阅读说明：本技术 铁氧体烧结磁铁和具备其的旋转电机 (Ferrite sintered magnet and rotating electrical machine provided with same ) 是由 村川喜堂 室屋尚吾 森田启之 池田真规 于 2020-03-26 设计创作，主要内容包括：铁氧体烧结磁铁(100)具备：具有六方晶结构的M型铁氧体晶粒(4)；形成于2个所述M型铁氧体晶粒(4)之间的二晶粒晶界(6a)；以及,被3个以上的M型铁氧体晶粒(4)包围的多晶粒晶界(6b)。该铁氧体烧结磁铁(100)至少包含Fe、Ca、B、以及Si,含有以B<Sub>2</Sub>O<Sub>3</Sub>换算计为0.005～0.9质量％的B,二晶粒晶界(6a)以及多晶粒晶界(6b)含有Si以及Ca,在铁氧体烧结磁铁的平行于c轴的截面,当将每76μm<Sup>2</Sup>截面积中具有0.49～5μm的最大长度的多晶粒晶界(6b)的个数设为N时,N为7以下。(A ferrite sintered magnet (100) is provided with: m-type ferrite grains (4) having a hexagonal structure; a two-grain boundary (6a) formed between 2 of the M-type ferrite grains (4); and a multi-grain boundary (6b) surrounded by 3 or more M-type ferrite grains (4). The ferrite sintered magnet (100) contains at least Fe, Ca, B and Si, and contains B 2 O 3 0.005-0.9% by mass of B in terms of B, wherein Si and Ca are contained in the two-grain boundaries (6a) and the multi-grain boundaries (6B), and the concentration of B in a cross section of the ferrite sintered magnet parallel to the c-axis is controlled to be 76 μm per unit 2 N is 7 or less when the number of the polycrystalline grain boundaries (6b) having the maximum length of 0.49 to 5 μm in the cross-sectional area is N.)

1. A ferrite sintered magnet characterized in that,

the ferrite sintered magnet comprises: m-type ferrite grains having a hexagonal structure; a two-grain boundary formed between 2 of the M-type ferrite grains; and a multi-grain boundary surrounded by 3 or more of the M-type ferrite grains,

the ferrite sintered magnet contains at least Fe, Ca, B and Si,

the ferrite sintered magnet contains B₂O₃0.005 to 0.9% by mass of B in terms of B,

the two-grain boundaries and the multi-grain boundaries contain Si and Ca,

in the section parallel to the c-axis of the ferrite sintered magnet, the thickness of the ferrite sintered magnet is 76 μm²N is 7 or less when the number of the polycrystalline grain boundaries having the maximum length of 0.49 to 5 μm in the cross-sectional area is N.

2. The ferrite sintered magnet as claimed in claim 1,

when Z is a ratio of areas of a two-grain boundary and a multi-grain boundary in a cross section parallel to the c-axis of the ferrite sintered magnet, Z is satisfied at 2.51% < Z < 5%.

3. The ferrite sintered magnet as claimed in claim 1 or 2,

when d is an average thickness of grain boundaries of two grains in a cross section of the ferrite sintered magnet parallel to the c-axis, 0.683nm < d < 2nm is satisfied.

4. The sintered ferrite magnet as claimed in any one of claims 1 to 3,

in the section parallel to the c-axis of the ferrite sintered magnet, the thickness of the ferrite sintered magnet is 76 μm²Q is 27 to 119, where Q represents the number of M-type ferrite grains having a maximum diameter of 1 μ M or less in cross-sectional area.

5. The sintered ferrite magnet as claimed in any one of claims 1 to 4,

the content of Si in the ferrite sintered magnet is SiO₂0.05 to 1.3% by mass in terms of the amount of the antioxidant.

6. The sintered ferrite magnet as claimed in any one of claims 1 to 5,

the content of Mn in the ferrite sintered magnet is 0.25 to 1.5 mass% in terms of MnO.

7. The sintered ferrite magnet as claimed in any one of claims 1 to 6,

the content of Cr in the ferrite sintered magnet is Cr₂O₃Converted to 0.03 to 0.2 mass%.

8. The sintered ferrite magnet as claimed in any one of claims 1 to 7,

the content of Zn in the ferrite sintered magnet is 0.01 to 1.47 mass% in terms of ZnO.

9. The sintered ferrite magnet as claimed in any one of claims 1 to 8,

the M-type ferrite grains are M-type Sr ferrite grains or M-type Ba ferrite grains, and the content of Ca in the ferrite sintered magnet is 0.15-2.0 mass% in terms of CaO.

10. The sintered ferrite magnet as claimed in any one of claims 1 to 8,

the M-type ferrite grains are M-type Ca ferrite grains, and the content of Ca in the ferrite sintered magnet is 2-5 mass% in terms of CaO.

11. The sintered ferrite magnet as claimed in any one of claims 1 to 10,

the ferrite sintered magnet contains substantially no La or Co.

12. A rotating electrical machine is characterized in that,

a sintered ferrite magnet as claimed in any one of claims 1 to 11.

Technical Field

The present invention relates to a ferrite sintered magnet and a rotating electric machine including the same.

