CN107799260A - 磁性粉末以及包含磁性粉末的电感器 - Google Patents
磁性粉末以及包含磁性粉末的电感器 Download PDFInfo
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Abstract
本发明提供一种磁性粉末以及包含磁性粉末的电感器。所述磁性粉末包括由直接包覆在具有磁性质的粉末颗粒核上的聚合物材料形成的绝缘层。还提供一种包含所述磁性粉末的电感器。所述磁性粉末在所述粉末颗粒核和所述绝缘层之间不包括单独的无机绝缘层,所述绝缘层具有相对均匀的厚度,并且使用所述磁性粉末形成的主体不包含单独的粘合剂和固化剂,使得可实现高的磁导率和优异的Q因子。
Description
本申请要求于2016年9月7日在韩国知识产权局提交的第10-2016-0115000号以及于2016年9月26日在韩国知识产权局提交的第10-2016-0123403号韩国专利申请的优先权的权益,所述韩国专利申请的公开内容通过引用被全部包含于此。
技术领域
本公开涉及一种磁性粉末以及包含磁性粉末的电感器。
背景技术
为了延续近来的电子产品的趋于小型化和多功能化的趋势,需要使电感器元件小型化。此外,在诸如智能电话的便携式装置中,因功能的多样化而导致需要较强的电流。便携式电子组件使用诸如直流(DC)-DC转换器的电源电路来提供具有不同的内部电路所需的各种电压的操作电力。在DC电路中使用的电感器中,结构上需要具有能够抑制磁饱和并具有高电感的性质的高磁导率材料。
同时,电感器的示例包括如图1A中所示的通过使用模具使金属粉末成型而形成的模制型电感器(mold type inductor)、如图1B中所示的在诸如智能电话的需要纤薄和轻巧化的组件中使用的绕线型电感器以及如图1C中所示的薄膜型电感器。
为了改善诸如上述的那些各种类型的电感器的电性质,已经对生产具有优异的绝缘性质同时具有高的磁导率的磁性材料进行了各种尝试。作为示例,已经公开了通过在合金磁性粉末颗粒的表面上包覆玻璃膜,并使用同时用作绝缘材料和粘合剂的热固性树脂包覆其外部而获得的磁性材料。然而,在使用玻璃以提高耐热性并获得高的绝缘性质的情况下,特别当磁性粉末由合金形成并且热冲击施加到核时,由于合金和玻璃之间的膨胀系数的差异,会产生热应力。结果,可在该玻璃的表面上产生裂纹。此外,难以将绝缘材料的涂层均匀地添加到玻璃涂层,并且,在用于制造电感器的每个工艺中可能产生裂纹。
发明内容
本公开的一方面描述一种能够提供高的磁导率主体的磁性粉末以及具有优异的品质(Q)因子的电感器。
根据本公开的一方面,一种磁性粉末可包括绝缘层,所述绝缘层包含设置在具有磁性质的粉末颗粒核的表面上的聚合物材料,在所述粉末颗粒核和所述聚合物材料之间没有另外的包覆层。
根据本公开的另一方面,一种电感器可包括:主体,包含如上所述的磁性粉末;以及外电极,设置在所述主体上并电连接到嵌在所述主体中的线圈的至少一个端部。
根据本公开的另一方面,一种磁性粉末可包括:粉末颗粒核,具有磁性质;以及绝缘层,设置在所述粉末颗粒核的表面上,其中,所述绝缘层包含聚合物材料,并且所述绝缘层的内表面设置为接触所述粉末颗粒核的所述表面。
根据本公开的另一方面,一种电感器可包括:主体,包括线圈;以及外电极,设置在所述主体的外表面上,其中,所述主体包含位于聚合物材料的基体中的具有磁性质的粉末颗粒核,并且彼此相邻的所述粉末颗粒核通过所述聚合物材料彼此绝缘。
根据本公开的另一方面,一种磁性粉末可包括:粉末颗粒核,具有磁性质,在所述粉末颗粒核的中央部分和表面部分中具有相同的成分;以及绝缘层,包括聚合物材料,并直接设置在所述粉末颗粒核的表面上以接触所述粉末颗粒核的所述表面部分。
