CN105304259B - Compressed-core and its manufacture method, electronic and electric components and electronic electric equipment - Google Patents
Compressed-core and its manufacture method, electronic and electric components and electronic electric equipment Download PDFInfo
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- CN105304259B CN105304259B CN201510303573.6A CN201510303573A CN105304259B CN 105304259 B CN105304259 B CN 105304259B CN 201510303573 A CN201510303573 A CN 201510303573A CN 105304259 B CN105304259 B CN 105304259B
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Abstract
A kind of compressed-core containing crystalline magnetic material powder and noncrystalline magnetic material powder and its manufacture method, electronic and electric components and electronic electric equipment are provided, also there is excellent magnetic characteristic even in the high frequency region of more than 1MHz.Compressed-core contains crystalline magnetic material powder and noncrystalline magnetic material powder, is using 2 constant khAnd keRepresented by following formula (1) in effective peakflux density BmFor the iron loss Pcv (units measured under conditions of 15mT：kW/m3) frequency f (units：KHz) during dependence, Pcv=k is meth×f×Bm 1.6+ke×f2×Bm 2(1) constant khFor 1.5 × 10- 3kW/m3/kHz/(mT)1.6Hereinafter, and another constant keFor 3.0 × 10- 7kW/m3/(kHz)2/(mT)2Below.
Description
Technical field
The present invention relates to compressed-core, the compressed-core manufacture method, possess the compressed-core electronic and electric components,
And the electronic electric equipment of the electronic and electric components is installed.
Background technology
Reactor (reactor) used in the booster circuit of hybrid vehicle etc., power generation/transformer equipment, transformer,
Compressed-core used in choking-winding etc., can be by carrying out press-powder shaping, and to resulting to many soft magnetic powders
Formed body be heat-treated and compressed-core.In following an examples Patent Document 1 discloses compressed-core.
In addition, Patent Document 1 discloses a kind of inductor, it is high as core intensity compared with the past and insulation resistance and
Core loses few inductor, which possesses following magnetic core (compressed-core), it contains the amorphous by 90~98mass%
The mixed-powder and insulating material that the match ratio of the crystalline soft magnetic powder of matter soft magnetic powder and 2~10mass% is formed
Mixture cure the material that forms.
Citation
Patent document
Patent document 1：Japanese Unexamined Patent Publication 2010-118486 publications
The content of the invention
In recent years, it is desirable to use the high frequency of the electronic and electric components such as the inductor of compressed-core reply working frequency.So
And in patent document 1, evaluation has used the excitation condition during core loss of the toroidal core of magnetic core (compressed-core) to stop at
300kHz, in the high frequency region of more than 1MHz, makees containing the material of crystalline soft magnetic powder and noncrystalline soft magnetic powder
Whether the material for magnetic core (compressed-core) is suitable, is still not clear.
It is an object of the invention to provide a kind of compressed-core, it is containing crystalline magnetic material powder and noncrystalline magnetic
The compressed-core of property material powder, also has excellent magnetic characteristic in the high frequency region of more than 1MHz.The problem of the present invention is also
It is the manufacture method of the compressed-core is provided, possess the electronic and electric components of the compressed-core and the electric portion is installed
The electronic electric equipment of part.
In order to solve the above problems, the result of the present inventor's research obtains following neodoxy：By making institute in equation below
The scope of 2 constants is prescribed limit, and the high frequency region that thus can provide more than MHz also possesses the pressure of excellent magnetic property
Powder magnetic core, above-mentioned formula are expression in effective peakflux density BmBy the iron loss Pcv (units measured under conditions of 15mT：
kW/m3) frequency f (units：KHz) the formula of dependence.
The invention completed based on the opinion is as follows.
The scheme of the present invention is compressed-core, containing crystalline magnetic material powder and noncrystalline magnetic material powder,
Using 2 constant khAnd keRepresented by following formula (1) in effective peakflux density BmFor what is measured under conditions of 15mT
Iron loss Pcv (units：kW/m3) frequency f (units：khZ) during dependence, meet
Pcv=kh×f×Bm 1.6+ke×f2×Bm 2 (1)
The constant khFor 1.5 × 10- 3kW/m3/kHz/(mT)1.6Hereinafter, and the constant keFor 3.0 × 10- 7kW/m3/
(kHz)2/(mT)2Below.
By making constant kh、keWithin the above range, so that the iron loss Pcv of compressed-core is with the rising of frequency f
And the degree risen is slow.Therefore, even the high frequency of more than 1MHz, the iron loss Pcv of compressed-core is also difficult to become higher.
Preferably, the content of the crystalline magnetic material powder relative to the crystalline magnetic material powder content
Quality ratio with the sum of the content of the noncrystalline magnetic material powder is more than 5 mass % and below 40 mass %.Pass through
Make the quality ratio within the above range, the raising of the insulation resistance thus, it is possible to more stably realize compressed-core, low-frequency band
The reduction of the iron loss Pcv in region.
Another program of the present invention is compressed-core, contains crystalline magnetic material powder and noncrystalline magnetic material powder
End, the content and the noncrystalline of the content of the crystalline magnetic material powder relative to the crystalline magnetic material powder
The quality ratio of the sum of the content of magnetic material powder is more than 5 mass % and below 40 mass %.By making the quality ratio
Within the above range, thus, it is possible to the reduction for the iron loss Pcv for stably realizing compressed-core.
The crystalline magnetic material can be included selected from Fe-Si-Cr classes alloy, Fe-Ni classes alloy, Fe-Co classes
1 in alloy, Fe-V classes alloy, Fe-Al classes alloy, Fe-Si classes alloy, Fe-Si-Al classes alloy, carbonyl iron and pure iron
Kind or material of more than two kinds.
Preferably described crystalline magnetic material is formed by carbonyl iron.
The noncrystalline magnetic material can include being selected from Fe-Si-B classes alloy, Fe-P-C classes alloy and Co-
One kind or two or more material in Fe-Si-B class alloys.
Preferably described noncrystalline magnetic material is formed by Fe-P-C class alloys.
Preferably described crystalline magnetic material powder is formed by the material for implementing insulation processing.By in above-mentioned model
In enclosing, the raising of the insulation resistance thus, it is possible to more stably realize compressed-core, the reduction of the iron loss Pcv of low frequency region.
Median particle diameter D50 there are the noncrystalline magnetic material powder is less than 6 μm more preferable situations.By this
Median particle diameter D50 is less than 6 μm, thus constant k sometimeseIt is easily reduced.There are the intermediate value of the noncrystalline magnetic material powder
Particle diameter D50 is less than 5 μm more preferable situations.It it is less than 5 μm by median particle diameter D50, sometimes in high frequency region
Iron loss Pcv is easily reduced or DC superposition characteristic becomes easily to improve.
The compressed-core can contain bonding component, and the bonding component makes the crystalline magnetic material powder and institute
Noncrystalline magnetic material powder is stated to bond with other materials contained in the compressed-core.
The bonding component preferably contains the component based on resin material.
The invention adopt another scheme that the manufacture method of above-mentioned compressed-core, including shaped by shaping processing
The forming process of thing is manufactured, the shaping processing includes the press molding of mixture, and the mixture contains the crystalline magnetic
Property material powder and the noncrystalline magnetic material powder and the adhesive ingredients formed by the resin material.Pass through this
The manufacture method of sample, it can be achieved that higher efficiency manufacture above-mentioned compressed-core.
And the figuration manufacture thing obtained can be the press-powder magnetic by the forming process in above-mentioned manufacture method
Core.Alternatively, above-mentioned manufacture method can include heat treatment step, it passes through described into shape to being obtained through the forming process
The heat treatment that the divine force that created the universe is heated, obtains the compressed-core.