Background

As magnetic materials for ferrite sintered magnets, Ba ferrite, Sr ferrite, and Ca ferrite having a crystal structure of hexagonal system are known. In recent years, among these, as a magnet material for a rotating electrical machine such as a motor, a magnetoplumbite (M-type) ferrite has been mainly focused. M type ferrite is represented by the general formula AFe₁₂O₁₉And (4) showing.

In recent years, as the M-type ferrite, from the viewpoint of reducing the raw material cost, a ferrite containing no rare earth element and Co, for example, a ferrite containing Na has been developed.

Disclosure of Invention

Technical problem to be solved by the invention

Incidentally, strength characteristics such as flexural strength are important in ferrite sintered magnets. However, the conventional ferrite sintered magnet cannot be said to have a sufficient strength. The present invention has been made in view of the above circumstances, and an object thereof is to provide a ferrite sintered magnet which does not contain a rare earth element and Co and is excellent in magnetic properties and strength, and a rotating electrical machine using the ferrite sintered magnet.

Means for solving the problems

The ferrite sintered magnet according to the present invention comprises: m-type ferrite grains having a hexagonal structure; a two-grain boundary formed between 2 of the M-type ferrite grains; and a ferrite sintered magnet having a multi-grain boundary surrounded by 3 or more of the M-type ferrite grains. The ferrite sintered magnet contains at least Fe, Ca, B and Si, and contains B₂O₃0.005-0.9% by mass of B in terms of B. The two-grain boundaries and the multi-grain boundaries contain Si and Ca. And, in the section parallel to the c-axis of the ferrite sintered magnet, the thickness is set to be 76 μm per²N is 7 or less when the number of the polycrystalline grain boundaries having the maximum length of 0.49 to 5 μm in the cross-sectional area is N.

When the ratio of the areas of the two-grain boundaries and the multi-grain boundaries in the cross section parallel to the c-axis of the ferrite sintered magnet is Z, it can satisfy 2.51% < Z < 5%.

Further, when d is an average thickness of grain boundaries of two grains in a cross section parallel to the c-axis of the ferrite sintered magnet, 0.683nm < d < 2nm can be satisfied.

In addition, in the section parallel to the c-axis of the ferrite sintered magnet, the thickness of the ferrite sintered magnet is set to be 76 μm²Q is 27 to 119, where Q represents the number of M-type ferrite grains having a maximum diameter of 1 μ M or less in cross-sectional area.

The content of Si in the ferrite sintered magnet is SiO₂The content may be 0.05 to 1.3% by mass in terms of the content.

The content of Mn in the ferrite sintered magnet may be 0.25 to 1.5 mass% in terms of MnO.

The content of Cr in the ferrite sintered magnet is Cr₂O₃The content may be 0.03 to 0.2% by mass in terms of the content.

The content of Zn in the ferrite sintered magnet may be 0.01 to 1.47 mass% in terms of ZnO.

The M-type ferrite grains may be M-type Sr ferrite grains or M-type Ba ferrite grains, and in this case, the content of Ca in the ferrite sintered magnet may be 0.15 to 2.0 mass% in terms of CaO.

The M-type ferrite grains may be M-type Ca ferrite grains, and the content of Ca in the ferrite sintered magnet may be 2 to 5 mass% in terms of CaO.

The ferrite sintered magnet may be substantially free of La and Co.

The rotating electric machine according to the present invention includes the ferrite sintered magnet.

ADVANTAGEOUS EFFECTS OF INVENTION

According to the present invention, a ferrite sintered magnet which does not substantially contain a rare earth element and Co and is excellent in magnetic characteristics and strength can be obtained.

Drawings

Fig. 1 is a schematic diagram showing an example of a cross-sectional structure of a sintered ferrite magnet according to the present invention.

Fig. 2 is a schematic cross-sectional view of a motor having a ferrite sintered magnet according to the present invention.

Fig. 3A is a perspective view of the ferrite sintered magnet S subjected to the bending strength test, and fig. 3B is a schematic view of the bending strength test.

Description of the symbols

4 … … M type ferrite sintered magnet grains (main phase), 6 … … grain boundary phase, 6a … … two grain boundary, 6b … … multiple grain boundary, 100 … … ferrite sintered magnet or bonded magnet.

Detailed Description

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings as necessary.

(ferrite sintered magnet)

As shown in fig. 1, a sintered ferrite magnet 100 according to an embodiment of the present invention includes M-type ferrite crystal grains 4 having a hexagonal structure and a grain boundary phase 6 present between the M-type ferrite crystal grains 4.

The M-type ferrite grain may include an M-type ferrite represented by formula (1) as a main component.

AX₁₂O₁₉(1)

Here, a contains at least one selected from Sr, Ba and Ca.

The M-type ferrite may be Sr ferrite in which Sr accounts for 34 at% or more of A, Ba ferrite in which Ba accounts for 34 at% or more of A, or Ca ferrite in which Ca accounts for 34 at% or more of A. The Sr ferrite, Ba ferrite, and Ca ferrite may be contained in the atomic ratio of A, and Sr, Ba, and Ca are the largest components.

