JP6520168B2 - Iron nitride based magnetic powder and bonded magnet using the same - Google Patents
Iron nitride based magnetic powder and bonded magnet using the same Download PDFInfo
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本発明は、Fe16N2化合物相を主相とし、高い飽和磁化を維持しつつ、かつ高い保磁力を有する窒化鉄系磁性粉末に関する。さらに、該窒化鉄系磁性粉末を用いたボンド磁石を提供する。 The present invention relates to an iron nitride-based magnetic powder having a Fe 16 N 2 compound phase as a main phase, maintaining high saturation magnetization, and having high coercivity. Furthermore, a bonded magnet using the iron nitride magnetic powder is provided.
近年、電気自動車やハイブリッド自動車などのモーター用磁石として、Nd−Fe−B系の磁石が広く使われている。しかしながら、Ndに代表されるレアアースは、産業分野を支える高付加価値な部材の原料であり、近年需要が拡大しているため、資源の枯渇や原料価格が不安定であることが懸念されている。さらには、途上国においても著しく需要が拡大していることや、その偏在性ゆえに特定の産出国への依存度が高いことから、安定供給確保に対する問題が生じている。 In recent years, Nd-Fe-B based magnets are widely used as magnets for motors of electric vehicles, hybrid vehicles and the like. However, rare earths typified by Nd are raw materials for high-value-added components that support industrial fields, and demand is expanding in recent years, so there is concern that resource exhaustion and raw material prices may be unstable. . Furthermore, the growing demand in developing countries and the high degree of reliance on specific producing countries due to their uneven distribution have led to problems with securing stable supply.
上記問題を回避するため、レアアースを使用しない、自然界に無尽蔵に存在する元素(鉄、窒素)から高性能磁石を開発することが求められている。 In order to avoid the above problems, it is required to develop high-performance magnets from elements (iron, nitrogen) which are inexhaustible in nature without using rare earth.
Fe−N系の化合物、特にFe16N2は、Feよりも巨大な飽和磁化を示す材料のひとつとして注目されている。 Fe-N compounds, in particular Fe 16 N 2, are attracting attention as one of the materials exhibiting a saturation magnetization larger than that of Fe.
特許文献1では、共沈法により酸化鉄を合成し、還元・窒化する手法で窒化鉄系磁性粉末を合成している。しかしながら、得られた窒化鉄粉末の保磁力が低いために、高保磁力かつ高飽和磁化が要求されるモーター用途の磁性材料としての使用は困難である。
In
本発明は、上記を鑑みたものであり、高い保磁力を有する窒化鉄系磁性粉及び該磁性粉を用いたボンド磁石の提供を目的とする。 The present invention has been made in view of the above, and an object thereof is to provide an iron nitride-based magnetic powder having a high coercive force and a bonded magnet using the magnetic powder.
すなわち本発明は、Fe16N2粒子を主成分とする窒化鉄系磁性粉末であって、前記窒化鉄系磁性粉末のFe16N2粒子が磁化容易軸方向に長い円板系異方形状であり、前記Fe16N2粒子の平均粒子長径/平均粒子短径であらわされる形状アスペクト比が2〜8である窒化鉄系磁性粉末及び前記窒化鉄系磁性粉末を用いたボンド磁石に関するものである。 That is, the present invention is an iron nitride-based magnetic powder containing Fe 16 N 2 particles as a main component, wherein the Fe 16 N 2 particles of the iron nitride-based magnetic powder have a disk-like anisotropic shape elongated in the easy magnetization axis direction. The present invention relates to an iron nitride-based magnetic powder having a shape aspect ratio of 2 to 8 expressed by an average particle major axis / an average particle minor axis of the Fe 16 N 2 particles and a bonded magnet using the iron nitride-based magnetic powder. .
さらに、前記Fe16N2粒子の平均粒子長径が30〜150nmである、前記窒化鉄系磁性粉末及び前記窒化鉄系磁性粉末を用いたボンド磁石に関するものである。 Further, the present invention relates to the iron nitride-based magnetic powder and the bonded magnet using the iron nitride-based magnetic powder, wherein the average particle major diameter of the Fe 16 N 2 particles is 30 to 150 nm.
前記窒化鉄系磁性粉末を構成するFe16N2粒子の形状が磁化容易軸方向に長い円板型異方形状であるため、前記Fe16N2粒子が形状異方性を有し、良好な保磁力を得ることができる。 Since the shape of the Fe 16 N 2 particles constituting the iron nitride-based magnetic powder is a disk-shaped anisotropic shape having a long axis in the direction of easy magnetization, the Fe 16 N 2 particles have shape anisotropy and are favorable. Coercivity can be obtained.
前記Fe16N2粒子の形状アスペクト比を2〜8とすることで、窒化鉄系磁性粉末が良好な保磁力を得ることができる。 By setting the shape aspect ratio of the Fe 16 N 2 particles to 2 to 8, the iron nitride-based magnetic powder can obtain good coercivity.
前記Fe16N2粒子の平均粒子長径を30〜150nmとすることで、窒化鉄系磁性粉末がさらに良好な保磁力を得ることができる。 By setting the average particle long diameter of the Fe 16 N 2 particles to 30 to 150 nm, the iron nitride-based magnetic powder can obtain even better coercivity.
本発明によれば、Fe16N2相を含む窒化鉄系磁性粉末がFe16N2粒子で構成されており、前記Fe16N2粒子が形状異方性を有し、平均粒子長径/平均粒子短径であらわされる形状アスペクト比が2〜8であることにより、結晶磁気異方性に加え形状磁気異方性を有するため、良好な保磁力を得ることができる。 According to the present invention, the iron nitride-based magnetic powder containing the Fe 16 N 2 phase is composed of Fe 16 N 2 particles, and the Fe 16 N 2 particles have shape anisotropy, and the average particle length / average diameter When the shape aspect ratio represented by the particle minor diameter is 2 to 8, since it has shape magnetic anisotropy in addition to the magnetocrystalline anisotropy, good coercivity can be obtained.
