CN107924743A - 软磁性粉末 - Google Patents
软磁性粉末 Download PDFInfo
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- CN107924743A CN107924743A CN201680044417.5A CN201680044417A CN107924743A CN 107924743 A CN107924743 A CN 107924743A CN 201680044417 A CN201680044417 A CN 201680044417A CN 107924743 A CN107924743 A CN 107924743A
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- 239000006247 magnetic powder Substances 0.000 title claims abstract description 102
- 239000002245 particle Substances 0.000 claims abstract description 56
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Abstract
本公开的软磁性粉末包含不具有中空部的粒子作为主成分,在将软磁性粉末压粉成型以使积填充率为75%~77%而得到的成型体的截面中,存在于2.5mm见方的区域的中空粒子的个数为40以下。
Description
技术领域
本发明涉及软磁性粉末及其制造方法。
背景技术
在电子设备中使用的线圈部件的磁芯(core)材料等用途中广泛使用具有非晶结构的软磁性粉末。作为软磁性粉末的制造方法,例如已知利用高速旋转水流的水雾化法(SWAP法,Spinning Water Atomization Process)来制作软磁性Fe-Si-B-C合金的方法(非专利文献1)。根据非专利文献1中记载的方法,使用由真空熔化部、基于高压气体喷射的熔液断开部、圆筒容器高速旋转水流部和粉末回收部构成的SWAP装置,将从坩埚底部取出的熔融合金利用气体射流细碎地断开,喷射到高速旋转水流中使其凝固,由此制作非晶体合金粉末。
现有技术文献
非专利文献
非专利文献1:远藤功,其他7名,“利用新的水雾化法(SWAP法)进行的非晶软磁性粉末的制作”,粉体和粉末冶金,2001年8月,第48卷,第8号,p.697-702
发明内容
但是,根据本发明人等的研究,可知利用现有方法得到的软磁性粉末中有含大量中空粒子的趋势。将含大量中空粒子的软磁性粉末用作线圈部件的磁芯材料时,存在功率损耗(铁芯损耗)增大的问题。
本发明的目的在于提供一种减少了中空粒子的含量且在作为磁芯材料使用时能够降低铁芯损耗的软磁性粉末及其制造方法。
本发明人等反复进行深入研究,结果发现在利用气体雾化法制造软磁性粉末时,通过适当地控制母合金熔液流量与喷射气体流量的比率,能够减少软磁性粉末中含有的中空粒子的个数,从而完成了本发明。
根据本发明的第1要旨,提供一种软磁性粉末,其含有不具有中空部的粒子作为主成分,在将软磁性粉末压粉成型以使体积填充率为75%~77%而得到的成型体的截面中,存在于2.5mm见方的区域的中空粒子的个数为40以下。
根据本发明的第2要旨,提供一种软磁性粉末的制造方法,其通过气体雾化法将母合金熔液利用喷射气体粉碎而形成软磁性粉末,其中,将熔液流量(重量基准)除以喷射气体流量(体积基准)而得的值为3.1g/L以下。
根据本发明的第3要旨,提供一种线圈部件,其具有磁性体部以及埋设于磁性体部的线圈导体,所述磁性体部含有上述的软磁性粉末和树脂,磁性体部中的软磁性粉末的含量为60vol%以上。
根据本发明的第4要旨,提供一种线圈部件,其包含磁芯以及卷绕于磁芯的线圈导体,所述磁芯含有上述的软磁性粉末和树脂,磁芯中的软磁性粉末的含量为60vol%以上。