附图说明
通过下面结合附图进行的详细描述,本公开的以上和其它方面、特征和优点将被更清楚地理解,在附图中:
图1A至图1C示出了各种类型的电感器;
图2是根据示例性实施例的磁性粉末颗粒的示意性截面图;
图3是根据另一示例性实施例的电感器的示意性截面图;
图4A示出了图3的区域A的放大图的示例;以及
图4B示出了图3的区域A的放大图的另一示例。
具体实施方式
在下文中,将参照附图详细地描述示例性实施例。
在下文中,将描述根据示例性实施例的磁性粉末以及包含该磁性粉末的电感器,但磁性粉末和电感器不必受限于此。
磁性粉末颗粒
图2是根据示例性实施例的磁性粉末颗粒的示意性截面图。参照图2,磁性粉末颗粒1包括具有磁性质的粉末颗粒核1a以及直接设置在粉末颗粒核1a的表面上的绝缘层1b。绝缘层1b直接设置在粉末颗粒核1a的表面上,这意味着由聚合物材料形成的绝缘层1b直接包覆在粉末颗粒核1a的表面上而没有另外的涂层或其它中间层。
作为粉末颗粒核1a的材料,可使用任意材料而没有限制,只要其具有磁性质即可。例如,粉末颗粒核可由从Fe、Fe-Ni基合金、Fe-Si基合金、Fe-Si-Al基合金、Fe-Cr-Si基合金、Fe基非晶合金、Fe基纳米晶合金、Co基非晶合金、Fe-Co基合金、Fe-N基合金、MnZn基铁氧体、NiZn基铁氧体等中选择的一种或更多种形成。
选择粉末颗粒核1a的材料的自由度大,从材料设计的角度来看这是极好的优点。
在根据现有技术的受到氧化处理的电感器中使用的合金的限制在于为了在合金的表面上形成Cr氧化物(Cr2O3)层,需要仅使用包含Cr的Fe-Si-Cr基粉末,这意味着因不能改变基体粉末材料而在提高磁导率方面存在限制。
由于在根据本公开的磁性粉末中,由作为单独的材料的聚合物材料形成的绝缘层设置在粉末颗粒核1a上,因此在选择粉末颗粒核1a的材料方面不存在限制,并可使用能够实现高磁导率的各种合金。
粉末颗粒核1a可具有如图2中所示的基本上球形形状或者椭圆形形状。可选地,粉末颗粒核1a可具有包括部分地形成拐角的各种其它形状。粉末颗粒核1a的形状没有限制。
同时,粉末颗粒核1a的中央部分和表面部分具有基本上彼此相同的成分,这意味着粉末颗粒核1a的表面不受到单独的氧化处理等。在粉末颗粒核1a由合金形成的情况下,粉末颗粒核1a被自然地氧化,从而可形成预定的氧化物层。然而,氧化物层的量可显著地少,并且粉末颗粒核1a的中央部分和表面部分可具有基本上彼此相同的成分。
接下来,将描述由聚合物材料形成并包覆在粉末颗粒核1a的表面的至少一部分上的绝缘层1b。参照图2,绝缘层1b可以以均匀的厚度设置在粉末颗粒核1a的外周表面上。根据现有技术,为了保持合金粉末的绝缘性质,通过使用高岭土、MgO、滑石、水玻璃等形成无机绝缘层来保持产品的强度,然后利用例如环氧树脂的聚合物材料包覆无机绝缘层的表面并使其固化。然而,在根据现有技术的磁性粉末具有由如上所述的无机绝缘层和环氧树脂层组成的双层的情况下,磁性粉末颗粒和与其相邻的另一磁性粉末颗粒之间的距离相对增大,使得磁导率会减小。在增大磁性粉末的颗粒尺寸以确保磁导率在同等水平的情况下,会减小品质(Q)值。
由于根据示例性实施例的磁性粉末颗粒1具有由聚合物材料形成的绝缘层1b直接包覆在粉末颗粒核1a上的结构,因此磁性粉末具有与根据现有技术的双绝缘层明确地区分开的单个绝缘层,且没有根据现有技术的双绝缘层中存在的问题。具体地,根据示例性实施例,由聚合物材料形成的绝缘层1b直接包覆在粉末颗粒核1a上,使得粉末颗粒核1a不包含具有与粉末颗粒核的成分不同的成分并设置在粉末颗粒核1a和绝缘层1b之间的另外的无机层。