また、前記Fe16N2粒子の平均粒子長径を30〜150nmであることにより、さらに良好な保磁力を得ることができる。 Further, by setting the average particle major axis of the Fe 16 N 2 particles to 30 to 150 nm, a further favorable coercive force can be obtained.
以下、本発明の好適な実施形態について説明する。なお、本発明は以下に記載の実施形態及び実施例の内容により限定されるものではない。また、以下に記載の実施形態及び実施例にて示された構成要素は適宜組み合わせても良いし、適宜選択してもよい。 Hereinafter, preferred embodiments of the present invention will be described. The present invention is not limited by the contents of the embodiments and examples described below. In addition, the components shown in the embodiments and examples described below may be combined as appropriate or selected as appropriate.
本実施形態に係る窒化鉄系磁性粉末は、主相がFe16N2粒子からなる。また、前記主相以外に、Fe2O3、Fe3O4及びFeO等の酸化鉄相を有していてもよい。 In the iron nitride based magnetic powder according to the present embodiment, the main phase is made of Fe 16 N 2 particles. In addition to the main phase may have a Fe 2 O 3, Fe 3 O 4 and iron oxide phase such as FeO.
本実施形態に係る窒化鉄系磁性粉末は、主相がFe16N2化合物相であり、Fe4N化合物相を含んでもよい。また、窒化鉄系磁性粒子の表面に酸化物からなる相を有していてもよい。 The iron nitride-based magnetic powder according to the present embodiment may have a main phase of an Fe 16 N 2 compound phase and may contain an Fe 4 N compound phase. In addition, it may have a phase composed of an oxide on the surface of the iron nitride based magnetic particles.
前記Fe16N2粒子が、Mn、Ni、Co、Ti、Zn等の遷移金属を含んでいてもよい。 The Fe 16 N 2 particles may contain a transition metal such as Mn, Ni, Co, Ti, Zn or the like.
本実施形態に係る窒化鉄系磁性粉末は、主相であるFe16N2粒子の形状が磁化容易軸方向に長い円板型異方形状である。 In the iron nitride-based magnetic powder according to the present embodiment, the shape of Fe 16 N 2 particles as the main phase is a disk-like anisotropic shape having a long axis in the direction of easy magnetization.
本実施形態に係る窒化鉄系磁性粉末は、前記Fe16N2粒子の平均粒子長径/平均粒子短径であらわされる形状アスペクト比が2〜8である。前記Fe16N2粒子の形状アスペクト比が2未満の場合は十分な形状異方性を得ることができないため、十分な保磁力を有さず、形状アスペクト比が8を超える場合はFe16N2粒子の結晶構造が歪むため、十分な保磁力を有さない。また好ましくは、前記Fe16N2粒子の平均粒子長径が30〜150nmである。前記平均粒子長径をこの範囲とすることで、単磁区臨界径以上の粒子の割合を小さくすることができ、より良好な保磁力を得ることができる。 The iron nitride-based magnetic powder according to the present embodiment has a shape aspect ratio of 2 to 8 represented by the average particle major axis / average particle minor axis of the Fe 16 N 2 particles. When the shape aspect ratio of the Fe 16 N 2 particles is less than 2, sufficient shape anisotropy can not be obtained, and therefore the coercivity is not sufficient and when the shape aspect ratio exceeds 8, Fe 16 N Because the crystal structure of the two particles is distorted, it does not have a sufficient coercive force. Also preferably, the average particle length of the Fe 16 N 2 particles is 30 to 150 nm. By setting the average particle long diameter in this range, the ratio of particles having a single magnetic domain critical diameter or more can be reduced, and a better coercivity can be obtained.
本実施形態に係る窒化鉄系磁性粉末の好適な製造法について述べる。本実施形態に係る窒化鉄系磁性粉末は、酸化鉄粒子を合成した後、前記酸化鉄粒子に還元処理および窒化処理を順に施して得た窒化鉄系磁性粒子をカレンダー処理することにより得られる。 The suitable manufacturing method of the iron nitride type magnetic powder which concerns on this embodiment is described. The iron nitride-based magnetic powder according to the present embodiment is obtained by synthesizing iron oxide particles and then subjecting the iron oxide particles to a reduction treatment and a nitriding treatment in order, followed by calendering the iron nitride-based magnetic particles.
前記酸化鉄粒子は、第一鉄塩および/または第二鉄塩を含む鉄塩水溶液と、アルカリ水溶液とを混合させた後、熟成し、洗浄することにより製造することができる。 The iron oxide particles can be produced by mixing an aqueous iron salt solution containing a ferrous salt and / or a ferric salt with an aqueous alkaline solution, followed by aging and washing.
前記鉄塩としては、硫酸塩、塩化物、硝酸塩等を挙げることができ、これらを適宜組み合わせて使用してもよい。また、それらの水和物を使用することができる。 As said iron salt, a sulfate, a chloride, nitrate etc. can be mentioned, You may use it combining these suitably. Also, their hydrates can be used.
前記アルカリ水溶液としては、水酸化ナトリウム水溶液、アンモニア水、アンモニア塩水溶液、および尿素水溶液を1つ以上用いることができるが、この限りではない。 As the aqueous alkali solution, one or more of aqueous sodium hydroxide solution, aqueous ammonia, aqueous ammonia salt solution, and aqueous urea solution can be used, but it is not limited thereto.
また、酸化鉄製造後、結晶性改良や粒子サイズ、粒子形状制御のために、オートクレーブによる水熱処理など液中熟成反応を行ってもよい。 In addition, after iron oxide production, in-liquid aging reaction such as hydrothermal treatment with an autoclave may be performed to improve crystallinity and control particle size and particle shape.
酸化鉄製造後、水溶液をろ過し、必要に応じて水洗等の洗浄処理を施すことで酸化鉄粒子を回収することができる。 After the production of iron oxide, the aqueous solution is filtered, and if necessary, washing treatment such as water washing can be performed to recover iron oxide particles.
