Iron-based magnetic alloy powder containing rare earth element, method for producing same, resin composition for bonded magnet obtained from same, bonded magnet, and compacted magnet

A manufacturing method and technology of alloy powder, applied in the field of dense magnets, can solve the problems of insufficient affinity of binder resin, low mechanical strength, breakage, etc., and achieve excellent corrosion resistance, high mechanical strength and high industrial value. Effect

Active Publication Date: 2011-05-25
SUMITOMO METAL MINING CO LTD
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  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

However, when the bonded magnet made of this magnet alloy powder is immersed in salt water for 24 hours, although the generation of red rust can be reduced to a large extent, it cannot be completely avoided.
In addition, the magnet alloy powder produced by this method may cause stress concentration at the interface with the binder resin due to thermal deformation during injection molding, and has insufficient affinity with the binder resin. Therefore, the mechanical strength of the molded body as a bonded magnet is low, and it may be damaged when subjected to strict processing.

Method used

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  • Iron-based magnetic alloy powder containing rare earth element, method for producing same, resin composition for bonded magnet obtained from same, bonded magnet, and compacted magnet
  • Iron-based magnetic alloy powder containing rare earth element, method for producing same, resin composition for bonded magnet obtained from same, bonded magnet, and compacted magnet
  • Iron-based magnetic alloy powder containing rare earth element, method for producing same, resin composition for bonded magnet obtained from same, bonded magnet, and compacted magnet

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1～11

[0192] Magnet powder A was used directly without crushing. Magnet powder B was crushed to an average particle size of 50 μm with an organic solvent as a crushing solvent by a media stirring roller. Magnet powder C was similarly crushed to an average particle size of 70 μm. They were used as Magnet alloy powder for processing.

[0193] Next, add the coating treatment liquid containing phosphoric acid compound, polyphenol, alcohol solvent and water described in Table 1 to the above-mentioned alloy powder at a ratio of 15 g per 1 kg of magnet alloy powder, and stir with a mixer for 5 g. ~60 minutes to make a slurry. As the alcohol-based solvent, methanol, ethanol, isopropanol, butanol, and acetone are used alone or in combination. The residual solvent other than the alcoholic solvent is water.

[0194] Here, in Examples 2, 3, 6, 7, 9, and 10, a water-soluble resin was also added, and in Example 11, 2% by mass of zinc oxide was mixed with phosphoric acid instead of the water-sol...

Embodiment 12～22

[0201] The magnet powder D was mixed with an organic solvent, put into a media agitation mill whose inside of the container was replaced with nitrogen, and pulverized to an average particle size of 3 μm to produce a magnet alloy powder.

[0202] Next, add the coating treatment solution containing phosphoric acid compound, polyphenol, alcohol solvent, and water described in Table 2 to the alloy powder at a ratio of 50 g per 1 kg of magnet alloy powder, and stir for 5 to 60 minutes. , to make it slurry. As the alcohol-based solvent, methanol, ethanol, isopropanol, butanol, and acetone are used alone or in combination. The residual solvent other than the alcoholic solvent is water.

[0203] Here, in Examples 13, 14, 17, 18, 20, and 21, a water-soluble resin was also added, and in Example 22, 2% by mass of zinc oxide was mixed with phosphoric acid instead of the water-soluble resin, and slurry was performed. . Then, the slurry was filtered, and the filtrate was put into a Hensc...

Embodiment 23～27

[0219] Magnet powders A to E shown in Table 5 were used alone or in combination, and injection-molded bonded magnets were prepared according to the method described in Evaluation of Salt Water Resistance. The molded body was coated to evaluate salt water resistance. In addition, the magnet powder D was pulverized by the same method as in Comparative Example 7, and used as a magnet alloy powder.

[0220] [table 5]

[0221]

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Abstract

Disclosed is a magnetic alloy powder containing a rare earth element, which has a surface covered with a strong coating film and does not rust even in a corrosive environment, while exhibiting excellent corrosion resistance and resin adhesion. Also disclosed are: a method for producing the magnetic alloy powder containing a rare earth element; a resin composition for bonded magnets using the magnetic alloy powder and having excellent mechanical strength; a bonded magnet; and a compacted magnet. Specifically disclosed is an iron-based magnetic alloy powder containing a rare earth element, wherein an inorganic-organic composite coating film is uniformly formed on the surface of the magnetic powder, said coating film being composed of a complex metal phosphate that contains iron phosphate and a rare earth metal phosphate, and an organic compound that contains a polyphenol. Also specifically disclosed is a compacted magnet or bonded magnet which is characterized in that an inorganic-organic composite coating film is formed on the surface of a molded body which is obtained by molding an iron-based magnetic alloy powder containing a rare earth element, or molding a resin composition containing an iron-based magnetic alloy powder containing a rare earth element and a resin binder, said coating film being composed of a complex metal phosphate that contains iron phosphate and a rare earth metal phosphate, and an organic compound that contains a polyphenol.

Description

technical field [0001] The present invention relates to an iron-based magnet alloy powder containing rare earth elements and its production method, the obtained resin composition for bonded magnets, bonded magnets, and compacted magnets, and more specifically, to an iron-based magnet alloy powder whose surface is hardened. Iron-based magnet alloy powder containing rare earth elements, which is coated with a coating film and does not rust even in a corrosive environment, and has excellent corrosion resistance and resin adhesion, and its manufacturing method, and has excellent mechanical strength using the magnet alloy powder A resin composition for a bonded magnet, a bonded magnet, and a compact magnet. Background technique [0002] In recent years, ferrite magnets, Alnico magnets, rare earth magnets, etc. have been used as components such as motors and sensors in various products such as general home appliances, communication or audio equipment, medical equipment, and genera...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B22F1/02B22F1/00B22F9/04H01F1/08H01F1/09B22F1/102B22F1/16
CPCB22F1/0062H01F1/0572B22F1/02H01F1/0578H01F1/059H01F41/026B22F1/102B22F1/16
Inventor 林真一渡边邦夫山边秀敏石川尚石井纯一
Owner SUMITOMO METAL MINING CO LTD
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