绝缘层1b中使用的聚合物材料不受具体限制,但可优选为热固性树脂。特别优选的是,聚合物材料是环氧树脂。可根据磁性粉末的将需要的特性对环氧树脂进行各种改变。例如,在需要高电阻绝缘性质的情况下,环氧树脂可以是不包括苯环的环氧树脂并且可以是通常用作粘合剂的环氧树脂,但不限于此。
绝缘层1b可根据粉末颗粒核1a的外型形成为具有相对均匀的厚度,并可根据所需的绝缘性质具有各种厚度,但绝缘层通常可具有在优选大于等于1.0nm至小于等于5.0μm的范围内的厚度。当绝缘层1b的厚度薄于1.0nm时,难以确保足够的绝缘性质,当其厚度厚于5.0μm时,彼此相邻的磁性粉末之间的距离会相对增大,从而会难以确保足够的磁导率。
在当前的应用中,绝缘层的厚度是均匀的,这意味着绝缘层的最小厚度为1.0nm,绝缘层的最大厚度为5.0μm。例如,即使设置在粉末颗粒核上的绝缘层的厚度不相同,厚度也至多不会超过1.0nm至5.0μm的范围。即使在粉末颗粒核1a不具有球形形状的情况下,也可将绝缘层的厚度设定为在从粉末颗粒核1a的重心延伸到粉末颗粒核1a的表面的直线上从粉末颗粒核1a的表面到绝缘层1b的外表面之间的距离。
接下来,将描述磁性粉末1的具体制备方法的示例。然而,根据本公开的磁性粉末1的制备方法不限于以下将描述的制备方法,并且磁性粉末1不限于通过以下将描述的制备方法所制备的磁性粉末。
作为具有磁性质的粉末颗粒核材料,可选择具有期望的成分和含量的合金。类似地,可选择能够实现期望的绝缘性质的聚合物材料。粉末颗粒核1a和聚合物材料可被制备为使得聚合物材料相对于100wt%的粉末颗粒的重量比在大于等于1wt%至小于等于5wt%的范围内,但可根据聚合物材料的物理性质适当地改变该重量比。如上所述制备的粉末颗粒核1a和聚合物材料可以是使用V型混合机、球磨机、研磨机、珠磨机、各种旋转混合机等的干式搅拌和混合或湿式搅拌和混合。可执行混合持续5分钟至200小时。与干式混合方法不同,在使用湿式混合方法在磁性粉末上包覆聚合物材料的情况下,有必要使用溶剂。在对磁性粉末颗粒和聚合物材料进行湿式搅拌和混合的情况下,可使用流化床干燥器、喷雾干燥器等来干燥磁性粉末颗粒。
如上所述获得的磁性粉末可包括以相对均匀的厚度包覆在粉末颗粒核1a上的单个绝缘层,使得当在以下将要描述的电感器的主体中使用磁性粉末的情况下,可实现高的磁导率和优异的Q因子。
电感器
接下来,将描述根据另一示例性实施例的包含磁性粉末的电感器。
图3是根据另一示例性实施例的电感器的示意性截面图,图4A和图4B示出了图3的区域A的放大图的示例。
参照图3,根据示例性实施例的电感器100可包括:主体10,主体10中嵌入有具有两个端部的线圈12;以及第一外电极21和第二外电极22,设置在主体10的外表面的至少部分上并连接到线圈12的相应的端部。
根据制造方法,嵌在主体中的线圈12可以是绕线线圈、层叠线圈或者薄膜线圈,并可根据设计变化进行适当地选择。线圈可具有螺旋形形状或者是平面线圈。线圈的材料没有限制,只要其具有优异的导电性即可。例如,线圈可由从金(Au)、银(Ag)、铂(Pt)、铜(Cu)、镍(Ni)、钯(Pd)、铝(Al)、钛(Ti)等选择的一种金属形成,或者可以是它们的合金。
主体10可包含上述磁性粉末1,并将参照图4A和图4B进行描述,图4A和图4B是图3的区域A的放大图。
除了在主体中的磁性粉末的布置中磁性粉末之间的邻近程度或磁性粉末的形状之外,图4B中示出的构造与图4A中示出的构造大体上相同。因此,在下文中,将基于图4A描述电感器的主体中的区域A,并将基于与图4A的不同来描述图4B。
参照图4A,磁性粉末1中的粉末颗粒核1a可设置为通过设置在粉末颗粒核1a的表面上的绝缘层1b的厚度与另一粉末颗粒核1a’相邻。