前記酸化鉄粒子は、還元処理によって粒子同士が焼結することを抑制するために、粒子表面をSi化合物で被覆する。Si化合物としては、コロイダルシリカ、シランカップリング剤、シラノール化合物等が使用できる。 The iron oxide particles cover the particle surface with a Si compound in order to suppress sintering of the particles due to reduction treatment. As the Si compound, colloidal silica, a silane coupling agent, a silanol compound or the like can be used.
Si化合物の被覆量は、酸化鉄粒子に対しSi換算で0.1質量%以上20質量%以下である。0.1質量%未満の場合には熱処理時に粒子間の焼結を抑制する効果が十分得られないため、最終的に得られる窒化鉄系磁性粒子が大きくなる。20質量%を超える場合には熱処理時に粒子間の焼結を抑制する効果が過剰となり、最終的に得られる窒化鉄系磁性粒子が小さくなる。また、非磁性成分が増加することとなり好ましくない。より好ましい表面被覆量は0.15質量%以上15質量%以下、更により好ましくは0.2質量%以上10質量%以下である。 The coating amount of the Si compound is 0.1% by mass or more and 20% by mass or less in terms of Si based on iron oxide particles. If the amount is less than 0.1% by mass, the effect of suppressing sintering between particles can not be sufficiently obtained during heat treatment, so that the finally obtained iron nitride-based magnetic particles become large. If it exceeds 20% by mass, the effect of suppressing sintering between particles during heat treatment becomes excessive, and the finally obtained iron nitride-based magnetic particles become smaller. In addition, the nonmagnetic component is increased, which is not preferable. A more preferable surface coverage is 0.15% by mass to 15% by mass, and still more preferably 0.2% by mass to 10% by mass.
前記酸化鉄粒子は、平均粒子径は10nm以上150nm以下が好ましい。平均粒子径をこの範囲とすることで、最終的に得られる円板型異方形状のFe16N2粒子の平均粒子長径を30〜150nmとすることができる。 The iron oxide particles preferably have an average particle size of 10 nm or more and 150 nm or less. By setting the average particle diameter to this range, it is possible to set the average particle major diameter of the finally obtained disk-shaped anisotropic shaped Fe 16 N 2 particles to 30 to 150 nm.
前記酸化鉄粒子は、マグネタイト、γ−Fe2O3、α−Fe2O3、α−FeOOH、β−FeOOH、γ−FeOOH、FeOなどである、この限りではない。 The iron oxide particles are not limited to magnetite, γ-Fe 2 O 3 , α-Fe 2 O 3 , α-FeOOH, β-FeOOH, γ-FeOOH, FeO, and the like.
前記酸化鉄粒子の粒子形状は、球状、針状、粒状、紡錘状、直方体状などいずれでもよい。 The particle shape of the iron oxide particles may be spherical, needle-like, granular, spindle-like, rectangular or the like.
次に、得られた酸化鉄粒子の還元処理を行い、鉄粒子を得る。還元処理の温度は200〜400℃である。還元処理の温度が200℃未満の場合には酸化鉄粒子が十分に還元されない。還元処理の温度が400℃を超える場合には酸化鉄粒子は十分に還元されるが、粒子間の焼結が進行するため好ましくない。より好ましくは230〜350℃である。 Next, reduction processing of the obtained iron oxide particles is performed to obtain iron particles. The temperature of the reduction treatment is 200 to 400 ° C. When the temperature of the reduction treatment is less than 200 ° C., the iron oxide particles are not sufficiently reduced. When the temperature of the reduction treatment exceeds 400 ° C., the iron oxide particles are sufficiently reduced, but this is not preferable because sintering between particles proceeds. More preferably, it is 230 to 350 ° C.
還元処理の時間は特に限定されないが、1〜96時間が好ましい。96時間を超えると還元温度によっては焼結が進み後段の窒化処理が進みにくくなってしまう。1時間未満では十分に還元が進行しない。より好ましくは2〜72時間である。 Although the time of a reduction process is not specifically limited, 1 to 96 hours are preferable. If it exceeds 96 hours, depending on the reduction temperature, sintering will proceed and it will be difficult to advance the subsequent stage nitriding treatment. The reduction does not proceed sufficiently in less than one hour. More preferably, it is 2 to 72 hours.
還元処理の雰囲気は、水素雰囲気である。 The atmosphere of the reduction treatment is a hydrogen atmosphere.
次に、得られた鉄粒子の窒化処理を行い、窒化鉄系磁性粒子を得る。窒化処理の温度は100〜200℃である。窒化処理の温度が100℃未満の場合には窒化が十分に進行しない。窒化処理の温度が200℃を超える場合には、窒化が過剰に進行するため、磁気特性が低下する。より好ましくは120〜180℃である。 Next, the iron particles obtained are subjected to a nitriding treatment to obtain iron nitride-based magnetic particles. The temperature of the nitriding treatment is 100 to 200 ° C. When the temperature of the nitriding treatment is less than 100 ° C., the nitriding does not proceed sufficiently. When the temperature of the nitriding treatment exceeds 200 ° C., the nitriding progresses excessively, and the magnetic properties are degraded. More preferably, it is 120-180 ° C.
窒化処理の時間は特に限定されないが、1〜48時間が好ましい。48時間を超えると窒化温度によっては磁気特性が低下する。1時間未満では十分な還元ができない場合が多い。より好ましくは3〜24時間である。 Although the time of the nitriding treatment is not particularly limited, 1 to 48 hours are preferable. If it exceeds 48 hours, depending on the nitriding temperature, the magnetic properties deteriorate. In less than one hour, sufficient reduction can often not be achieved. More preferably, it is 3 to 24 hours.
