JP2023138191A - Powder materials and rotating electric machines - Google Patents

Abstract

The present invention provides a compacted powder material and a rotating electric machine having excellent magnetic properties. A compacted powder material according to an embodiment has a flat surface and a magnetic metal phase containing at least one first element selected from the group consisting of Fe, Co, and Ni, and has an average thickness of 10 nm or more and 100 μm or less, and the average ratio of the average length in the flat plane to the thickness is 5 or more and 10,000 or less, and exists between the flat magnetic metal particles, and oxygen ( O), an intervening phase containing at least one second element selected from the group consisting of carbon (C), nitrogen (N), and fluorine (F), and in the compacted powder material, In a predetermined cross section perpendicular to a plane of the compacted powder material, the orientation variation of the plurality of flat magnetic metal particles is 30 degrees or more and 45 degrees or less, and the proximity ratio of the plurality of flat magnetic metal particles is 3%. 10% or less, and the curvature of the plurality of flat magnetic metal particles is 0.01% or more and 0.6% or less. [Selection diagram] Figure 12

Description

Embodiments of the present invention relate to a compacted powder material and a rotating electric machine.

Currently, soft magnetic materials are used in parts of various systems and devices such as rotating electric machines (e.g. motors, generators, etc.), transformers, inductors, transformers, magnetic inks, antenna devices, etc., and are extremely important materials. It is. These parts utilize the real part of magnetic permeability (real part of relative magnetic permeability) μ' of the soft magnetic material, so when actually used, it is preferable to control μ' according to the frequency band used. . Furthermore, in order to realize a highly efficient system, it is preferable to use a material with as low a loss as possible. In other words, it is preferable to make the imaginary part of magnetic permeability (imaginary part of relative magnetic permeability) μ" (corresponding to loss) as small as possible. Regarding loss, the loss coefficient tan δ (= μ" / μ' × 100 (%)) is As a guideline for It is preferable to reduce loss, ferromagnetic resonance loss, and residual loss (other losses) as much as possible.To reduce eddy current loss, increase electrical resistance, reduce the size of metal parts, and improve magnetic domain structure. It is effective to subdivide the hysteresis loss.In order to reduce the hysteresis loss, it is effective to reduce the coercive force or increase the saturation magnetization.In order to reduce the ferromagnetic resonance loss, it is effective to , it is effective to increase the ferromagnetic resonance frequency by increasing the anisotropic magnetic field of the material.In addition, as the demand for handling high-power electric power has increased in recent years, it is especially important to increase the ferromagnetic resonance frequency by increasing the anisotropic magnetic field of the material. etc., it is required that the loss be small under operating conditions where the effective magnetic field applied to the material is large.To this end, it is preferable that the saturation magnetization of the soft magnetic material be as large as possible to prevent magnetic saturation.Furthermore, In recent years, higher frequencies have made it possible to miniaturize equipment, so systems and devices are increasingly using higher frequency bands. There is an urgent need to develop materials.

In addition, in recent years, due to increasing awareness of energy saving issues and environmental issues, it has become necessary to increase the efficiency of the system as much as possible. In particular, since motor systems are responsible for much of the world's power consumption, increasing the efficiency of motors is extremely important. Among these, the core and the like constituting the motor are made of soft magnetic material, and it is required to increase the magnetic permeability and saturation magnetization of the soft magnetic material as much as possible, and to minimize the loss. Furthermore, it is required to minimize loss in magnetic wedges used in some motors. Note that the same requirements apply to systems using transformers. In motors, transformers, etc., there is a strong demand for higher efficiency and smaller size. In order to achieve miniaturization, it is important to increase the magnetic permeability and saturation magnetization of the soft magnetic material as much as possible. Furthermore, in order to prevent magnetic saturation, it is important to increase the saturation magnetization as much as possible. Furthermore, there is a strong demand for increasing the operating frequency of systems, and there is a need to develop materials with low loss in high frequency bands.

In addition, soft magnetic materials having high magnetic permeability and low loss are also used for inductance elements, antenna devices, and the like, and among these, in recent years, attention has been particularly focused on their application to power inductance elements used in power semiconductors. In recent years, the importance of energy conservation and environmental protection has been widely advocated, and there has been a demand for reductions in _CO2 emissions and dependence on fossil fuels. As a result, the development of electric and hybrid vehicles to replace gasoline-powered vehicles is being actively pursued. Furthermore, technologies that utilize natural energy such as solar power generation and wind power generation are said to be key technologies for an energy-saving society, and developed countries are actively developing technologies that utilize natural energy. Furthermore, as environmentally friendly power-saving systems, we have introduced HEMS (Home Energy Management System) and BEMS (Home Energy Management System), which control electricity generated by solar power generation, wind power generation, etc. using smart grids, and supply and demand electricity to homes, offices, and factories with high efficiency. The importance of building and energy management systems (Building and Energy Management Systems) has been widely advocated. Power semiconductors play an important role in this trend toward energy conservation. Power semiconductors are semiconductors that control high power and energy with high efficiency, and are used in power discrete semiconductors such as IGBTs (insulated gate bipolar transistors), MOSFETs, power bipolar transistors, and power diodes, as well as linear regulators and switching devices.・Includes power supply circuits such as regulators, and power management logic LSIs for controlling these circuits. Power semiconductors are widely used in various devices such as home appliances, computers, automobiles, and railways, and it is expected that these applied devices will become more popular and the ratio of power semiconductors installed in these devices will increase. Significant market growth is expected. For example, power semiconductors are used in most of the inverters installed in many home appliances, making it possible to significantly save energy. Currently, Si is the mainstream power semiconductor, but it is considered effective to use SiC and GaN to further improve efficiency and downsize devices. SiC and GaN have larger band gaps and dielectric breakdown electric fields than Si, and can have higher withstand voltages, allowing devices to be made thinner. Therefore, it is possible to lower the on-resistance of the semiconductor, which is effective in reducing loss and increasing efficiency. Furthermore, since SiC and GaN have high carrier mobility, it is possible to increase the switching frequency, which is effective in reducing the size of the device. Furthermore, since SiC in particular has a higher thermal conductivity than Si, it has a higher heat dissipation ability and can operate at high temperatures, making it possible to simplify the cooling mechanism and making it effective for miniaturization. From the above viewpoint, SiC and GaN power semiconductors are being actively developed. However, in order to achieve this, it is essential to develop power inductor elements used with power semiconductors, that is, the development of high magnetic permeability soft magnetic materials (high magnetic permeability and low loss). At this time, the characteristics required of the magnetic material are not only high magnetic permeability and low magnetic loss in the driving frequency band, but also high saturation magnetization that can handle large currents. When the saturation magnetization is high, magnetic saturation is unlikely to occur even when a high magnetic field is applied, and a decrease in the effective inductance value can be suppressed. This improves the DC superimposition characteristics of the device and improves the efficiency of the system.

Furthermore, magnetic materials with high magnetic permeability and low loss at high frequencies are expected to be applied to high-frequency communication devices such as antenna devices. As a method of miniaturizing antennas and saving power, we use an insulated substrate with high magnetic permeability (high magnetic permeability and low loss) as an antenna substrate, and use it to incorporate radio waves that reach electronic components and substrates in communication equipment from the antenna. There is a method of transmitting and receiving without allowing the radio waves to reach the circuit board. This makes it possible to make the antenna smaller and save power, but at the same time, it is also possible to widen the resonant frequency of the antenna, which is preferable.

Other properties required when incorporated into each of the above systems and devices include high thermal stability, high strength, and high toughness. In addition, in order to apply it to a complicated shape, a green compact is preferable to a plate or ribbon shape. However, it is generally known that when used as a green compact, the properties deteriorate in terms of saturation magnetization, magnetic permeability, loss, strength, toughness, hardness, etc., and it is preferable to improve the properties.

Next, the types and problems of existing soft magnetic materials will be explained.

Existing soft magnetic materials for systems below 10 kHz include silicon steel (FeSi). Silicon steel sheets have a long history and are used as the core material for most of the rotating electric machines and transformers that handle large amounts of power. Although improvements in properties have been made from non-oriented silicon steel sheets to grain-oriented silicon steel sheets, and although progress has been made since the time of its discovery, improvements in properties have reached a plateau in recent years. As for the characteristics, it is particularly important to simultaneously satisfy high saturation magnetization, high magnetic permeability, and low loss. Research into materials that surpass silicon steel sheets has been actively conducted around the world, with a focus on amorphous and nanocrystalline compositions, but no material composition has yet been found that surpasses silicon steel sheets in all aspects. Research is also being carried out on green compacts that can be applied to complex shapes, but green compacts have the disadvantage of poor properties compared to plates and ribbons.

Existing soft magnetic materials for 10kHz to 100kHz systems include Sendust (Fe-Si-Al), nanocrystalline Finemet (Fe-Si-B-Cu-Nb), Fe-based or Co-based amorphous glass. Examples include ribbons, green compacts, and MnZn-based ferrite materials. However, none of them is sufficient because they do not completely satisfy the requirements of high magnetic permeability, low loss, high saturation magnetization, high thermal stability, high strength, high toughness, and high hardness.

Existing soft magnetic materials of 100 kHz or higher (MHz band or higher) include NiZn-based ferrite, hexagonal ferrite, etc., but their magnetic properties at high frequencies are insufficient.

From the above, it is preferable to develop magnetic materials that have high saturation magnetization, high magnetic permeability, low loss, high thermal stability, and excellent mechanical properties.

JP2017-059816A

The problem to be solved by the present invention is to provide a compacted powder material having excellent magnetic properties and a rotating electric machine using the same.

The compacted powder material of the embodiment has a flat surface and a magnetic metal phase containing at least one first element selected from the group consisting of Fe, Co, and Ni, and has an average thickness of 10 nm or more and 100 μm or less. and the average ratio of the average length in the flat plane to the thickness is 5 or more and 10,000 or less. (C), an intervening phase containing at least one second element selected from the group consisting of nitrogen (N) and fluorine (F), wherein the In a predetermined cross section perpendicular to a plane that has, the orientation variation of the plurality of flat magnetic metal particles is 30 degrees or more and 45 degrees or less, and the proximity ratio of the plurality of flat magnetic metal particles is 3% or more and 10% or less. and the curvature of the plurality of flat magnetic metal particles is 0.01% or more and 0.6% or less.

FIG. 2 is a conceptual diagram showing an example of how to determine the thickness of the flat magnetic metal particles of the first embodiment. FIG. 2 is a conceptual diagram for explaining how to determine the maximum length and minimum length within a flat plane in the flat magnetic metal particles of the first embodiment. FIG. 7 is a conceptual diagram for explaining another example of how to obtain the maximum length and minimum length in the flat plane in the flat magnetic metal particles of the first embodiment. FIG. 2 is a schematic diagram showing the direction in which the coercive force of the flat magnetic metal particle of the first embodiment is measured by changing the direction every 22.5 degrees with respect to the 360 degree angle in the flat plane. FIG. 2 is a schematic perspective view of flat magnetic metal particles according to the first embodiment. FIG. 2 is a schematic diagram of flat magnetic metal particles of the first embodiment viewed from above. FIG. 3 is a schematic diagram of flat magnetic metal particles according to a second embodiment. It is a schematic diagram of the compacted powder material of 3rd Embodiment. FIG. 7 is a schematic diagram showing an example of arrangement of flat magnetic metal particles in a plane parallel to each cross section in a third embodiment. FIG. 7 is a schematic diagram showing the angle between a plane parallel to the flat surface of the flat magnetic metal particles and a plane of the compacted powder material in the third embodiment. It is a schematic diagram which shows the manufacturing method of the compacted powder material of 3rd Embodiment. It is a microscope (SEM) photograph of a predetermined cross section of a compacted powder material in a 3rd embodiment. FIG. 7 is a schematic diagram showing a method of calculating a proximity ratio in a predetermined cross section of a powder compact material according to a third embodiment. FIG. 7 is a schematic diagram showing a method of calculating the curvature in a predetermined cross section of the powder compact material according to the third embodiment. FIG. 3 is a conceptual diagram of a motor system according to a fourth embodiment. FIG. 7 is a conceptual diagram of a motor according to a fourth embodiment. It is a conceptual diagram of a motor core (stator) of a 4th embodiment. It is a conceptual diagram of a motor core (rotor) of a 4th embodiment. It is a conceptual diagram of the transformer/transformer of 4th Embodiment. It is a conceptual diagram of the inductor (ring-shaped inductor, rod-shaped inductor) of 4th Embodiment. It is a conceptual diagram of the inductor (chip inductor, planar inductor) of 4th Embodiment. It is a conceptual diagram of the generator of 4th Embodiment. It is a conceptual diagram showing the relationship between the direction of magnetic flux and the arrangement direction of powdered powder material.

Embodiments will be described below with reference to the drawings. In addition, in the drawings, the same or similar parts are given the same or similar symbols.

(First embodiment)
The plurality of flat magnetic metal particles of this embodiment have flat surfaces and a magnetic metal phase containing Fe, Co, and Si, and the amount of Co is 0.001 at% or more and 80 at% with respect to the total amount of Fe and Co. % or less, the amount of Si is 0.001 at% or more and 30 at% or less based on the entire magnetic metal phase, and the average thickness of the plurality of flat magnetic metal particles is 10 nm or more and 100 μm or less, and the amount of Si is The average value of the average length ratio in the flat plane is 5 or more and 10,000 or less, and the plurality of flat magnetic metal particles have a coercive force difference depending on the direction in the flat plane.

Further, the plurality of flat magnetic metal particles of the present embodiment have flat surfaces and a magnetic metal phase made of at least one first element selected from the group consisting of Fe, Co, and Ni and an additive element, and The elements include B and Hf, the total amount of the additional elements is 0.002 at% or more and 80 at% or less based on the entire magnetic metal phase, and the average thickness of the plurality of flat magnetic metal particles is 10 nm or more and 100 μm or less. The average value of the ratio of the average length in the flat plane to the thickness is 5 or more and 10,000 or less, and the plurality of flat magnetic metal particles have a coercive force difference depending on the direction in the flat plane.

The flattened magnetic metal particles are flattened particles having a flaky shape.

Thickness refers to the average thickness of one flat magnetic metal particle. Any method for determining the thickness may be used as long as it can determine the average thickness of one flat magnetic metal particle. For example, a cross section perpendicular to the flat plane of flat magnetic metal particles is observed using a transmission electron microscope (TEM), a scanning electron microscope (SEM), or an optical microscope, and the observed flat magnetic metal particles are In the cross section, a method may be used in which ten or more arbitrary points are selected in the direction within the flat plane, the thickness at each selected point is measured, and the average value thereof is adopted. In addition, in the cross section of the observed flat magnetic metal particles, ten or more points were selected at equal intervals from one end to another in the direction within the flat plane (at this time, the end and the other end were (It is preferable not to select such a location because of the location), a method may be used in which the thickness at each selected location is measured and the average value thereof is adopted. FIG. 1 is a conceptual diagram showing an example of how to determine the thickness of the flat magnetic metal particles of the first embodiment. FIG. 1 specifically shows how to determine the thickness in this case. Ten points were selected at equal intervals from one end to another in the direction within the flat surface (excluding the ends), and the thickness at each point was set as t ₁ , t ₂ , ..., t ₁₀ In this case, the thickness of the flat magnetic metal particles is expressed as (t ₁ +t ₂ +...+t ₁₀ )/10.
In either case, it is preferable to measure as many locations as possible because average information can be obtained. In addition, if the contour line of the cross section has severe irregularities or a rough surface, and it is difficult to determine the average thickness in that state, use the contour line as an average straight line or curve to It is preferable to perform the above method after smoothing as appropriate.

