JP2002004129A - Ferromagnetic material containing fiber, textile and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a ferromagnetic material containing textile soft and fitting to a human body. SOLUTION: This ferromagnetic material containing fiber is provided by uniformly dispersing spherical ferromagnetic alloy particles having a nanocomposite structure which is an aggregate of fine particles of a ferromagnetic alloy and each of the individual fine particles is separated each other by a metal oxide layer, interspersed materials or voids, and has <=30 μm mean particle diameter. The ferromagnetic material-containing fiber can be processed as a final product shape after making it as a woven fabric, non-woven fabric or knitted fabric (a knit), or may be directly processed as a knitwear. In accordance with the purpose of uses, it can be used as non-magnetized state or as totally or partially magnetized state.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a ferromagnetic material-containing fiber, a ferromagnetic material-containing fiber product, a ferromagnetic fiber product, and a method for producing a ferromagnetic material-containing fiber used in consumer and industrial applications. .

[0002]

2. Description of the Related Art In addition to various industrial uses, magnets are expected to be used in magnetic therapy devices and in consumer applications with the aim of preventing static electricity generation and preventing radio interference. Is required. However, simply adhering the magnetic powder to the fiber or fiber product easily peels off the magnet powder and cannot withstand long-term use. Therefore, it is desirable that the ferromagnetic powder is uniformly dispersed inside the fiber.

[0003] When producing fibers in which ferromagnetic particles are uniformly dispersed therein, a mixture of ferromagnetic particles and a fiber-forming synthetic resin is melt-spun, or a mixture of ferromagnetic particles and cellulosic fibers is produced. Dry spinning or wet spinning of the mixture with the solution can be considered, but their spinnability, fiber strength and magnetic properties are greatly affected by the type, shape, and magnetic properties of the ferromagnetic particles to be mixed. Receive.

A ferromagnetic alloy powder is usually obtained by mechanically pulverizing an alloy having a predetermined composition. For example, the powder of a rare earth-containing iron alloy (R, Fe, B type: R is a rare earth), which is said to be the most powerful magnet at present, first forms a molten alloy into a film, quenches it, and mechanically cools it. Obtained by grinding. When the film is mechanically pulverized, it is microscopically obtained in the form of flakes, and the size is not constant. When such particles are used, the fluidity during spinning is poor, and the strength of the obtained fiber is significantly reduced. Therefore, a small amount of ferromagnetic alloy powder cannot be added, and a desired magnetic property can be obtained. Can not obtain fibers and fiber products having the characteristic properties.

[0005]

SUMMARY OF THE INVENTION The present invention provides a ferromagnetic material-containing fiber, a ferromagnetic material-containing fiber product, a ferromagnetic fiber product, and a method for producing a ferromagnetic material-containing fiber, which overcomes the above-mentioned problems. The purpose is to:

[0006]

According to the present invention, there is provided a ferromagnetic material-containing fiber comprising a collection of fine particles of a ferromagnetic alloy, wherein the individual fine particles are isolated from each other by a metal oxide layer or interspersed objects or voids. Spherical ferromagnetic alloy particles having an average particle size of 30 μm or less having a nanocomposite structure are uniformly dispersed in fibers.

Further, the ferromagnetic material-containing fiber product according to the present invention is an aggregate of fine particles of a ferromagnetic alloy, and the individual fine particles are isolated from each other by a metal oxide layer or interspersed objects or voids. Average particle size 30 with nanocomposite structure
It is formed using a woven, non-woven or knitted fabric of ferromagnetic material-containing fibers in which spherical ferromagnetic alloy particles having a diameter of μm or less are uniformly dispersed in the fibers.

Further, the ferromagnetic fiber product according to the present invention comprises:
Aggregate of ferromagnetic alloy microparticles with nanocomposite structure in which individual microparticles are isolated from each other by metal oxide layers or interspersed or voids.
The following ferromagnetic alloy particles are magnetized on a ferromagnetic material-containing fiber product formed using a woven, non-woven, or knitted fabric of ferromagnetic material-containing fibers uniformly dispersed in the fibers.