The remaining element of a in the Sr ferrite may be at least one selected from Ba and Ca. The remaining element of a in Ba ferrite may be at least one selected from Sr and Ca. The remaining element of a in the Ca ferrite may be at least one selected from Sr and Ba.

X must comprise Fe. The atomic ratio of Fe may be 50% or more. The remainder of X may be one or more elements selected from Zn (zinc), Mn (manganese), Al (aluminum), and Cr (chromium).

The M-type Sr ferrite can be represented by, for example, the following general formula (3).

Sr_1-zR_z(Fe_12-xM_x)_yO₁₉(3)

In the formula (3), x is, for example, 0.01 to 0.5; y is, for example, 0.7 to 1.2; z is 0 to 0.5, for example, 0, or 0.01 to 0.49. R may be Ca and/or Ba.

The M-type Ba ferrite can be represented by, for example, the following general formula (4).

Ba_1-zR_z(Fe_12-xM_x)_yO₁₉(4)

In the formula (4), x is, for example, 0.01 to 0.5; y is, for example, 0.7 to 1.2; z is 0 to 0.5, for example, 0, or 0.01 to 0.49. R may be Sr and/or Ca.

The M-type Ca ferrite can be represented by, for example, the following general formula (5).

Ca_1-zR_z(Fe_12-xM_x)_yO₁₉(5)

In the formula (5), x is, for example, 0.01 to 0.5; y is, for example, 0.7 to 1.2; z is 0 to 0.5, for example, 0, or 0.01 to 0.49. R may be Sr and/or Ba.

M in the above formulas (3) to (5) may be one or more elements selected from Zn (zinc), Mn (manganese), Al (aluminum), and Cr (chromium).

In addition, the ratio of the a site and the X site or the ratio of oxygen (O) in the above formulas (3) to (5) may be slightly different from the above values because they are actually slightly out of the above ranges.

When the M-type ferrite in the sintered ferrite magnet is represented by the above formulas (3) to (5), M preferably contains Mn and Cr, and more preferably contains Mn, Cr, and Zn.

The mass fraction of the M-type ferrite in the M-type ferrite crystal grains is preferably 90% or more, more preferably 95% or more, and further preferably 97% or more.

The mass ratio of the M-type ferrite crystal grains (main phase) to the entire crystal grains in the sintered ferrite magnet is preferably 90% or more, more preferably 95% or more, and still more preferably 97% or more. In this way, the magnetic properties can be further improved by lowering the mass ratio of the crystal phase (heterogeneous phase) different from the M-type ferrite phase. The mass ratio (%) of the M-type ferrite phase in all the crystal grains of the sintered ferrite magnet can be confirmed by determining the existence ratio (mol%) of the M-type ferrite phase by X-ray diffraction. The presence ratio of the M-type ferrite phase can be calculated by mixing M-type ferrite, orthoferrite, hematite, spinel, W-type ferrite, and respective powder samples at a predetermined ratio and comparing the X-ray diffraction intensities thereof.

In the section parallel to the c-axis of the ferrite sintered magnet, the thickness of the ferrite sintered magnet should be 76 μm each²Q is preferably 27 to 119, where Q represents the number of M-type ferrite crystal grains having a maximum diameter of 1 μ M or less in cross-sectional area. The maximum diameter means the diameter of the M-type ferrite crystal grain 4 measured in the maximum direction. The c-axis in the ferrite sintered magnet means an axis on which magnetization in the ferrite sintered magnet is easy.

The squareness ratio is improved by setting the number of M-type ferrite crystal grains having a maximum diameter of 1 μ M or less to a certain number or more.

The grain boundary phase 6 is disposed between the M-type ferrite grains 4. The grain boundary phase 6 contains an oxide as a main component. The constituent element of the oxide may be at least one selected from B (boron), Si (silicon), Ca (calcium), Sr (strontium), Ba (barium), Fe (iron), Mn (manganese), Zn (zinc), Cr (chromium), and Al (aluminum), or a combined oxide of any 2 or more. An example of the oxide is, for example, SiO₂、CaO、BaO、SrO、Al₂O₃，ZnO、Fe₂O₃、MnO、Cr₂O₃、B₂O₃And the like. In addition, silicate glass may be contained. The oxide may occupy 90 mass of the grain boundary phase 6The amount is not less than 95% by mass, more preferably not less than 97% by mass.

The grain boundary phase 6 must contain Si and Ca. The grain boundary phase may further include B.

The grain boundary phase 6 has a two-grain boundary formed between 2M-type ferrite grains 4, and a multi-grain boundary 6b surrounded by 3 or more M-type ferrite grains 4.

In the section parallel to the c-axis of the ferrite sintered magnet, the thickness of the ferrite sintered magnet should be 76 μm each²N is 7 or less when the number of the polycrystalline grain boundaries having the maximum length of 0.49 to 5 μm in the cross-sectional area is N. Here, the maximum length is a length (diameter) of the polycrystalline grain boundary 6b measured in a direction to be the maximum. N may be 6 or less. N may also be 0.

