較例4及び5其々のモノマー組成物其々の粘度が測定された。実施例2~9、比較例4及び5其々のモノマー組成物其々の粘度は、下記表1に示される。
実施例2~9及び比較例1~5其々の多孔質の成形体中の金属粉末の含有量は、各表1に示される。
上記の事項を除いて実施例1と同様の方法で、実施例2~9及び比較例1~5其々の多孔質の成形体が作製された。実施例1と同様の方法で、実施例2~9及び比較例1~5其々の多孔質の成形体の密度が測定された。実施例2~9及び比較例1~5其々の多孔質の成形体の密度は、下記表1に示される。
Claims (14)
- 多孔質の成形体中の空隙へ含浸するためのモノマー組成物であって、
前記成形体は、金属粉末と、熱硬化性樹脂組成物と、を備え、
前記モノマー組成物は、ジシクロペンタン構造を有するアクリレート、ジシクロペンテン構造を有するアクリレート、ジシクロペンタン構造を有するメタクリレート、及びジシクロペンテン構造を有するメタクリレートからなる群より選ばれる少なくとも一種の化合物を備える、
モノマー組成物。 - 前記モノマー組成物は、グリシジル基を有するアクリレート、及びグリシジル基を有するメタクリレートのうち少なくともいずれかを更に備える、
請求項1に記載のモノマー組成物。 - 前記モノマー組成物は、水酸基を有するアクリレート、及び水酸基を有するメタクリレートのうち少なくともいずれかを更に備える、
請求項1又は2に記載のモノマー組成物。 - 前記熱硬化性樹脂組成物は、グリシジル基、水酸基、アミド基、及びイミド基からなる群より選ばれる少なくとも一種の官能基を含む、
請求項1~3のいずれか一項に記載のモノマー組成物。 - 金属粉末と、
熱硬化性樹脂組成物と、
ジシクロペンタン構造及びジシクロペンテン構造のうち少なくともいずれかの構造を有する樹脂と、
を備える、
成形体。 - グリシジル基を有するアクリル樹脂を更に備える、
請求項5に記載の成形体。 - 水酸基を有するアクリル樹脂を更に備える、
請求項5又は6に記載の成形体。 - 前記ジシクロペンタン構造及び前記ジシクロペンテン構造のうち少なくともいずれかの構造を有する前記樹脂は、アクリル樹脂である、
請求項5~7のいずれか一項に記載の成形体。 - 前記ジシクロペンタン構造及び前記ジシクロペンテン構造のうち少なくともいずれかの構造を有する前記樹脂は、グリシジル基及び水酸基のうち少なくともいずれかの官能基を更に有する、
請求項5~8のいずれか一項に記載の成形体。 - 前記ジシクロペンタン構造及び前記ジシクロペンテン構造のうち少なくともいずれかの構造を有する前記樹脂は、-CH(OH)-CH2-を含む架橋構造を有する、
請求項5~9のいずれか一項に記載の成形体。 - 前記ジシクロペンタン構造及び前記ジシクロペンテン構造のうち少なくともいずれかの構造を有する前記樹脂は、前記架橋構造を介して、前記熱硬化性樹脂組成物と結合されている、
請求項10に記載の成形体。 - 前記金属粉末は、永久磁石又は軟磁性体である、
請求項5~11のいずれか一項に記載の成形体。 - 請求項5~12のいずれか一項に記載の成形体を備え、
前記金属粉末は、Sm‐Fe‐N系磁石及びNd-Fe‐B系磁石のうち少なくともいずれかである、
ボンド磁石。 - 請求項5~12のいずれか一項に記載の成形体を備え、
前記金属粉末は、純鉄、及び鉄を含む合金のうち少なくともいずれかである、
圧粉磁心。
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