CN104766684A - Magnetically soft alloy powder composition - Google Patents
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- CN104766684A CN104766684A CN201410007599.1A CN201410007599A CN104766684A CN 104766684 A CN104766684 A CN 104766684A CN 201410007599 A CN201410007599 A CN 201410007599A CN 104766684 A CN104766684 A CN 104766684A
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Abstract
The invention provides a magnetically soft alloy powder composition. The magnetically soft alloy powder composition comprise amorphous magnetically soft alloy powder A and crystallized magnetically soft alloy powder B; inorganic substance film layers are arranged on the surfaces of the amorphous magnetically soft alloy powder A and the crystallized magnetically soft alloy powder B; the powder B has the advantage particle size D50 the same as or less than the powder A, and is small in hardness; the content of the powder B is 1.0 to 20wt% by weight of the content of the powder A.
Description
Technical field
The present invention relates to magnetic alloy material association area, particularly a kind of soft-magnetic alloy powder constituent.
Background technology
Along with the development of modern integrated circuits, chip, various electronic component technology and wireless Internet, the intelligent main trend having become information-intensive society at present; Various DC load is widely used in various electronic equipment, such as smart mobile phone, automotive electronics, intelligent television, panel computer, notebook computer, LED television, various communicating terminal and server, intelligent appliance etc. due to reasons such as its higher energy conversion efficiency, less volume and higher stability.
The appearance of various smart machine, has driven the technological progress of associated electronic components.Wherein, magnetic element obtains and generally applies as the buck of various intelligent electronic device, filter inductance, such as alloy magnetic powder core and integrated inductance etc.
Integrated inductance is also called " integrated inductor ", its technical characteristics is copper coil to be placed in magnetic alloy powder inside, and it is simultaneously shaping with magnetic alloy powder on forming machine, therefore loaded down with trivial details coiling program can be saved, and obtain good EMI(electromagnetic interference) characteristic, the simultaneously convenient attachment of automation on the integrated.Total, integrated inductance a kind ofly has short route, high-performance, modern electronics that automaticity is high, is the indispensable important electronic component of modern DC load equipment (especially intelligent electronic device).
Usually, the material of integrated inductance is made up of soft-magnetic alloy powder and copper cash.Soft-magnetic alloy powder is carbonyl iron dust, FeCrSi alloy powder, FeSi alloy powder, atomized iron powder etc. normally, and above alloy powder has good soft magnetic characteristic.
For amorphous soft magnetic alloy powder, its special crystal structure causes it plastic deformation cannot occur at normal temperatures, therefore cannot form the high inductance of density and sufficiently high intensity.In order to improve intensity and the density of amorphous soft magnetic alloy inductance, usually needing higher briquetting pressure, in pressing process, therefore very easily making coil breakage and gross distortion, thus cause inductance short circuit in use.
Summary of the invention
An object of the present invention; be to provide a kind of soft-magnetic alloy powder constituent; by the protective layer of the soft crystalline state soft-magnetic alloy powder of amorphous soft magnetic alloy Powder Blending as copper coil; and change the state of amorphous soft magnetic alloy powder surface; both improve the density of amorphous soft magnetic alloy inductance; the damage of copper coil can be avoided again, thus obtain a kind of low cost, high efficiency, high performance integrated inductance element.
In order to reach above-mentioned object, the present invention is a kind of soft-magnetic alloy powder constituent, comprise amorphous soft magnetic alloy powders A and crystalline state soft-magnetic alloy powder B, the surface of amorphous soft magnetic alloy powders A and crystalline state soft-magnetic alloy powder B all has an inorganic matter thin layer, and powder B has the average grain diameter D identical or less than powders A
50lower hardness, wherein the content of powder B is the 1.0-20.0wt% of powders A.
Furthermore, A powder has Vickers hardness: 800-1300, B powder has Vickers hardness: 200-600.
Furthermore, the Vickers hardness of powders A and powder B differs by more than 400.
Furthermore, the particle diameter of powders A is between 1-300 micron.
Furthermore, the chemical composition of amorphous soft magnetic alloy powders A can be iron-based, Ni-based, cobalt base amorphous state magnetically soft alloy.
Furthermore, the surface of powders A and powder B all has a phosphorus borate thin layer.
Furthermore, the shape of powders A is spherical, oval, strip or polyhedron.