Since the number of large polycrystalline grain boundaries is small, the thickness of the two grain boundaries 6a becomes large. Therefore, it is considered that the magnetic interaction between the M-type ferrite grains is suppressed, HcJ is improved, and mechanical hardness is also increased.

In the section parallel to the c-axis of the ferrite sintered magnet, the thickness of the ferrite sintered magnet should be 76 μm each²P may be 8 or more, where P represents the number of grain boundaries of the polycrystalline grains having a maximum length of 0.088 to less than 0.49 μm in cross-sectional area. P may be 10 or more, or 15 or more. P may be 200 or less.

Since the number of small polycrystalline grain boundaries is large, the thickness of the two grain boundaries 6a becomes large. Therefore, it is considered that the magnetic interaction between the M-type ferrite grains is suppressed, HcJ is improved, and mechanical hardness is also increased.

In a cross section parallel to the c-axis of the ferrite sintered magnet, the ratio Z of the area of the grain boundary phase 6 (the two grain boundaries 6a and the multiple grain boundaries 6b) can satisfy 2.51% < Z < 5%. The ratio Z of the areas of the grain boundary phases 6 may be 76 μm²Measured in cross-sectional area.

If the area of the grain boundary phase 6 is small, it is difficult to obtain the effect of suppressing the magnetic interaction between the M-type ferrite grains, while if the area of the grain boundary phase 6 is too large, the nonmagnetic layer occupying the whole becomes too large and Br decreases.

When d is the average thickness of the grain boundaries 6a of two grains in a cross section of the sintered ferrite magnet parallel to the c-axis, 0.683nm < d < 2nm can be satisfied. The average thickness d is, for example, a measurement value in the central portion of 10 different two grain boundaries in which the multiple grain boundaries are arranged at both ends, and the average value thereof is used as the average thickness d.

By satisfying this, the thickness of the two-grain boundary 6a is not excessively small, and the effect of suppressing the magnetic interaction between the M-type ferrite grains is easily obtained. If the thickness of the two grain boundaries 6a is too large, the proportion of the nonmagnetic layer increases and Br decreases.

The ferrite sintered magnet according to the embodiment of the present invention is an oxide containing at least Fe, Ca, B, and Si.

Fe content in ferrite sintered magnet₂O₃The amount of the surfactant is preferably 80 to 95% by mass, more preferably 87 to 90% by mass. By setting the above range, favorable magnetic characteristics can be obtained.

When the M-type ferrite grains are Sr ferrite grains, the Sr content in the ferrite sintered magnet is preferably 9 to 11 mass%, more preferably 9 to 10 mass%, in terms of SrO.

In the case where the M-type ferrite grains are Ba ferrite grains, the content of Ba in the ferrite sintered magnet is Ba₂O₃The amount of the compound is preferably 13 to 17% by mass, more preferably 13 to 15% by mass.

When the M-type ferrite grains are Ca ferrite grains, the content of Ca in the ferrite sintered magnet is preferably 2 to 5 mass%, more preferably 2 to 4 mass%, in terms of CaO.

The ferrite sintered magnet contains B. The content of B in the ferrite sintered magnet is B₂O₃0.005-0.9% by mass in terms of the amount of the metal oxide. From the viewpoint of further improving the coercive force and squareness ratio (Hk/HcJ) of the ferrite sintered magnet, the content of B is represented by B₂O₃The conversion is preferably 0.01 mass% or more. In addition, the residual magnetic flux density (Br) of the ferrite sintered magnet is further improvedIn view of (1), the content of B is defined as B₂O₃Preferably 0.4% by mass or less, more preferably 0.2% by mass or less in terms of conversion.

The ferrite sintered magnet contains Si (silicon). The content of Si in the ferrite sintered magnet is SiO₂The amount is preferably 0.05 to 1.3% by mass, more preferably 0.2 to 0.5% by mass, and still more preferably 0.25 to 0.36% by mass. Presence of SiO₂When Br is too large, Br tends to decrease, and when HcJ is too small, SiO is added₂When the content is within the above range, an optimum grain boundary phase is formed, and high magnetic properties are easily obtained.

The ferrite sintered magnet contains Ca (calcium) regardless of whether the main phase is Sr ferrite or Ba ferrite. When the main phase is Sr ferrite or Ba ferrite, the content of Ca in the ferrite sintered magnet is preferably 0.15 to 2.0 mass%, more preferably 0.4 to 1.0 mass%, and still more preferably 0.47 to 0.62 mass%, in terms of CaO. Since HcJ tends to decrease when Ca is excessive and Br tends to decrease when Ca is insufficient, an optimum grain boundary phase is formed by setting the Ca content within the above range, and high magnetic properties are easily obtained.

In the case where the main phase is Sr ferrite, the ferrite sintered magnet may contain Ba. The content of Ba is preferably 0 to 0.2 mass% in terms of BaO.

When the main phase is Ca ferrite, the ferrite sintered magnet may contain at least one selected from Sr and Ba, and the content of Ba is preferably 0 to 1.5 mass% in terms of BaO. The Sr content is preferably 0 to 1.0 mass% in terms of SrO.