总之,可被认为是,主体10包含位于由包覆在粉末颗粒核1a上的绝缘层1b之间的连接而形成的基体中的粉末颗粒核1a。这意味着除了包含在绝缘层1b中的聚合物材料之外,主体10不包含单独的固化剂、粘合剂的残余物等。
虽然图4A中示出了粉末颗粒核1a具有基本上球形形状的情况,但粉末颗粒核材料可通过混合形状和平均粒径彼此不同的两种或更多种粉末颗粒核而构成。在使用具有不同的晶体粒径的粉末颗粒核1a的情况下,可通过增大磁性粉末在主体10中的填充密度来增大磁导率。此外,可改变粉末颗粒核1a的形状。例如,在粉末颗粒具有长轴和短轴彼此不同的片形状的情况下,可提高由线圈12产生的磁通量的密度。
关于主体10中包含的粉末颗粒核1a和包覆到粉末颗粒核1a的表面上的绝缘层1b之间的体积比,优选的是,基于100vol%的粉末颗粒核1a,绝缘层1b的体积比在3vol%至15vol%的范围内。在绝缘层1b的体积比小于3vol%的情况下,不能充分地展现绝缘性质,在绝缘层1b的体积比大于15vol%的情况下,可能难以确保足够的磁导率。
接下来,将详细地描述主体中的绝缘层1b的功能。
首先,包覆在粉末颗粒核1a上的绝缘层1b可用作将磁性粉末颗粒彼此绝缘的绝缘层,从而不导电。与根据现有技术的在无机绝缘层上再次包覆有机绝缘层的情况相比,可实现具有相对薄且均匀的厚度并具有绝缘性质的绝缘层1b。
此外,包覆在粉末颗粒核1a上的绝缘层1b可用作通过热处理将粉末颗粒彼此固定并赋予磁性粉末的强度的固化剂。这意味着,当在形成主体期间固化磁性粉末的混合粉末的情况下,磁性粉末通过直接包覆在粉末颗粒核1a上的绝缘层1b被固化,而不需要添加单独的固化剂,例如苯酚、酸酐、胺等。
然后,包覆在粉末颗粒核1a上的绝缘层1b可用作粘合剂。由于绝缘层1b可具有粘合剂树脂的功能以及绝缘功能,因此并不必然需要单独的粘合剂树脂。当然,可将粘合剂树脂添加到主体,但在没有添加粘合剂树脂的情况下,可提高磁导率,并可减小核损耗。
接下来,参照图4B,与图4A类似,磁性粉末1中的粉末颗粒核1a可通过设置在粉末颗粒核1a的表面上的绝缘层1b而设置为与另一粉末颗粒核1a’相邻。
然而,图4B中的彼此相邻的磁性粉末的粉末颗粒核1a和1a’之间的距离比图4A中的彼此相邻的磁性粉末的粉末颗粒核1a和1a’之间的距离短。邻近程度可以是彼此独立的粉末颗粒核1a和1a’形成基本上单个粉末颗粒的程度。在这种情况下,形成单个粉末颗粒核,这意味着不能通过裸眼来区分在固化的主体中的不同的粉末颗粒材料的各自的粒径。当然,单个电感器的主体中的粉末颗粒之间的距离可以是变化的,并且可通过诸如在固化工艺中施加到其上的温度、固化压力、绝缘层的厚度等各种因素来多样性地并综合地确定该距离。
如上所述,主体中包含的磁性粉末1包括单个绝缘层1b,并且绝缘层1b可同时实现绝缘功能、粘合剂的功能以及固化剂的功能,使得可提供能够具有高的磁导率和高的Q值的电感器而不受用作粉末颗粒核的材料的限制。
由于除了形成主体之外,电感器的制造方法与一般的电感器的制造方法相同,因此在下文中,将主要描述电感器的主体10的形成方法。
首先,可制备通过上述方法制备的磁性粉末1。磁性粉末1可由粉末颗粒核和直接涂敷在粉末颗粒核的表面上的绝缘层组成。在将制备的磁性粉末填充在模具的腔中之后,对磁性粉末执行模具加紧,并可压制填充在模具腔中的磁性粉末。优选的是,以例如5ton/cm2至20ton/cm2来压制磁性粉末,以适于使芯成型。此后,可从腔中取出已压制的磁性粉末的成型的主体,并在适当的温度(例如100℃至300℃)下进行固化。在将线圈缠绕在如上所述进行设置并根据通常的芯组装工艺成型的磁芯的中央部分中之后,可通过将外电极和线圈的引线部彼此连接来制造电感器。
除了先前给出的描述之外,将省略与根据示例性实施例的磁性粉末和电感器的描述重复的描述。