The yet another aspect of the present invention is a kind of electronic and electric components, including above-mentioned compressed-core, coil and with the line
The connection terminal of each end connection of circle, at least a portion of the compressed-core are configured in via the connection
In the induced field that terminal is produced by the electric current when flowing through electric current to the coil.It is inductance element in the electronic and electric components
When, based on the excellent specific property of above-mentioned compressed-core, high frequency and excellent DC superposition characteristic and low loss can be realized at the same time.
The yet another aspect of the present invention is a kind of electronic electric equipment, it is characterised in that is provided with above-mentioned electric portion
Part, the electronic and electric components are connected to substrate via the connection terminal.As the electronic electric equipment, illustration has and has
The supply unit of power switch circuit, voltage up-down circuit, smooth circuit etc., miniature portable communication equipment etc..The present invention relates to
Electronic electric equipment due to above-mentioned electronic and electric components, easily reply miniaturization, high speed.
The compressed-core that above-mentioned invention is related to, the high frequency region magnetic characteristic even in more than 1MHz are also excellent.In addition,
According to the present invention, it is possible to provide the manufacture method of above-mentioned compressed-core, the electronic and electric components for possessing above-mentioned compressed-core and installation
There is the electronic electric equipment of the electronic and electric components.
Brief description of the drawings
Fig. 1 is the stereogram for the shape for schematically showing the compressed-core that one embodiment of the present invention is related to.
Fig. 2 is the spray-drying installation and its work used in an example for the method for being schematically illustrated in manufacture pelletizing
Figure.
Fig. 3 is to schematically show the electronic and electric components i.e. ring for possessing the compressed-core that one embodiment of the present invention is related to
The stereogram of the shape of shape magnetic core.
Fig. 4 is the electricity that the compressed-core that the embodiment for possessing this invention Do is related to is represented in a manner of partial perspective
The stereogram being monolithically fabricated of sub- electric component, that is, inductance element.
Fig. 5 is the partial front elevation view of state for representing to be installed on the inductance element shown in Fig. 4 on installation base plate.
Fig. 6 is the curve map of the measurement result for the frequency dependence for representing the iron loss Pcv in embodiment.
Fig. 7 is to represent constant khRelative to the curve map of the dependence of the first blending ratio.
Fig. 8 is to represent constant keRelative to the curve map of the dependence of the first blending ratio.
Fig. 9 is curve of iron loss change rate when representing 100kHz and 2MHz relative to the dependence of the first blending ratio
Figure.
Figure 10 is to represent curve map of based on the table 2 and 4, insulation resistance relative to the dependence of the first blending ratio.
Figure 11 is to represent curve maps of iron loss Pcv when frequency is 100kHz relative to the dependence of the first blending ratio.
Figure 12 is to represent curve maps of iron loss Pcv when frequency is 1MHz relative to the dependence of the first blending ratio.
Figure 13 is to represent curve maps of iron loss Pcv when frequency is 2MHz relative to the dependence of the first blending ratio.
Figure 14 is to represent curve maps of iron loss Pcv when frequency is 3MHz relative to the dependence of the first blending ratio.
Figure 15 be represent inductance L variation delta L apply relative to superimposed current before (initial stage) inductance L value L0Ratio
Example (Δ L/L0) dependence application current value (Isat), relative to the first blending ratio when reaching 30% curve map.
The explanation of reference numeral
1 ... compressed-core (toroidal core)
10 ... loop coils
2 ... coated conductor wires
2a ... coils
2b, 2c ... are coated to the end of conductor wire 2
The end of 2d, 2e ... coil 2a
20 ... inductance elements
3 ... compressed-cores
The mounting surface of 3a ... compressed-cores 3
The side of 3b, 3c ... compressed-core 3
4 ... portion of terminal
5 ... hollow coils
The wound portion of 5a ... hollow coils 5
The extraction end of 5b ... hollow coils 5
30 ... accommodate recess
40 ... connection ends
The 1st zigzag parts of 42a ...
The 2nd zigzag parts of 42b ...
100 ... installation base plates
110 ... welding disks
120 ... brazing layers
200 ... spray-drying installations
201 ... rotors
S ... slurries
P ... pelletizings
Embodiment
Hereinafter, the embodiment that the present invention will be described in detail.
1. compressed-core
The compressed-core 1 that one embodiment of the present invention shown in Fig. 1 is related to, its appearance are ring-type, contain crystalline magnetic
Property material powder and noncrystalline magnetic material powder.Compressed-core 1 of the present embodiment is by including following shaping
The manufacture method of processing and manufacture, the shaping processing includes the press molding of the mixture containing these powder.As not
An example of restriction, compressed-core 1 of the present embodiment, which contains, makes crystalline magnetic material powder and noncrystalline magnetic material
(there is same material, there is also the situation of different kinds material with the other materials contained by compressed-core 1 in powder.) viscous
The bonding component of knot.Hereinafter, these components are illustrated.
(1) crystalline magnetic material powder
What one embodiment of the present invention was related to assigns the crystallization of the crystalline magnetic material powder contained by compressed-core 1
Matter magnetic material, as long as meeting (to obtain with being capable of certain material species by common X-ray diffraction measure for crystalline
Degree clear peak value diffracting spectrum) and be ferromagnetic, specific species does not limit.As crystalline magnetism material
The concrete example of material, can enumerate Fe-Si-Cr classes alloy, Fe-Ni classes alloy, Fe-Co classes alloy, Fe-V classes alloy, Fe-
Al classes alloy, Fe-Si classes alloy, Fe-Si-Al classes alloy, carbonyl iron and pure iron.Above-mentioned crystalline magnetic material can be with
It is made of, can also be made of multiple material a kind of material.The crystalline magnetic material for assigning crystalline magnetic material powder is preferred
It is the one kind or two or more material selected from above-mentioned material, wherein preferably containing carbonyl iron, is more preferably formed by carbonyl iron.
The shape for the crystalline magnetic material powder that the compressed-core 1 that one embodiment of the present invention is related to contains is unrestricted
It is fixed.The shape of powder can be spherical or non-spherical.Can be scale in the case that the shape of powder is non-spherical
Shape, oval spherical, droplet-like, needle-shaped such shape with shape anisotropy or do not have special shape
It is anisotropic unsetting.As the example of unsetting powder, the feelings that multiple spherical powders combine with contacting with each other can be enumerated
The situation that condition or multiple spherical powders are combined in a manner of being partly embedded to other powders.For such unsetting powder,
Easily observed in carbonyl iron.
The shape of powder can be the shape that is formed of stage in manufacture powder or by the powder to producing
The shape that end carries out secondary operation and formed.As the former shape, illustration has spherical, oval spherical, droplet-like, needle-shaped etc.,
As the shape of the latter, illustration has flakey.
The particle diameter for the crystalline magnetic material powder that the compressed-core 1 that one embodiment of the present invention is related to contains is unrestricted
It is fixed.If based on median particle diameter D50 (in the volume distributed median of the particle diameter for the soft magnetic powder being measured to by laser diffraction scattering method
Particle diameter when volume aggregate-value is 50%) provide the particle diameter, then the particle diameter is usually in 1 μm~20 μm of scope.Handled from raising
Property viewpoint, the viewpoint of packed density of crystalline magnetic material powder etc. that improves in compressed-core set out, crystalline is magnetic
The median particle diameter D50 (be also referred to as in the present specification " the first median particle diameter d1 ") of material powder is preferably more than 1 μm and 15 μm
Hereinafter, more than 1 μm and less than 10 μm, particularly preferably more than 1 μm and less than 5 μm are more preferably.
The content of crystalline magnetic material powder in the compressed-core 1 that one embodiment of the present invention is related to, based on
Relation between the content of noncrystalline magnetic material in compressed-core 1 and set so that compressed-core 1 meets described later and iron
Damage the relevant conditions of Pcv.