In the case where the main phase is Ba ferrite, the ferrite sintered magnet may contain Sr. The Sr content is preferably 0 to 0.8 mass% in terms of SrO.

The ferrite sintered magnet may contain Mn. The content of Mn in the ferrite sintered magnet is preferably 0.25 to 1.5 mass% in terms of MnO. It is presumed that substitution of the sites of Fe by Mn satisfying the above range can easily obtain the effect of improving the magnetic properties, and can promote the action of solid solution of Zn.

The ferrite sintered magnet may contain Cr. Ferrite sintered magnetThe content of Cr in iron is Cr₂O₃Preferably 0.03 to 0.2 mass% in terms of conversion. It is presumed that the substitution of the sites of Fe by Cr satisfying the above range can easily obtain the effect of improving the magnetic properties and can also promote the action of solid solution of Zn.

The ferrite sintered magnet may contain Zn. The Zn content in the ferrite sintered magnet is preferably 0.01 to 1.47 mass% in terms of ZnO. From the viewpoint of further improving the residual magnetic flux density (Br) of the ferrite sintered magnet, the content of Zn is preferably 0.08 mass% or more, more preferably 0.15 mass% or more in terms of ZnO. In addition, the content of Zn is preferably 1.0 mass% or less, more preferably 0.5 mass% or less in terms of ZnO, from the viewpoint of further improving the coercive force and squareness ratio (Hk/HcJ) of the ferrite sintered magnet.

It is considered that the saturation magnetization Br increases by selective substitution of Zn for the sites of Fe having a magnetic moment oriented in the antiparallel direction. On the other hand, while the coercivity is decreased because the magnetocrystalline anisotropy is decreased by Zn substitution, it is presumed that the coercivity can be maintained by suppressing the magnetic interaction between crystal grains by uniformly forming a grain boundary phase containing B, and suppressing the decrease in coercivity.

The ferrite sintered magnet is preferably substantially free of rare earth elements and Co (cobalt). The rare earth elements are Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu.

Although the ferrite sintered magnet may contain Ni, it is preferable that Ni is not substantially contained. The concentration of Ni may be 0.02 mass% or less.

Although the ferrite sintered magnet may contain Cu, it is preferable that Cu is not substantially contained. The concentration of Cu may be 0.02 mass% or less.

By not containing these metals, the cost can be reduced.

The term "ferrite sintered magnet" as used herein means that the ferrite sintered magnet contains substantially no element a, and the concentration of element a in the ferrite sintered magnet is less than 0.005% by mass in terms of oxide. The concentration of the element a is preferably less than 0.001 mass% in terms of oxide.

Although the ferrite sintered magnet does not necessarily contain Al, Al may be contained. The content of Al can be controlled to be Al₂O₃Converted to 0 to 0.2 mass%.

The ferrite sintered magnet does not necessarily contain Na, and preferably does not substantially contain Na. The content of Na is as Na₂Preferably, the content is 0.005% by mass or less in terms of O. More preferably 0.001 mass% or less. The smaller the Na content, the more excellent the moldability.

In addition to these components, the ferrite sintered magnet may contain impurities contained in the raw materials and inevitable components derived from manufacturing facilities. Examples of such a component include various oxides such as Mg (magnesium), Ti (titanium), Mo (molybdenum), and V (vanadium). The total content of these components is preferably 0.06% by mass or less.

The contents of the respective components of the ferrite sintered magnet can be measured by fluorescent X-ray analysis and inductively coupled plasma emission spectroscopy (ICP analysis).

The residual magnetic flux density (Br) of the sintered ferrite magnet is preferably 420mT or more, more preferably 440mT or more, and still more preferably 450mT or more. The coercive force of the sintered ferrite magnet is preferably 260kA/m or more, more preferably 270kA/m or more, and still more preferably 280kA/m or more. The squareness ratio (Hk/HcJ) of the ferrite sintered magnet is preferably 85% or more, more preferably 88% or more, and still more preferably 90% or more. In particular, the ferrite sintered magnet preferably has a remanence (Br) of 440mT or more and a squareness ratio (Hk/HcJ) of 85% or more. By having such excellent magnetic properties, the magnetic material can be further suitably used for a motor or a generator.

In addition, the ferrite sintered magnet can have sufficient mechanical strength. The ferrite sintered magnet having high mechanical strength is easy to handle, and can effectively prevent breakage or chipping during transportation, thereby improving the product yield and contributing to cost reduction. Further, the ferrite sintered magnet having high mechanical strength is not easily broken even after being incorporated into a product such as a motor, and thus the reliability of the product can be improved.

The shape of the ferrite sintered magnet is not particularly limited, and various shapes such as a segment (C-shape) shape curved so that the end face becomes an arc shape, a flat plate shape, and the like can be made.

The ferrite sintered magnet can be used as a magnetic field generating member such as a rotating electric machine such as a motor and a generator, a magnet for a speaker and a headphone, a magnetron, a magnetic field generating device for MRI, a clamper for CD-ROM, a sensor for dispenser, a sensor for ABS, a fuel/oil level sensor, a magnetic latch (magnetic latch), or an isolator. Further, the magnetic material can be used as a target (pellet) for forming a magnetic layer of a magnetic storage medium by vapor deposition, sputtering, or the like.