窒化処理の雰囲気は、NH3雰囲気が望ましく、NH3の他、N2、H2などを混合させてもよい。 The atmosphere for the nitriding treatment is preferably an NH 3 atmosphere, and in addition to NH 3 , N 2 , H 2 and the like may be mixed.
この時、窒化鉄系磁性粒子が、粒子表面に酸化鉄相を有していてもよい。 At this time, the iron nitride based magnetic particles may have an iron oxide phase on the surface of the particles.
得られた窒化鉄系磁性粒子を十分に脱水した有機溶剤と混合し、さらに分散剤を添加し、窒化鉄系磁性粒子を含むスラリーを作製する。 The obtained iron nitride-based magnetic particles are mixed with an organic solvent sufficiently dehydrated, and a dispersant is further added to prepare a slurry containing iron nitride-based magnetic particles.
前記有機溶剤にはヘキサン、シクロヘキサン、オクタン等のアルカン類や、シクロヘキサノン、MEK等のケトン類等のいずれか一つ以上を用いた、単体液体もしくは混合液体を用いることができるが、この限りではない。 As the organic solvent, a single liquid or mixed liquid using any one or more of alkanes such as hexane, cyclohexane and octane, and ketones such as cyclohexanone and MEK can be used, but not limited to this .
前記分散剤には、オレイン酸、オレイルアミン、トリオクチルアミン等の何れか一つ以上を用いることができるが、この限りではない。 As the dispersant, any one or more of oleic acid, oleylamine, trioctylamine and the like can be used, but it is not limited thereto.
前記分散剤の添加量は、前記窒化鉄系磁性粒子に対して0.1質量%以上5質量%以下である。分散剤量をこの範囲にすることにより後段のカレンダー処理時に窒化鉄系磁性粒子の平均粒子長径/平均粒子短径であらわされる形状アスペクト比を制御することができる。 The addition amount of the dispersant is 0.1% by mass or more and 5% by mass or less with respect to the iron nitride-based magnetic particles. By setting the amount of the dispersing agent in this range, it is possible to control the shape aspect ratio represented by the average particle major axis / average particle minor axis of the iron nitride magnetic particles at the subsequent calendering process.
前記窒化鉄系磁性粒子を含むスラリーを、粒子カレンダー処理機で処理し、窒化鉄系磁性粒子を扁平させることにより、円板型異方形状の窒化鉄系磁性粒子を含むスラリーを作製する。 The slurry containing the iron nitride-based magnetic particles is treated with a particle calendar processing machine to flatten the iron nitride-based magnetic particles, thereby producing a slurry containing iron-nitride-based magnetic particles in an anisotropic disk shape.
この時、前記粒子カレンダー処理機のカレンダー方向に対して垂直方向に磁場を印加する。磁場中で窒化鉄系磁性粒子が回転し、窒化鉄系磁性粒子の磁化容易軸方向と磁場印加方向が同一になる。これにより、磁化容易軸方向に長い円板型異方形状の窒化鉄系磁性粒子を作製することができる。 At this time, a magnetic field is applied in a direction perpendicular to the calendar direction of the particle calendar processor. The iron nitride-based magnetic particles rotate in the magnetic field, and the direction of easy magnetization of the iron nitride-based magnetic particles and the direction of the magnetic field application become the same. As a result, it is possible to produce iron-nitride-based magnetic particles of an anisotropic disk shape long in the direction of easy magnetization axis.
前記円板型異方形状の窒化鉄系磁性粒子の平均粒子長径/平均粒子短径であらわされる形状アスペクト比が2〜8となるようにする。前記スラリー中の分散剤量が窒化鉄系磁性粒子に対して0.1質量%未満の場合、カレンダー処理時に窒化鉄系磁性粒子の形状が著しく変形し、形状アスペクト比が8を超え、さらに窒化鉄磁性粒子同士の連結粒子を生成してしまうため、好ましくない。また、前記スラリー中の分散剤量が窒化鉄系磁性粒子に対して5質量%を超える場合、窒化鉄系磁性粒子を含むスラリーの粘度が低下し、カレンダー処理時に窒化鉄系磁性粒子に対し圧力が十分にかからず、形状アスペクト比が2未満となり、窒化鉄系磁性粒子が十分な形状磁気異方性を有することができないため、好ましくない。 The shape aspect ratio represented by the average particle major axis / average particle minor axis of the disk-shaped anisotropic iron nitride-based magnetic particles is set to 2 to 8. When the amount of the dispersant in the slurry is less than 0.1% by mass with respect to the iron nitride-based magnetic particles, the shape of the iron nitride-based magnetic particles is significantly deformed during calendering, and the shape aspect ratio exceeds 8 and further nitriding This is not preferable because it produces connected particles of iron magnetic particles. In addition, when the amount of the dispersant in the slurry exceeds 5% by mass with respect to the iron nitride-based magnetic particles, the viscosity of the slurry containing the iron nitride-based magnetic particles decreases, and the pressure is applied to the iron nitride-based magnetic particles at the time of calendering. However, it is not preferable because the shape aspect ratio is less than 2 and the iron nitride-based magnetic particles can not have sufficient shape magnetic anisotropy.
次に、得られた円板型異方形状の窒化鉄系磁性粒子を含むスラリーを100℃で20時間乾燥し、窒化鉄系磁性粉末を作製することができる。 Next, the obtained slurry containing the disc-shaped anisotropic iron nitride-based magnetic particles can be dried at 100 ° C. for 20 hours to produce an iron nitride-based magnetic powder.
本実施形態によって得られた窒化鉄系磁性粉末を用いて、ボンド磁石を得ることができる。以下、その製造方法を述べる。 A bonded magnet can be obtained using the iron nitride based magnetic powder obtained by the present embodiment. Hereafter, the manufacturing method is described.