Moreover, the average thickness refers to the average value of the thickness of a plurality of flat magnetic metal particles, and is distinguished from the above-mentioned mere "thickness". When determining the average thickness, it is preferable to use the average value for 20 or more flat magnetic metal particles. Further, it is preferable to obtain the information for as many flat magnetic metal particles as possible because average information can be obtained. Furthermore, if it is not possible to observe 20 or more flat magnetic metal particles, it is preferable to observe as many flat magnetic metal particles as possible and use the average value for them. The average thickness of the flat magnetic metal particles is preferably 10 nm or more and 100 μm or less. The thickness is more preferably 10 nm or more and 1 μm or less, and even more preferably 10 nm or more and 100 nm or less. Further, the flat magnetic metal particles preferably have a thickness of 10 nm or more and 100 μm or less, more preferably 10 nm or more and 1 μm or less, and even more preferably 10 nm or more and 100 nm or less. This is preferable because eddy current loss can be sufficiently reduced when a magnetic field is applied in a direction parallel to the flat surface. Further, it is preferable that the thickness is small because the magnetic moment is confined in a direction parallel to the flat plane and magnetization progresses more easily due to rotational magnetization. When magnetization progresses by rotational magnetization, the magnetization tends to progress reversibly, so the coercive force becomes small, which reduces hysteresis loss, which is preferable.

The average length of the flat magnetic metal particles is defined as (a+b)/2 using the maximum length a and the minimum length b in the flat plane. The maximum length a and the minimum length b can be determined as follows. For example, consider a rectangle with the smallest area among the rectangles circumscribing a flat plane. The length of the long side of the rectangle is the maximum length a, and the length of the short side is the minimum length b. FIG. 2 is a conceptual diagram for explaining how to determine the maximum length and minimum length in the flat plane of the flat magnetic metal particles of the first embodiment. FIG. 2 is a schematic diagram showing the maximum length a and minimum length b determined by the above method using some flat magnetic metal particles as an example. Note that, in FIG. 2, the flat surface of the flat magnetic metal particles is illustrated as viewed from above. Like the average thickness, the maximum length a and the minimum length b can be determined by observing the flat magnetic metal particles using a TEM, SEM, optical microscope, or the like. Furthermore, it is also possible to perform image analysis of the micrograph on a computer to determine the maximum length a and the minimum length b. In either case, it is preferable to use 20 or more flat magnetic metal particles as targets. Further, it is preferable to obtain the information for as many flat magnetic metal particles as possible because average information can be obtained. In addition, if it is not possible to observe 20 or more flat magnetic metal particles, it is preferable to observe as many flat magnetic metal particles as possible and use the average value for them. At this time, it is preferable to obtain the average value as much as possible, so the flat magnetic metal particles are uniformly dispersed (the flat magnetic metal particles with different maximum and minimum lengths are dispersed as randomly as possible). ), observation or image analysis is preferably performed. For example, a plurality of flat magnetic metal particles are sufficiently mixed and pasted on the tape, or a plurality of flat magnetic metal particles are dropped from above and then lowered and pasted on the tape. It is preferable to perform observation or image analysis by.

However, depending on the flat magnetic metal particles, when the maximum length a and the minimum length b are determined by the above method, the determination method may not capture the essence. FIG. 3 is a conceptual diagram for explaining another example of how to obtain the maximum length and minimum length in the flat plane in the flat magnetic metal particles of the first embodiment. Note that in FIG. 3, the flat surface of the flat magnetic metal particles is shown as viewed from above. For example, in the case shown in FIG. 3, the flat magnetic metal particles are in an elongated and curved state, but in this case, essentially, the maximum and minimum lengths of the flat magnetic metal particles are as shown in FIG. These are the lengths of a and b shown in . In this way, the maximum lengths a and b cannot be determined completely uniquely, but basically, ``consider the rectangle with the smallest area among the rectangles circumscribing the flat plane, There is no problem with this method, where the length of the long side of the rectangle is the maximum length a, and the length of the short side is the minimum length b, but depending on the shape of the particle, if this method does not capture the essence, it may be necessary to Depending on the situation, determine the maximum length a and minimum length b that capture the essence. The thickness t is defined as the length in the direction perpendicular to the flat surface. The ratio A of the average length in the flat plane to the thickness is defined as A=((a+b)/2)/t using maximum length a, minimum length b, and thickness t.

The average value of the ratio of the average length in the flat plane to the thickness of the flat magnetic metal particles is preferably 5 or more and 10,000 or less. This is because the magnetic permeability increases. Furthermore, since the ferromagnetic resonance frequency can be increased, the ferromagnetic resonance loss can be reduced.

The average value is adopted as the ratio of the average length in the flat plane to the thickness. Preferably, the average value for 20 or more flat magnetic metal particles is used. Further, it is preferable to obtain the information for as many flat magnetic metal particles as possible because average information can be obtained. In addition, if it is not possible to observe 20 or more flat magnetic metal particles, it is preferable to observe as many flat magnetic metal particles as possible and use the average value for them. For example, if there are particles Pa, Pb, and Pc, and their thicknesses are Ta, Tb, and Tc, and their average lengths in the flat plane are La, Lb, and Lc, the average thickness is (Ta+Tb+Tc)/3. The average value of the ratio of the average length in the flat plane to the thickness is calculated as (La/Ta+Lb/Tb+Lc/Tc)/3.

Preferably, the flat magnetic metal particles have a coercive force difference depending on the direction within the flat plane. The ratio of the coercive force difference depending on the direction is preferably as large as possible, and is preferably 1% or more. More preferably, the ratio of the coercive force difference is 10% or more, still more preferably the ratio of the coercive force difference is 50% or more, and still more preferably the ratio of the coercive force difference is 100% or more. The ratio of coercive force difference here means (Hc (max) - Hc (min)) using the maximum coercive force Hc (max) and the minimum coercive force Hc (min) in the flat plane. /Hc (min) x 100 (%). Note that the coercive force can be evaluated using a vibrating sample magnetometer (VSM) or the like. If the coercive force is low, by using a low magnetic field unit, it is possible to measure coercive forces of 0.1 Oe or less. Measurement is performed by changing the direction within the flat plane with respect to the direction of the measurement magnetic field.

Note that "having a coercive force difference" means the direction in which the coercive force is maximum and the direction in which the coercive force is minimum when measuring the coercive force by applying a magnetic field in 360 degrees in a flat plane. It means that there exists. For example, when measuring the coercive force by changing the direction every 22.5 degrees for a 360 degree angle in a flat plane, a difference in coercive force will appear, that is, the angle at which the coercive force is larger and the coercive force If an angle at which the is smaller appears, it is said that there is a coercive force difference. FIG. 4 is a schematic diagram showing the direction in which the coercive force of the flat magnetic metal particles of the first embodiment is measured by changing the direction every 22.5 degrees with respect to the 360-degree angle in the flat plane. It is a diagram. Note that, in FIG. 4, the flat surface of the flat magnetic metal particles is illustrated as viewed from above. By having a coercive force difference within the flat plane, the minimum coercive force value is smaller than in an isotropic case where there is almost no coercive force difference, which is preferable. In a material that has magnetic anisotropy within the flat plane, the coercive force differs depending on the direction within the flat plane, and the minimum coercive force value is smaller than that of a magnetically isotropic material. This reduces hysteresis loss and improves magnetic permeability, which is preferable.

Coercive force is related to magnetocrystalline anisotropy, Hc = αHa-NMs (Hc: coercive force, Ha: magnetocrystalline anisotropy, Ms: saturation magnetization, α, N: changes depending on composition, structure, shape, etc. It is sometimes discussed using an approximation formula called (value). That is, in general, the larger the magnetocrystalline anisotropy, the larger the coercive force tends to be, and the smaller the magnetocrystalline anisotropy, the smaller the coercive force tends to be. However, the α value and N value in the above approximate formula vary greatly depending on the composition, structure, and shape of the material. Even if the magnetocrystalline anisotropy is small (if the α value is large or the N value is small), the coercive force may be relatively large. That is, magnetocrystalline anisotropy is a property inherent to a material that is determined by the composition of the material, whereas coercive force is not determined solely by the composition of the material, but is a property that can vary greatly depending on the structure, shape, etc. In addition, magnetocrystalline anisotropy is a factor that indirectly affects hysteresis loss rather than directly, but coercive force is a factor that affects the loop area of the DC magnetization curve (this area is the largest factor in hysteresis loss). Since it is a factor that directly affects the amount of hysteresis loss (corresponding to In other words, coercive force, unlike magnetocrystalline anisotropy, can be said to be a very important factor that directly influences hysteresis loss.

Furthermore, just because the flat magnetic metal particles have magnetic anisotropy including magnetocrystalline anisotropy, it does not necessarily mean that a coercive force difference is expressed depending on the direction of the flat plane of the flat magnetic metal particles. This is because, as described above, the coercive force is not a value uniquely determined by the magnetocrystalline anisotropy, but is a property that varies depending on the composition, structure, and shape of the material. As mentioned above, the factor that directly and greatly influences the hysteresis loss is not the magnetic anisotropy but the coercive force. From the above, a very preferable condition for improving characteristics is "to have a coercive force difference depending on the direction within the flat surface." This is preferable because it reduces hysteresis loss and increases magnetic permeability.

The ratio a/b of the maximum length a to the minimum length b in the flat plane is preferably 2 or more on average, more preferably 3 or more, still more preferably 5 or more, still more preferably 10 or more. It is preferable to include those in which the ratio a/b of the maximum length a to the minimum length b in the flat plane is 2 or more, more preferably 3 or more, still more preferably 5 or more, still more preferably 10 or more. It is preferable to include. This makes it easier to impart magnetic anisotropy, which is desirable. When magnetic anisotropy is imparted, a coercive force difference occurs within the flat plane, and the minimum coercive force value becomes smaller than that of a magnetically isotropic material. This reduces hysteresis loss and improves magnetic permeability, which is preferable. More preferably, in the flat magnetic metal particles, one or both of a plurality of recesses and a plurality of projections, which will be described later, are arranged in the first direction in the maximum length direction. In addition, when compacting flat magnetic metal particles, since the a/b of the flat magnetic metal particles is large, the area (or area ratio) where the flat surfaces of individual flat magnetic metal particles overlap becomes large, so that the flat magnetic metal particles cannot be compacted. The strength of the material increases, which is preferable. Further, it is preferable that the ratio of the maximum length to the minimum length is large because the magnetic moment is confined in a direction parallel to the flat surface, and the magnetization progresses easily by rotational magnetization. When magnetization progresses by rotational magnetization, the magnetization tends to progress reversibly, so the coercive force becomes small, which reduces hysteresis loss, which is preferable. On the other hand, from the viewpoint of increasing strength, the ratio a/b of the maximum length a to the minimum length b in the flat plane is preferably 1 or more and less than 2 on average, and more preferably 1 or more and 1 More preferably, it is smaller than .5. This is desirable because it improves the fluidity and filling properties of the particles. Furthermore, compared to the case where a/b is large, the strength in the direction perpendicular to the flat plane becomes higher, which is preferable from the viewpoint of increasing the strength of the flat magnetic metal particles. Furthermore, when the particles are compacted, they are less likely to be bent and compacted, and stress on the particles is likely to be reduced. In other words, distortion is reduced, coercive force and hysteresis loss are reduced, and stress is reduced, making it easier to improve mechanical properties such as thermal stability, strength, and toughness.

Moreover, a flat surface having at least a part of its contour shape is preferably used. For example, it is desirable that the contour shape is square or rectangular, in other words, the angles of the corners are approximately 90 degrees. As a result, the symmetry of the atomic arrangement is reduced at the corners and the electron orbits are restrained, which is desirable because it facilitates imparting magnetic anisotropy within the flat plane.

On the other hand, from the viewpoint of reducing loss and increasing strength, it is preferable that the contour shape of the flat surface be formed by a rounded curve. As an extreme example, it is more desirable to have a rounded outline shape such as a circle or an ellipse. These are desirable because they improve the wear resistance of the particles. In addition, it is desirable that stress is less likely to concentrate around the contour shape, magnetic distortion of the flat magnetic metal particles is reduced, coercive force is lowered, and hysteresis loss is reduced. Since stress concentration is reduced, thermal stability and mechanical properties such as strength and toughness can be easily improved, which is desirable.

It is desirable that the flat magnetic metal particles have a magnetic metal phase containing Fe, Co, and Si. This case will be explained in detail below. In the magnetic metal phase, the amount of Co is preferably 0.001 at% or more and 80 at% or less, more preferably 1 at% or more and 60 at% or less, and even more preferably is preferably 5 at% or more and 40 at% or less, more preferably 10 at% or more and 20 at% or less. This is preferable because a suitably large magnetic anisotropy can easily be imparted and the above-mentioned magnetic properties can be improved. Further, Fe--Co based materials are preferable because they can easily achieve high saturation magnetization. Furthermore, it is preferable that the composition range of Fe and Co falls within the above range, since higher saturation magnetization can be achieved. Further, the amount of Si is preferably 0.001 at% or more and 30 at% or less, more preferably 1 at% or more and 25 at% or less, and even more preferably 5 at% or more and 20 at% or less, based on the entire magnetic metal phase. % or less. This is preferable because the magnetocrystalline anisotropy becomes appropriate, the coercive force is easily reduced, and low hysteresis loss and high magnetic permeability are easily achieved.

Note that when the magnetic metal phase is a system containing Fe, Co, and Si, and the amount of Co and the amount of Si are each within the above ranges, the above-mentioned anisotropy imparting effect is particularly effective. manifest. Compared to monoatomic systems containing only Fe or Co, diatomic systems containing only Fe and Si, or only Fe and Co, triatomic systems consisting of Fe, Co, and Si have particularly moderate magnetic anisotropy. It is preferable that a large magnetic field is easily applied, and the coercive force becomes small, thereby reducing hysteresis loss and improving magnetic permeability. This great effect is only brought about especially when the composition is within the abovementioned range. Furthermore, it is preferable that the composition of the three-atomic system of Fe, Co, and Si falls within the above-mentioned composition range, since thermal stability and oxidation resistance are significantly improved. Further, since thermal stability and oxidation resistance are improved, mechanical properties at high temperatures are also improved, which is preferable. Furthermore, mechanical properties such as strength, hardness, and abrasion resistance are improved at room temperature, which is preferable. Further, when synthesizing the flat magnetic metal particles, if a ribbon is synthesized by a roll quenching method or the like and the flat magnetic metal particles are obtained by pulverizing the ribbon, the magnetic metal phase may include Fe, Co and Si. If the metal particles are triatomic and the amounts of Co and Si are within the above ranges, they are particularly easily pulverized, thereby realizing a state in which distortion is relatively difficult to cause in the flat magnetic metal particles. It's good to be able to do it. It is preferable that the flat magnetic metal particles are less likely to be strained, since the coercive force can be easily reduced, and low hysteresis loss and high magnetic permeability can be easily achieved. In addition, it is preferable that the strain is small, since stability over time is high, thermal stability is high, and mechanical properties such as strength, hardness, and abrasion resistance are excellent.

The average crystal grain size of the magnetic metal phase is preferably 1 μm or more, more preferably 10 μm or more, even more preferably 50 μm or more, and still more preferably 100 μm or more. preferable. It is preferable that the average crystal grain size of the magnetic metal phase becomes larger, since the proportion of the surface of the magnetic metal phase becomes smaller, thereby reducing the number of pinning sites, thereby reducing coercive force and hysteresis loss. Further, it is preferable that the average crystal grain size of the magnetic metal phase is large within the above range because it is easy to impart a suitably large magnetic anisotropy and the above magnetic properties are improved.

In particular, when the magnetic metal phase is a system containing Fe, Co, and Si, and the amount of Co and the amount of Si are each within the above-mentioned ranges, and the average crystal grain size of the magnetic metal phase is When it falls within the above range, a suitably large magnetic anisotropy is likely to be imparted, and the above magnetic properties are significantly improved, which is more preferable. In particular, the magnetic metal phase is a system containing Fe, Co, and Si, and the Co amount is 5 at% or more and 40 at% or less, more preferably 10 at% or more and 20 at% or less, based on the total amount of Fe and Co. and the amount of Si is 1 at% or more and 25 at% or less, more preferably 5 at% or more and 20 at% or less, based on the entire magnetic metal phase, and the average crystal grain size of the magnetic metal phase is 10 μm or more, More preferably, the thickness is 50 μm or more, and even more preferably 100 μm or more, since it is easy to impart a suitably large magnetic anisotropy, and the above-mentioned magnetic properties are particularly significantly improved.