(rotating electric machine)

Next, fig. 2 shows a motor according to an embodiment of the present invention. The motor 200 has a stator 31 and a rotor 32. The rotor 32 has a rotating shaft 36 and a rotor core 37. In the motor 200 of the present embodiment, the stator 31 is provided with a C-shaped ferrite sintered magnet 100 as a permanent magnet, and the rotor core 37 of the rotor 32 is provided with an electromagnet (coil).

Since ferrite sintered magnet 100 can be made thin due to high Br, the gap between stator 31 and rotor 32 can be sufficiently small. Therefore, the motor 200 can be miniaturized while maintaining its performance.

In addition, a motor may be provided in which a ferrite sintered magnet is provided in the rotor and an electromagnet (coil) is provided in the stator. The form of the motor is not particularly limited. Another example of the rotating electric machine is a generator having a rotor and a stator. In this case, the ferrite sintered magnet may be provided in the rotor or the stator.

(production method)

Next, an example of a method for producing a ferrite sintered magnet will be described. A method for producing a ferrite sintered magnet includes a blending step, a firing step, a pulverizing step, a molding step in a magnetic field, and a firing step. The following describes the details of the respective steps.

The blending step is a step of preparing a mixed powder for calcination. The mixed powder for calcination may be a powder containing all the metal elements constituting the M-type ferrite. In the blending step, it is preferable that plural kinds of powders such as Fe-containing powder and Sr-containing powder are mixed by an attritor or a ball mill for about 1 to 20 hours and then pulverized to obtain a mixed powder.

In the mixing step, a powder containing a metal element other than the metal elements constituting the ferrite and contained in the ferrite sintered magnet and a powder containing a semimetal element may be mixed. Examples of the other powders are a Si-containing powder, a Ca-containing powder, a Zn-containing powder, and a B-containing powder.

Examples of the powder containing each element are a monomer, an oxide, a hydroxide, a carbonate, a nitrate, a silicate, and an organic metal compound of each element. One kind of powder may contain 2 or more kinds of metal elements, and one kind of powder may contain substantially only one kind of metal element. A powder may also contain metallic elements and semimetallic elements.

An example of the powder containing Fe is Fe₂O₃。

An example of the Sr-containing powder is SrCO₃And SrO.

An example of the Si-containing powder is SiO₂。

An example of a Ca-containing powder is CaCO₃And CaO.

An example of a powder containing Zn is ZnO.

An example of the Ba-containing powder is BaO.

An example of a powder containing B is H₃BO₃。

B is preferably added in an appropriate amount because B tends to be dissolved in water and evaporated by heating.

In particular, as the compound containing B, it may be other than B₂O₃But is H₃BO₃And it is desirable to add the whole amount in the blending step. Due to H₃BO₃And B₂O₃In contrast, the polymer has high solubility in water and can be uniformly dispersed at a molecular level (boric acid 5.7g/100ml, boron oxide 3.6g/100ml at 25 ℃ C.) because of its high solubility in waterBoric acid has a lighter specific gravity and therefore is easily dispersed during stirring and mixing (boric acid 1.5 g/cm)³Boron oxide 1.9g/cm³Above). Further, even if the undissolved portion remains, boric acid is decomposed at a relatively low temperature, and therefore uniform dispersion can be expected. (decomposition temperature: boric acid 171 ℃ C., boron oxide 450 ℃ C.). Further, by adding the entire amount in the blending step, the effect of forming a homogeneous structure of boron and other components at the time of calcination can be obtained to the maximum.

I.e. by reacting H₃BO₃The total amount added in the blending step can reduce the number N of large polycrystalline grain boundaries 6b, increase the number P of small polycrystalline grain boundaries 6b, form two grain boundaries 6a having a large average thickness d, and increase the number Q of ferrite grains of 1 μm or less, for example. Therefore, it is considered that high magnetic characteristics and strength can be obtained.

The average particle size of the raw material powder is not particularly limited, and is, for example, 0.1 to 2.0 μm.

Among them, a small amount of additive elements such as Cr, Mn, Al, Ba, etc., which may be contained in the ferrite sintered magnet to be a final product, may be contained in the powder. When the small amount of these elements added to the powder is small, a powder containing Cr (Cr) may be added in the blending step as necessary₂O₃) Mn-containing powder (MnO), Al-containing powder (Al)₂O₃) And Ba-containing powder (BaO), to obtain a mixed powder for calcination.

The composition of the metal and semimetal elements in the mixed powder is roughly the same as that of the final product of the ferrite sintered magnet, but is not precisely the same because of the elements that disappear in the manufacturing process.

The calcination step is a step of calcining the mixed powder obtained in the blending step. The calcination may be carried out in an oxidizing atmosphere such as air. The calcination temperature is preferably 850 to 1450 ℃, more preferably 900 to 1350 ℃, and still more preferably 1000 to 1300 ℃, and the calcination time at the calcination temperature is preferably 1 second to 10 hours, and more preferably 1 minute to 3 hours. The content of the M-type ferrite in the calcined product obtained by the calcination is preferably 70 mass% or more, more preferably 90 mass% or more. The primary particle size of the calcined product is preferably 10 μm or less, more preferably 3.0 μm or less.