[0009]

First, a spherical ferromagnetic alloy particle having a nanocomposite structure used as a magnetic material in the present invention and a method for producing the same will be described. The spherical ferromagnetic alloy particles having a nanocomposite structure are, as specifically described in Examples and drawings described later, an aggregate of fine particles of a ferromagnetic alloy, and each fine particle is formed of a metal oxide. They are separated from each other by layers or scattered objects or voids. The spherical ferromagnetic alloy particles having such a nanocomposite structure are formed on a dish-shaped disk which rotates a molten ferromagnetic alloy at high speed in a gas atmosphere composed of at least one of argon, oxygen, nitrogen, hydrogen and helium. And scattered as small droplets by the action of centrifugal force, and quenched in a gas atmosphere to self-assemble.

FIG. 1 shows an example of the structure of a centrifugal granulator used for producing spherical ferromagnetic alloy particles having a nanocomposite structure. The granulation chamber 1 has a cylindrical shape at the top and a cone shape at the bottom, and has a lid 2 at the top. A nozzle 3 is inserted vertically into the center of the lid 2, and a dish-shaped rotating disk 4 is provided directly below the nozzle 3. Reference numeral 5 denotes a mechanism for supporting the dish-shaped rotary disk 4 so as to be movable up and down. A discharge pipe 6 for generated particles is connected to a lower end of the cone portion of the granulation chamber 1. The upper part of the nozzle 3 is connected to an electric furnace (high frequency furnace) 7 for melting the ferromagnetic alloy to be granulated. The atmosphere gas adjusted to a predetermined component in the mixed gas tank 8 is supplied to the granulation chamber 1 by the pipes 9 and 10.
It is supplied to the inside and the upper part of the electric furnace 7, respectively. The pressure in the granulation chamber 1 is controlled by a valve 11 and an exhaust device 12, and the pressure in the electric furnace 7 is controlled by a valve 13 and an exhaust device 14. If the internal pressure of the electric furnace 7 is maintained slightly higher than the atmospheric pressure and the internal pressure of the granulation chamber 1 is maintained slightly lower than the atmospheric pressure, the electric furnace 7
The ferromagnetic alloy melted in the above is supplied from the nozzle 3 onto the dish-shaped rotating disk 4 by the differential pressure. The supplied ferromagnetic alloy is scattered as fine droplets by the action of the centrifugal force of the dish-shaped rotating disk 4, and is cooled to solid particles. The generated solid particles are supplied from the discharge pipe 6 to the automatic filter 15 and separated. Reference numeral 16 denotes a particle collection device.

When the high-speed rotating body is a disk or a cone,
Since the centrifugal force applied to the molten ferromagnetic alloy varies greatly depending on the position on the rotating body where the molten ferromagnetic alloy is supplied, it is difficult to obtain spherical powder with uniform grains. When the liquid is supplied onto a high-speed rotating dish-shaped disk, it receives uniform centrifugal force at the peripheral edge of the dish and is dispersed and scattered into small droplets having uniform grains. The scattered droplets are rapidly cooled in the atmosphere gas, fall into solidified small particles, and are collected.

The present inventors have conducted research on powdering a molten ferromagnetic alloy using the above-described apparatus. As a result, the molten ferromagnetic alloy is self-assembled during rapid cooling and solidification, and individual fine particles are formed. Becomes metal particles having a nanocomposite structure separated from each other by layers, interspersed matter, or voids such as metal oxides, metal nitrides or metal hydrides, and the composition of the source metal and the type of atmosphere gas It has been found that individual microparticles are isolated from each other by any of layers such as metal oxides and metal nitrides, interspersed objects, or voids (Japanese Patent Application No. 2000-68490).
issue). The self-assembly means that the molten metal that is a homogeneous phase
During the process of dispersion and rapid cooling and solidification, it automatically forms a nanocomposite structure.