Further, it is preferable that the magnetic metal phase has a portion having a body-centered cubic (BCC) crystal structure. This is preferable because a suitably large magnetic anisotropy can easily be imparted and the above-mentioned magnetic properties can be improved. In addition, even with a "mixed phase crystal structure of BCC and FCC" that partially has a face-centered cubic (FCC) crystal structure, a moderately large magnetic anisotropy is likely to be imparted, and the above magnetic properties are improved. It is preferable to do so.

Further, it is preferable that the flat surfaces of the flat magnetic metal particles are generally crystallized. As for the orientation direction, (110) plane orientation is preferred. This is preferable because a suitably large magnetic anisotropy can easily be imparted and the above-mentioned magnetic properties can be improved. A more preferred orientation direction is the (110)[111] direction. This is preferable because a suitably large magnetic anisotropy can easily be imparted and the above-mentioned magnetic properties can be improved. The crystal plane of the flat plane of the flat magnetic metal particle is such that crystal planes other than (110) and (220) (for example, (200), (211), (310), and (222)) are (110). In contrast, the peak intensity ratio measured by XRD (X-ray diffraction method) is preferably 10% or less, more preferably 5% or less, still more preferably 3% or less. This is preferable because a suitably large magnetic anisotropy can easily be imparted and the above-mentioned magnetic properties can be improved.

In order to orient the flat planes of the flat magnetic metal particles (110), it is effective to select appropriate heat treatment conditions. The heat treatment temperature is preferably set at 800°C or higher and 1200°C or lower, more preferably 850°C or higher and 1100°C or lower, even more preferably 900°C or higher and 1000°C or lower, and even more preferably 920°C or higher and 980°C or lower (around 940°C). preferred). Even if the heat treatment temperature is too low or too high, the (110) orientation will be difficult to advance, so a heat treatment temperature within the above range is most preferable. The heat treatment time is preferably 10 minutes or longer, more preferably 1 hour or longer, and even more preferably about 4 hours. Even if the heat treatment time is too short or too long, the (110) orientation will be difficult to advance, so a heat treatment time of about 4 hours is most preferable. The heat treatment atmosphere is preferably a vacuum atmosphere with a low oxygen concentration, an inert atmosphere, or a reducing atmosphere, and more preferably a reducing atmosphere such as H ₂ (hydrogen), CO (carbon monoxide), CH ₄ (methane), etc. is preferred. This is preferable because oxidation of the flat magnetic metal particles can be suppressed and the oxidized portion can be reduced. By selecting the above heat treatment conditions, the (110) orientation progresses easily, and crystal planes other than (110) and (220) (for example, (200), (211), (310), (222) For the first time, it becomes possible for the peak intensity ratio of (110) to be 10% or less, further 5% or less, and even 3% or less, as measured by XRD (X-ray diffraction method). Further, distortion can be appropriately removed, and a state in which oxidation is suppressed (reduced state) can also be realized, which is preferable.

Moreover, it is preferable that the flat magnetic metal particles have a magnetic metal phase consisting of at least one first element selected from the group consisting of Fe, Co, and Ni and an additional element. This case will be explained in detail below. More preferably, the additive element includes B and Hf. Further, the total amount of the additive elements is preferably 0.002 at% or more and 80 at% or less, more preferably 5 at% or more and 80 at% or less, and even more preferably 5 at% or less, based on the entire magnetic metal phase. % or more and 40 at% or less, more preferably 10 at% or more and 40 at% or less. This is preferable because amorphization progresses, it becomes easier to impart magnetic anisotropy, and the above-mentioned magnetic properties are improved. Further, the amount of Hf is preferably 0.001 at% or more and 40 at% or less, more preferably 1 at% or more and 30 at% or less, and even more preferably 1 at% or more and 20 at% or less, based on the entire magnetic metal phase. % or less, more preferably 1 at% or more and 15 at% or less, still more preferably 1 at% or more and 10 at% or less. This is preferable because amorphization progresses, it becomes easier to impart magnetic anisotropy, and the above-mentioned magnetic properties are improved.

In addition, when the magnetic metal phase is a system containing the first element and B and Hf as the additive elements, and the total amount of the additive elements and the amount of Hf are each within the above ranges, In particular, the above-mentioned effect of imparting anisotropy is greatly improved. This great effect is only brought about especially when the composition is within the abovementioned range. In addition, compared to systems containing other additive elements, especially in systems containing Hf, amorphization progresses more easily with a small amount, making it easier to impart magnetic anisotropy, achieving both high saturation magnetization. Easy and preferable. In addition, Hf has a high melting point, and is preferably included in the magnetic metal phase in the above amount because thermal stability and oxidation resistance are significantly improved. Further, since thermal stability and oxidation resistance are improved, mechanical properties at high temperatures are also improved, which is preferable. Furthermore, mechanical properties such as strength, hardness, and abrasion resistance are improved at room temperature, which is preferable. Further, when synthesizing the flat magnetic metal particles, a ribbon is synthesized by a roll quenching method or the like, and the flat magnetic metal particles are obtained by pulverizing the ribbon, the magnetic metal phase is composed of the first element. If the system contains B and Hf as the additive elements, and the total amount of the additive elements and the amount of Hf are within the above ranges, it is particularly likely to be crushed relatively easily. This is preferable because a state in which distortion is relatively less likely to occur in the flat magnetic metal particles can be achieved. It is preferable that the flat magnetic metal particles are less likely to be strained, since the coercive force can be easily reduced, and low hysteresis loss and high magnetic permeability can be easily achieved. In addition, it is preferable that the strain is small, since stability over time is high, thermal stability is high, and mechanical properties such as strength, hardness, and abrasion resistance are excellent.

Further, when the magnetic metal phase is a system containing the first element and B and Hf as the additive elements, and the total amount of the additive elements and the amount of Hf are each within the above range, Since the thermal stability is excellent, it becomes possible to set the optimum heat treatment conditions for the flat magnetic metal particles at a high level. That is, in the method for producing flat magnetic metal particles, it is preferable to synthesize a ribbon, apply heat treatment (or not) to pulverize the obtained ribbon, and then perform heat treatment to remove distortion. (More preferably, heat treatment in a magnetic field is preferred.) The heat treatment temperature at this time can be set relatively high. This makes it easier to release strain, making it easier to create a material with less strain and lower loss. For example, by performing heat treatment at 500°C or higher, it becomes easier to create a material with low loss (low loss can be achieved at a higher heat treatment temperature than with other systems or compositions.For other systems or compositions, for example, around 400°C is optimal) heat treatment temperature).

Preferably, the additive element includes one or more "another different element" in addition to B and Hf. "Other different elements" include C, Ta, W, P, N, Mg, Al, Si, Ca, Zr, Ti, Zn, Mn, Ba, Sr, Cr, Mo, Ag, Ga, Sc, V , Nb, Pb, Cu, In, Sn, and rare earth elements are preferable, and among these, rare earth elements are more preferable, and Y is even more preferable. By containing "another different element", the diffusion of the element contained in the magnetic metal phase is effectively suppressed, the amorphization progresses, and it becomes easier to impart magnetic anisotropy. This is preferable (low coercive force, low hysteresis loss, and high magnetic permeability are easily achieved, which is preferable). In particular, when the "another different element" has an atomic radius different from that of B and Hf, the diffusion of the element contained in the magnetic metal phase is effectively suppressed. For example, since Y and the like have a larger atomic radius than B and Hf, they can very effectively suppress the diffusion of elements contained in the magnetic metal phase. Hereinafter, an appropriate composition range will be explained using an example in which "another different element" is Y. The amount of Y is preferably 1 at% or more and 80 at% or less, more preferably 2 at% or more and 60 at% or less, and even more preferably 4 at% or more and 60 at% or less, based on the total amount of Hf and Y. Further, the total amount of Hf and Y is preferably 0.002 at% or more and 40 at% or less, more preferably 1 at% or more and 30 at% or less, and even more preferably 1 at% % or more and 20 at% or less, more preferably 1 at% or more and 15 at% or less, still more preferably 1 at% or more and 10 at% or less. This is preferable because amorphization progresses, it becomes easier to impart magnetic anisotropy, and the above-mentioned magnetic properties are improved. By falling within the above composition range, the above-mentioned anisotropy imparting effect is particularly significantly greater than when the additive elements are only B and Hf. This particularly large effect is only brought about within the abovementioned composition ranges. In addition, it is preferable that a small amount facilitates amorphization, provides magnetic anisotropy, and easily achieves high saturation magnetization. By appropriately selecting the composition of a Y-added system, it becomes possible to achieve characteristics that cannot be achieved with a BHf system. Further, thermal stability and oxidation resistance are significantly improved, which is preferable. Further, since thermal stability and oxidation resistance are improved, mechanical properties at high temperatures are also improved, which is preferable. Furthermore, mechanical properties such as strength, hardness, and abrasion resistance are improved at room temperature, which is preferable.

Further, the average crystal grain size of the magnetic metal phase is preferably 100 nm or less, more preferably 50 nm or less, still more preferably 20 nm or less, and still more preferably 10 nm or less. The smaller it is, the more preferable it is, the more preferable it is 5 nm or less, and the more preferable it is 2 nm or less. This is preferable because it becomes easier to impart anisotropy and improve the above-mentioned magnetic properties. In addition, a small crystal grain size means that it approaches an amorphous state, so the electrical resistance is higher than that of a highly crystalline material, which makes it easier to reduce eddy current loss, which is preferable. Further, it is preferable because it has better corrosion resistance and oxidation resistance than highly crystalline ones.

In addition, the above-mentioned additive element includes one or more "another different element (for example, Y)" in addition to B and Hf, and the amount of "another different element (for example, Y)" and the amount of "another different element (for example, Y)" are different from Hf. It is preferable that the total amount of different elements (for example, Y) falls within the above-mentioned range because it is possible to relatively easily achieve an average crystal grain size of 30 nm or less. That is, since it approaches an amorphous state, the electrical resistance becomes higher than that of a highly crystalline material, which makes it easier to reduce eddy current loss, which is preferable. Further, it is preferable because it has better corrosion resistance and oxidation resistance than highly crystalline ones. Further, it is preferable because it becomes easier to impart anisotropy and the above-mentioned magnetic properties are improved.

In particular, when the magnetic metal phase is a system containing the first element and B and Hf as the additive elements, and the total amount of the additive elements and the amount of Hf are each within the above ranges. , and when the average crystal grain size of the magnetic metal phase falls within the above range, improved magnetic properties due to the effect of imparting magnetic anisotropy, increased electrical resistance due to amorphization (reduced eddy current loss), high corrosion resistance, This is more preferable since the effect of high oxidation resistance is significantly improved. In particular, the magnetic metal phase is a system containing the first element and B and Hf as the additive elements, and the total amount of the additive elements is 5 at% or more with respect to the entire magnetic metal phase. 40 at% or less, more preferably 10 at% or more and 40 at% or less, and the Hf amount is 1 at% or more and 20 at% or less, more preferably 1 at% or more and 15 at% or less, and even more preferably 1 at% or more, based on the entire magnetic metal phase. 10 at% or less, and when the average crystal grain size of the magnetic metal phase is 50 nm or less, more preferably 20 nm or less, and even more preferably 10 nm or less, improved magnetic properties due to the effect of imparting magnetic anisotropy, The effects of high electrical resistance (reduced eddy current loss), high corrosion resistance, and high oxidation resistance due to amorphization are particularly significantly improved, which is more preferable.

The crystal grain size of 100 nm or less can be easily calculated using the Scherrer equation using XRD measurement, or can be calculated by observing a large number of magnetic metal phases using a TEM (Transmission Electron Microscope) observation. It can also be determined by averaging the particle sizes. If the crystal grain size is small, it is preferable to obtain it by XRD measurement, and if the crystal grain size is large, it is preferable to obtain it by TEM observation, but the measurement method should be selected depending on the situation, or both methods should be used together. It is preferable to make a comprehensive judgment.

The flat magnetic metal particles preferably have a high saturation magnetization, preferably 1T or more, more preferably 1.5T or more, still more preferably 1.8T or more, even more preferably 2.0T or more. It is preferable that This is preferable because magnetic saturation is suppressed and the magnetic properties can be fully exhibited on the system. However, depending on the application (for example, a magnetic wedge for a motor), it can be used satisfactorily even if the saturation magnetization is relatively small, and it may be preferable to specialize in low loss. The magnetic wedge of a motor is like a cover for the slot in which the coil is placed.Normally, a non-magnetic wedge is used, but by using a magnetic wedge, the density of the magnetic flux can be reduced. , harmonic losses are reduced and motor efficiency is improved. At this time, it is preferable that the saturation magnetization of the magnetic wedge is large, but even if the saturation magnetization is relatively small, a sufficient effect is exerted. Therefore, it is important to select the composition depending on the application.

The lattice strain of the flat magnetic metal particles is preferably 0.01% or more and 10% or less, more preferably 0.01% or more and 5% or less, still more preferably 0.01% or more and 1% or less, and even more preferably 0.01%. % or more and 0.5% or less. This is preferable because a suitably large magnetic anisotropy can easily be imparted and the above-mentioned magnetic properties can be improved.

Note that the lattice strain can be calculated by analyzing in detail the line width obtained by X-ray diffraction (XRD). That is, by performing the Halder-Wagner plot and the Hall-Williamson plot, the contribution of line width broadening can be separated into the crystal grain size and lattice strain. This allows calculation of lattice distortion. The Halder-Wagner plot is preferable from the viewpoint of reliability. Regarding the Halder-Wagner plot, for example, N. C. Halder, C. N. J. Wagner, Acta Cryst. 20 (1966) 312-313. Please refer to the following. Here, the Halder-Wagner plot is expressed by the following formula.

That is, β ² /tan ² θ is plotted on the vertical axis and β/tan θ sin θ is plotted on the horizontal axis, and the grain size D is calculated from the slope of the approximate straight line, and the lattice strain ε is calculated from the vertical axis intercept. The lattice strain (lattice strain (root mean square)) according to the Halder-Wagner plot of the above formula is 0.01% or more and 10% or less, more preferably 0.01% or more and 5% or less, and even more preferably 0.01% or more1 % or less, more preferably 0.01% or more and 0.5% or less, it is preferable because a suitably large magnetic anisotropy is likely to be imparted and the above-mentioned magnetic properties are improved.

The above lattice strain analysis is an effective method when multiple peaks can be detected in XRD, but on the other hand, when the peak intensity in XRD is weak and there are few detectable peaks (for example, when only one peak is detected), the analysis is effective. is difficult. In such a case, it is preferable to calculate the lattice distortion using the following procedure. First, the composition was determined using high frequency inductively coupled plasma (ICP) emission spectroscopy, energy dispersive X-ray spectroscopy (EDX), etc., and the three magnetic metal elements Fe, Co, and Ni were determined. Calculate the composition ratio (if there are only two magnetic metal elements, two composition ratios; if there is only one magnetic metal element, one composition ratio (=100%)). Next, calculate the ideal lattice spacing d ₀ from the Fe-Co-Ni composition (see literature values, etc.; in some cases, create an alloy with that composition and calculate the lattice spacing by measurement) . Thereafter, the amount of strain can be determined by determining the difference between the peak lattice spacing d of the measured sample and the ideal lattice spacing _d0 . That is, in this case, the amount of distortion is calculated as (d−d ₀ )/d ₀ ×100(%). As described above, it is preferable to analyze lattice strain by using the above two methods depending on the state of the peak intensity, and in some cases using both methods in combination.