まず、本実施形態によって得られた窒化鉄系磁性粉末を用いたボンド磁石の製造方法の一例について説明する。樹脂を含む樹脂バインダーと磁性粉とを例えば加圧ニーダー等の加圧混練機で混練して、ボンド磁石用コンパウンド(組成物)を調製する。樹脂は、エポキシ樹脂、フェノール樹脂等の熱硬化性樹脂や、スチレン系、オレフィン系、ウレタン系、ポリエステル系、ポリアミド系のエラストマー、アイオノマー、エチレンプロピレン共重合体(EPM)、エチレン−エチルアクリレート共重合体等の熱可塑性樹脂がある。なかでも、圧縮成形をする場合に用いる樹脂は、熱硬化性樹脂が好ましく、エポキシ樹脂又はフェノール樹脂がより好ましい。また、射出成形をする場合に用いる樹脂は熱可塑性樹脂が好ましい。また、ボンド磁石用コンパウンドには、必要に応じて、カップリング剤やその他の添加材を加えてもよい。 First, an example of a method of manufacturing a bonded magnet using the iron nitride based magnetic powder obtained by the present embodiment will be described. The resin binder containing the resin and the magnetic powder are kneaded, for example, by a pressure kneader such as a pressure kneader to prepare a compound magnet composition (composition). Resins include thermosetting resins such as epoxy resins and phenol resins, styrene-based, olefin-based, urethane-based, polyester-based and polyamide-based elastomers, ionomers, ethylene propylene copolymer (EPM), ethylene-ethyl acrylate copolymer There is a thermoplastic resin such as coalescence. Among them, a thermosetting resin is preferable, and an epoxy resin or a phenol resin is more preferable, as a resin used in compression molding. The resin used for injection molding is preferably a thermoplastic resin. Further, if necessary, a coupling agent and other additives may be added to the bonded magnet compound.
また、ボンド磁石における磁性粉と樹脂との含有比率は、磁性粉100質量%に対して、樹脂を例えば0.5質量%以上20質量%以下含むことが好ましい。磁性粉100質量%に対して、樹脂の含有量が0.5質量%未満であると、保形性が損なわれる傾向があり、樹脂が20質量%と超えると、十分に優れた磁気特性が得られ難くなる傾向がある。 Further, the content ratio of the magnetic powder to the resin in the bond magnet preferably includes, for example, 0.5% by mass or more and 20% by mass or less of the resin with respect to 100% by mass of the magnetic powder. When the content of the resin is less than 0.5% by mass with respect to 100% by mass of the magnetic powder, the shape retention tends to be impaired, and when the content of the resin exceeds 20% by mass, sufficiently excellent magnetic properties are obtained. It tends to be difficult to obtain.
上述のボンド磁石用コンパウンドを調製した後、このボンド磁石用コンパウンドを射出成形することにより、磁性粉と樹脂とを含むボンド磁石を得ることができる。射出成形によりボンド磁石を作製する場合、ボンド磁石用コンパウンドを、必要に応じてバインダー(熱可塑性樹脂)の溶融温度まで加熱し、流動状態とした後、このボンド磁石用コンパウンドを所定の形状を有する金型内に射出して成形を行う。その後、冷却し、金型から所定形状を有する成形品(ボンド磁石)を取り出す。このようにしてボンド磁石が得られる。ボンド磁石の製造方法は、上述の射出成形による方法に限定されるものではなく、例えばボンド磁石用コンパウンドを圧縮成形することにより磁性粉と樹脂とを含むボンド磁石を得るようにしてもよい。圧縮成形によりボンド磁石を作製する場合、上述のボンド磁石用コンパウンドを調製した後、このボンド磁石用コンパウンドを所定の形状を有する金型内に充填し、圧力を加えて金型から所定形状を有する成形品(ボンド磁石)を取り出す。金型にてボンド磁石用コンパウンドを成形し、取り出す際には、機械プレスや油圧プレス等の圧縮成形機を用いて行なわれる。その後、加熱炉や真空乾燥炉などの炉に入れて熱をかけることにより硬化させることで、ボンド磁石が得られる。 After preparing the above-described bonded magnet compound, the bonded magnet compound including the magnetic powder and the resin can be obtained by injection molding the bonded magnet compound. When a bonded magnet is produced by injection molding, the bonded magnet compound is heated to the melting temperature of the binder (thermoplastic resin) as necessary to bring it into a fluidized state, and then the bonded magnet compound has a predetermined shape. It injects in the mold and performs molding. Then, it cools and takes out the molded article (bond magnet) which has a predetermined shape from a metal mold | die. Thus, a bonded magnet is obtained. The method of manufacturing the bonded magnet is not limited to the above-described injection molding method. For example, the bonded magnet containing a magnetic powder and a resin may be obtained by compression molding a bonded magnet compound. When producing a bonded magnet by compression molding, after preparing the above-mentioned bonded magnet compound, the bonded magnet compound is filled in a mold having a predetermined shape, and pressure is applied to have a predetermined shape from the mold Take out the molded product (bond magnet). When molding the bonded magnet compound with a mold and taking it out, it is carried out using a compression molding machine such as a mechanical press or hydraulic press. Thereafter, it is placed in a furnace such as a heating furnace or a vacuum drying furnace and hardened by applying heat to obtain a bonded magnet.
成形して得られるボンド磁石の形状は特に限定されるものではなく、用いる金型の形状に応じて、例えば平板状、柱状、断面形状がリング状等、変更することができる。また、得られたボンド磁石は、その表面上に酸化層や樹脂層等の劣化を防止するためにめっきや塗装を施すようにしてもよい。 The shape of the bonded magnet obtained by molding is not particularly limited, and may be changed to, for example, a flat plate shape, a columnar shape, or a ring shape in cross section depending on the shape of a mold to be used. Further, the obtained bonded magnet may be plated or coated on its surface to prevent deterioration of the oxide layer, the resin layer and the like.
ボンド磁石用コンパウンドは目的とする所定の形状に成形する際、磁場を印加して成形して得られる成形体を一定方向に配向させる。これにより、ボンド磁石が特定方向に配向するので、より磁性の強い異方性ボンド磁石が得られる。 When the compound for a bonded magnet is formed into a predetermined shape, the molded product obtained by applying a magnetic field is oriented in a certain direction. As a result, the bonded magnet is oriented in a specific direction, so that a more magnetically anisotropic bonded magnet can be obtained.