The pulverization step is a step of pulverizing the calcined product to obtain a powder of an M-type ferrite magnet. The pulverization step may be performed in one stage, or may be performed in two stages, i.e., a coarse pulverization step and a fine pulverization step. Since the calcined product is usually in the form of particles or lumps, it is preferable to perform the coarse pulverization step first. In the coarse grinding step, the powder is ground in a dry manner using a vibrating rod mill or the like to prepare a ground powder having an average particle diameter of 0.5 to 5.0 μm. The pulverized powder thus prepared is pulverized in a wet manner using a wet mill, a ball mill, a jet mill or the like to obtain a fine powder having an average particle diameter of 0.08 to 5.0 μm, preferably 0.1 to 2.5 μm, more preferably 0.2 to 2 μm.

The specific surface area of the fine powder obtained by the BET method is preferably 5 to 14m²(ii)/g, more preferably 7 to 12m²(ii) in terms of/g. The grinding time is, for example, 30 minutes to 20 hours when a wet grinder is used, and 5 to 50 hours when a ball mill is used. The time is preferably adjusted as appropriate according to the pulverization method.

In the pulverizing step, a powder containing a metal element and/or a semimetal element (e.g., Si, Ca, Ba, Sr, Zn, and B) and/or a powder containing a small amount of an additive element such as Cr, Mn, Al, and Ba may be added to the M-type ferrite magnet powder.

In order to increase the degree of magnetic orientation of the ferrite sintered magnet, it is preferable to add a polyol in the fine grinding step in addition to the above components. The amount of the polyhydric alcohol added is 0.05 to 5.0% by mass, preferably 0.1 to 3.0% by mass, and more preferably 0.1 to 2.0% by mass, based on the object to be added. The added polyol is thermally decomposed and removed in a firing step after the molding step in a magnetic field.

The in-magnetic-field forming step is a step of forming the fine powder obtained in the pulverizing step in a magnetic field to produce a molded body. The molding step in a magnetic field may be performed by any of dry molding and wet molding. From the viewpoint of improving the degree of magnetic orientation, wet molding is preferred. In the case of wet molding, the fine pulverization step may be performed in a wet manner, and the obtained slurry may be adjusted to a predetermined concentration to prepare a slurry for wet molding. The concentration of the slurry may be performed by centrifugal separation, filter press (filter press), or the like.

The content of the fine powder in the slurry for wet molding is preferably 30 to 85 mass%. As a dispersion medium of the slurry, water or a nonaqueous solvent can be used. In the slurry for wet molding, a surfactant such as gluconic acid, gluconate, or sorbitol may be added in addition to water. The slurry for wet molding is used for molding in a magnetic field. The molding pressure is, for example, 0.1 to 0.5 ton/cm²The applied magnetic field is, for example, 5 to 15 kOe.

The firing step is a step of firing the molded body to obtain a sintered body. The firing step is usually performed in an oxidizing atmosphere such as the atmosphere. The firing temperature is preferably 1050 to 1300 ℃, and more preferably 1150 to 1250 ℃. The firing time at the firing temperature is preferably 0.5 to 3 hours. Through the above steps, a sintered body, that is, a ferrite sintered magnet can be obtained. The method for producing a sintered ferrite magnet according to the present invention is not limited to the above-described method.

The present invention will be described in further detail with reference to examples and comparative examples, but the present invention is not limited to these examples.

(production of ferrite sintered magnet)

First, the following starting materials were prepared.

·Fe₂O₃Powder (primary particle size: 0.3 μm)

·SrCO₃Powder (primary particle size: 2 μm)

·SiO₂Powder (primary particle size: 0.01 μm)

·CaCO₃Powder of

ZnO powder

·H₃BO₄Powder of

[ example 1]

Mixing Fe₂O₃Powder 1000g, SrCO₃Powder 161g, CaCO₃Powder 12.1g、SiO₂4.33g of powder, 3.5g of ZnO powder and H₃BO₄0.34g of the powder was mixed by grinding with a wet grinder, and dried and granulated. The powder thus obtained was fired at 1250 ℃ for 1 hour in the air to obtain a granular calcined product. The calcined material was coarsely pulverized by a dry vibration rod mill to prepare a powder having a specific surface area of 1m measured by the BET method²Powder per gram.

A predetermined amount of sorbitol was added to 200g of the coarsely pulverized powder, and wet-pulverized for 24 hours using a ball mill to obtain a slurry. The amount of sorbitol added was 0.25 mass% based on the mass of the powder after the coarse pulverization. The specific surface area of the pulverized micropowder is 8 to 10m²/g。

Then, the solid content concentration of the slurry was adjusted, and the slurry was molded in an applied magnetic field of 12kOe using a wet magnetic field molding machine to obtain a molded article. 3 such molded articles were produced. These molded bodies were fired in the air at 1180 ℃, 1195 ℃ and 1210 ℃ to obtain cylindrical ferrite sintered magnets (example 1).