The lattice spacing in the flat plane varies depending on the direction, and the ratio of the difference between the maximum lattice spacing d _max and the minimum lattice spacing d _min (=(d _max − d _min )/d _min ×100(%) ) is preferably 0.01% or more and 10% or less, more preferably 0.01% or more and 5% or less, even more preferably 0.01% or more and 1% or less, and even more preferably 0.01% or more and 0.5%. It is preferable to do the following. This is preferable because a suitably large magnetic anisotropy is likely to be imparted and the above-mentioned magnetic properties are improved. Note that the lattice spacing can be easily determined by XRD measurement. By performing this XRD measurement while changing the direction within the plane, it is possible to determine the difference in lattice constant depending on the direction.

It is preferable that the crystallites of the flattened magnetic metal particles are either strung together in a unidirectional manner within the flattened plane, or the crystallites are rod-shaped and oriented in one direction within the flattened plane. This is preferable because a suitably large magnetic anisotropy can easily be imparted and the above-mentioned magnetic properties can be improved.

The flat surfaces of the flat magnetic metal particles are preferably arranged in the first direction and have one or both of a plurality of concave portions and a plurality of convex portions having a width of 0.1 μm or more, a length of 1 μm or more, and an aspect ratio of 2 or more. . As a result, magnetic anisotropy is easily induced in the first direction, and the difference in coercive force depending on the direction increases within the flat plane, which is preferable. From this point of view, it is more preferable that the width be 1 μm or more and the length be 10 μm or more. The aspect ratio is preferably 5 or more, more preferably 10 or more. In addition, by providing such concave portions or convex portions, the adhesion between the flat magnetic metal particles is improved when compressing the flat magnetic metal particles to synthesize a powder material (the concave portions or convex portions are This is preferable because it improves mechanical properties such as strength and hardness, as well as thermal stability.

FIG. 5 is a schematic perspective view of flat magnetic metal particles according to the first embodiment. Note that in the upper diagram of FIG. 5, only the concave portion is provided, and in the center diagram of FIG. 5, only the convex portion is provided, but as shown in the bottom diagram of FIG. It may have both. FIG. 6 is a schematic diagram of the flat magnetic metal particles of the first embodiment viewed from above. Note that, in FIG. 6, the flat surface of the flat magnetic metal particles is shown as viewed from above. The width and length of the recesses or protrusions and the distance between the recesses or protrusions are shown. One flat magnetic metal particle may have both concave portions and convex portions. Note that the aspect ratio of a concave portion or a convex portion is the length of the major axis/the length of the minor axis. In other words, if the length of the concave or convex part is greater (longer) than the width, the aspect ratio is defined as length/width, and if the width is greater (longer) than the length, the aspect ratio is defined as width/length. Defined by The larger the aspect ratio, the more likely it is to have magnetic uniaxial anisotropy (anisotropy), which is more preferable. In FIG. 6, a concave portion 2a, a convex portion 2b, a flat surface 6, and a flat magnetic metal particle 10 are shown.

Moreover, "arranged in the first direction" means that the longer of the length and width of the recessed part or the protrusion is arranged in parallel to the first direction. Note that if the longer of the length and width of the concave portion or the convex portion is arranged within ±30 degrees from a direction parallel to the first direction, it is assumed that the concave portion or the convex portion is “aligned in the first direction”. These are preferable because the flat magnetic metal particles tend to have magnetic uniaxial anisotropy in the first direction due to the effect of shape magnetic anisotropy. Note that it is preferable that the flat magnetic metal particles have magnetic anisotropy in one direction within the flat plane, but this will be explained in detail. First, when the magnetic domain structure of flat magnetic metal particles is a multi-domain structure, the magnetization process proceeds by domain wall movement, but in this case, the coercive force is smaller in the easy axis direction within the flat plane than in the hard axis direction. Loss (hysteresis loss) is reduced. Also, the magnetic permeability is greater in the easy axis direction than in the hard axis direction. Note that, compared to isotropic flat magnetic metal particles, flat magnetic metal particles having magnetic anisotropy have a smaller coercive force, especially in the easy axis direction, which reduces loss, which is preferable. . Moreover, the magnetic permeability is also high, which is preferable. In other words, by having magnetic anisotropy in the flat plane direction, the magnetic properties are improved compared to isotropic materials. In particular, the easy axis direction in the flat plane has better magnetic properties than the hard axis direction, and is therefore preferable. Next, when the magnetic domain structure of flat magnetic metal particles is a single domain structure, the magnetization process proceeds by rotational magnetization, but in this case, the coercive force is greater in the difficult axis direction within the flat plane than in the easy axis direction. The smaller the loss, the lower the loss. When magnetization progresses completely by rotational magnetization, the coercive force becomes zero and the hysteresis loss becomes zero, which is preferable. Note that whether magnetization proceeds by domain wall movement (domain wall movement type) or rotational magnetization (rotational magnetization type) is determined by whether the magnetic domain structure is a multidomain structure or a single domain structure. . At this time, whether the structure is a multi-domain structure or a single-domain structure is determined by the size (thickness and aspect ratio) of the flat magnetic metal particles, the composition, the state of interaction between the particles, and the like. For example, the smaller the thickness t of the flat magnetic metal particles, the more likely they are to have a single magnetic domain structure, and when the thickness is 10 nm or more and 1 μm or less, particularly when the thickness is 10 nm or more and 100 nm or less, they are more likely to have a single magnetic domain structure. As for the composition, a composition with a large magnetocrystalline anisotropy can easily maintain a single domain structure even if the thickness is large, and a composition with a small magnetocrystalline anisotropy cannot maintain a single domain structure unless the thickness is small. It tends to be difficult. In other words, the thickness at the boundary between a single-domain structure and a multi-domain structure varies depending on the composition. Furthermore, when flat magnetic metal particles are magnetically coupled to each other and the magnetic domain structure is stabilized, a single magnetic domain structure is more likely to be formed. Note that whether the magnetization behavior is a domain wall displacement type or a rotational magnetization type can be easily determined as follows. First, magnetization is measured by changing the direction in which the magnetic field is applied within the material plane (a plane parallel to the flat plane of the flat magnetic metal particles), and the two directions in which the difference in magnetization curves is the largest (in this case, the two directions are (directions tilted 90 degrees to each other). Next, by comparing the curves in the two directions, it is possible to determine whether it is a domain wall displacement type or a rotating magnetization type.

As described above, it is preferable that the flat magnetic metal particles have magnetic anisotropy in one direction within the flat plane, but more preferably, the flat magnetic metal particles are arranged in the first direction and have a width of 0.1 μm or more. By having one or both of a plurality of concave portions and a plurality of convex portions each having a length of 1 μm or more and an aspect ratio of 2 or more, magnetic anisotropy is more likely to be induced in the first direction, which is more preferable. From this point of view, it is further preferable that the width be 1 μm or more and the length be 10 μm or more. The aspect ratio is preferably 5 or more, more preferably 10 or more. In addition, by providing such concave portions or convex portions, the adhesion between the flat magnetic metal particles is improved when compressing the flat magnetic metal particles to synthesize a powder material (the concave portions or convex portions are This is preferable because it improves mechanical properties such as strength and hardness, as well as thermal stability.

Further, in the flat magnetic metal particles, it is preferable that one or both of the plurality of recesses and the plurality of projections are arranged in the first direction in the direction of the axis of easy magnetization. In other words, when a large number of arrangement directions (=first direction) exist in the flat plane of flat magnetic metal particles, the arrangement direction (=first direction) with the largest number among the many arrangement directions (=first direction) exists. direction) preferably coincides with the easy axis direction of the flat magnetic metal particles. The length direction in which the concave portions or convex portions are arranged, that is, the first direction, tends to become the axis of easy magnetization due to the effect of shape magnetic anisotropy, so aligning this direction as the axis of easy magnetization will improve the magnetic anisotropy. is more easily imparted, which is preferable.

It is desirable that one or both of the plurality of concave portions and the plurality of convex portions are included in one flat magnetic metal particle on average at five or more. Here, five or more recesses may be included, five or more protrusions may be included, or the sum of the number of recesses and the number of protrusions may be five or more. In addition, it is more preferable that 10 or more are included. Further, it is desirable that the average distance in the width direction between each concave portion or convex portion is 0.1 μm or more and 100 μm or less. Furthermore, a plurality of deposited metals containing at least one of the first elements selected from the group consisting of Fe, Co, and Ni and having an average size of 1 nm or more and 1 μm or less are arranged along the concave portion or the convex portion. It is desirable that The average size of the deposited metal is calculated by averaging the sizes of multiple deposited metals arranged along the concave or convex portions based on observation using a TEM, SEM, optical microscope, etc. . Satisfying these conditions is preferable because magnetic anisotropy is easily induced in one direction. In addition, when compressing flat magnetic metal particles to synthesize a powder material, the adhesion between the flat magnetic metal particles is improved (the concave or convex portions have an anchoring effect that sticks the particles together). , is preferable because mechanical properties such as strength and hardness and thermal stability are improved.

It is desirable that the flat magnetic metal particles further include a plurality of small magnetic metal particles, on average, five or more on the flat surface. The small magnetic metal particles contain at least one first element selected from the group consisting of Fe, Co, and Ni, and have an average particle size of 10 nm or more and 1 μm or less. More preferably, the small magnetic metal particles have the same composition as the flat magnetic metal particles. By providing the small magnetic metal particles on the surface of the flat surface or by integrating the small magnetic metal particles into the flat magnetic metal particles, the surface of the flat magnetic metal particles becomes pseudo-slightly roughened. This greatly improves the adhesion when compacting the flat magnetic metal particles together with the intervening phase described below. This makes it easier to improve thermal stability and mechanical properties such as strength and toughness. In order to maximize this effect, the average particle size of the magnetic metal particles should be set to 10 nm or more and 1 μm or less, and an average of 5 or more small magnetic metal particles should be placed on the surface of the flat magnetic metal particles, i.e. It is desirable to integrate it into a flat surface. It is more preferable that the small magnetic metal particles are arranged in one direction within the flat plane because magnetic anisotropy is easily imparted within the flat plane and high magnetic permeability and low loss are easily achieved. The average particle size of the small magnetic metal particles is determined by observation using a TEM, SEM, optical microscope, or the like.

The particle size distribution variation of flat magnetic metal particles can be defined by the coefficient of variation (CV value). That is, CV value (%)=[standard deviation of particle size distribution (μm)/average particle diameter (μm)]×100. It can be said that the smaller the CV value, the smaller the variation in particle size distribution and the sharper the particle size distribution. It is preferable that the CV value as defined above is 0.1% or more and 60% or less because low coercive force, low hysteresis loss, high magnetic permeability, and high thermal stability can be achieved. Furthermore, since there is little variation, it is easy to achieve a high yield. A more preferable range of CV value is 0.1% or more and 40% or less.

One effective method for imparting a coercive force difference depending on direction within the flat plane of flat magnetic metal particles is to perform heat treatment in a magnetic field. It is desirable to perform the heat treatment while applying a magnetic field in one direction within the flat surface. Before performing heat treatment in a magnetic field, it is desirable to find the easy axis direction within the flat plane (search for the direction in which the coercive force is the smallest) and perform heat treatment while applying a magnetic field in that direction. The larger the applied magnetic field is, the more preferable it is, but it is preferable to apply 1 kOe or more, more preferably 10 kOe or more. This is preferable because magnetic anisotropy can be expressed in the flat plane of the flat magnetic metal particles, and a coercive force difference depending on the direction can be imparted, and excellent magnetic properties can be realized. The heat treatment is preferably performed at a temperature of 50°C or higher and 800°C or lower. The atmosphere for the heat treatment is preferably a vacuum atmosphere with a low oxygen concentration, an inert atmosphere, or a reducing atmosphere, and more preferably, H ₂ (hydrogen), CO (carbon monoxide), CH ₄ (methane), etc. It is preferable to use a reducing atmosphere. The reason for this is that even if the flat magnetic metal particles are oxidized, by performing heat treatment in a reducing atmosphere, the oxidized metal can be reduced and returned to metal. Thereby, the flat magnetic metal particles whose saturation magnetization has decreased due to oxidation can be reduced to restore the saturation magnetization. Note that if the crystallization of the flat magnetic metal particles significantly progresses due to heat treatment, the properties will deteriorate (coercive force increases, magnetic permeability decreases), so conditions were selected to suppress excessive crystallization. It is preferable to do so.

In addition, when synthesizing flat magnetic metal particles, if ribbons are synthesized by a roll quenching method or the like and flat magnetic metal particles are obtained by crushing the ribbons, multiple concave portions and multiple convex portions may be formed during ribbon synthesis. One or both of them are likely to be arranged in the first direction (concave portions and convex portions are likely to be formed in the rotational direction of the roll), which is preferable because it is easy to have a coercive force difference depending on the direction within the flat plane. In other words, the direction in which one or both of the plurality of concave portions and the plurality of convex portions in the flat plane are arranged in the first direction tends to be the axis of easy magnetization, and the coercive force difference depending on the direction in the flat plane is effectively It is preferred that it be given.

According to this embodiment, it is possible to provide flat magnetic metal particles having excellent magnetic properties such as low magnetic loss.

(Second embodiment)
The plurality of flat magnetic metal particles of this embodiment have at least a part of the surface of the flat magnetic metal particles with a thickness of 0.1 nm or more and 1 μm or less, and contain oxygen (O), carbon (C), nitrogen (N), and fluorine. This embodiment differs from the first embodiment in that it is covered with a coating layer containing at least one second element selected from the group consisting of (F).

Note that the description of content that overlaps with the first embodiment will be omitted.

FIG. 7 is a schematic diagram of flat magnetic metal particles according to the second embodiment. A covering layer 9 is shown.

The coating layer includes Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, Ba, Sr, Cr, Mo, Ag, Ga, Sc, V, Y, Nb, Pb, Cu, In, Sn, Containing at least one non-magnetic metal selected from the group consisting of rare earth elements, and at least one second selected from the group consisting of oxygen (O), carbon (C), nitrogen (N) and fluorine (F) It is more preferable to include an element. As the non-magnetic metal, Al and Si are particularly preferable from the viewpoint of thermal stability. Flat magnetic metal particles include Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, Ba, Sr, Cr, Mo, Ag, Ga, Sc, V, Y, Nb, Pb, Cu, In, Sn. , when the coating layer contains at least one nonmagnetic metal selected from the group consisting of rare earth elements, the coating layer must contain at least one nonmagnetic metal that is the same as the nonmagnetic metal that is one of the constituent components of the flat magnetic metal particles. is more preferable. Among oxygen (O), carbon (C), nitrogen (N), and fluorine (F), it is preferable that oxygen (O) is included, and oxides and composite oxides are preferable. The above is from the viewpoints of ease of forming the coating layer, oxidation resistance, and thermal stability. As a result of the above, it is possible to improve the adhesion between the flat magnetic metal particles and the coating layer, and it is possible to improve the thermal stability and oxidation resistance of the compacted powder material, which will be described later. The coating layer can not only improve the thermal stability and oxidation resistance of the flat magnetic metal particles, but also improve the electrical resistance of the flat magnetic metal particles. By increasing the electrical resistance, it becomes possible to suppress eddy current loss and improve the frequency characteristics of magnetic permeability. For this reason, it is preferable that the coating layer 14 has high electrical resistance, for example, a resistance value of 1 mΩ·cm or more.

Further, the presence of the coating layer is also preferable from a magnetic viewpoint. Since the flat magnetic metal particles have a thickness smaller than the size of the flat surface, they can be regarded as a pseudo thin film. At this time, what is formed by forming a coating layer on the surface of the flat magnetic metal particles and integrating them can be regarded as a pseudo laminated thin film structure, and the magnetic domain structure becomes energetically stable. This makes it possible to reduce the coercive force (thereby reducing hysteresis loss), which is preferable. At this time, the magnetic permeability also increases, which is preferable. From this point of view, it is more preferable that the coating layer is non-magnetic (the magnetic domain structure is more likely to be stabilized).