At least a portion of crystalline magnetic material powder is preferably to be formed by implementing the material after insulation processing, more excellent
Choosing is that crystalline magnetic material powder is formed by the material after implementing insulation processing.Implement to crystalline magnetic material powder
In the case of insulation processing, the trend that the insulation resistance of compressed-core improves is shown.In addition, sometimes not only in high frequency zone
Domain, the trend of iron loss Pcv reductions is also shown in low frequency region.
The species for the insulation processing implemented to crystalline magnetic material powder is not limited.Illustration has phosphoric acid processing, phosphoric acid
Salt treatment, oxidation processes etc..
In the case where crystalline magnetic material powder is formed by the material after implementing insulation processing, crystalline magnetism material
The content at feed powder end relative to the sum of the content of content and the noncrystalline magnetic material powder of crystalline magnetic material powder matter
Measure ratio (unit：Quality %, is also referred to as " the first blending ratio " in the present specification) it is preferred for more than 5 mass % and 40 matter
Measure below %.By making the first blending ratio be in above range, show in high frequency region and low frequency region, iron loss
The trend that Pcv is easily reduced.First blending ratio is more preferably more than 5 mass % and below 35 mass %, is further preferred that 5
More than quality % and below 30 mass %, particularly preferably more than 5 mass % and below 25 mass %, if more than 10 mass %
And 20 is then extremely preferred below mass %.
(2) noncrystalline magnetic material powder
What one embodiment of the present invention was related to assigns the amorphous of the noncrystalline magnetic material powder contained by compressed-core 1
Matter magnetic material, as long as meeting (not obtaining with being capable of certain material kind by common X-ray diffraction measure for noncrystalline
The diffracting spectrum of the clear peak value of the degree of class) and be ferromagnetic (being especially soft-magnetic body), then specific species is unlimited
It is fixed.As the concrete example of noncrystalline magnetic material, Fe-Si-B classes alloy, Fe-P-C classes alloy and Co-Fe- can be enumerated
Si-B class alloys.Above-mentioned noncrystalline magnetic material can be made of a kind of material, can also be made of multiple material.Form non-
The magnetic material of crystalloid magnetic material powder is preferably selected from the one kind or two or more material of above-mentioned material, wherein preferably containing
There are Fe-P-C class alloys, more preferably formed by Fe-P-C class alloys.
As the concrete example of Fe-P-C class alloys, following Fe base amorphous alloys can be enumerated, i.e. composition formula is expressed as
Fe100-a-b-c-x-y-z-tNiaSnbCrcPxCyBzSit, the atom % of 0 atom %≤a≤10 atom %, 0 atom %≤b≤3,0 is former
Sub- %≤c≤6 atom %, 6.8 atom %≤x≤10.8 atom %, 2.2 atom %≤y≤9.8 atom %, 0 atom %≤z
The atom % of≤4.2 atom %, 0 atom %≤t≤7.In above-mentioned composition formula, Ni, Sn, Cr, B and Si are any addition member
Element.
The additive amount a of Ni is preferably more than 0 atom % and below 6 atom %, more preferably more than 0 atom % and 4 originals
Sub- below %.The additive amount b of Sn is preferably more than 0 atom % and below 2 atom %, more preferably more than 1 atom % and 2 originals
Sub- below %.The additive amount c of Cr is preferably more than 0 atom % and below 2 atom %, more preferably more than 1 atom % and 2 originals
Sub- below %.Additive amount x there is also P is preferably situation more than 8.8 atom %.Additive amount y there is also C is preferably 5.8
The situation of more than atom % and below 8.8 atom %.The additive amount z of B is preferably more than 0 atom % and below 3 atom %, more excellent
Elect as more than 0 atom % and below 2 atom %.The additive amount t of Si is preferably more than 0 atom % and below 6 atom %, more preferably
For more than 0 atom % and below 2 atom %.
The shape for the noncrystalline magnetic material powder contained by compressed-core 1 that one embodiment of the present invention is related to from
Limit.On the species of powder shape, identical with the situation of crystalline magnetic material powder, and the description is omitted.According to manufacture
The relation of method, it is spherical or oval spherical to have that noncrystalline magnetic material is easily formed.In addition, typically, amorphous
Matter magnetic material and crystalline magnetic material are hard, therefore preferably crystalline magnetic material is made non-spherical and is made sometimes
Obtain and be easily deformed in press molding.
The shape for the noncrystalline magnetic material powder contained by compressed-core 1 that one embodiment of the present invention is related to can be with
Manufacture powder the shape that is formed of stage or by carrying out secondary operation to the powder produced the shape that is formed
Shape.As the former shape, illustration has spherical, ellipse is spherical, needle-shaped etc., and as the shape of the latter, illustration has flakey.
The particle diameter for the noncrystalline magnetic material powder contained by compressed-core 1 that one embodiment of the present invention is related to from
Limit.If providing the particle diameter based on median particle diameter D50, the particle diameter is usually in 1 μm~20 μm of scope.From raising treatability
Viewpoint is set out, the median particle diameter D50 of noncrystalline magnetic material powder (be also referred to as in the present specification " Second Intermediate Value particle diameter d2 ")
Preferably more than 1 μm, more preferably more than 2 μm, particularly preferably more than 3 μm.
Go out from viewpoint of packed density of magnetic material powder of noncrystalline and crystalline improved in compressed-core 1 etc.
Hair, the median particle diameter D50 for preferably making noncrystalline magnetic material powder are less than 15 μm, more preferably less than 12 μm, especially excellent
Elect less than 6 μm as.In addition, in order to realize the high insulation resistance of compressed-core 1 and low iron loss Pcv, make noncrystalline magnetism material sometimes
The median particle diameter D50 at feed powder end is more preferred for less than 6 μm.From the excellent DC superposition characteristic and height for realizing compressed-core 1
The viewpoint of the low iron loss Pcv of band region, make sometimes the median particle diameter D50 of noncrystalline magnetic material powder for less than 5 μm more
It is preferred that.
The relation of first median particle diameter d1 and Second Intermediate Value particle diameter d2 are not limited.Typically, since noncrystalline is magnetic
Material and crystalline magnetic material are in a ratio of hard, thus make sometimes the first median particle diameter d1 it is relatively small, so that crystalline magnetic
Property material powder is easily filled in the caused space part when being filled with noncrystalline magnetic material powder, and such case is more excellent
Choosing.In such a situation it is preferred that it is to make d1/d2 be less than 0.8, sometimes more preferably less than 0.5.
The content of noncrystalline magnetic material powder, is based in the compressed-core 1 being related on one embodiment of the present invention
Relation between the content of the crystalline magnetic material in compressed-core 1 and set so that compressed-core 1 meet it is described later with
The relevant conditions of iron loss Pcv.
(3) frequency dependence of iron loss Pcv
The compressed-core 1 that one embodiment of the present invention is related to, for iron loss Pcv (units：kW/m3) frequency f it is (single
Position：KHz) dependence, meets following relation.That is, 2 constant k are being usedhAnd keRepresented using following formula (1) effectively most
Big magnetic flux density BmDuring the frequency f dependences of the iron loss Pcv measured for the condition of 15mT, a constant khFor 1.5 × 10- 3kW/
m3/kHz/(mT)1.6Below and another constant keFor 3.0 × 10- 7kW/m3/(kHz)2/(mT)2Below.
Pcv=kh×f×Bm 1.6+ke×f2×Bm 2 (1)
It should be noted that in the present specification, constant kh、keIt is the scope in 1MHz~3MHz based on iron loss Pcv
Frequency f dependences and calculate.