Furthermore, powder B is permalloy powder, iron powder, Fe
85-92(SiCr)
8-15one or more mixture of series alloy powder.
Furthermore, powder B is flat, and long or wide: be highly greater than 2:1.
In addition, the invention provides a kind of magnetic core, the binding agent that this magnetic core comprises above-mentioned soft-magnetic alloy powder constituent and makes an addition to wherein, the content of binding agent is 1-4wt%.Again, the invention provides a kind of inductance element, this inductance element formed in above-mentioned magnetic core by the coil applying to have at least one circle.
Compared to prior art; soft-magnetic alloy powder constituent of the present invention; by the protective layer of the soft crystalline state soft-magnetic alloy powder of amorphous soft magnetic alloy Powder Blending as copper coil; and change the state of amorphous soft magnetic alloy powder surface; both improve the density of amorphous soft magnetic alloy inductance, the damage of copper coil can have been avoided again.
Describe the present invention below in conjunction with the drawings and specific embodiments, but not as a limitation of the invention.
Accompanying drawing explanation
The stereoscopic figure of Fig. 1 one embodiment of the invention integrated inductance element;
The cross-sectional schematic of Fig. 2 one embodiment of the invention integrated inductance element;
The striograph of Fig. 3 one embodiment of the invention amorphous soft magnetic alloy powder;
Fig. 4 is the partial enlarged drawing of Fig. 3;
The manufacturing flow chart of Fig. 5 one embodiment of the invention soft-magnetic alloy powder constituent and integrated inductance element.
Embodiment
Coordinate embodiment by accompanying drawing below, describe technology contents of the present invention in detail.
Please refer to Fig. 1 and Fig. 2, the stereoscopic figure of Fig. 1 one embodiment of the invention integrated inductance element.Fig. 2 is the cross-sectional schematic of Fig. 1.In the present embodiment, inductance element 1 comprises: cell body 10, magnetic core 12, coil 14 and magnetic block 16.Magnetic core 12 is positioned at the middle position of cell body 10, coil 14 has a winder 141 and electrode pin 142, and winder 141 is overlapped as magnetic core 12 is positioned at cell body 10, and winder 141 is fixed in compressing magnetic block 16.Magnetic block 16 is that soft-magnetic alloy powder constituent of the present invention suppresses formation by compressing mode.
The striograph of Fig. 3 system one embodiment of the invention amorphous soft magnetic alloy powder.Fig. 4 is the partial enlarged drawing of Fig. 3.Amorphous soft magnetic alloy powder can be the amorphous soft magnetic alloy powder of any alloying component, and the average grain diameter of amorphous soft magnetic alloy powder is between 1-300 micron, and shape is spherical in shape, oval, strip or polyhedron substantially.The chemical composition of amorphous soft magnetic alloy powder can be iron-based, Ni-based, cobalt base amorphous state magnetically soft alloy.
The present invention has carried out being conducive to protection coil and carrying highdensity Composition Design on inductive material.First, the present invention is to the modifying surface of amorphous soft magnetic alloy powder, the object of modification is that its Surface Creation one deck has the surface film that hardness is lower, good with binding agent wettability, have certain cohesive force, and the main component of this film is phosphate and boratory compound.
Concrete grammar adopts phosphoric acid and boric acid as surface modifier, the preferential and parent metal atomic reaction of phosphate, and form phosphate, phosphate borate complex, borate film from inside to outside.This film has good insulation characterisitic, certain cohesive force and lower hardness.Surface modifier of the present invention is the mixture of phosphoric acid and boric acid, and total surface modification agent content is between the 0.0001-0.005 of amorphous soft magnetic alloy powder weight, its mesoboric acid: phosphoric acid=1:99-1:1.
The preparation process of surface modifier is as follows: phosphoric acid used herein is pure phosphoric acid, and boric acid is boric acid powder; First diluted by phosphoric acid according to a certain percentage, then boric acid also heats melting for clear solution, and diluent can be ethanol or water, and the blend of ethanol and water, and the percentage by weight of diluent is more than 2 times of surface modifier.In like manner, crystalline state soft-magnetic alloy powder also can use phosphoric acid and boric acid to carry out surface treatment as surface modifier.The surface of amorphous soft magnetic alloy powder and crystalline state soft-magnetic alloy powder all has a phosphorus borate thin layer.