The thickness of the coating layer is preferably as thick as possible from the viewpoints of thermal stability, oxidation resistance, and electrical resistance. However, if the thickness of the coating layer becomes too thick, the saturation magnetization becomes small and the magnetic permeability also becomes small, which is not preferable. Also, from a magnetic point of view, if the thickness becomes too thick, the "effects of stabilizing the magnetic domain structure and lowering the coercive force, lowering the loss, and increasing the magnetic permeability" will be reduced. Considering the above, the thickness of the coating layer is preferably 0.1 nm or more and 1 μm or less, more preferably 0.1 nm or more and 100 m or less.

As described above, according to the present embodiment, it is possible to provide flat magnetic metal particles having excellent properties such as high magnetic permeability, low loss, excellent mechanical properties, and high thermal stability.

(Third embodiment)

The compacted powder material of this embodiment has a flat surface and a magnetic metal phase containing Fe, Co, and Si, and the amount of Co is 0.001 at% or more and 80 at% or less based on the total amount of Fe and Co. The amount of Si is 0.001 at% or more and 30 at% or less based on the entire magnetic metal phase, the average thickness is 10 nm or more and 100 μm or less, and the ratio of the average length in the flat plane to the thickness is a plurality of flat magnetic metal particles having an average value of 5 or more and 10,000 or less; and a group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F), which exists between the flat magnetic metal particles. and an intervening phase containing at least one second element selected from the following, and the powder material has a coercive force difference depending on the direction within a plane of the powder material.

Further, the compacted powder material of the present embodiment has a flat surface and a magnetic metal phase consisting of at least one first element selected from the group consisting of Fe, Co, and Ni and an additive element, and the additive element is B and Hf, the total amount of the additive elements is 0.002 at% or more and 80 at% or less based on the entire magnetic metal phase, the average thickness is 10 nm or more and 100 μm or less, and the thickness is within the flat plane with respect to the thickness. The average value of the average length ratio of (F) An intervening phase containing at least one second element selected from the group consisting of (F), and the powder material has a coercive force difference depending on the direction within the plane.

The composition, average crystal grain size, and crystal orientation (approximately (110) orientation) of the magnetic metal phase preferably satisfy the requirements described in the first embodiment, but since they overlap here, the content will be omitted. Description is omitted. An example of the powder material is a powder material obtained by compression molding the flat magnetic metal particles described in the first embodiment or the second embodiment.

Further, the saturation magnetization of the powder material is preferably higher, preferably 0.2T or more, more preferably 0.5T or more, 1.0T or more, still more preferably 1.8T or more, More preferably, it is 2.0T or more. This is preferable because magnetic saturation is suppressed and the magnetic properties can be fully exhibited on the system. However, depending on the application (for example, a magnetic wedge for a motor), it can be used satisfactorily even if the saturation magnetization is relatively small, and it may be preferable to specialize in low loss. Therefore, it is important to select the composition depending on the application.

FIG. 8 is a schematic diagram of a compacted powder material according to the third embodiment. The intervening phase 20, the green material 100, and the plane 102 of the green material are shown. Note that the diagram shown on the right side of FIG. 8 is a schematic diagram in which hatching has been removed from the diagram shown on the left side of FIG. 8 to make it easier to see the intervening phase.

An example of the predetermined cross sections 22a and 22b is shown on the right side of FIG. In this embodiment, the flat surface 6 is oriented parallel to the flat surface 102 of the compacted powder material. The "predetermined cross section 22" is a cross section of the powdered powder material 100 perpendicular to this plane 102. Note that the method of taking the "predetermined cross section 22" is, of course, not limited to that specified in FIG. 8.

FIG. 9 is a schematic diagram showing an example of arrangement of flat magnetic metal particles in a plane parallel to each cross section in the third embodiment. The compacted powder material 100 shown as an example in FIG. 9 has a rectangular parallelepiped shape with a vertical length a, a horizontal length b, and a height c. In FIG. 9, the flat surface 102 of the powder material is the upper surface (or lower surface) of the powder material 100. In this case, since the flat magnetic metal particles 10 are oriented parallel to the plane 102 (ab-plane) of the powder material, the arrangement of the flat magnetic metal particles 10 is, for example, as shown in the lower diagram of FIG. In the case of FIG. 9, elongated flat magnetic metal particles are used in which the ratio a/b of the maximum length a to the minimum length b in the flat plane of the flat magnetic metal particles is large. A plane perpendicular to the a-b plane becomes a "predetermined cross section." For example, a plane parallel to the bc plane or a plane parallel to the ac plane can be a "predetermined cross section" (in addition, a plane perpendicular to the ab plane can be determined arbitrarily, and that plane can be defined as a "predetermined cross section"). ). Note that the method of determining the "plane of the compacted powder material" and the "predetermined cross section" is not limited to this.

It is defined that the closer the angle between the plane parallel to the flat surface of the flat magnetic metal particle and the plane of the powdered powder material is 0 degrees, the more oriented it is. FIG. 10 is a schematic diagram showing the angle between a plane parallel to the flat surface of the flat magnetic metal particles and a plane of the powdered powder material in the third embodiment. The above angle is determined for 100 flat magnetic metal particles, and the orientation variation thereof is preferably 30 degrees or more and 45 degrees or less, more preferably 35 degrees or more and 45 degrees or less, and even more preferably 40 degrees or more and 45 degrees or less. is desirable. Here, for example, "orientation variation is 30 degrees or more and 45 degrees or less" means that "the angle between the plane parallel to the flat plane of each flat magnetic metal particle and the plane of the powder material is θ (rad). Then, for each flat magnetic metal particle, the vector with length 1 and angle θ is divided by the number of flat magnetic metal particles, and the result is the "average vector". , when the length of the average vector is R, the circumferential standard deviation S, which is determined by S=(−2ln(R)) ^0.5 ×π/180, is 30 degrees or more and 45 degrees or less.” That is, in the compacted powder material, it is preferable that the flat surfaces of the plurality of flat magnetic metal particles are arranged in directions with orientation variations of a certain amount or more. This is preferable because it is possible to reduce eddy current loss of the powder material when a magnetic field perpendicular to the plane of the powder material is applied. Further, since the demagnetizing field can be reduced, the magnetic permeability of the dust material can be increased, which is preferable. Further, since the ferromagnetic resonance frequency can be increased, the ferromagnetic resonance loss can be reduced, which is preferable. Furthermore, such a structure is preferable because the magnetic domain structure is stabilized and low magnetic loss can be achieved. On the other hand, it is preferable that the flat magnetic metal particles are arranged at various orientation angles due to orientation variations, since this can prevent a decrease in strength.

When measuring the coercive force depending on the direction in the plane of the powder material (in the plane parallel to the flat plane of the flat magnetic metal particles), for example, 22. Change the direction every 5 degrees and measure the coercive force.

By having a coercive force difference within the plane of the powder material, the minimum coercive force value becomes smaller than in the isotropic case where there is almost no coercive force difference, which is preferable. In a material that has magnetic anisotropy within a plane, the coercive force differs depending on the direction within the plane, and the minimum coercive force value is smaller than that of a magnetically isotropic material. This reduces hysteresis loss and improves magnetic permeability, which is preferable.

In the plane of the powder material (in the plane parallel to the flat plane of the flat magnetic metal particles), the ratio of the coercive force difference depending on the direction is preferably as large as possible, and is preferably 1% or more. More preferably, the ratio of the coercive force difference is 10% or more, still more preferably the ratio of the coercive force difference is 50% or more, and still more preferably the ratio of the coercive force difference is 100% or more. The ratio of coercive force difference here means (Hc (max) - Hc (min)) using the maximum coercive force Hc (max) and the minimum coercive force Hc (min) in the flat plane. /Hc (min) x 100 (%).

Note that the coercive force can be easily evaluated using a vibrating sample magnetometer (VSM) or the like. If the coercive force is low, by using a low magnetic field unit, it is possible to measure coercive forces of 0.1 Oe or less. Measurement is performed by changing the direction within the plane of the powdered powder material (in a plane parallel to the flat plane of the flat magnetic metal particles) with respect to the direction of the measurement magnetic field.

When calculating the coercive force, the value obtained by dividing the difference between the magnetic fields at two points intersecting the horizontal axis (the magnetic fields H1 and H2 where magnetization becomes zero) by 2 (that is, the coercive force = | H2 - It can be calculated as H1|/2).

From the viewpoint of imparting magnetic anisotropy, it is preferable that the magnetic metal particles are arranged with their maximum lengths aligned. To determine whether the maximum length directions are aligned, observe the magnetic metal particles contained in the compacted powder material using a TEM, SEM, or optical microscope, and determine the angle between the maximum length direction and an arbitrarily determined reference line. Judgment is made based on the degree of variation. Preferably, it is preferable to judge the average degree of variation for 20 or more flat magnetic metal particles, but if 20 or more flat magnetic metal particles cannot be observed, as many flat magnetic metal particles as possible are determined. It is preferable to observe metal particles and determine the average degree of variation therebetween. In this specification, when the degree of variation is within a range of ±30°, it is said that the maximum length directions are aligned. The degree of variation is more preferably within the range of ±20°, and even more preferably within the range of ±10°. This is desirable because it facilitates imparting magnetic anisotropy to the compacted powder material. More preferably, the first direction of one or both of the plurality of recesses and the plurality of protrusions on the flat surface is arranged in the maximum length direction. This is desirable because a large degree of magnetic anisotropy can be imparted.

In the compacted powder material, it is preferable that the "arrangement ratio" in which the approximate first direction is arranged in the second direction is 30% or more. More preferably, it is 50% or more, and still more preferably 75% or more. This increases the magnetic anisotropy appropriately and improves the magnetic properties as described above, which is preferable. First, for all the flat magnetic metal particles to be evaluated in advance, the direction in which the arrangement direction of the concave portions or convex portions of each flat magnetic metal particle is the largest is determined as the first direction, and the first direction of each flat magnetic metal particle is determined as the first direction. The direction in which the most number of particles are arranged in the entire powder compact material is defined as the second direction. Next, a direction is determined by dividing the 360 degree angle into angles every 45 degrees with respect to the second direction. Next, the angular direction in which the first direction of each flat magnetic metal particle is closest is classified, and that direction is defined as an "approximate first direction." That is, it is classified into one of four directions: 0 degree direction, 45 degree direction, 90 degree direction, and 135 degree direction. The ratio at which the approximate first direction is arranged in the same direction as the second direction is defined as the "arrangement ratio". When evaluating this "arrangement ratio," four adjacent flat magnetic metal particles are selected in order and evaluated. By performing this at least three times or more (the more the better, for example, five or more times, more preferably ten or more times), the average value is adopted as the arrangement ratio. Note that flat magnetic metal particles whose directions of concave portions or convex portions cannot be determined are excluded from the evaluation, and the flat magnetic metal particles immediately adjacent thereto are evaluated. For example, in flat magnetic metal particles obtained by pulverizing a ribbon synthesized in a single-roll quenching device, only one flat surface has concave portions or convex portions, and the other flat surface does not often have concave portions or convex portions. When such flat magnetic metal particles are observed with an SEM, there is about a half chance that a flat surface without concave or convex portions is visible on the observation screen (in this case as well, it is actually the back side). The flat surface should have a concave or convex portion, but this is excluded in the above evaluation).

Moreover, it is preferable that the largest number of approximate first directions are arranged in the direction of the axis of easy magnetization of the powder material. That is, it is preferable that the axis of easy magnetization of the powder material is parallel to the second direction. The length direction in which the concave portions or convex portions are arranged tends to become the axis of easy magnetization due to the effect of shape magnetic anisotropy, so it is easier to impart magnetic anisotropy if this direction is aligned as the axis of easy magnetization. That's preferable.

It is preferable that a portion of the intervening phase adheres along the first direction. In other words, it is preferable that a portion of the intervening phase adheres along the direction of the concave portion or convex portion on the flat surface of the flat magnetic metal particle. This makes it easier to induce magnetic anisotropy in one direction, which is preferable. Further, the attachment of such an intervening phase is preferable because it improves the adhesion between flat magnetic metal particles, thereby improving mechanical properties such as strength and hardness, and thermal stability. Moreover, it is preferable that the intervening phase includes a particulate phase. This maintains the adhesion between the flat magnetic metal particles at an appropriate level and reduces distortion (due to the intervening particulate phase between the flat magnetic metal particles, This is preferable because stress is relaxed) and coercive force can be easily reduced (hysteresis loss is reduced and magnetic permeability is increased).

FIG. 11 is a schematic diagram showing a method for producing a powdered powder material according to the third embodiment. Here, it is assumed that the powder material is manufactured by uniaxial pressure molding using a mold. FIGS. 11(a) and 11(b) show a comparative method for producing a compacted powder material. In the comparative embodiment, when performing magnetic field pressing as preliminary molding before hot press molding, a mold consisting of a magnetic die and punch is usually used to enhance the effect of magnetic field pressing. In this case, residual magnetization occurs in the mold in the same direction as the applied magnetic field. Therefore, it is possible to obtain a powder material in which the flat surfaces of the flat magnetic metal particles contained in the powder material are relatively parallel. Therefore, there is a problem in that the demagnetizing field becomes large in a situation where a magnetic field perpendicular to the molding surface is applied, making it impossible to obtain high magnetic permeability. Therefore, in this embodiment, as shown in FIG. 11(c), pressing in a magnetic field is performed using a mold that combines a magnetic punch and a non-magnetic die. As a result, residual magnetization does not occur in the die after pressing in a magnetic field. Then, due to the residual magnetization generated in the punch separated by the molded body, lines of magnetic force are generated in a direction different from the direction in which the magnetic field is applied during pressing in a magnetic field. Furthermore, the molding pressure during hot press molding is intentionally set to a low pressure of, for example, a surface pressure of about 0.1 to 10 MPa. This makes it easier for the flat magnetic metal particles to rotate due to the influence of magnetic lines of force passing through the molded body during hot press molding. Therefore, it is possible to obtain a compacted powder material having appropriate orientation variations. Moreover, the flat magnetic metal particles tend to aggregate along the lines of magnetic force passing through the molded body. Therefore, arrangement of flat magnetic metal particles with high proximity ratio is realized. Furthermore, since the molding pressure is low, the stress that bends the flat magnetic metal particles is low, so the curvature of the flat magnetic metal particles becomes small. By realizing the arrangement of these characteristic flat magnetic metal particles, it becomes possible to produce a dust material with high magnetic permeability without reducing strength. Incidentally, it goes without saying that the compacted powder material of this embodiment can be preferably manufactured without using the uniaxial pressure molding using the above-mentioned mold.