如上所述,根据示例性实施例,磁性粉末和包含磁性粉末的电感器可具有高的磁导率和优异的Q因子。
虽然以上已经示出并描述了示例性实施例,但对本领域的技术人员而言将显而易见的是,在不脱离由所附的权利要求所限定的本发明的范围的情况下,可做出修改和变型。
Claims (20)
1.一种磁性粉末,包括:
粉末颗粒核,具有磁性质;以及
绝缘层,设置在所述粉末颗粒核的表面上,
其中,所述绝缘层包含聚合物材料,并且所述绝缘层的内表面设置为接触所述粉末颗粒核的所述表面。
2.根据权利要求1所述的磁性粉末,其中,所述绝缘层包覆所述粉末颗粒核的整个所述表面,并且所述绝缘层是单层。
3.根据权利要求1所述的磁性粉末,其中,所述绝缘层包含热固性环氧树脂。
4.根据权利要求1所述的磁性粉末,其中,所述粉末颗粒核包含从Fe、Fe-Ni基合金、Fe-Si基合金、Fe-Si-Al基合金、Fe-Cr-Si基合金、Fe基非晶合金、Fe基纳米晶合金、Co基非晶合金、Fe-Co基合金、Fe-N基合金、MnZn基铁氧体和NiZn基铁氧体中选择的一种或更多种。
5.根据权利要求1所述的磁性粉末,其中,所述绝缘层基于100wt%的所述粉末颗粒核包含大于等于1wt%至小于等于5.0wt%的范围内的所述聚合物材料。
6.根据权利要求1所述的磁性粉末,其中,在从所述粉末颗粒核的重心延伸到所述粉末颗粒核的所述表面的直线上从所述粉末颗粒核的所述表面到所述绝缘层的外表面的距离为大于等于1.0nm且小于等于5.0μm。
7.根据权利要求1所述的磁性粉末,其中,在所述粉末颗粒核的中央部分和表面部分中具有相同的成分,并且所述绝缘层直接设置在所述粉末颗粒核的所述表面部分上。
8.一种电感器,包括:
主体,包括线圈;以及
外电极,设置在所述主体的外表面上,
其中,所述主体包含位于聚合物材料的基体中的具有磁性质的粉末颗粒核,并且
彼此相邻的所述粉末颗粒核通过所述聚合物材料彼此绝缘。
9.根据权利要求8所述的电感器,其中,位于所述基体中的所述聚合物材料直接接触每个粉末颗粒核的表面。
10.根据权利要求8所述的电感器,其中,所述聚合物材料包括热固性环氧树脂。
11.根据权利要求8所述的电感器,其中,基于所述主体中的100vol%的所述粉末颗粒核,所述基体的所述聚合物材料的体积比为大于等于3vol%至小于等于15vol%。
12.根据权利要求8所述的电感器,其中,每个粉末颗粒核的中央部分和每个粉末颗粒核的表面部分具有彼此相同的成分,并且每个粉末颗粒核的所述表面部分不包含具有与所述粉末颗粒核的成分不同的成分的另外的无机层。
13.根据权利要求8所述的电感器,其中,所述聚合物材料的绝缘层包覆每个粉末颗粒核的整个表面。
14.根据权利要求13所述的电感器,其中,每个粉末颗粒核仅包括包覆在所述粉末颗粒核上的一个绝缘层。
15.根据权利要求8所述的电感器,其中,除了包含在所述基体中的所述聚合物材料之外,剩余的固化剂或剩余的粘合剂的含量为0wt%。
16.一种磁性粉末,包括:
粉末颗粒核,具有磁性质,在所述粉末颗粒核的中央部分和表面部分中具有相同的成分;以及
绝缘层,包括聚合物材料,并直接设置在所述粉末颗粒核的表面上以接触所述粉末颗粒核的所述表面部分。
17.根据权利要求16所述的磁性粉末,其中,所述绝缘层包覆所述粉末颗粒核的整个表面。
18.根据权利要求16所述的磁性粉末,其中,仅一个绝缘层设置在所述粉末颗粒核上。
19.根据权利要求16所述的磁性粉末,其中,所述粉末颗粒核不含任何氧化物。
20.根据权利要求16所述的磁性粉末,其中,所述绝缘层在所述粉末颗粒核上具有均匀的厚度。
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