Due to constant kh、keWithin the above range, so that the degree that iron loss Pcv rises with the rising of frequency f becomes
Slowly, even if reaching the high frequency of more than 1MHz, iron loss Pcv is also difficult to raise.From making, the frequency f dependences of iron loss Pcv are more stable
From the viewpoint of ground tends to be good, constant khPreferably 1.0 × 10- 3kW/m3/kHz/(mT)1.6Hereinafter, be more preferably 0.8 ×
10- 3kW/m3/kHz/(mT)1.6Below.In addition, from the above point of view, constant kePreferably 2.8 × 10- 7kW/m3/(kHz)2/
(mT)2Hereinafter, 2.7 × 10 are more preferably- 7kW/m3/(kHz)2/(mT)2Below.
From the viewpoint of the frequency f dependences for making iron loss Pcv more stably tend to be good, constant kh、keLower limit from
Limit.In general, constant khFor 1.0 × 10- 4kW/m3/kHz/(mT)1.6More than, constant keFor 1.0 × 10- 7kW/m3/(kHz)2/
(mT)2More than.
In the compressed-core 1 that one embodiment of the present invention is related to, crystalline magnetic material powder content and amorphous
The above-mentioned constant k of relation pair between the content of matter magnetic material powderh、keInfluence, it is as follows.
Basic trend is：(content of crystalline magnetic material powder is relative to crystalline magnetism material for first blending ratio
The quality ratio of the content and the sum of the content of noncrystalline magnetic material powder at feed powder end) higher, then 2 constant kh、keAlso all get over
It is high.Thus, there are the trend that the first blending ratio is more high, and iron loss Pcv becomes higher.
Change and the constant k of the first blending ratio are confirmed in detailh、keChange between relation, it is believed that there are non-for the relation
Linear, its trend are more notable when the first blending ratio is lower.That is, when the first blending ratio is 40 mass % or so following,
Even if the first blending ratio increases, 2 constant kh、keIncreased degree is also less.According to the formula (1), 2 constant kh、
keIt is lower, even if then effectively peakflux density BmAnd frequency f becomes higher, iron loss Pcv is also difficult to increase.Therefore, the first blending ratio
It is lower, then easily and efficiently play and suppress the effect that iron loss Pcv rises (hereinafter also referred to as " iron loss suppression function ").From can be more
From the viewpoint of easily and efficiently playing iron loss suppression function, preferably the first blending ratio is below 35 mass %, more excellent
Choosing is for below 30 mass %, is particularly preferably below 20 mass %.In addition, in order to improve DC superposition characteristic, preferably
First blending ratio is more than 5 mass %, is more preferably more than 10 mass %, is particularly preferably more than 15 mass %.From
Have compressed-core 1 concurrently and play iron loss suppression function with from the viewpoint of raising DC superposition characteristic, the first blending ratio is preferably 5
40 mass % of more than quality %, more preferably more than 15 mass % and 30 mass %.
First blending ratio is higher, then has as basic trend, iron loss Pcv increases, but the trend of its increase as follows
Frequency dependence.Iron loss when namely based on the first blending ratio being 0 mass % (when being only noncrystalline magnetic material powder)
Iron loss Pcv when Pcv is by arbitrary first blending ratio is standardized and is obtained iron loss change rate, the more high then iron loss of the first blending ratio
Change rate is bigger, but the degree of the increase of iron loss change rate, becomes slow as frequency becomes higher.Embodiment institute as be described hereinafter
Show, the increase of iron loss change rate when the first blending ratio dependence of the increase of iron loss change rate during 2MHz is 100kHz
Half of first blending ratio dependence or so.Thus, the electronics for the compressed-core 1 being related to one embodiment of the present invention
Electric component, during the purposes used in high frequency region, iron loss Pcv is more difficult to have an impact.
(4) bonding component
As long as bonding component contributes to the crystalline magnetic material contained by by compressed-core 1 of the present embodiment
The material that powder and noncrystalline magnetic material powder (in this specification, these powder are collectively referred to as " Magnaglo " sometimes) are fixed
, its component is not limited.As the material for forming bonding component, illustration has the thermal decomposition of resin material and resin material residual
The material of the organics such as slag (this specification, these are collectively referred to as " component based on resin material "), material of inorganic etc..Make
For resin material, illustration has acrylic resin, silicones, epoxy resin, phenolic resin, urea resin, melamine resin etc..By nothing
The bonding component that machine class material is formed, which illustrates, the glass-like materials such as waterglass.Bonding component can be made of a kind of material,
It can be made of multiple material.Bonding component can also be organic-based material and the mixture of mineral-type materials.
As bonding component, usually using the material of insulating properties.Thus, it is possible to improve the insulating properties as compressed-core 1.
2. the manufacture method of compressed-core
The manufacture method for the compressed-core 1 that above-mentioned one embodiment of the present invention is related to is not particularly limited, according to such as
The manufacture method of lower explanation, can with higher efficiency manufacture compressed-core 1.
The manufacture method for the compressed-core 1 that one embodiment of the present invention is related to is as follows, including forming process, may be used also
With including heat treatment step.
(1) forming process
First, Magnaglo and the mixture containing the component that bonding component is assigned in compressed-core 1 are prepared.Assign
The component (being also referred to as in the present specification " adhesive ingredients ") of bonding component can refer to bonding component in itself or with
The different material of bonding component.As the concrete example of the latter, enumerate that adhesive ingredients is resin material and bonding component is its heat
The situation of residue decomposition.
It can be handled by the shaping of the press molding including the mixture to obtain figuration manufacture thing.Pressurized conditions from
Limit, can the composition based on adhesive ingredients etc. and suitably determine.For example, formed in adhesive ingredients by thermosetting resin
In the case of, preferably heated while pressurization, the curing reaction of resin is carried out in mould.On the other hand, adopting
In the case of with compression molding, although plus-pressure is high, heating is not necessary condition, is pressurizeed for the short time.
Hereinafter, in the case of mixture is pelletizing, is compressed shaping, slightly it is described in detail.Due to being granulated
The treatability of powder is excellent, therefore can improve the workability for the compression molding process that curring time is short, productivity is excellent.
(1-1) pelletizing
Pelletizing contains Magnaglo and adhesive ingredients.The content of adhesive ingredients in pelletizing is not particularly limited.
When the content is too low, adhesive ingredients is difficult to keep Magnaglo.In addition, in the too low situation of the content of adhesive ingredients
Under, in by compressed-core 1 obtained by heat treatment step, the bonding component that is formed by the thermal decomposition residues of adhesive ingredients,
It is difficult to a variety of Magnaglos is insulated toward each other.On the other hand, in the too high levels of above-mentioned adhesive ingredients, through overheat
The content of contained bonding component easily becomes higher in compressed-core 1 obtained by treatment process.If being bonded in compressed-core 1
The content divided becomes higher, then the magnetic characteristic of compressed-core 1 is easily reduced.Therefore, the content of the adhesive ingredients in pelletizing is preferred
Generally speaking it is the amount of more than 0.5 mass % and below 5.0 mass % relative to pelletizing to be.From more stably reducing press-powder
From the viewpoint of the magnetic characteristic of magnetic core 1 reduces possibility, the content of the adhesive ingredients in pelletizing is preferably, relative to granulation
Generally speaking powder is the amount of more than 1.0 mass % and below 3.5 mass %, be more preferably more than 1.2 mass % and 3.0 matter
Measure the amount of below %.
Pelletizing can contain the material beyond above-mentioned Magnaglo and adhesive ingredients.As such material, example
It is shown with lubricant, silane coupling agent, the filler etc. of insulating properties.In the case of containing lubricant, its species is not particularly limited.Can
To be organic series lubricant agent or inorganic series lubricant agent.As the concrete example of organic series lubricant agent, stearic acid can be enumerated
The metallic soaps such as zinc, aluminum stearate.Think this organic series lubricant agent, gasify in heat treatment step, hardly residue in pressure
Powder magnetic core 1.