FIG. 12 is a microscopic (SEM) photograph of a predetermined cross section of the compacted powder material in the third embodiment. The upper part of FIG. 12 shows a microscope (SEM) photograph of a cross section of a compacted powder material of a comparative form. It is observed that the orientation angles of the flat magnetic metal particles shown in light gray are aligned in the horizontal direction, and the orientation variation is small. In the compacted powder material of the comparative embodiment, since the orientation variation is small, the magnetic permeability to the magnetic field in the vertical direction in FIG. 12 becomes low. On the other hand, in the compressed powder material of the embodiment shown in the lower part of FIG. 12, the orientation variation of the flat magnetic metal particles is large. Due to the large variation in the orientation of the flat magnetic metal particles, the magnetic permeability is higher than that of the compact powder material of the comparative form even in the vertical magnetic field in FIG. If the orientation variation is large, there is a concern that the strength will decrease. However, since there are many places where the flat magnetic metal particles are close to each other, the substantial thickness of the flat magnetic metal particles increases with respect to external stress. Therefore, the bending rigidity is enhanced, and the effect of improving the strength can be obtained. Furthermore, since the flat magnetic metal particles are molded with a small curvature, the peeling stress acting on the interface between the flat magnetic metal particles and the intervening phase is reduced, and a decrease in strength can be prevented. Furthermore, since the curvature of the flat magnetic metal particles is a factor in increasing the coercive force, the small curvature allows the coercive force to be kept low. However, if the molding pressure is set to such a low pressure that the curvature ratio is almost zero, it will not be possible to obtain a high-density green compact, so the curvature ratio should be at least 0.01% or higher. It is necessary to control molding conditions. If a high-density powder material cannot be obtained and the porosity increases, the strength of the powder material will decrease. On the other hand, if there are no voids at all (the porosity is zero), there are no voids to pin the growth of cracks that occur when stress is applied to the powder material, so stress above a certain level is applied. In this case, the cracks develop rapidly and break in a very short time, making the material difficult to use in practice, so it is desirable that a small number of voids exist in the powder compact. Specifically, in a predetermined cross section of the compacted powder material, the orientation variation of the flat magnetic metal particles is 30 degrees or more and 45 degrees or less, the proximity ratio is 3% or more and 10% or less, and the curvature ratio is 0.01%. When the content is 0.6% or less, a powder material having both high magnetic permeability and strength can be obtained. Preferably, the alignment variation is 35 degrees or more and 45 degrees or less, the proximity ratio is 3% or more and 8% or less, and the curvature is 0.01% or more and 0.5% or less. More preferably, the orientation variation is 40 degrees or more and 45 degrees or less, the proximity ratio is 3% or more and 5% or less, and the curvature is 0.01% or more and 0.4% or less. Further, the porosity is desirably 0.01% or more and 10% or less, preferably 0.01% or more and 8% or less, and more preferably 0.01% or more and 5% or less. According to this embodiment, it is possible to manufacture and provide a compacted powder material that has both high magnetic permeability and high strength.

Incidentally, the orientation variation, proximity ratio, and curvature ratio of the flat magnetic metal particles in a predetermined cross section of the compacted powder material can be determined by, for example, SEM-EDX (Scanning Electron Microscope-Energy Dispersive X-ray Spectroscopy), TEM-EDX (Transmission ssion Electron Microscope- It can be determined from an observed image obtained using energy dispersive X-ray spectroscopy or the like.

FIG. 13 is a schematic diagram showing a method of calculating the proximity ratio of flat magnetic metal particles in a predetermined cross section of the powdered powder material according to the third embodiment. As an example, a method of calculating the proximity rate using SEM-EDX will be described below. First, a conductive film such as a carbon film is formed on the surface of the compacted powder material to be observed, and then observed. At this time, the magnification is set to such an extent that 50 or more flat magnetic metal particles can be accommodated, and a SEM-EDX image is obtained. In the SEM-EDX image, a region containing any one of iron (Fe), cobalt (Co), and nickel (Ni) as a main component is a flat magnetic metal particle phase, oxygen (O), carbon (C), A region containing more of either nitrogen (N) or fluorine (F) than the flat magnetic metal particle phase is defined as an intervening phase, and a region containing no element (or containing only below the detection limit) is defined as a void. Define each. At this time, the value obtained by dividing the area of the void by the total area of the flat magnetic metal phase, the intervening phase, and the void is calculated for at least five fields of view, and the average value is defined as the porosity of the compacted powder material. For all the flat magnetic metal particle phases, the interface between the flat magnetic metal particle phase and the intervening phase or the flat magnetic metal particle phase and the void is extracted, and the total length of the extracted interface is measured. Furthermore, where the interfaces of the flat magnetic metal particle phases are close to each other, specifically, among the two adjacent flat magnetic metal particle phases, the thickness of the flat magnetic metal particles calculated by the above method is Points that are close to each other at a distance of one-fifth or less of the thickness of the smaller flat magnetic metal particle phase are extracted, and the total length of the close points for all particles is measured. The length of the interface and adjacent points can be measured physically using a measuring instrument on the SEM image, or if the image is acquired electronically, it can be measured using a boundary line detection algorithm. Measurement is performed by detecting the boundary line and calculating the length of the boundary line. The value obtained by dividing the obtained total length of the proximate portions by the total length of the interface is defined as the proximity ratio in this SEM-EDX image. For one compacted powder material, calculate the proximity ratio for each SEM-EDX image for all SEM-EDX images acquired in at least 5 fields of view using the same method as above, and calculate the average of these values. , is adopted as the proximity ratio of this powder material. The proximity ratio means that the distance between the two flat magnetic metal particles of the plurality of flat magnetic metal particles is one-fifth or less of the thickness of the smaller one of the two flat magnetic metal particles. The sum of the circumferential lengths of the two flat magnetic metal particles for all of the plurality of flat magnetic metal particles is X, and the sum of the circumferential lengths of the plurality of flat magnetic metal particles is When is Y, it is X/Y.

FIG. 14 is a schematic diagram showing a method of calculating the curvature of flat magnetic metal particles in a predetermined cross section of the powdered powder material of the third embodiment. As an example, a method for calculating the curvature using SEM-EDX will be described below. First, a conductive film such as a carbon film is formed on the surface of the compacted powder material to be observed, and then observed. At this time, the magnification is set to such an extent that 50 or more flat magnetic metal particles can be accommodated, and a SEM-EDX image is acquired. In the SEM-EDX image, a region containing any one of iron (Fe), cobalt (Co), and nickel (Ni) as a main component is a flat magnetic metal particle phase, oxygen (O), carbon (C), A region containing more of either nitrogen (N) or fluorine (F) than the flat magnetic metal particle phase is defined as an intervening phase, and a region containing no element (or containing only below the detection limit) is defined as a void. Define each. For all the flat magnetic metal particle phases, a curve passing through the middle of the flat surfaces on both sides of the flat magnetic metal particle, that is, the center of the flat magnetic metal particle is extracted. The length of the extracted curve and the straight-line distance between the end points of the curve are measured, and the value obtained by subtracting 1 from the value obtained by dividing the length of the curve by the straight-line distance is defined as the curvature of the flat magnetic metal particle. For one compacted powder material, calculate the curvature of all the flat magnetic metal particles shown in all the SEM-EDX images obtained in at least 5 fields of view, and calculate the average of these values as this pressure. Adopted as the curvature of the powder material. The curvature of the flat magnetic metal particles is defined as: in a predetermined cross section of the powdered powder material, when the length of a curve passing through the center of the flat magnetic metal particles is _L1 , and the distance between the end points of the curve is _L2 , (L ₁ /L ₂ )-1.

In addition, the average orientation angle between the flat surface and the flat surface of the compacted powder material is, for example, such that the average thickness is 10 to 20 μm and the average ratio of the average length in the flat surface to the thickness is about 5 to 20. In the case of a powder material made of magnetic metal particles, it can be calculated by the following method using SEM. First, a SEM-EDX image with an observation area of 500 μm×500 μm is obtained. Note that the observation area may be changed as appropriate within the range of common sense depending on the size of the flat magnetic metal particles (average thickness, average ratio of the average length in the flat plane to the thickness), but at least the observation area It is preferable to select an area in which 20 or more flat magnetic metal particles are included. In the acquired SEM-EDX image, regions containing any one of iron (Fe), cobalt (Co), and nickel (Ni) as a main component are identified as flat magnetic metal particles. Considering the rectangle with the smallest area among the rectangles circumscribing the flat magnetic metal particles, the angle formed by the long side of the rectangle with respect to the plane of the powdered powder material is defined as the orientation angle of the flat magnetic metal particles. do. Calculate the orientation angle of the flat magnetic metal particles for all flat magnetic metal particles within the same observation field, and use the average value of the remaining values after excluding the maximum and minimum values as the orientation angle of the observation target surface. . However, flat magnetic metal particles may include particles that are very difficult to identify, and in that case, they may be excluded from the observation object within the range of common sense. Using the same calculation method, the orientation angles are calculated for all other planes that the powder material has, and the orientation angle of the plane with the smallest orientation angle is defined as the orientation angle of the powder material.

Further, it is preferable that the lattice mismatch ratio between the intervening phase and the flat magnetic metal particles is 0.1% or more and 50% or less. This is preferable because a suitably large magnetic anisotropy can easily be imparted and the above-mentioned magnetic properties can be improved. Setting the lattice mismatch within the above range can be achieved by selecting a combination of the composition of the intervening phase and the composition of the flat magnetic metal particles 10. For example, Ni with an fcc structure has a lattice constant of 3.52 Å, and MgO with a NaCl type structure has a lattice constant of 4.21 Å, and the lattice mismatch between the two is (4.21-3.52)/3.52×100. =20%. That is, the lattice mismatch can be set to 20% by making the main composition of the flat magnetic metal particles FCC-structured Ni and making the intervening phase 20 MgO. In this way, by selecting a combination of the main composition of the flat magnetic metal particles and the main composition of the intervening phase, it is possible to set the lattice mismatch within the above range.

The intervening phase contains at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F). This is because the resistance can be increased thereby. The electrical resistivity of the intervening phase is preferably higher than the electrical resistivity of the flat magnetic metal particles. This is because the eddy current loss of the flat magnetic metal particles can be reduced by this. Since the intervening phase exists surrounding the flat magnetic metal particles, it is preferable because it can improve the oxidation resistance and thermal stability of the flat magnetic metal particles. Among these, those containing oxygen are more preferable from the viewpoint of high oxidation resistance and high thermal stability. The intervening phase also plays a role in mechanically adhering the flat magnetic metal particles to each other, and is therefore preferable from the viewpoint of high strength.

In addition, the intervening phase may be an oxide having a eutectic system, a resin, or at least one magnetic metal selected from Fe, Co, and Ni, or at least one of these three. You may have one. These points will be explained below.

First, the first "case of an oxide in which the intervening phase has a eutectic system" will be explained. In this case, the intervening phase is B (boron), Si (silicon), Cr (chromium), Mo (molybdenum), Nb (niobium), Li (lithium), Ba (barium), Zn (zinc), La (lanthanum). ), P (phosphorus), Al (aluminum), Ge (germanium), W (tungsten), Na (sodium), Ti (titanium), As (arsenic), V (vanadium), Ca (calcium), Bi (bismuth) ), Pb (lead), Te (tellurium), and Sn (tin). In particular, it is preferable to include a eutectic system containing at least two elements of B, Bi, Si, Zn, and Pb. This strengthens the adhesion between the flat magnetic metal particles and the intervening phase (increases the bonding strength), making it easier to improve mechanical properties such as thermal stability, strength, and toughness.

Further, the softening point of the above-mentioned oxide having a eutectic system is preferably 200°C or more and 600°C or less, more preferably 400°C or more and 500°C or less. More preferably, it is an oxide having a eutectic system containing at least two elements of B, Bi, Si, Zn, and Pb, and has a softening point of 400°C or more and 500°C or less. As a result, the bond between the flat magnetic metal particles and the eutectic oxide becomes strong, and mechanical properties such as thermal stability, strength, and toughness are easily improved. When the flat magnetic metal particles are integrated with the oxide having the above-mentioned eutectic system, they are integrated while being heat-treated at a temperature near the softening point of the oxide having the above-mentioned eutectic system, preferably at a temperature slightly higher than the softening point. By this, it is possible to improve the adhesion between the flat magnetic metal particles and the above-mentioned oxide having a eutectic system, and improve the mechanical properties. In general, the higher the heat treatment temperature is to a certain extent, the better the adhesion between the flat magnetic metal particles and the above eutectic oxide and the better the mechanical properties. However, if the heat treatment temperature becomes too high, the coefficient of thermal expansion increases, which may actually reduce the adhesion between the flat magnetic metal particles and the above-mentioned oxide having a eutectic system (flat magnetic metal particles If the difference between the coefficient of thermal expansion of the oxide and the coefficient of thermal expansion of the oxide having the above-mentioned eutectic system becomes large, the adhesion may further deteriorate). Further, if the crystallinity of the flat magnetic metal particles is amorphous or non-crystalline, a high heat treatment temperature is not preferable because crystallization progresses and the coercive force increases. Therefore, in order to achieve both mechanical properties and coercive force properties, the softening point of the oxide having the above-mentioned eutectic system is set to 200°C or more and 600°C or less, more preferably 400°C or more and 500°C or less, and the above-mentioned It is preferable to integrate them while performing heat treatment at a temperature near the softening point of the oxide having a eutectic system, preferably at a temperature slightly higher than the softening point. Further, when the integrated material is actually used in a device or system, it is preferable to use it at a temperature lower than its softening point.

Moreover, it is desirable that the oxide having the above-mentioned eutectic system has a glass transition point. Furthermore, it is desirable that the oxide having the above-mentioned eutectic system has a coefficient of thermal expansion of 0.5×10 ⁻⁶ /°C or more and 40×10 ⁻⁶ /°C or less. This strengthens the bond between the flat magnetic metal particles 10 and the oxide having the above-mentioned eutectic system, making it easier to improve mechanical properties such as thermal stability, strength, and toughness.

In addition, it is more preferable to include at least one eutectic particle having a particle size of 10 nm or more and 10 μm or less (preferably spherical). This eutectic particle contains the same material as the oxide having the above-mentioned eutectic system except in particulate form. Voids may also exist partially in the compacted powder material, and it can be easily observed that some of the oxides having the above-mentioned eutectic system are present in the form of particles, preferably spherical shapes. can do. Particulate or spherical interfaces can be easily distinguished even when there are no voids. The particle size of the eutectic particles is more preferably 10 nm or more and 1 μm, and even more preferably 10 nm or more and 100 nm or less. As a result, during heat treatment, while maintaining the adhesion between the flat magnetic metal particles, stress is moderately relaxed, thereby reducing the strain applied to the flat magnetic metal particles and reducing the coercive force. . This also reduces hysteresis loss and improves magnetic permeability. Note that the particle size of the eutectic particles can be measured by TEM or SEM observation.

Further, the intervening phase has a softening point higher than that of the oxide having the above-mentioned eutectic system, more preferably a softening point higher than 600°C, O (oxygen), C (carbon), N( It is preferable to further include intermediate particles containing at least one element selected from the group consisting of (nitrogen) and F (fluorine). The presence of the intermediate particles between the flat magnetic metal particles can prevent the flat magnetic metal particles from thermally fusing with each other and deteriorating the properties when the powdered powder material is exposed to high temperatures. That is, it is desirable that intermediate particles exist mainly for thermal stability. In addition, thermal stability can be further enhanced by having the softening point of the intermediate particles higher than that of the oxide having the above-mentioned eutectic system, and more preferably having a softening point of 600° C. or higher. .

Intermediate particles include Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, Ba, Sr, Cr, Mo, Ag, Ga, Sc, V, Y, Nb, Pb, Cu, In, Sn. , at least one non-magnetic metal selected from the group consisting of rare earth elements, and at least one element selected from the group consisting of O (oxygen), C (carbon), N (nitrogen) and F (fluorine). It is preferable to include. More preferably, from the viewpoint of high oxidation resistance and high thermal stability, it is an oxide or a composite oxide containing oxygen. In particular, oxides such as aluminum oxide (Al ₂ O ₃ ), silicon dioxide (SiO ₂ ), titanium oxide (TiO ₂ ), zirconium oxide (ZrO ₃ ), and composite oxides such as Al-Si-O are high. Preferable from the viewpoint of oxidation resistance and high thermal stability.

As a method for producing a powder material containing intermediate particles, for example, flat magnetic metal particles and intermediate particles (aluminum oxide (Al ₂ O ₃ ) particles, silicon dioxide (SiO ₂ ) particles, titanium oxide (TiO ₂ ) Examples include a method of mixing particles (such as zirconium oxide (ZrO ₃ ) particles) using a ball mill or the like to create a dispersed state, and then integrating them by press molding or the like. The method of dispersion is not particularly limited as long as it can disperse appropriately.