次に、本発明に係る窒化鉄系磁性粉末について、実施例・比較例を用いてさらに詳細に説明するが、本発明は実施例に示す態様に限定されるものではない。 Next, the iron nitride-based magnetic powder according to the present invention will be described in more detail using Examples and Comparative Examples, but the present invention is not limited to the embodiments shown in the Examples.
(実施例1)まず、硫酸鉄七水和物(FeSO4・7H2O)167gと塩化鉄六水和物(FeCl3・6H2O)85gをイオン交換水に溶解し、鉄塩水溶液を作製した。2.5molアンモニア水溶液600gを30℃に保持し、先に調整した鉄塩水溶液を添加した後、液中熟成反応として70℃で一定となるように温度コントロールし、30分撹拌後、遠心分離機にて2Lのイオン交換水で3回洗浄を行い、酸化鉄スラリーを作製した。 Example 1 First, 167 g of iron sulfate heptahydrate (FeSO 4 · 7 H 2 O) and 85 g of iron chloride hexahydrate (FeCl 3 · 6 H 2 O) are dissolved in ion-exchanged water, and an iron salt aqueous solution is dissolved. Made. After holding 600 g of a 2.5 mol aqueous ammonia solution at 30 ° C. and adding the previously prepared iron salt aqueous solution, the temperature is controlled to be constant at 70 ° C. as an in-liquid aging reaction, and after stirring for 30 minutes, centrifuge The reaction mixture was washed three times with 2 L of ion-exchanged water to prepare an iron oxide slurry.
前記酸化鉄スラリーに、テトラエトキシシラン5.0g、エタノール21g、ジエチレングリコールモノブチルエーテル78gを添加し、Si被着処理を施した。この酸化鉄スラリーを85℃で24時間乾燥し、Fe2O3を含む酸化鉄粒子を作製した。 To the above-mentioned iron oxide slurry, 5.0 g of tetraethoxysilane, 21 g of ethanol and 78 g of diethylene glycol monobutyl ether were added to carry out Si deposition treatment. The iron oxide slurry was dried at 85 ° C. for 24 hours to prepare iron oxide particles containing Fe 2 O 3 .
前記酸化鉄粒子2gを焼成ボートに入れ、熱処理炉に静置した。炉内に窒素ガスを充填した後、水素ガスを1L/minの流量で流しながら、5℃/minの昇温速度で250℃まで昇温し、48時間保持して還元処理を行った。その後、水素ガスの供給を止めて窒素ガスを2L/minの流量で流しながら140℃まで降温した。続いて、アンモニアガスを0.2L/minにて流しながら、140℃で24時間窒化処理を行った。その後、窒素ガスを2L/minの流量で流しながら50℃まで降温し、空気置換を24時間実施し、窒化鉄系磁性粒子を得た。 2 g of the iron oxide particles were placed in a baking boat and allowed to stand in a heat treatment furnace. The furnace was filled with nitrogen gas, and while flowing hydrogen gas at a flow rate of 1 L / min, the temperature was raised to 250 ° C. at a temperature rising rate of 5 ° C./min and held for 48 hours for reduction treatment. Thereafter, the supply of hydrogen gas was stopped, and the temperature was lowered to 140 ° C. while flowing nitrogen gas at a flow rate of 2 L / min. Subsequently, nitriding treatment was performed at 140 ° C. for 24 hours while flowing ammonia gas at 0.2 L / min. Thereafter, the temperature was lowered to 50 ° C. while flowing nitrogen gas at a flow rate of 2 L / min, air replacement was carried out for 24 hours, and iron nitride based magnetic particles were obtained.
得られた窒化鉄系磁性粒子100gを十分に脱水したオクタン60gと混合し、さらに分散剤としてオレイルアミンを3g添加し、窒化鉄系磁性粒子を含むスラリーを作製した。得られた窒化鉄系磁性粒子を含むスラリーを粒子カレンダー処理機に投入し、窒化鉄系磁性粒子を扁平させ、円板型異方形状の窒化鉄系磁性粒子を含むスラリーを得た。この時、磁化容易軸方向に長い円板型異方形状の窒化鉄系磁性粒子を得るため、カレンダーロールの上下に電磁石による磁気回路を設置し、カレンダーの圧力方向に対して垂直方向に磁場を発生させた。 100 g of the obtained iron nitride-based magnetic particles were mixed with 60 g of fully dehydrated octane, and 3 g of oleylamine as a dispersant was further added to prepare a slurry containing iron nitride-based magnetic particles. The obtained slurry containing iron nitride based magnetic particles was charged into a particle calendering machine to flatten the iron nitride based magnetic particles to obtain a slurry containing disc-shaped anisotropic iron nitride based magnetic particles. At this time, in order to obtain an iron nitride-based magnetic particle in the shape of a circular disk that is long in the easy magnetization direction, a magnetic circuit with electromagnets is installed above and below the calendar roll, and a magnetic field is applied in the direction perpendicular to the pressure direction of the calendar. It occurred.
次に得られた円板型異方形状の窒化鉄系磁性粒子を含むスラリーを200℃で20時間乾燥し、窒化鉄系磁性粉末を作製した。 Next, the obtained slurry containing the disc-shaped anisotropic iron nitride-based magnetic particles was dried at 200 ° C. for 20 hours to produce an iron nitride-based magnetic powder.
(実施例2、3、4、5)酸化鉄スラリーに添加するテトラエトキシシランの量を4.0、2.5、1.0、0.5gとした以外は、実施例1と同様の方法で窒化鉄系磁性粉末を作製した。 (Examples 2, 3, 4, 5) The same method as in Example 1 except that the amount of tetraethoxysilane added to the iron oxide slurry was 4.0, 2.5, 1.0, and 0.5 g. An iron nitride based magnetic powder was produced.