Examples 2 to 6 and comparative example 1

Except for changing H₃BO₄Except for the amount of the powder added, magnets of examples 2 to 6 and comparative example 1 were obtained in the same manner as in example 1.

[ examples 7 to 8]

Magnets of examples 7 and 8 were obtained in the same manner as in example 4, except that the amount of Mn added was changed by selecting the types of the raw materials having different Mn contents.

[ examples 9 to 10]

Magnets of examples 9 and 10 were obtained in the same manner as in example 4, except that the amount of Cr added was changed by selecting the types of the raw materials having different Cr contents.

[ examples 11 to 12]

Magnets of examples 11 and 12 were obtained in the same manner as in example 4, except that the amount of ZnO to be added was changed.

[ examples 13 to 14]

Except for changing SiO₂Except for the amount of (c), the same procedures as in example 4 were carried out to obtain magnets of examples 13 and 14.

[ examples 15 to 16]

Except for changing CaCO₃Except for the amount of (c), the same procedures as in example 4 were carried out to obtain magnets of examples 15 and 16.

(evaluation of ferrite sintered magnet)

< compositional analysis >

The compositions of the ferrite sintered magnets of the respective examples and comparative examples thus produced were measured by inductively coupled plasma emission spectroscopy (ICP analysis). In the ferrite sintered magnet, elements (Ba, Al, Mn, Cr, etc.) derived from impurities contained in the starting materials were detected in addition to Fe, Sr, Si, Ca, Zn, B, etc.

Table 1 shows the results of converting detected Fe, Sr, Ba, Al, Si, Ca, Mn, Zn, Cr, Na and B into Fe₂O₃、SrO、BaO、Al₂O₃、SiO₂、CaO、MnO、ZnO、Cr₂O₃、Na₂O and B₂O₃The content of (A) to (B). These contents are values (mass%) based on the whole of the ferrite sintered magnet.

< evaluation of magnetic Properties >

After the upper and lower surfaces of the prepared cylindrical ferrite sintered magnet were processed, the magnetic properties were measured by using a B-H tracer with a maximum applied magnetic field of 25 kOe. In the measurement, the remanence (Br) and the coercive force (HcJ) were determined, and the external magnetic field strength (Hk) at which the remanence (Br) reached 90% was measured, and based on these, the squareness ratio (Hk/HcJ) (%) was determined. In each of the examples and comparative examples, the ferrite sintered magnets manufactured at 1180 ℃, 1195 ℃ and 1210 ℃ had the best balance between the remanence density (Br) and the squareness ratio (Hk/HcJ) and were manufactured at 1195 ℃, and the magnetic properties of the ferrite sintered magnets manufactured at 1195 ℃ are shown in table 1.

< evaluation of mechanical Strength >

The flexural strength (σ) of the ferrite sintered magnet was measured by a 3-point bending test under the following conditions. First, unlike the above-described cylindrical ferrite sintered magnet, an arc-shaped ferrite sintered magnet S (length L34 mm, width W25.5 mm, thickness T3.7 mm, and angle R between the wirings drawn from the center of the circle to the both ends of the arc assuming that the circle including the arc is 130 degrees) as shown in fig. 3A was prepared. The firing temperature was set to 1195 ℃.

Next, as shown in fig. 3B, an arc-shaped ferrite sintered magnet S was placed on a horizontal table 70, a load F (speed 3mm/min) was applied in the direction of the arrow from the top to the bottom by a jig 72, the maximum breaking load fn at the time of breaking of the ferrite sintered magnet S was measured, and the flexural strength (σ) was obtained by the following equation. The flexural strength (. sigma.) was an average of 30 samples.

σ[N/mm²]＝3×L×F/(2×W×T²)

< observation of the Cross section of ferrite sintered magnet >

The cross section (i.e., a-plane) of the obtained anisotropic sintered ferrite magnet parallel to the c-axis was observed with a STEM (scanning Transmission Electron microscope), and 76 μm was calculated from an HAADF-STEM image enlarged by 10000 times²The number Q of M-type ferrite grains of 1 μ M or less in the range of (2).

Further, the image data obtained by STEM-EDX (energy dispersive X-ray analysis apparatus attached to a scanning transmission electron microscope) observation of the above cross section was subjected to binarization processing using 10000 times element mapping to separate the main phase and the grain boundary phase at 76 μm²The ratio Z of the size and number N, P of the grain boundary of the polycrystalline grain and the area of the grain boundary phase was calculated.

The cross section was observed by TEM (transmission electron microscope), and the average thickness d of the grain boundary of two crystal grains was measured from the HAADF-STEM image enlarged by 200 to 300 ten thousand times.

As shown in tables 1 and 2, the sintered ferrite magnets of the examples had residual magnetic flux densities (Br) of 420mT or more. The coercive force (HcJ) is 260kA/m or more, and the squareness ratio (Hk/HcJ) is 85% or more. Also, the intensity σ was shown to be 172N/mm²The above. In other words, it was confirmed that the ferrite sintered magnet of the present invention exhibits excellent magnetic properties and strength when N is 6 or less.