In addition, in order to improve the shaping density of amorphous soft magnetic alloy powder, improvement of the present invention is to add some flat, crystalline state soft-magnetic alloy powder that hardness is low, makes it to form mixture with amorphous soft magnetic alloy powder.In shaping pressing process, first there is plastic deformation to alleviate concentrating of pressing pressure in these soft crystalline state soft-magnetic alloy powders, and the final stress direction changing this regional area, thus protection copper cash avoids being subject to breakage and locally serious distortion.
Soft crystalline state soft-magnetic alloy powder can be permalloy powder, iron powder, FeSiCr series alloy powder etc., this powder shape is flat, and long or wide: thickness G reatT.GreaT.GT2:1, long and be widely of a size of 1.0 times of amorphous soft magnetic alloy powder average particle size (D50) and following, the content of this crystalline state soft-magnetic alloy powder is the 1-20wt% of amorphous soft magnetic alloy powder.Amorphous soft magnetic alloy powder has Vickers hardness: 800-1300, and crystalline state soft-magnetic alloy powder has Vickers hardness: 200-600.Preferably, the Vickers hardness of amorphous soft magnetic alloy powder and crystalline state soft-magnetic alloy powder differs by more than 400.
In addition, the present invention adopts the silicone sealants of organic binder bond modification as the shaping binding agent of inductance, and this binding agent has following characteristics: (a) and amorphous soft magnet powder have less infiltration angle; B normal temperature inductance intensity that () is higher; C resistivity that () is higher; D () be ageing-resistant performance well.
Specifically, binding agent of the present invention is configured to: epoxy resin: organic siliconresin=1:1-1:20(weight ratio), binding agent: alloy powder=1:30-1:100(weight ratio).
Then, please refer to Fig. 5, the manufacturing flow chart of Fig. 5 one embodiment of the invention soft-magnetic alloy powder constituent and integrated inductance element.The manufacturing process of soft-magnetic alloy powder constituent of the present invention and integrated inductance element is described as follows:
(1) surface treatment (step S100) of amorphous soft magnetic alloy powder:
Concrete grammar adopts phosphoric acid and boric acid as surface modifier, the preferential and parent metal atomic reaction of phosphate, and form phosphate, phosphate borate complex, borate film from inside to outside.Surface modifier of the present invention is the mixture of phosphoric acid and boric acid, and total surface modification agent content is between the 0.0001-0.005 of amorphous soft magnetic alloy powder weight, its mesoboric acid: phosphoric acid=1:99-1:1.The preparation process of surface modifier is as follows: this place uses phosphoric acid to be pure phosphoric acid, and boric acid is boric acid powder; First diluted by phosphoric acid according to a certain percentage, then boric acid also heats melting for clear solution, and diluent can be ethanol or water, and the blend of ethanol and water, and the percentage by weight of diluent is more than 2 times of surface modifier.
After surface conditioning agent configures, little by little this liquid is sprayed into respectively amorphous soft magnetic alloy powder and soft crystalline state soft-magnetic alloy powder, and continuous stirring makes diluent volatilize completely under the condition of negative pressure, heating can be selected if desired, heating-up temperature is between 40-80 DEG C, makes it final and forms the dried powder with mobility.In like manner, crystalline state soft-magnetic alloy powder also can use phosphoric acid and boric acid to carry out surface treatment as surface modifier.
The mixing (step S102) of (2) two kinds of soft-magnetic alloy powders:
Two kinds of soft-magnetic alloy powders are the crystalline state soft-magnetic alloy powder that amorphous soft magnetic alloy powder that hardness is higher and hardness are lower respectively.Amorphous soft magnetic alloy powder can be the amorphous soft magnetic alloy powder of any alloying component, and the average grain diameter of amorphous soft magnetic alloy powder is between 1-300 micron, and shape is spherical in shape, oval, strip or polyhedron substantially.Crystalline state soft-magnetic alloy powder can be one or more mixture of permalloy powder, iron powder, FeSiCr series alloy powder, the shape of crystalline state soft-magnetic alloy powder is flat, and long or wide in its size: thickness G reatT.GreaT.GT=2:1, the long and wide average grain diameter (D being of a size of amorphous soft magnetic alloy powder
50) 1.0 times and following, the content of soft crystalline state alloy powder is the 1.0-20.0wt% of amorphous soft magnetic alloy powder.