(実施例6、7、8)酸化鉄スラリーに添加するテトラエトキシシランの量を4.0、2.5、1.0gとし、窒化鉄系磁性粒子を含むスラリーに添加するオレイルアミンの量を5gとした以外は、実施例1と同様の方法で窒化鉄系磁性粉末を作製した。 (Examples 6, 7 and 8) The amount of tetraethoxysilane added to the iron oxide slurry is 4.0, 2.5 and 1.0 g, and the amount of oleylamine added to the slurry containing iron nitride based magnetic particles is 5 g An iron nitride-based magnetic powder was produced in the same manner as in Example 1 except that
(実施例9、10、11)酸化鉄スラリーに添加するテトラエトキシシランの量を4.0、2.5、1.0gとし、窒化鉄系磁性粒子を含むスラリーに添加するオレイルアミンの量を1gとした以外は、実施例1と同様の方法で窒化鉄系磁性粉末を作製した。 (Examples 9, 10, 11) The amount of tetraethoxysilane added to the iron oxide slurry is 4.0, 2.5, 1.0 g, and the amount of oleylamine added to the slurry containing iron nitride magnetic particles is 1 g An iron nitride-based magnetic powder was produced in the same manner as in Example 1 except that
(比較例1、2)窒化鉄系磁性粒子を含むスラリーに添加するオレイルアミンの量を7、0.5gとした以外は、実施例3と同様の方法で窒化鉄系磁性粉末を作製した。 Comparative Examples 1 and 2 An iron nitride-based magnetic powder was produced in the same manner as in Example 3 except that the amount of oleylamine added to the slurry containing the iron nitride-based magnetic particles was changed to 7 and 0.5 g.
(比較例3)窒化鉄系磁性粒子を含むスラリーを粒子カレンダー処理しなかった以外は、実施例3と同様の方法で窒化鉄系磁性粉末を作製した。 Comparative Example 3 An iron nitride based magnetic powder was produced in the same manner as in Example 3 except that the slurry containing the iron nitride based magnetic particles was not subjected to the particle calendering treatment.
このようにして得られた窒化鉄系磁性粉末の構成相、相対密度、粒子長径、形状アスペクト比、残留磁束密度(Br)及び保磁力(HcJ)を以下の手法により測定した。結果を表1に示す。 The constituent phase, relative density, particle long diameter, shape aspect ratio, residual magnetic flux density (Br) and coercivity (HcJ) of the iron nitride-based magnetic powder thus obtained were measured by the following method. The results are shown in Table 1.
≪窒化鉄系磁性粉末の構成相≫
得られた窒化鉄系磁性粉末の構成相は、粉末X線回折装置(XRD、リガク製RINT−2500)により同定を行った。
«Constituent phase of iron nitride based magnetic powder»
The constituent phase of the obtained iron nitride-based magnetic powder was identified using a powder X-ray diffractometer (XRD, manufactured by Rigaku RINT-2500).
≪窒化鉄系磁性粉末の粒子長径、形状アスペクト比≫
得られた窒化鉄系磁性粉末を、Φ6mmのディスク型ケースに秤量し、融点50〜52℃のパラフィンを加え、ホットプレートで加熱し、パラフィンが融解したところで、20kOeの磁場中に10分間静置した。磁場を印加中にパラフィンを放冷し固化させ窒化鉄系磁性粉末を含むパラフィンを作製した。図1に示すとおり、得られた窒化鉄系磁性粉末1を含むパラフィンを、磁場印加方向2に対して垂直な方向に断面が出るように削り出した。またボンド磁石の場合は、ボンド磁石を磁気配向方向に対して垂直な方向に断面が出るように削り出す。得られた断面を磁場型電子顕微鏡(TEM、日本電子製JEM−2000FX)にて観察した。TEM観察像の中から1000個の粒子を選び、粒子の中心をとおる弦の長さが最も長い径3を粒子長径とし、粒子の中心をとおり粒子長径に対して垂直に交わる径4を粒子短径とし、それぞれの平均値を算出した。また、平均粒子長径/平均粒子短径で表される形状アスペクト比とした。
<< Particle major axis of iron nitride magnetic powder, shape aspect ratio >>
The obtained iron nitride-based magnetic powder is weighed in a disc-shaped case of 66 mm, paraffin with a melting point of 50-52 ° C. is added, and heating is performed with a hot plate. When the paraffin melts, standing for 10 minutes in a magnetic field of 20 kOe did. While applying a magnetic field, the paraffin was allowed to cool and solidify to produce a paraffin containing an iron nitride-based magnetic powder. As shown in FIG. 1, the paraffin containing iron nitride-based
≪窒化鉄系磁性粉末の飽和磁化(σs)及び保磁力(HcJ)≫
得られた窒化鉄系磁性粉末の飽和磁化(σs)と保磁力(HcJ)をB−Hトレーサー(東英工業製TRF−5BH)による減磁曲線の測定結果から求めた。保磁力(HcJ)が2.3kOe以上の窒化鉄系磁性粉末を許容とした。
The saturation magnetization (σs) and the coercivity (HcJ) of the obtained iron nitride-based magnetic powder were determined from the measurement results of the demagnetization curve using a BH tracer (TRF-5BH manufactured by Toei Kogyo Co., Ltd.). An iron nitride magnetic powder having a coercive force (HcJ) of 2.3 kOe or more was accepted.
全ての実施例と比較例で、Fe16N2相が主相であることが確認された。 In all the examples and comparative examples, it was confirmed that the Fe 16 N 2 phase is the main phase.