The manufacture method of pelletizing is not particularly limited.Can directly be kneaded the component for assigning above-mentioned pelletizing, with public affairs
Mixture crushing of gained etc. is obtained pelletizing or is modulated in above-mentioned component to add scattered be situated between by the method known
The slurry that matter (can enumerate water as an example) forms, makes the slurry dry and crushes and obtain pelletizing.Can after being pulverized into
Row screening and/or classification, to control the size distribution of pelletizing.
As an example for the method that pelletizing is obtained from above-mentioned slurry, the method using spray drying can be enumerated.Such as Fig. 2
It is shown, rotor 201 is set in spray-drying installation 200, slurry S is injected from device top to rotor 201.Rotor 201 is with rule
Determine rotating speed and rotate, the chamber inside device 200 makes slurry S form droplet-shaped and sprays using centrifugal force.Further to dress
Put the chamber inside 200 and import hot wind, make decentralized medium contained in the slurry S of droplet-shaped with thus maintain droplet shape
(water) volatilizees.As a result, form pelletizing P from slurry S.Pelletizing P is recycled from the lower part of device 200.On turning for rotor 201
As long as each parameters such as the temperature of speed, the hot blast temperature imported into spray-drying installation 200, chamber lower portion are suitably set.
As the concrete example of the setting range of these parameters, can enumerate：Rotating speed as rotor 201 is 4000~6000rpm, as to
The hot blast temperature imported in spray-drying installation 200 is 130~170 DEG C, and the temperature as chamber lower portion is 80~90 DEG C.Chamber
Interior atmosphere and its pressure are also suitably set.As an example, can enumerate makes in chamber to be air (air) atmosphere, with it is big
The differential manometer of air pressure, its pressure are 2mmH2O (about 0.02kPa).Can be by sieve etc. and to obtained pelletizing P
Size distribution further control.
(1-2) pressurized conditions
Pressurized conditions in compression molding are not particularly limited.As long as considering shape of the composition of pelletizing, formed products etc.
Appropriate setting.When plus-pressure when to pelletizing compression molding is too low, the mechanical strength of formed products reduces.Therefore, into
The treatability of shape product reduces, and easily producing from the mechanical strength for the compressed-core 1 that formed products obtain reduces the problem of such.This
Outside, the problem of magnetic characteristic reduction there is also compressed-core 1 or insulating properties reduce.On the other hand, to pelletizing compression molding
When plus-pressure it is excessive when, to make and be resistant to the shaping dies of its pressure and become difficult.Pressurize from compression is more stably reduced
Process can bring mechanical property, the magnetic characteristic of compressed-core 1 dysgenic possibility, easily carry out industrial a large amount of lifes
From the viewpoint of production, plus-pressure when to pelletizing compression molding is preferably more than 0.3GPa and below 2GPa, more preferably
More than 0.5GPa and below 2GPa, particularly preferably more than 0.8GPa and below 2GPa.
In compression molding, it can heat while pressurize, can also pressurize at normal temperatures.
(2) heat treatment step
Can be compressed-core 1 of the present embodiment by figuration manufacture thing obtained by forming process, can also be as
Lower explanation so implements heat treatment step to figuration manufacture thing and obtains compressed-core 1.
In heat treatment step, by being heated to the figuration manufacture thing as obtained by above-mentioned forming process, to relax
Correct and put on the strain of Magnaglo in the adjustment of the magnetic characteristic of distance and forming process between Magnaglo, carry out magnetic characteristic
Adjustment, obtain compressed-core 1.
Its object is to adjust the magnetic characteristic of compressed-core 1, therefore the heat such as heat treatment temperature as described above for heat treatment step
Treatment conditions are set so that the magnetic characteristic of compressed-core 1 is optimal.As an example of the method for setting heat treatment condition, can lift
Go out：Change the heating-up temperature of figuration manufacture thing, make the other conditions such as the retention time of programming rate and heating-up temperature constant.
The metewand of the magnetic characteristic of compressed-core 1 when setting heat treatment condition is not particularly limited.As assessment item
Concrete example can enumerate the iron loss Pcv of compressed-core 1.In this case, if be set to the heating-up temperature of the shape divine force that created the universe with
The iron loss Pcv for making compressed-core 1 is minimum.Determination condition on iron loss Pcv can suitably be set, and as an example, can be lifted
Go out to become frequency 100kHz, the condition of peakflux density 100mT.
Atmosphere during heat treatment is not particularly limited.Due to the heat point of the adhesive ingredients in the case of using oxidizing atmosphere
The possibility for high, Magnaglo the oxidation progress of possibility that solution is excessively in progress is high, therefore preferably in inertia such as nitrogen, argon gas
The reducing atmospheres such as atmosphere, hydrogen are heat-treated.
3. electronic and electric components
The electronic and electric components that one embodiment of the present invention is related to are related to including above-mentioned one embodiment of the present invention
Compressed-core 1, coil and be connected to the coil each end connection terminal.Here, at least a portion of compressed-core 1
It is configured in when flowing through electric current to coil via connection terminal as caused by the electric current in induced field.
As an example of such electronic and electric components, the loop coil 10 shown in Fig. 3 can be enumerated.Loop coil 10 includes
The coil 2a for winding coated conductor wire 2 in cricoid compressed-core (toroidal core) 1 and being formed.Positioned at coated by what is wound
The part of conductor wire between coil 2a and end 2b, 2c of coated conductor wire 2 that conductor wire 2 is formed, definable coil 2a's
End 2d, 2e.In this way, electronic and electric components of the present embodiment, can be component and the composition connecting pin for forming coil
The component of son is made of same component.
The electronic and electric components that one embodiment of the present invention is related to, possess and are related to above-mentioned one embodiment of the present invention
And 1 compressed-core of different shapes of compressed-core.As the concrete example of such electronic and electric components, can enumerate shown in Fig. 4
Inductance element 20.Fig. 4 is the inductance element 20 that one embodiment of the present invention is related to is represented in a manner of partial perspective whole
The stereogram that body is formed.In Fig. 4, represented with the posture of the lower surface (mounting surface) of inductance element 20 upward.Fig. 5 be represent by
Inductance element 20 shown in Fig. 4 is installed on the partial front elevation view of the state on installation base plate 100.
Inductance element 20 shown in Fig. 4 includes compressed-core 3；Hollow as the coil being embedded in inside compressed-core 3
Coil 5；By welding and a pair of end sub-portion 4 as connection terminal for being electrically connected with hollow coil 5.
Hollow coil 5 is the component that the conducting wire of insulating film is wound and formed in the shape of a spiral.Hollow coil 5 has winding
Portion 5a and from wound portion 5a draw extraction end 5b, 5b and form.The winding book of hollow coil 5 is fitted according to required inductance
Work as setting.
As shown in figure 4, in compressed-core 3, in the mounting surface 3a opposite with installation base plate formed with for accommodating terminal portion 4
A part receiving recess 30.The both sides that recess 30 is formed at mounting surface 3a are accommodated, towards side 3b, 3c of compressed-core 3
Formed openly.
A part for the portion of terminal 4 protruded from side 3b, 3c of compressed-core 3 bends towards mounting surface 3a and is contained in appearance
Receive the inside of recess 30.
Portion of terminal 4 is formed by laminal Cu base materials.Portion of terminal 4 has：It is embedded in the inside of compressed-core 3 and and hollow
The connection end 40 drawn end 5b, 5b and be electrically connected of coil 5；It is exposed to the outer surface of compressed-core 3, and from the press-powder magnetic
The 1st zigzag part 42a and the 2nd zigzag part 42b that side 3b, 3c of core 3 to mounting surface 3a are bent to form successively.Connection end 40 is
It is welded in the weld part of hollow coil 5.1st zigzag part 42a and the 2nd zigzag part 42b is soldered joint in the pricker of installation base plate 100
Weld junction surface.Soldered joint portion is the part that the slave compressed-core 3 in portion of terminal 4 exposes, and is represented at least towards compressed-core 3
The surface in outside.