The temperature of the atmosphere gas supplied to the granulation chamber may be room temperature. However, in the case of continuous operation for a long time, the temperature of the granulation chamber is set at 300 to maintain the effect of rapidly cooling the molten metal droplets.
It is desirable to control the air flow rate so as to be lower than or equal to ° C.

A production example of a spherical ferromagnetic alloy particle having a nanocomposite structure used in the present invention will be described. Using the apparatus shown in FIG. 1, in an argon gas atmosphere containing 500 ppm of oxygen, an inner diameter of 35 mm rotating at a high speed,
Rare earth-containing iron alloy (R-
Fe-B; R was a rare earth metal) melt, supplied with a centrifugal force and dispersed as small droplets, and quenched to obtain particles. Table 1 shows the relationship between the rotation speed and the particle size.

[0015]

[Table 1]

The higher the number of revolutions of the dish disk, the smaller the diameter of the obtained particles. Inside diameter 35mm, depth 5m
In the case of using a dish-shaped disk having a diameter of m, it is desirable that the rotation speed is 60,000 rpm or more in order to obtain particles having an average particle diameter of 30 μm or less.

FIG. 2 shows an electron micrograph of the particles (particle diameter 30 μm) obtained in the above Test 7, and FIG. 3 shows an electron micrograph at a higher magnification. According to FIG. 2, it is recognized that the obtained particles are true spheres and have a fine network structure. According to FIG. 3 at a high magnification, the particles shown in FIG. 2 are aggregates of fine particles (nanoparticles), and have a structure in which individual fine particles are isolated from each other. Another test confirmed that the individual fine particles (main phase) were a rare earth-containing iron alloy and the isolation layer (black streak portion) was a rare earth oxide.

The average particle size thus obtained is 30 μm.
The following describes a method for producing a fiber in which spherical ferromagnetic alloy particles having a nanocomposite structure are uniformly dispersed. When a synthetic resin is used as the fiber material, a mixture of a synthetic resin and a spherical ferromagnetic alloy particle having a nanocomposite structure and having an average particle diameter of 30 μm or less is melt-spun.

As the synthetic resin, a polyester resin,
A polyamide resin, a polyolefin resin, a polyvinyl chloride resin, a polyvinylidene chloride resin, a polyacrylonitrile resin, a polyurethane resin, a polyvinyl alcohol resin, or the like can be used.

When a cellulosic fiber is used as the fiber material, the average particle size of the nanocomposite is 3
A mixture of a spherical ferromagnetic alloy particle having a diameter of 0 μm or less and a solution of a cellulosic fiber is dry-spun or wet-spun.

As the cellulosic fiber, rayon, acetate fiber, triacetate fiber or the like can be used.

The ferromagnetic-containing fiber thus obtained may be used alone, but may be blended with other man-made fibers or natural fibers to improve the strength or texture, or to be waterproofed or crimped. Processing is free.

These ferromagnetic material-containing fibers may be processed into a final product form after being formed into a woven fabric, a nonwoven fabric or a knitted fabric (knit), or may be directly formed into knitwear. Depending on the purpose of use, it may be used without being magnetized, or may be magnetized entirely or partially.

The final product form includes, for example, underwear, socks, work clothes, brassieres, filters and the like.

[0025]

According to the present invention, a ferromagnetic substance-containing fiber product or a ferromagnetic fiber product in the form of a soft and fit human body can be obtained.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram of an apparatus for producing spherical ferromagnetic alloy particles having a nanocomposite structure.