The crystalline state soft-magnetic alloy powder of surface treated flattening is progressively poured in surface treated amorphous soft magnetic alloy powder, constantly stir until mix.
(3) granulation (step S104) of soft-magnetic alloy powder is mixed:
Weigh the binding agent of 1.0-3.0% weight, and be dissolved as transparent solution with this weight of binder 2-5 diluent doubly; Then, this solution is progressively poured in the soft-magnetic alloy powder mixed and also constantly stir, until liquid fully contacts with powder; Again this powder is carried out granulation process on comminutor, obtain granularity sprills of reuniting equably, in drying box, dry the powder for having mobility subsequently.
(4) the shaping compacting (step S106) of integrated inductance
Forming processes is carried out in forming machine and corresponding mould.The manufacture method of the present embodiment inductance element lies in cell body inserts magnetic, utilize compressing mode by compressing for those magnetics be a center pillar magnetic core, then, a coil is installed in cell body, coil central hollow position is made to be placed on center pillar magnetic core, afterwards, then in cell body, insert above-mentioned magnetic, then, by compressing mode, coil is fixed in compressing magnetic block, and make two termination pin of coil, to be convexly exposed to outside cell body, so that assemble on circuit board.
(5) annealing of integrated inductance
The integrated inductance suppressed is put into drying box and carries out annealing in process, treatment temperature is between 100-220 DEG C, and temperature retention time is between 0.5-5 hour.
(6) subsequent treatment of integrated inductance
Integrated inductance after baking is carried out cutting, the subsequent job such as electrode moulding.
(embodiment)
(embodiment 1)
The present embodiment adopts composition to be Fe
76(SiB)
24amorphous soft magnetic alloy powder as main material, its average grain diameter (D
50) be 15 microns, shape is spherical and strip substantially, and surperficial Vickers (HV) hardness is 820; Adopt Fe
17ni
81mo
2flattening alloy powder is as the soft crystalline state soft-magnetic alloy powder added, and Vickers hardness is 400, length: between thickness=3:1-10:1, the average grain diameter (D of in-plane
50) be 12 microns; Both mixed weight ratios are amorphous soft magnetic alloy powder: Fe
17ni
81mo
2flattening alloy powder=100:10.
Surface conditioning agent selects phosphoric acid and the mebor of 0.001, and the weight ratio of phosphoric acid and boric acid is 100:20, and alcohol selected by diluent, and the weight of alcohol is 3% of alloy powder.
Binding agent selects epoxy resin and silicones part by weight to be the mixed glue solution of 20:100, and total weight of binder is 3% of alloy powder, and diluent adopts acetone, and the weight of acetone is 8% of alloy powder.
Suppress and the performance data of integrated inductance after annealing as following table 1:
Table 1
| Material composition | Overall dimension | Inductance value (uH) | Saturation current | Light-load efficiency |
| Fe 76（SiB） 24 | 6.6*7.0*3.0 | 3.3 | 12.0 | 98.9% |
| Fe 92Si 4.5Cr 3.5 | 6.6*7.0*3.0 | 3.3 | 10 | 98.2% |
(embodiment 2)
The present embodiment adopts composition to be Fe
74cr
2(SiB)
22c
2amorphous soft magnetic alloy powder as main material, its average grain diameter (D
50) be 15 microns, shape is spherical and strip substantially, and surperficial HV hardness is 820; Adopt Fe
17ni
81mo
2flattening soft-magnetic alloy powder is as the soft crystalline state soft-magnetic alloy powder added, and HV hardness is 400, length: between thickness=3:1-10:1, the average grain diameter (D of in-plane
50) be 12 microns; Both mixed weight ratios are amorphous alloy powder: Fe
17ni
81mo
2flattening alloy powder=100:10.
Surface conditioning agent selects phosphoric acid and the mebor of 0.001, and the weight ratio of phosphoric acid and boric acid is 100:20, and alcohol selected by diluent, and the weight of alcohol is 3% of alloy powder.
Binding agent selects epoxy resin and silicones part by weight to be the mixed glue solution of 20:100, and total weight of binder is 3% of alloy powder, and diluent adopts acetone, and the weight of acetone is 8% of alloy powder.