The connection end 40 of portion of terminal 4 is engaged with the extraction end 5b of hollow coil 5 by resistance welding.
As shown in figure 5, inductance element 20 is installed on installation base plate 100.
On the surface of installation base plate 100 formed with the conductive pattern turned on external circuit, pass through the one of the conductive pattern
Part, forms a pair of of the welding disk 110 for being used for installing inductance element 20.
As shown in figure 5, in inductance element 20, mounting surface 3a is exposed to towards 100 side of installation base plate from compressed-core 3
The 1st exterior zigzag part 42a and the 2nd zigzag part 42b between the welding disk 110 of installation base plate 100 by brazing layer 120 and
Engagement.
Soldering operation is after printing process is coated with the soldering of paste-like to welding disk 110, with the 2nd zigzag part 42b
Facing mode installs inductance element 20 with welding disk 110, and melts soldering in heating process.As shown in Figure 4 and Figure 5,
2nd zigzag part 42b is opposite with the welding disk 110 of installation base plate 100, and the 1st zigzag part 42a is exposed to the side of inductance element 20
3b, 3c, therefore the brazing layer 120 of fillet welding shape is consolidated in welding disk 110, and in the 2nd zigzag part 42b as soldered joint portion
Fully extend and consolidate with the surface of both the 1st zigzag part 42a.
4. electronic electric equipment
The electronic electric equipment that one embodiment of the present invention is related to, which is provided with, possesses an above-mentioned embodiment party of the invention
The electronic and electric components for the compressed-core that formula is related to.As such electronic electric equipment, illustration have possess power switch circuit,
The supply unit of voltage up-down circuit, smooth circuit etc., miniature portable communication equipment etc..
Power switch circuit, voltage up-down circuit, smooth circuit etc. usually become high frequency, increase damage with miniaturization
Lose.In the case where the electronic and electric components that one embodiment of the present invention is related to are inductance element 20, height can be realized at the same time
Frequencyization, excellent DC superposition characteristic and low loss.Thus, even in electronic electric equipment to miniaturized high-speed (high frequency
Change) in the case of development, also can high efficiency circuit same easy to implement, the work(of electronic electric equipment can not be increased
Consumption.
Embodiments described above be for easy understanding the present invention and records, be not used to limit it is of the invention and
Record.Therefore, the whole that each key element meaning disclosed in the above embodiment is to include belonging to protection scope of the present invention is set
Meter change, equivalent.
For example, the compressed-core that one embodiment of the present invention is related to is containing crystalline magnetic material powder and noncrystalline
The compressed-core of magnetic material powder, its feature can be that the quality of the content of crystalline magnetic material powder is relative to crystallization
The ratio of the sum of the content of matter magnetic material powder and the content of noncrystalline magnetic material powder is more than 5 mass % and 40 matter
Measure below %.Also, the compressed-core for possessing features described above can also be with the features described above (one on above-mentioned formula (1)
Constant khFor 1.5 × 10- 3kW/m3/kHz/(mT)1.6Hereinafter, and another constant keFor 3.0 × 10- 7kW/m3/(kHz)2/(mT)2
Below).
【Embodiment】
Hereinafter, the present invention is further elaborated with by embodiment etc., but the scope of the present invention is not limited to these implementations
Example etc..
(embodiment 1)
(1) making of Fe base amorphous alloys powder
, will be with Fe using water atomization71 atom %Ni6 atom %Cr2 atom %P11 atom %C8 atom %B2 atom %The obtained amorphous of composition weighing
Matter magnetic material powder is fabricated to Magnaglo.(content of crystalline magnetic material powder is relative to crystallization for first blending ratio
The quality ratio of the sum of the content of matter magnetic material powder and the content of noncrystalline magnetic material powder) it is 0 mass %.
On the size distribution of obtained Magnaglo, using Ji Zhuan societies system, " Microtrac particle size distributions fill
MT3300EX " is put to be measured based on volume distributed median.As a result, in volume distributed median, reach 50% particle diameter i.e. median particle diameter D50
For 5 μm.
(2) pelletizing is made
By the above-mentioned Magnaglo of 97.2 mass parts, 2~3 mass parts formed by acrylic resin and phenolic resin it is exhausted
Edge binding material and 0~0.5 mass parts by the mix lubricant that zinc stearate is formed in the water as solvent, starched
Material.
Using the spray-drying installation 200 shown in Fig. 2, obtained slurry is granulated by above-mentioned condition, is made
Grain powder.
(3) compression molding
Obtained pelletizing is filled in mould, press molding is carried out with 0.5~1.5GPa of face pressure, is obtained with outside diameter
The formed body of the annular shape of 20mm × internal diameter 12mm × thickness 3mm.
(4) it is heat-treated
Obtained formed body is placed in the stove of nitrogen stream atmosphere, by in-furnace temperature from room temperature (23 DEG C) with the speed that heats up
10 DEG C/min of degree is heated to optimal magnetic core heat treatment temperature i.e. 200~400 DEG C, when holding 1 is small at such a temperature, thereafter, in stove
Inside carry out being cooled to the heat treatment of room temperature, obtain the toroidal core formed by compressed-core.
(embodiment 2 and 3)
When modulating Magnaglo, by the noncrystalline magnetic material powder used in embodiment 1 and by implementing insulation position
Crystalline magnetic material powder (the median particle diameter D50 that the carbonyl iron of reason is formed：4.3 μm) mix, the first mixing ratio in embodiment 2
Rate is 10 mass %, and first blending ratio is 20 mass % in embodiment 3, is used respectively with above-mentioned first in embodiment 2,3
The Magnaglo that blending ratio mixes, in addition manufactures toroidal core similarly to Example 1.
(embodiment 4)
When modulating Magnaglo, noncrystalline magnetic material powder used in embodiment 1 is substituted in, is fully used in implementation
Carbonyl iron that the grade of example 2 uses, implementing insulation processing, i.e. the first blending ratio of Magnaglo are 100 mass %, except this it
Toroidal core is manufactured similarly to Example 1 outside.
(embodiment 5,6 and 7)
When modulating Magnaglo, by the noncrystalline magnetic material powder used in embodiment 1 and by implementing insulation position
Crystalline magnetic material powder (the median particle diameter D50 that the carbonyl iron of reason is formed：4.3 μm) mixing, using the first blending ratio into
For the Magnaglo being worth as follows, toroidal core is in addition manufactured similarly to Example 1.
Embodiment 5：5 mass %
Embodiment 6：15 mass %
Embodiment 7：30 mass %
(embodiment 8~12)
When modulating Magnaglo, substitute the crystalline magnetic material powder used in embodiment 2~4, using by being not carried out
Crystalline magnetic material powder (the median particle diameter D50 that the carbonyl iron of insulation processing is formed：4.3 μm), by the crystalline magnetism material
Feed powder end and the noncrystalline magnetic material powder mixing modulated in embodiment 1, become what is be worth as follows using the first blending ratio
Magnaglo, in addition manufactures toroidal core similarly to Example 1.
Embodiment 8：5 mass %
Embodiment 9：10 mass %
Embodiment 10：20 mass %
Embodiment 11：30 mass %
(embodiment 12)
When modulating Magnaglo, noncrystalline magnetic material powder used in embodiment 1 is substituted in, is fully used in implementation
Carbonyl iron that the grade of example 8 uses, that insulation processing is not carried out, i.e. the first blending ratio of Magnaglo are 100 mass %, except this it
Toroidal core is manufactured similarly to Example 1 outside.
(embodiment 13)
Median particle diameter D50 is 6 μm, in addition modulates noncrystalline magnetic material powder similarly to Example 1.Use this
Noncrystalline magnetic material powder, manufactures toroidal core similarly to Example 1.