Next, the second "case where the intervening phase contains a resin" will be explained. In this case, resins include, but are not particularly limited to, polyester resins, unsaturated polyester resins, polyethylene resins, polystyrene resins, polyvinyl chloride resins, polyvinyl butyral resins, polyvinyl alcohol resins, polybutadiene resins, and Teflon (registered trademark). , polytetrafluoroethylene) resin, polyurethane resin, cellulose resin, ABS resin, nitrile-butadiene rubber, styrene-butadiene rubber, silicone resin, other synthetic rubbers, natural rubber, epoxy resin, phenolic resin, allyl resin , polybenzimidazole resin, amide resin, polyimide resin, polyamideimide resin, bismaleimide resin, or a copolymer obtained by mixing these resins with any copolymer material. In particular, in order to achieve high thermal stability, it is preferable to include a silicone resin, polyimide resin, or bismaleimide resin that has high heat resistance. This strengthens the bond between the flat magnetic metal particles and the intervening phase, making it easier to improve mechanical properties such as thermal stability, strength, and toughness.

The resin (intervening phase) preferably has a weight loss rate of 5% or less, more preferably 3% or less, even more preferably 1% or less, even more preferably 0. .1% or less is preferable. Furthermore, the weight loss rate after heating at 220°C for 200 hours in the air is preferably 5% or less, more preferably 3% or less, even more preferably 1% or less, even more preferably 0.1% or less. It is preferable that Furthermore, the weight loss rate after heating at 250°C for 200 hours in the air is preferably 5% or less, more preferably 3% or less, even more preferably 1% or less, even more preferably 0.1% or less. It is preferable that the weight loss rate be evaluated using unused materials. An unused state is one that has been molded into a usable state and has not been exposed to heat (e.g., heat above 40 degrees Celsius), chemicals, sunlight (ultraviolet rays), etc. be. The weight loss rate shall be calculated from the mass before and after heating using the following formula: weight loss rate (%) = [mass before heating (g) - mass after heating (g)] / mass before heating (g) )×100. Preferably, the strength after heating at 180° C. for 20,000 hours in the air is at least half of the strength before heating. More preferably, the strength after heating at 220° C. for 20,000 hours in the air is at least half the strength before heating. Further, it is preferable that the H type specified by the Japanese Industrial Standards (JIS) be satisfied. In particular, it is preferable to satisfy heat resistance that can withstand a maximum temperature of 180°C. More preferably, it satisfies the H class specified by the Japanese National Railway Standards (JRE). In particular, it is preferable to satisfy heat resistance that can withstand a temperature rise of 180°C with respect to ambient temperature (standard: 25°C, maximum: 40°C). Preferred resins for this purpose include polysulfone, polyethersulfone, polyphenylene sulfide, polyetheretherketone, aromatic polyimide, aromatic polyamide, aromatic polyamideimide, polybenzoxazole, fluororesin, silicone resin, and liquid crystal polymer. These resins are preferable because they have a large intermolecular cohesive force and therefore have high heat resistance. Among these, aromatic polyimide and polybenzoxazole are preferable because they have a high proportion of rigid units in the molecule and therefore have higher heat resistance. Moreover, it is preferable that it is a thermoplastic resin. The above-mentioned regulations on the heating weight loss rate, strength, and resin type are each effective for increasing the heat resistance of the resin. In addition, when a powder material made of a plurality of flat magnetic metal particles and an intervening phase (resin here) is formed, the heat resistance of the powder material increases (increases thermal stability) and high temperature ( For example, mechanical properties such as strength and toughness are easily improved after exposure to temperatures (for example, 200° C. and 250° C.) or at high temperatures (200° C. and 250° C., as described above), which is preferable. Further, since many intervening phases exist surrounding the flat magnetic metal particles even after heating, the oxidation resistance is excellent, and deterioration of magnetic properties due to oxidation of the flat magnetic metal particles is less likely to occur, which is preferable.

In addition, the weight loss rate of the compacted powder material after heating at 180°C for 3000 hours is preferably 5% or less, more preferably 3% or less, even more preferably 1% or less, even more preferably 0.1% or less. It is preferable that In addition, the weight loss rate of the compacted powder material after heating at 220°C for 3000 hours is preferably 5% or less, more preferably 3% or less, even more preferably 1% or less, even more preferably 0.1% or less. It is preferable that Furthermore, the weight loss rate of the powdered powder material after heating at 250°C for 200 hours in the air is preferably 5% or less, more preferably 3% or less, even more preferably 1% or less, and even more preferably 0. .1% or less is preferable. Note that the evaluation of the weight reduction rate is the same as in the case of the above resin. Preferably, the strength of the powder material after heating at 180° C. for 20,000 hours in the air is at least half the strength before heating. More preferably, the strength of the compacted powder material after being heated at 220° C. for 20,000 hours in the air is at least half the strength before heating. Further, it is preferable that the H type specified by the Japanese Industrial Standards (JIS) be satisfied. In particular, it is preferable to satisfy heat resistance that can withstand a maximum temperature of 180°C. More preferably, it satisfies the H class specified by the Japanese National Railway Standards (JRE). In particular, it is preferable to satisfy heat resistance that can withstand a temperature rise of 180°C with respect to ambient temperature (standard: 25°C, maximum: 40°C). The above-mentioned specifications of the heating weight reduction rate, the specifications of the strength, and the above-mentioned regulations of the resin type are each effective for increasing the heat resistance of the compacted powder material, and it is possible to realize a highly reliable material. In addition, it has increased heat resistance as a powder material (higher thermal stability), and after being exposed to high temperatures (e.g. 200°C and 250°C above), or after being exposed to high temperatures (e.g. 200°C and 250°C above). Mechanical properties such as strength and toughness can be easily improved, which is preferable. Further, since many intervening phases exist surrounding the flat magnetic metal particles even after heating, the oxidation resistance is excellent, and deterioration of magnetic properties due to oxidation of the flat magnetic metal particles is less likely to occur, which is preferable.

Furthermore, it is preferable to include a crystalline resin that does not have a glass transition point up to the thermal decomposition temperature. Further, it is preferable that a resin having a glass transition temperature of 180°C or higher is contained, and more preferably a resin having a glass transition temperature of 220°C or higher is contained. More preferably, it contains a resin having a glass transition temperature of 250° C. or higher. Note that, in general, the crystal grain size of flat magnetic metal particles increases as the heat treatment temperature increases. Therefore, when it is necessary to reduce the crystal grain size of the flat magnetic metal particles, it is preferable that the glass transition temperature of the resin used is not too high, and specifically, it is preferably 600° C. or lower. Further, it is preferable that the crystalline resin that does not have a glass transition temperature up to the thermal decomposition temperature includes a resin having a glass transition temperature of 180° C. or higher, and more preferably a resin having a glass transition temperature of 220° C. or higher. Specifically, it preferably contains a polyimide having a glass transition temperature of 180°C or higher, more preferably a polyimide having a glass transition temperature of 220°C or higher, and still more preferably a thermoplastic polyimide. . This facilitates fusion to the magnetic metal particles, making it particularly suitable for powder compaction. Examples of thermoplastic polyimides include thermoplastic aromatic polyimide, thermoplastic aromatic polyamideimide, thermoplastic aromatic polyetherimide, thermoplastic aromatic polyesterimide, and thermoplastic aromatic polyimide siloxane, which have imide bonds in their polymer chains. It is preferable to have one. Among these, it is preferable that the glass transition temperature is 250° C. or higher because the heat resistance becomes higher.

Aromatic polyimide and polybenzoxazole have a planar structure in which aromatic rings and heterocycles are directly bonded, and are immobilized by π-π stacking, thereby exhibiting high heat resistance. This makes it possible to increase the glass transition temperature and improve thermal stability. Further, it is preferable to appropriately introduce a bending unit such as an ether bond into the molecular structure, since the desired glass transition point can be easily adjusted. Among these, it is preferable from the viewpoint of strength that the benzene ring structure of the acid anhydride-derived unit constituting the imide polymer is one of biphenyl, triphenyl, and tetraphenyl structures. The symmetrical structure between imide groups, which affects heat resistance, is not impaired, and the orientation extends over long distances, which improves material strength. The structure of the aromatic polyimide preferable for this purpose is shown by the following chemical formula (1). In other words, the polyimide resin of this embodiment includes a repeating unit represented by the following chemical formula (1).
(1)
In the chemical formula (1), R represents a biphenyl, triphenyl, or tetraphenyl structure, and R' represents a structure having at least one aromatic ring within the structure.

When determining the properties (weight loss rate, resin type, glass transition temperature, molecular structure, etc.) of the intervening phase (in this case resin), which is a component of the powder material, it is necessary to extract only the resin part from the powder material. Cut it out and perform various characteristic evaluations. If it cannot be determined visually whether the particles are resin or not, elemental analysis using EDX or the like is used to distinguish between resin and magnetic metal particles.

The higher the resin content in the entire powder material, the greater the difference between the polymer wetting (covering) the flat magnetic metal particles and the polymer wetting (covering) the adjacent flat magnetic metal particles. The polymer can be easily connected between the two, improving mechanical properties such as strength. Further, the electrical resistivity is also high, which is preferable because it reduces eddy current loss of the powder compact material. On the other hand, as the resin content increases, the proportion of flat magnetic metal particles decreases, which is not preferable because the saturation magnetization of the powder material decreases and the magnetic permeability also decreases. In order to achieve a well-balanced material by comprehensively considering mechanical properties such as strength, electrical resistivity/eddy current loss, saturation magnetization, and magnetic permeability, it is necessary to determine the resin content in the entire powder material. It is preferable to set the content to 93 wt% or less, more preferably 86 wt% or less, still more preferably 2 wt% or more and 67 wt% or less, and still more preferably 2 wt% or more and 43 wt% or less. Further, the content of flat magnetic metal particles is preferably 7 wt% or more, more preferably 14 wt% or more, still more preferably 33 wt% or more and 98 wt% or less, even more preferably 57 wt%. The content is preferably 98 wt% or less. Further, as the particle size of the flat magnetic metal particles decreases, the surface area increases and the amount of resin required increases dramatically, so it is preferable that the flat magnetic metal particles have a suitably large particle size. This makes it possible to make the dust material highly saturated magnetized and increase its magnetic permeability, which is advantageous for downsizing and increasing the output of the system.

Next, the third "case where the intervening phase contains at least one magnetic metal selected from Fe, Co, and Ni and has magnetism" will be explained. In this case, it is preferable that the intervening phase has magnetism because it facilitates magnetic coupling between the flat magnetic metal particles and improves magnetic permeability. Furthermore, since the magnetic domain structure is stabilized, the frequency characteristics of magnetic permeability are also improved, which is preferable. Note that magnetism here refers to ferromagnetism, ferrimagnetism, weak magnetism, antiferromagnetism, and the like. In particular, ferromagnetism and ferrimagnetism are preferred because of their increased magnetic bonding strength. The magnetic property of the intervening phase can be evaluated using a VSM (Vibrating Sample Magetometer) or the like. The fact that the intervening phase contains at least one magnetic metal selected from Fe, Co, and Ni and has magnetism can be easily investigated using EDX or the like.

The three forms of the intervening phase have been described above, and it is preferable that at least one of these three forms is satisfied, but two or more, or even all three forms may be satisfied. "In the case where the intervening phase is an oxide with a eutectic system" (the first case), compared to the case where the intervening phase is a resin (the second case), the mechanical properties such as strength are slightly inferior, but On the other hand, it is very good and preferable from the viewpoint that strain is easily released and, in particular, coercive force decreases easily (this makes it easy to achieve low hysteresis loss and high magnetic permeability, which is preferable). . In addition, it is preferable because it often has higher heat resistance than resins and has excellent thermal stability. On the other hand, in the case where the intervening phase contains a resin (the second case), the adhesion between the flat magnetic metal particles and the resin is high, so it is easy to apply stress (distortion), which makes it difficult to maintain the structure. Although it has the disadvantage that magnetic force tends to increase easily, it is preferable because it has excellent mechanical properties such as strength. "When the intervening phase contains at least one magnetic metal selected from Fe, Co, and Ni and has magnetism" (the third case), the flat magnetic metal particles are likely to be magnetically coupled to each other. In particular, it is preferable because it is excellent in terms of high magnetic permeability and low coercive force (therefore, low hysteresis loss). Based on the above advantages and disadvantages, you can create a well-balanced product by using them properly or by combining several of them.

It is desirable that the flat magnetic metal particles contained in the compacted powder material satisfy the requirements described in the first and second embodiments. The description is omitted here because the content is duplicated.

The compacted powder material may have a laminated structure consisting of a magnetic layer containing the flat magnetic metal particles and an intermediate layer containing any one of O, C, and N. In the magnetic layer, the flat magnetic metal particles are preferably oriented (orientated so that their flat surfaces are parallel to each other). Further, it is preferable that the magnetic permeability of the intermediate layer is lower than that of the magnetic layer. These measures are preferable because a pseudo thin film laminated structure can be realized and the magnetic permeability in the layer direction can be increased. Further, in such a structure, the ferromagnetic resonance frequency can be increased, so that the ferromagnetic resonance loss can be reduced, which is preferable. Furthermore, such a laminated structure is preferable because the magnetic domain structure is stabilized and low magnetic loss can be achieved. Note that in order to further enhance these effects, it is more preferable to make the magnetic permeability of the intermediate layer smaller than the magnetic permeability of the intervening phase (intervening phase in the magnetic layer). This is preferable because it is possible to further increase the magnetic permeability in the layer direction in the pseudo thin film laminated structure. Further, since the ferromagnetic resonance frequency can be further increased, the ferromagnetic resonance loss can be reduced, which is preferable.

As described above, according to this embodiment, it is possible to provide a compacted powder material having excellent magnetic properties such as low magnetic loss.

(Fourth embodiment)
The system and device device of this embodiment include the compacted powder material of the third embodiment. Therefore, descriptions of contents that overlap with those of the first to third embodiments will be omitted. The powder material parts included in this system and device equipment include cores of rotating electric machines (e.g., motors, generators, etc.), transformers, inductors, transformers, choke coils, filters, etc. and magnetic wedges for rotating electric machines. FIG. 15 is a conceptual diagram of a motor system according to the fourth embodiment. The motor system is an example of a rotating electric machine system. A motor system is a system that includes a control system that controls the rotation speed and electric power (output power) of a motor. Methods for controlling the rotation speed of the motor include control methods using a bridge servo circuit, proportional current control, voltage comparison control, frequency synchronous control, PLL (Phase Locked Loop) control, and the like. As an example, a control method using a PLL is shown in FIG. A motor system that controls the rotation speed of a motor using a PLL includes a motor, a rotary encoder that converts the amount of mechanical displacement of the rotation of the motor into an electrical signal to detect the rotation speed of the motor, and a motor control system that controls the rotation speed of the motor given by a certain command. The motor includes a phase comparator that compares the rotation speed and the rotation speed of the motor detected by a rotary encoder and outputs a difference between the rotation speeds, and a controller that controls the motor so as to reduce the rotation speed difference. On the other hand, methods for controlling the power of the motor include PWM (Pulse Width Modulation) control, PAM (Pulse Amplitude Modulation) control, vector control, pulse control, bipolar drive, pedestal control, and resistance control. There are control methods such as control. Other control methods include microstep drive control, multiphase drive control, inverter control, and switching control. As an example, a control method using an inverter is shown in FIG. A motor system that controls the power of a motor using an inverter includes an AC power supply, a rectifier that converts the output of the AC power supply into DC current, an inverter circuit that converts the DC current to AC at a given frequency, and a motor system that is controlled by the AC power. and a motor.

FIG. 16 shows a conceptual diagram of a motor according to the fourth embodiment. Motor 200 is an example of a rotating electric machine. In the motor 200, a first stator (stator) and a second rotor (rotor) are arranged. Although the figure shows an inner rotor type in which the rotor is disposed inside the stator, an outer rotor type in which the rotor is disposed outside the stator may also be used.