実施例1、2、3、4、5のように、窒化鉄系磁性粉末の平均粒子長径が26nm、31nm、72nm、148nm、156nmアスペクト比が4.1、4.3、4.1、4.2、4.3の場合、保磁力(HcJ)が2.3kOe以上であることが確認できた。特に平均粒子長径が30〜150nmの範囲にある場合、保磁力(HcJ)が2.5kOe以上の良好な特性が得られた。 As in Examples 1, 2, 3, 4 and 5, the average particle length of the iron nitride magnetic powder is 26 nm, 31 nm, 72 nm, 148 nm, 156 nm aspect ratio is 4.1, 4.3, 4.1, 4 In the cases of .2 and 4.3, it was confirmed that the coercivity (HcJ) was 2.3 kOe or more. In particular, when the average particle major axis was in the range of 30 to 150 nm, good characteristics with a coercive force (HcJ) of 2.5 kOe or more were obtained.
実施例6、7、8のように、窒化鉄系磁性粉末の平均粒子長径が32nm、68nm、148nm、アスペクト比が2.1、2.2、2.1の場合、保磁力(HcJ)が2.5kOe以上であることが確認できた。 As in Examples 6, 7 and 8, in the case where the average particle major axis of the iron nitride magnetic powder is 32 nm, 68 nm, 148 nm and the aspect ratio is 2.1, 2.2, 2.1, the coercivity (HcJ) is It was confirmed that it was 2.5 kOe or more.
実施例9、10、11のように、窒化鉄系磁性粉末の平均粒子長径が35nm、74nm、147nm、アスペクト比が8.0、7.9、8.0の場合、保磁力(HcJ)が2.6kOe以上であることが確認できた。 As in Examples 9, 10 and 11, when the average particle major axis of iron nitride based magnetic powder is 35 nm, 74 nm and 147 nm, and the aspect ratio is 8.0, 7.9 and 8.0, the coercivity (HcJ) is It was confirmed that it was 2.6 kOe or more.
比較例1のように、窒化鉄系磁性粉末の平均粒子長径が68nm、アスペクト比が1.5の場合、保磁力(HcJ)が2.2kOeと、十分に高い保磁力を得ることができなかった。これは窒化鉄系磁性粉末中のFe16N2粒子のアスペクト比が2未満では、Fe16N2粒子が十分な形状異方性を有さないため、保磁力が低下したと考えられる。 As in Comparative Example 1, when the average particle major axis of the iron nitride magnetic powder is 68 nm and the aspect ratio is 1.5, a coercivity (HcJ) of 2.2 kOe, which is sufficiently high, can not be obtained. The It is considered that when the aspect ratio of the Fe 16 N 2 particles in the iron nitride magnetic powder is less than 2, the Fe 16 N 2 particles do not have sufficient shape anisotropy, so the coercivity is lowered.
比較例2のように、窒化鉄系磁性粉末の平均粒子長径が73nm、アスペクト比が8.3の場合、保磁力(HcJ)が2.2kOeと、十分に高い保磁力を得ることができなかった。これは窒化鉄系磁性粉末中のFe16N2粒子のアスペクト比が4を超える場合では、窒化鉄系磁石中のFe16N2粒子の結晶構造が歪むため、保磁力が低下したと考えられる。 As in Comparative Example 2, when the average particle length of the iron nitride magnetic powder is 73 nm and the aspect ratio is 8.3, a coercivity (HcJ) of 2.2 kOe can not be obtained, which is sufficiently high. The This is considered to be because when the aspect ratio of the Fe 16 N 2 particles in the iron nitride based magnetic powder exceeds 4, the crystal structure of the Fe 16 N 2 particles in the iron nitride based magnet is distorted, and the coercive force is lowered. .
比較例3のように、窒化鉄系磁性粉末の平均粒子長径が71nm、アスペクト比が1の場合、保磁力(HcJ)が2.0kOeと、十分に高い保磁力を得ることができなかった。これは窒化鉄系磁性粉末中のFe16N2粒子をカレンダー処理しなかったため、形状異方性による保磁力向上の効果が得られなかったためと考えられる。 As in Comparative Example 3, when the average particle length of the iron nitride-based magnetic powder is 71 nm and the aspect ratio is 1, a sufficiently high coercivity (HcJ) of 2.0 kOe could not be obtained. It is considered that this is because the Fe 16 N 2 particles in the iron nitride-based magnetic powder were not calendered, and therefore the effect of improving the coercive force by shape anisotropy was not obtained.
以上のように、本発明に係る、窒化鉄系磁性粉末は、十分な保磁力を有することから、レアアースを使用しない磁石として有用である。 As described above, the iron nitride-based magnetic powder according to the present invention is useful as a magnet that does not use rare earth because it has a sufficient coercive force.
1 窒化鉄系磁性粉末
2 磁場印加方向
3 粒子長径
4 粒子短径
1 iron nitride-based magnetic powder end
2 Magnetic field application direction
3 particle long diameter
4 particle minor diameter
Claims (3)
前記Fe 16 N 2 粒子の前記磁化容易軸方向に対して垂直な断面において、前記Fe 16 N 2 粒子の中心をとおる弦の長さが最も長い径を粒子長径とし、前記Fe 16 N 2 粒子の中心をとおり前記粒子長径に対して垂直に交わる径を粒子短径として、前記Fe16N2粒子の平均粒子長径/平均粒子短径であらわされる形状アスペクト比が2〜8である、窒化鉄系磁性粉末。 An iron nitride-based magnetic powder containing an Fe 16 N 2 phase, wherein the shape of the Fe 16 N 2 particles constituting the iron nitride-based magnetic powder is a disk-like anisotropic shape having a long axis in the direction of easy magnetization;
In the cross section perpendicular to the easy magnetization axis of the Fe 16 N 2 particles, the Fe 16 N around the passing length of the chord of the 2 particles the longest diameter and the particle diameter, of the Fe 16 N 2 particles Iron nitride-based iron having a shape minor aspect ratio of 2 to 8 represented by the average particle major axis / average particle minor axis of the Fe 16 N 2 particles , wherein the diameter which intersects the center and intersects perpendicularly to the particle major axis is the particle minor axis Magnetic powder.
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