(embodiment 14 and 15)
By the median particle diameter D50 after embodiment 13 adjusts be 6 μm noncrystalline magnetic material powder and in embodiment 2 etc.
Crystalline magnetic material powder (the median particle diameter D50 formed by the carbonyl iron for implementing insulation processing used：4.3 μm) it is mixed
Close, become the Magnaglo being worth as follows using the first blending ratio, in addition manufacture toroidal core similarly to Example 1.
Embodiment 14：10 mass %
Embodiment 15：20 weight %
The measure of (test example 1) iron loss Pcv
For being coated to copper wire, 2 in 1 15 circle of side winding respectively in the toroidal core produced by embodiment 1~15
Loop coil obtained by the coated copper wire of 10 circle of secondary side winding, using BH analyzers (Yan Qi communication equipments society system " SY-8218 "),
Effective peakflux density BmUnder conditions of 15mT, iron loss Pcv (units are measured：kW/m3) frequency dependence (measure frequency
Scope：100kHz~3MHz).A part for its result is shown in table 1.From each iron loss Pcv being measured under these conditions
In the result of frequency dependence of scope of 1~3MHz obtain 2 constant kh、ke.It the results are shown in table 2~4.Need
It is bright, in table 2~4 according to from the low embodiment of the first blending ratio to the order of the high embodiment of the first blending ratio successively
Arrangement represents.In addition, there is also such as embodiment 1 in this way, for the embodiment for easily contrasting and repeatedly representing.Shown in table 2~4
Each iron loss Pcv of 100kHz, 1MHz, 2MHz and 3MHz are to make effective peakflux density BmRespectively 100mT, 25mT,
The result measured under conditions of 15mT and 15mT.
The measure of (test example 2) magnetic conductivity
For being twined respectively in the coated copper wire of 1 40 circle of side winding, 2 sides in the toroidal core produced by embodiment
Around loop coil obtained by the 10 coated copper wire of circle, using electric impedance analyzer (HP societies system " 4192A "), under conditions of 100kHz,
Initial permeability μ and DC current are superimposed, measures the relative permeability μ when direct current application magnetic field being consequently formed is 5500A/m
5500.The results are shown in table 2~4.
The measure of (test example 3) DC superposition characteristic
The loop coil formed using the toroidal core by being made by embodiment, according to JISC2560-2, by direct current
Stream is superimposed on loop coil.The value L of the inductance L at (initial stage) before variation delta L based on inductance L applies relative to superimposed current0
Ratio (Δ L/L0) application current value Isat (units when reaching 30%：A), DC superposition characteristic is evaluated.The results are shown in table 2
~4.
The measure of (test example 4) insulation resistance
Insulation resistance (the unit of the toroidal core made of 2 terminal method of surface measure by embodiment：Ω).The results are shown in table
2~4.
【Table 1】
【Table 2】
【Table 3】
【Table 4】
Fig. 6~15 are that the above results are plotted the figure that curve map forms.Specifically, Fig. 6 is the iron loss for representing embodiment
The curve map of the measurement result of the frequency dependence of Pcv.Fig. 7 is to represent constant khRelative to the dependence of first blending ratio
Curve map.Fig. 8 is to represent constant keRelative to the curve map of the dependence of the first blending ratio.Fig. 9 be represent 100kHz and
Iron loss change rate (iron loss Pcv when based on the first blending ratio being 0 mass %, by arbitrary first blending ratio during 2MHz
Iron loss Pcv standardization obtained by value) relative to the first blending ratio dependence curve map.It should be noted that scheming
9, iron loss change rate measures as follows, and toroidal core is twined in the coated copper wire of 1 40 circle of side winding, 2 sides respectively
Around the coated copper wire of 10 circles, in 100kHz with Bm=100mT is measured, in 2MHz with Bm=15mT is measured.Figure 10 is
Represent curve map of the insulation resistance relative to the dependence of the first blending ratio.Figure 11~14 are to represent that frequency is respectively 100kHz
Iron loss Pcv when (Figure 11), 1MHz (Figure 12), 2MHz (Figure 13) and 3MHz (Figure 14) relative to the first blending ratio dependence
Curve map.It should be noted that B during measuremAs shown in each curve map, it is 100mT in 100kHz, is in 1MHz
25mT, is 15mT in 2MHz.Figure 15 be represent inductance L variation delta L apply relative to superimposed current before (initial stage) electricity
Feel the value L of L0Ratio (Δ L/L0) dependence application current value (Isat), relative to the first blending ratio when reaching 30%
The curve map of property.
Based on table 1~4 and Fig. 6~15, it will be appreciated that to following item.
(A) compressed-core containing the Magnaglo modulated in a manner of meeting above-mentioned formula (1), in wider frequency
Region, especially the high frequency region in more than 1MHz, have the excellent magnetic characteristic (iron loss Pcv, initial permeability, DC stacked
Characteristic).
(B) according to Fig. 7 and Fig. 8, for ke、kh, remain relatively low if the 1st blending ratio is below 30 weight %
Value, becomes lower value if the 1st blending ratio is below 20 weight %.If thus, it can be known that the 1st blending ratio is 30 weight %
Below, it is preferably below 20 weight %, then can expects to suppress the effect of the iron loss Pcv increases of high-frequency region.If on the contrary, the 1st is mixed
Composition and division in a proportion rate then shows k more than 30 weight %e、khThe trend of rising, as a result, think that the iron loss Pcv of high-frequency region significantly increases.
In addition, as can be seen from FIG. 15, apply current value Isat raisings if the 1st blending ratio is more than 10 weight %, if the 1st blending ratio
For more than 15 weight %, then apply current value Isat and further become larger.
(C) although the first blending ratio of the powder that is magnetic becomes higher the then increased basic trends of iron loss Pcv, frequency and gets over
Height, even if then the first blending ratio becomes higher, iron loss Pcv is also difficult to increase.The trend is confirmed from Fig. 9.According to Fig. 9,
In the case of 100kHz, iron loss change rate is 2.5 when the first blending ratio is 10%, and iron loss becomes when the first blending ratio is 20%
Rate is 3.6, and on the other hand, in the case of 2MHz, even if the first blending ratio is 20%, the increase of iron loss change rate also stops
Walk in 1.4 or so.Therefore, there are the electronic and electric components of compressed-core of the present embodiment, used in high-frequency circuit
In the case of, its effect is easily more notable.Further, since the electronic circuit in the electronic electric equipment of small-size light-weight is high frequency
Change circuit, therefore be also suitable for the dc-dc of mobile phone etc..
(D) as shown in Figure 10, the Magnaglo containing the crystalline magnetic material powder for implementing insulation processing is being used
In the case of, compared with using the situation of the Magnaglo containing the crystalline magnetic material powder that insulation processing is not carried out, table
Reveal the trend that the insulation resistance of compressed-core becomes higher.
(E) as shown in figure 11, the Magnaglo containing the crystalline magnetic material powder for implementing insulation processing is being used
In the case of, can compared with using the situation of the Magnaglo containing the crystalline magnetic material powder that insulation processing is not carried out
Know less in low frequency region iron loss Pcv.On this point, from the constant k shown in Fig. 7hFrequency dependence it will be understood that.
(F) on the constant k shown in Fig. 8eFrequency dependence, it is magnetic using the crystalline that implements insulation processing is contained
The magnetic powder of the situation of the Magnaglo of material powder and the crystalline magnetic material powder that insulation processing is not carried out using containing
The situation at end obtains identical result.Based on the result it is contemplated that using magnetic containing the crystalline for implementing insulation processing
The magnetic powder of the situation of the Magnaglo of material powder and the crystalline magnetic material powder that insulation processing is not carried out using containing
The situation at end, the iron loss Pcv of high frequency region are equal.However, as a result, exhausted containing being not carried out with using as shown in Figure 12~14
The situation of Magnaglo of the crystalline magnetic material powder of edge processing is compared, using containing the crystalline for implementing insulation processing
The situation of the Magnaglo of magnetic material powder, the iron loss Pcv of high frequency region are few.