FIG. 17 is a conceptual diagram of a motor core (stator) according to the fourth embodiment. FIG. 18 is a conceptual diagram of a motor core (rotor) according to the fourth embodiment. The motor core 300 (motor core) corresponds to stator and rotor cores. This point will be explained below. FIG. 17 is an example of a cross-sectional conceptual diagram of the first stator. The first stator has a core and a winding. The winding wire is wound around a portion of the protrusion provided inside the core. The compacted powder material of the third embodiment can be placed within this core. FIG. 18 is an example of a cross-sectional conceptual diagram of the first rotor. The first rotor has a core and a winding. The winding wire is wound around a part of the protrusion provided on the outside of the core. The compacted powder material of the third embodiment can be placed within this core.

Note that FIGS. 17 and 18 only show an example of the motor, and the application of the powdered powder material is not limited to this. It can be applied to all types of motors as a core to help guide magnetic flux.

FIG. 19 is a conceptual diagram of a transformer/transformer according to the fourth embodiment. FIG. 20 is a conceptual diagram of an inductor (ring-shaped inductor, rod-shaped inductor) according to the fourth embodiment. FIG. 21 is a conceptual diagram of an inductor (chip inductor, planar inductor) according to the fourth embodiment. These are also shown as examples only. In the transformer/transformer 400 and inductor 500 as well as the motor core, powder material is applied to all types of transformers/transformers and inductors in order to make it easier to guide magnetic flux or to utilize high magnetic permeability. Can be done.

FIG. 22 is a conceptual diagram of a generator 600 according to the fourth embodiment. Generator 600 is an example of a rotating electric machine. The generator 600 includes a second stator 630 using the powdered powder materials of the first to third embodiments as a core, and a second stator 630 using the powdered powder materials of the first to third embodiments as the core. Either one or both of the second rotors (rotors) 640 are provided. In the figure, the second rotor (rotor) 640 is arranged inside the second stator 630, but it may be arranged outside. The second rotor 640 is connected to a turbine 610 provided at one end of the generator 600 via a shaft 620. The turbine 610 is rotated by, for example, fluid supplied from an outside (not shown). Note that instead of using a turbine rotated by fluid, it is also possible to rotate the shaft by transmitting dynamic rotation such as regenerative energy of an automobile. Various known configurations can be adopted for the second stator 630 and the second rotor 640.

The shaft is in contact with a commutator (not shown) located on the opposite side of the turbine to the second rotor 640. The electromotive force generated by the rotation of the second rotor 640 is boosted to a grid voltage and transmitted as power from a generator via a phase separation bus (not shown) and a main transformer (not shown). Note that charging occurs in the second rotor 640 due to static electricity from the turbine and shaft current accompanying power generation. For this reason, the generator includes a brush 650 for discharging the electrical charge on the second rotor 640.

Further, the rotating electrical machine of this embodiment can be preferably used for railway vehicles. For example, it can be preferably used in a motor 200 that drives a railroad vehicle or a generator 500 that generates electricity to drive a railroad vehicle.

Moreover, FIG. 23 is a conceptual diagram showing the relationship between the direction of magnetic flux and the arrangement direction of powdered powder material. Note that in FIG. 23, a case is considered in which the flat surfaces of the flat magnetic metal particles are arranged parallel to the XY plane. First, in both the domain wall displacement type and the rotating magnetization type, it is necessary to arrange the flat surfaces of the flat magnetic metal particles contained in the dust material in a direction that is as parallel to each other as possible and aligned in a layered manner with respect to the direction of magnetic flux. preferable. This is because eddy current loss can be reduced by making the cross-sectional area of the flat magnetic metal particles that penetrate the magnetic flux as small as possible. In addition, in the domain wall displacement type, it is preferable that the axis of easy magnetization (direction of the arrow) in the flat plane of the flat magnetic metal particles be arranged parallel to the direction of magnetic flux. This is preferable because it can be used in a direction where the coercive force is further reduced, thereby reducing hysteresis loss. It is also preferable because it has high magnetic permeability. Conversely, in the rotating magnetization type, it is preferable that the axis of easy magnetization (arrow direction) in the flat plane of the flat magnetic metal particles be arranged perpendicular to the direction of magnetic flux. This is preferable because it can be used in a direction where the coercive force is further reduced, thereby reducing hysteresis loss. In other words, it is preferable to understand the magnetization characteristics of the powder material, determine whether it is a domain wall displacement type or a rotational magnetization type (the determination method is as described above), and then arrange it as shown in FIG. 17. If the direction of the magnetic flux is complicated, it may be difficult to arrange them completely as shown in FIG. 17, but it is preferable to arrange them as shown in FIG. 17 as much as possible. The above arrangement method applies to all systems and devices of this embodiment (for example, rotating electric machines such as various motors and generators, transformers, inductors, transformers, choke coils, filters, etc.). It is desirable to apply it to cores such as , magnetic wedges for rotating electric machines, etc.).

In order to be applied to this system and device arrangement, the powdered powder material allows various processing to be performed. For example, in the case of a sintered body, mechanical processing such as polishing or cutting is performed, and in the case of a powder, it is mixed with a resin such as epoxy resin or polybutadiene. Further surface treatment is performed as necessary. Further, winding processing is performed as necessary.

According to the system and device device of this embodiment, a motor system, motor, transformer, transformer, inductor, and generator with excellent characteristics (high efficiency, low loss) can be realized.

(Example)
Examples 1 to 20 will be explained in more detail below while comparing them with Comparative Examples 1 to 6. Regarding the powder materials obtained in the Examples and Comparative Examples shown below, the orientation variation, proximity ratio, and curvature of the flat magnetic metal particles in a predetermined cross section of the powder material, the average thickness t of the flat magnetic metal particles, and the thickness Table 1 summarizes the average value A of the ratio of the average length in the flat plane to the average length in the flat plane.

(Example 1)
First, using a single roll quenching device, Fe-Co-B-Si (Fe:Co:B:Si=552:23:19:6 (at%), Fe:Co=70:30 (at%), The total amount of additive elements B+Si is 25 at % with respect to the total amount of Fe+Co+B+Si. Next, the obtained ribbon is heat-treated at 300° C. in an H ₂ atmosphere. Next, this ribbon is pulverized using a mixer device and subjected to heat treatment in a magnetic field at 400° C. in an H ₂ atmosphere to obtain flat magnetic metal particles. The average thickness t of the obtained flat magnetic metal particles was 10 μm, and the average value A of the ratio of the average length in the flat plane to the thickness was 20. The obtained flat magnetic metal particles were mixed with an intervening phase (polyester resin), press-molded in a magnetic field (to orient the flat particles), and hot press-molded. Note that the hot press molding conditions are 120° C., 5 MPa, and 2 hours.

(Examples 2 to 15)
By controlling the material of the mold used for hot press molding, the pressing conditions in a magnetic field, and the hot press molding conditions, the orientation variation, proximity ratio, and curvature of flat magnetic metal particles in a predetermined cross section of the obtained powder material can be expressed. Example 1 is the same as Example 1 except that the values are as shown in Examples 2 to 15 of Example 1.

(Examples 16-20)
The average thickness t of the flat magnetic metal particles, the ratio A of the average length in the flat plane to the thickness, and the orientation variation, proximity ratio, and curvature ratio of the flat magnetic metal particles in a predetermined cross section of the obtained powdered powder material are shown. The values are the same as Examples 1 and 2 to 15, except that the values shown in Examples 6 to 20 of No. 1 are the same.

(Comparative Examples 1 to 6)
By controlling the material of the mold used for hot press molding, the pressing conditions in a magnetic field, and the hot press molding conditions, the orientation variation, proximity ratio, and curvature of flat magnetic metal particles in a predetermined cross section of the obtained powder material can be expressed. The results are the same as in Example 1 except for the values shown in Comparative Examples 1 to 6 of No. 1.

Next, the magnetic permeability ratio and strength ratio of the evaluation materials of Examples 1 to 20 and Comparative Examples 1 to 6 are evaluated using the following method. The evaluation results are shown in Table 2.

(1) Strength ratio: The bending strength of the evaluation sample was measured according to the measurement method of JIS-K7171, and the ratio with the bending strength of the sample of Comparative Example 1 (= bending strength of the evaluation sample / bending strength of Comparative Example 1) ). If the evaluation sample is small and does not meet the test piece shape specified by JIS K7171, use a calibration curve created using a test piece of the same size with known bending strength to determine the bending strength of the evaluation sample. Estimate and use it as the value of the bending strength of the sample.

(2) Magnetic permeability ratio: Measure the real part and imaginary part of the magnetic permeability of the ring-shaped sample at a frequency of 100 Hz using an impedance analyzer, and take the value of the real part as the magnetic permeability of the sample, and calculate the magnetic permeability of the sample of Comparative Example 1. (=magnetic permeability of evaluation sample/magnetic permeability of comparative example 1).

表１から明らかなように、実施例１～２０に係る圧粉材料は、圧粉材料の所定の断面における扁平磁性金属粒子の配向ばらつきが３０度以上４５度以下、近接率が３％以上１０％以下、湾曲率が０．０１％以上０．６％以下である。一方で、比較例１～６では配向ばらつき、近接率、湾曲率のいずれかが上記の範囲に含まれていない。

As is clear from Table 1, the powder materials according to Examples 1 to 20 have orientation variations of flat magnetic metal particles of 30 degrees or more and 45 degrees or less in a predetermined cross section of the powder material, and a proximity ratio of 3% or more and 10 degrees. % or less, and the curvature is 0.01% or more and 0.6% or less. On the other hand, in Comparative Examples 1 to 6, any of the orientation variation, proximity ratio, and curvature ratio is not included in the above range.

As is clear from Table 2, the powder materials of Examples 1 to 20 are superior to the powder material of Comparative Example 1 in terms of magnetic permeability ratio and strength ratio. This is because the compacted powder material of Comparative Example 1 has a low magnetic permeability due to small orientation variations, and a decrease in strength due to a lack of proximity. In Comparative Examples 2, 3, and 6, the strength ratio is superior to Comparative Example 1, but in Comparative Examples 2 and 6, the orientation variation is too small, and in Comparative Example 3, the curvature is too high. , each is inferior in terms of magnetic permeability ratio. In Comparative Example 5, the magnetic permeability ratio is superior to Comparative Example 1 due to large orientation variations, but the strength ratio decreases significantly due to orientation variations, and even if the proximity ratio and curvature ratio are controlled within appropriate ranges, A decrease in strength ratio is unavoidable. In Comparative Example 4, both the magnetic permeability ratio and the strength ratio are lower than in Comparative Example 1 under manufacturing conditions such that the curvature becomes too low and the compacted powder material cannot be densified. As mentioned above, it is noticeable only when the orientation variation is in the range of 30 degrees or more and 45 degrees or less, the proximity ratio is in the range of 3% or more and 10% or less, and the curvature is in the range of 0.01% or more and 0.6% or less. It is possible to obtain a high magnetic permeability ratio and a high strength ratio at the same time.

Although several embodiments and examples of the invention have been described, these embodiments and examples are presented by way of example and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and changes can be made without departing from the gist of the invention. These embodiments and their modifications are included within the scope and gist of the invention, as well as within the scope of the invention described in the claims and its equivalents.

Note that the above embodiments can be summarized into the following technical proposal.

Technical proposal 1
It has a flat plane and a magnetic metal phase containing at least one first element selected from the group consisting of Fe, Co, and Ni, and has an average thickness of 10 nm or more and 100 μm or less, and the flat plane with respect to the thickness. a plurality of flat magnetic metal particles having an average length ratio of 5 or more and 10,000 or less;
an intervening phase existing between the flat magnetic metal particles and containing at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F). It is a powder material,
In the compacted powder material, in a predetermined cross section perpendicular to a plane of the compacted powder material, the orientation variation of the plurality of flat magnetic metal particles is 30 degrees or more and 45 degrees or less, and the plurality of flat magnetic metal particles The compacted powder material has a proximity ratio of 3% or more and 10% or less, and a curvature ratio of the plurality of flat magnetic metal particles is 0.01% or more and 0.6% or less.
Technical plan 2
The compacted powder material according to technical proposal 1, wherein the compacted powder material has a porosity of 0.01% or more and 10% or less.
Technical plan 3
The powdered powder material according to Technical Plan 1 or 2, which has a coercive force difference depending on the direction within a plane of the powdered powder material.
Technical plan 4
At least a portion of the surface of the flat magnetic metal particles has a thickness of 0.1 nm or more and 1 μm or less, and contains at least one member selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F). The compacted powder material according to any one of technical proposals 1 to 3, which is covered with a coating layer containing two of the second elements.
Technical plan 5
The compacted powder material according to any one of Technical Plans 1 to 4, wherein the intervening phase contains a resin whose weight loss rate after heating at 180° C. for 3000 hours is 5% or less.
Technical plan 6
The compacted powder material according to any one of Technical Plans 1 to 5, wherein the compacted powder material has a weight reduction rate of 5% or less after being heated at 180° C. for 3000 hours.
Technical plan 7
The compacted powder material according to any one of technical proposals 1 to 6, wherein the intervening phase is an unsaturated polyester resin.
Technical plan 8
The compacted powder material according to any one of technical proposals 1 to 6, wherein the intervening phase is a bismaleimide resin.
Technical plan 9
A rotating electric machine comprising the compacted powder material according to any one of technical proposals 1 to 8.
Technical proposal 10
A rotating electrical machine comprising a magnetic wedge containing the powdered powder material according to any one of Technical Proposals 1 to 8.

2a Concave portion 2b Convex portion 4 Small magnetic metal particles 6 Flat surface 8 Adhesive metal 9 Covering layer 10 Flat magnetic metal particles 20 Intervening phase 22 Predetermined cross section 100 Powder material 102 Plane 200 Motor 300 Motor core 400 Transformer/transformer 500 Inductor 600 Power generation Machine (rotating electric machine)
610 Turbine 620 Shaft 630 Second stator (stator)
640 Second rotor (rotor)
650 brush

Claims (10)

It has a flat plane and a magnetic metal phase containing at least one first element selected from the group consisting of Fe, Co, and Ni, and has an average thickness of 10 nm or more and 100 μm or less, and the flat plane with respect to the thickness. a plurality of flat magnetic metal particles having an average length ratio of 5 or more and 10,000 or less;
an intervening phase existing between the flat magnetic metal particles and containing at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F). It is a powder material,
In the compacted powder material, in a predetermined cross section perpendicular to a plane of the compacted powder material, the orientation variation of the plurality of flat magnetic metal particles is 30 degrees or more and 45 degrees or less, and the plurality of flat magnetic metal particles The compacted powder material has a proximity ratio of 3% or more and 10% or less, and a curvature ratio of the plurality of flat magnetic metal particles is 0.01% or more and 0.6% or less. The compacted powder material according to claim 1, wherein the compacted powder material has a porosity of 0.01% or more and 10% or less. The powdered powder material according to claim 1 or 2, which has a coercive force difference depending on the direction within a plane of the powdered powder material. At least a portion of the surface of the flat magnetic metal particles has a thickness of 0.1 nm or more and 1 μm or less, and contains at least one member selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F). The compacted powder material according to any one of claims 1 to 3, which is covered with a coating layer containing two of the second elements. The compacted powder material according to any one of claims 1 to 4, wherein the intervening phase contains a resin whose weight loss rate after heating at 180°C for 3000 hours is 5% or less. The compacted powder material according to any one of claims 1 to 5, wherein the compacted powder material has a weight reduction rate of 5% or less after being heated at 180° C. for 3000 hours. The compacted powder material according to any one of claims 1 to 6, wherein the intervening phase is an unsaturated polyester resin. The compacted powder material according to any one of claims 1 to 6, wherein the intervening phase is a bismaleimide resin. A rotating electrical machine comprising the compacted powder material according to any one of claims 1 to 8. A rotating electric machine comprising a magnetic wedge containing the powdered powder material according to any one of claims 1 to 8.