Suppress and the performance data of integrated inductance after annealing as following table 2:
Table 2
| Material composition | Overall dimension | Inductance value (uH) | Saturation current | Light-load efficiency |
| Fe 74Cr 2（SiB） 22C 2 | 6.6*7.0*3.0 | 3.3 | 11.2 | 99.1% |
| Fe 92Si 4.5Cr 3.5 | 6.6*7.0*3.0 | 3.3 | 10.0 | 98.2% |
Certainly; the present invention also can have other various embodiments; when not deviating from the present invention's spirit and essence thereof; those of ordinary skill in the art are when making various corresponding change and distortion according to the present invention, but these change accordingly and are out of shape the protection range that all should belong to the claim appended by the present invention.
Claims (11)
1. a soft-magnetic alloy powder constituent, it is characterized in that, comprise an amorphous soft magnetic alloy powders A and a crystalline state soft-magnetic alloy powder B, the surface of this amorphous soft magnetic alloy powders A and this crystalline state soft-magnetic alloy powder B all has an inorganic matter thin layer, and this powder B has the average grain diameter D identical or less than this powders A
50lower hardness, wherein the content of this powder B is the 1.0-20.0wt% of this powders A.
2. soft-magnetic alloy powder constituent according to claim 1, is characterized in that, the average grain diameter of this powders A is between 1-300 micron.
3. soft-magnetic alloy powder constituent according to claim 1, is characterized in that, the surface of this powders A and this powder B all has a phosphorus borate thin layer.
4. soft-magnetic alloy powder constituent according to claim 1, is characterized in that, the shape of this powders A is spherical, oval, strip or polyhedron.
5. soft-magnetic alloy powder constituent according to claim 1, is characterized in that, this powder B is permalloy powder, iron powder, Fe
85-92(SiCr)
8-15one or more mixture of series alloy powder.
6. soft-magnetic alloy powder constituent according to claim 1, is characterized in that, this powder B is flat, and long or wide: be highly greater than 2:1.
7. soft-magnetic alloy powder constituent according to claim 1, is characterized in that, the chemical composition of this amorphous soft magnetic alloy powders A is iron-based, Ni-based, cobalt base amorphous state magnetically soft alloy.
8. soft-magnetic alloy powder constituent according to claim 1, is characterized in that, this A powder has Vickers hardness: 800-1300, and this B powder has Vickers hardness: 200-600.
9. soft-magnetic alloy powder constituent according to claim 1, is characterized in that, the Vickers hardness of this powders A and this powder B differs by more than 400.
10. a magnetic core, is characterized in that, the binding agent comprising soft-magnetic alloy powder constituent according to claim 1 and make an addition to wherein, and the content of binding agent is the 1-4wt% of this powders A and B total amount.
11. 1 kinds of inductance elements, formed in magnetic core according to claim 10 by the coil applying to have at least one circle.
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| CN107134346A (en) * | 2016-02-26 | 2017-09-05 | 阿尔卑斯电气株式会社 | Inductance element |
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| JP2017108098A (en) * | 2015-11-26 | 2017-06-15 | アルプス電気株式会社 | Dust core, method of producing dust core, inductor including dust core, and electronic/electrical apparatus mounting inductor |
| CN107093514A (en) * | 2015-11-26 | 2017-08-25 | 阿尔卑斯电气株式会社 | Compressed-core, the manufacture method of compressed-core, the inductor for possessing compressed-core and the electronics electrical equipments for being equipped with inductor |
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| CN107134346B (en) * | 2016-02-26 | 2019-03-22 | 阿尔卑斯电气株式会社 | Inductance element |
| US10283266B2 (en) | 2016-04-25 | 2019-05-07 | Alps Alpine Co., Ltd. | Powder core, manufacturing method of powder core, inductor including powder core, and electronic/electric device having inductor mounted therein |
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| US11842833B2 (en) | 2017-04-19 | 2023-12-12 | Murata Manufacturing Co., Ltd. | Coil component |
| CN108962530A (en) * | 2017-05-17 | 2018-12-07 | 松下知识产权经营株式会社 | Compressed-core and mixing soft magnetic powder |
| CN109950016A (en) * | 2019-04-18 | 2019-06-28 | 中南大学 | A method of improving hard brittleness Fe base powder core magnetic property |
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