(G) in the case where Magnaglo contains and implements the crystalline magnetic material of insulation processing, institute in Magnaglo
When the median particle diameter D50 of the noncrystalline magnetic material powder contained is 5 μm, with noncrystalline magnetism material contained in Magnaglo
The median particle diameter D50 at feed powder end is compared when being 6 μm, show trend that the iron loss Pcv in high frequency region is lower (Figure 12~
14).The high frequency trend is more notable.If in addition, the use of median particle diameter D50 is 5 μm of noncrystalline magnetic material powder, with
Compared during using the noncrystalline magnetic material powder that median particle diameter D50 is 6 μm, show the trend that DC superposition characteristic becomes good
(Figure 15).On the other hand, in the case where Magnaglo contains and implements the crystalline magnetic material of insulation processing, Magnaglo
When the median particle diameter D50 of contained noncrystalline magnetic material powder is 6 μm, with the noncrystalline magnetism material contained by Magnaglo
The median particle diameter D50 at feed powder end is compared when being 5 μm, shows the trend (Figure 10) that insulation resistance becomes higher.Therefore, according to this implementation
Example confirms, and based on the characteristic required by compressed-core, controls in the noncrystalline magnetic material powder contained by Magnaglo
Value particle diameter D50 is effective.
(H) result more than confirms, regardless of whether insulation processing is implemented, by using by noncrystalline magnetism material
The Magnaglo that feed powder end and crystalline magnetic material powder are formed, the iron loss Pcv in high frequency region tail off.In addition confirm
Arrive：In the case of the Magnaglo formed using crystalline magnetic material by the material for implementing insulation processing, even in low
Band region, iron loss Pcv also diminish.And then further acknowledge：By controlling noncrystalline magnetic material contained in Magnaglo
The median particle diameter D50 of powder, can adjust magnetic characteristic, the electrical characteristic of compressed-core.
Industrial applicability
Using the electronic and electric components of the compressed-core of the present invention, it may be adapted to the boosting electricity for being used as hybrid vehicle etc.
Reactor used, transformer, choking-winding etc. in road, power generation transformer equipment.
Claims (12)
1. a kind of compressed-core, contains crystalline magnetic material powder and noncrystalline magnetic material powder, it is characterised in that
Using 2 constant khAnd keRepresented by following formula (1) in effective peakflux density BmTo be surveyed under conditions of 15mT
Fixed iron loss Pcv relative to frequency f dependence when, meet：
Pcv=kh×f×Bm 1.6+ke×f2×Bm 2 (1)
The constant khFor 1.5 × 10- 3kW/m3/kHz/(mT)1.6Hereinafter, and
The constant keFor 3.0 × 10- 7kW/m3/(kHz)2/(mT)2Hereinafter,
The unit of the iron loss Pcv is kW/m3, the unit of the frequency f is kHz,
Content and the amorphous of the content of the crystalline magnetic material powder relative to the crystalline magnetic material powder
The quality ratio of the sum of the content of matter magnetic material powder is more than 15 mass % and below 40 mass %,
The crystalline magnetic material is included selected from Fe-Si-Cr classes alloy, Fe-Ni classes alloy, Fe-Co classes alloy, Fe-
1 kind or 2 kinds in V classes alloy, Fe-Al classes alloy, Fe-Si classes alloy, Fe-Si-Al classes alloy, carbonyl iron and pure iron with
On material,
The noncrystalline magnetic material includes being selected from Fe-Si-B classes alloy, Fe-P-C classes alloy and Co-Fe-Si-B classes
One kind or two or more material in alloy.
2. compressed-core according to claim 1, it is characterised in that
The crystalline magnetic material is formed by carbonyl iron.
3. compressed-core according to claim 1, it is characterised in that
The noncrystalline magnetic material is formed by Fe-P-C class alloys.
4. compressed-core according to claim 1 or 2, it is characterised in that
The crystalline magnetic material powder is formed by the material for implementing insulation processing.
5. compressed-core according to claim 1 or 2, it is characterised in that
The median particle diameter D50 of the noncrystalline magnetic material powder is less than 6 μm.
6. compressed-core according to claim 1 or 2, it is characterised in that
The compressed-core contains bonding component, and the bonding component makes the crystalline magnetic material powder and the noncrystalline
Magnetic material powder is bonded with other materials contained in the compressed-core.
7. compressed-core according to claim 6, it is characterised in that
The bonding component contains the component based on resin material.
A kind of 8. manufacture method of compressed-core, it is characterised in that it is the manufacture method of the compressed-core described in claim 7,
Including obtaining the forming process of figuration manufacture thing by shaping processing, the shaping processing includes the press molding of mixture,
The mixture contains the crystalline magnetic material powder and the noncrystalline magnetic material powder and by the resinous wood
Expect the adhesive ingredients formed.
9. the manufacture method of compressed-core according to claim 8, it is characterised in that
And the figuration manufacture thing obtained it is the compressed-core by the forming process.
10. the manufacture method of compressed-core according to claim 8, it is characterised in that
Including heat treatment step, it passes through at the heat that is heated to the figuration manufacture thing obtained through the forming process
Reason, obtains the compressed-core.
11. a kind of electronic and electric components, it is characterised in that including compressed-core according to any one of claims 1 to 7, line
Circle and the connection terminal being connected with each end of the coil, at least a portion of the compressed-core are configured in
In the induced field produced when flowing through electric current to the coil via the connection terminal by the electric current.
12. a kind of electronic electric equipment, it is characterised in that be provided with the electronic and electric components described in claim 11, the electricity
Sub- electric component is connected to substrate via the connection terminal.
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| JP2014-118198 | 2014-06-06 | ||
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| JP2015078963A JP6513458B2 (en) | 2014-06-06 | 2015-04-08 | Dust core, method of manufacturing the dust core, electronic / electrical component comprising the dust core, and electronic / electrical device on which the electronic / electrical component is mounted |
| JP2015-078963 | 2015-04-08 |
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| JP2017208462A (en) * | 2016-05-19 | 2017-11-24 | アルプス電気株式会社 | Powder compact core, manufacturing method thereof, inductor with powder compact core, and electronic/electric device with inductor mounted thereon |
| US11854727B2 (en) * | 2017-03-24 | 2023-12-26 | Proterial, Ltd. | Powder magnetic core with terminal and method for manufacturing the same |
| CN112912976B (en) * | 2018-10-30 | 2024-01-12 | 阿尔卑斯阿尔派株式会社 | Powder compact core, method for manufacturing the same, inductor provided with the same, and electronic/electrical device provided with the inductor |
| CN113275560B (en) * | 2021-05-21 | 2022-08-23 | 东莞市三体微电子技术有限公司 | Alloy finished product powder and preparation method thereof |
| CN117681352B (en) * | 2024-01-29 | 2024-04-05 | 四川金元管业有限公司 | FRTP composite material heating forming system |
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| JP4558664B2 (en) * | 2006-02-28 | 2010-10-06 | 株式会社日立産機システム | Amorphous transformer for power distribution |
| JP5288405B2 (en) * | 2008-11-13 | 2013-09-11 | Ｎｅｃトーキン株式会社 | Inductor and method of manufacturing inductor |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN101523694A (en) * | 2006-05-25 | 2009-09-02 | 莱特工程公司 | Efficient high-speed electric device using low-loss materials |
| CN103540872A (en) * | 2007-03-20 | 2014-01-29 | Nec东金株式会社 | Soft magnetic alloy, magnetic component using the same, and their production methods |
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