FIG. 2 is an electron micrograph of rare earth-containing iron alloy (R—Fe—B; R is a rare earth metal) particle produced using the apparatus of FIG. 1;

FIG. 3 is a higher magnification electron micrograph of rare earth-containing iron alloy particles produced using the apparatus of FIG.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Granulation chamber 2 Cover 3 Nozzle 4 Rotating disk 5 Rotating disk support mechanism 6 Particle discharge pipe 7 Electric furnace 8 Mixed gas tank 9 Piping 10 Piping 11 Valve 12 Exhaust device 13 Valve 14 Exhaust device 15 Automatic filter 16 Particle recovery device

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) D04B 1/14 D04B 1/14 4L048 21/00 21/00 B 5E040 H01F 1/00 H01F 1/00 ZF Terms (reference) 3B029 HA00 HA01 HB00 HB06 4D019 BA17 BB02 BB03 BC02 4G004 CA06 4L002 AA00 AC00 DA03 EA00 FA02 FA03 FA05 FA06 4L035 EE12 JJ04 KK10 4L048 AA13 AA42 AA46 AA56 AC00 CA00 DA01 DA40 AEB EB01

Claims (10)

[Claims] 1. A sphere having an average particle size of 30 μm or less having a nanocomposite structure in which individual microparticles are aggregates of microparticles of a ferromagnetic alloy and are separated from each other by metal oxide layers or interspersed objects or voids. A ferromagnetic material-containing fiber, wherein ferromagnetic alloy particles are uniformly dispersed in the fiber. 2. A sphere having an average particle size of 30 μm or less having a nanocomposite structure in which individual microparticles are aggregates of microparticles of a ferromagnetic alloy and are separated from each other by metal oxide layers or interspersed objects or voids. The ferromagnetic alloy particles have at least one of argon, oxygen, nitrogen, hydrogen and helium.
In a gas atmosphere consisting of different types, a molten ferromagnetic alloy is supplied onto a disk that rotates at high speed, and is spun as small droplets by the action of centrifugal force. The ferromagnetic material-containing fiber according to claim 1, which is obtained. 3. The ferromagnetic material-containing fiber according to claim 1, wherein the ferromagnetic alloy is a rare earth / iron / boron alloy. 4. A sphere having an average particle size of 30 μm or less having a nanocomposite structure in which individual microparticles are aggregates of microparticles of a ferromagnetic alloy and are separated from each other by metal oxide layers or interspersed objects or voids. A ferromagnetic material-containing fiber product, which is formed using a woven, nonwoven or knitted fabric of ferromagnetic material-containing fibers in which ferromagnetic alloy particles are uniformly dispersed in the fibers. 5. A sphere having an average particle size of 30 μm or less having a nano-composite structure in which individual fine particles are aggregates of fine particles of a ferromagnetic alloy and are separated from each other by metal oxide layers or interspersed objects or voids. It is characterized in that the ferromagnetic alloy particles are magnetized on a ferromagnetic material-containing fiber product formed using a woven, nonwoven or knitted fabric of ferromagnetic material-containing fibers uniformly dispersed in the fiber. Ferromagnetic fiber products. 6. The ferromagnetic fiber product is one of an undergarment, a sock, a workwear, a bra, and a filter.
The ferromagnetic fiber product according to the above. 7. A sphere having an average particle size of 30 μm or less having a nanocomposite structure in which individual microparticles are aggregates of microparticles of a ferromagnetic alloy and are separated from each other by metal oxide layers or interspersed objects or voids. A method for producing a ferromagnetic material-containing fiber, comprising melt-spinning a mixture of ferromagnetic alloy particles and a synthetic resin. 8. The synthetic resin is a polyester resin, a polyamide resin, a polyolefin resin, a polyvinyl chloride resin, a polyvinylidene chloride resin, a polyacrylonitrile resin, a polyurethane resin, or a polyvinyl alcohol resin. Item 7. A method for producing a ferromagnetic material-containing fiber according to Item 7. 9. A sphere having an average particle size of 30 μm or less having a nanocomposite structure in which individual microparticles are aggregates of microparticles of a ferromagnetic alloy and are separated from each other by metal oxide layers or interspersed objects or voids. A method for producing a ferromagnetic material-containing fiber, wherein a mixture of a ferromagnetic alloy particle and a solution of a cellulosic fiber is dry-spun or wet-spun. 10. The method according to claim 9, wherein the cellulosic fiber is rayon, acetate fiber, or triacetate fiber.