本发明的软磁性粉末具有中空粒子的含量少的优点。另外,本发明的软磁性粉末的制造方法通过具有上述构成,能够提供减少了中空粒子的含量且在作为磁芯材料使用时可降低铁芯损耗的软磁性粉末。此外,本发明的线圈部件通过具有上述构成,能够降低铁芯损耗。
附图说明
图1是使用例5的软磁性粉末制作的成型体的截面的显微镜照片。
具体实施方式
以下,对本发明的实施方式进行说明。但是以下示出的实施方式是以例示为目的的,本发明并不限于以下的实施方式。
本发明的一个实施方式的软磁性粉末含有不具有中空部的粒子作为主成分。即,本实施方式的软磁性粉末为减少了中空粒子的含量的软磁性粉末。应予说明,在本说明书中,“中空粒子”表示在内部具有中空部的粒子。本实施方式的软磁性粉末中的中空粒子的含量可以按照以下说明的将软磁性粉末压粉成型以成为规定的体积填充率而得到的成型体的截面中的中空粒子的个数来进行评价。本实施方式的软磁性粉末中,在将软磁性粉末压粉成型以使体积填充率为75%~77%而得到的成型体的截面中,存在于2.5mm见方的区域的中空粒子的个数为40以下。其中,以下说明的成型体的制作和中空粒子数的测量是为了评价软磁性粉末中的中空粒子的含量而进行的,对使用本发明的软磁性粉末的制品的体积填充率没有任何限定。本实施方式的软磁性粉末可以适用于任意的体积填充率的制品。
首先,将软磁性粉末压粉成型以使体积填充率为75%~77%而得到成型体。具体而言,将软磁性粉末和有机硅树脂的树脂以规定的比例混合,将该混合物以100MPa左右的压力加压成型而得到成型体。成型体的形状没有特别限定,例如,可以为外径10mm、厚度2.5mm的圆板。使通过加压成型得到的成型体利用热处理进行固化,得到体积填充率为75%~77%的成型体。体积填充率是通过测定成型体的外径和重量而求出密度并将其除以软磁性粉末的真比重而得的值。软磁性粉末的真比重可以通过阿基米德法求出。
将上述的成型体的表面在厚度方向研磨0.5mm左右而露出截面,利用显微镜等拍摄该截面的照片。显微镜的倍率优选为100倍左右。在得到的照片中,随机抽取2.5mm见方(面积6.25mm2)的区域,测定存在于该区域内的中空粒子的个数。中空粒子的个数可以通过目视进行测定。在成型体的截面中,存在于2.5mm见方(面积6.25mm2)的区域的中空粒子的个数为40以下。软磁性粉末中的中空粒子是将软磁性粉末作为磁芯材料使用时的铁芯损耗增大的原因。中空粒子的个数为40以下时,能够降低铁芯损耗,能够得到优异的软磁特性。
应予说明,如上所述,本实施方式的软磁性粉末中的中空粒子的个数虽然使用体积填充率为75%~77%的成型体进行了规定,但即便使用体积填充率为上述范围外的成型体也可以规定中空粒子数。具体而言,可以利用图像解析求出成型体的截面中的树脂成分的面积和软磁性粉末的面积,基于这些面积的值按体积填充率75%~77%进行换算而求出中空粒子的个数。另外,在本实施方式中,虽然规定了存在于2.5mm见方的区域内的中空粒子的个数,但并非是对测定中空粒子的个数的区域的面积进行的限定,可以将在任意面积的区域内测量的中空粒子的个数以2.5mm见方(面积6.25mm2)的面积进行换算而求出中空粒子的个数。
在本实施方式的软磁性粉末中减少中空粒子的含量的机制尽管不受任何理论的约束,但认为大致如下。本实施方式的软磁性粉末如后所述通过利用喷射气体对母合金熔液进行高压粉碎而得到。此时,认为因在粉碎时喷射气体被卷入到熔液而形成中空粒子。本实施方式的软磁性粉末可以通过适当地控制熔液的流量和喷射气体的流量来抑制喷射气体被卷入,其结果,能够减少中空粒子的个数。
本实施方式的软磁性粉末优选包含作为主成分含有Fe的合金组合物。合金组合物除了Fe以外,还可以含有Co和/或Ni。合金组合物中的Fe、Co和Ni的含量的合计优选为72at.%~85at.%(其中,Co和/或Ni的含量可以为0at.%)。另外,本实施方式的软磁性粉末优选含有非晶结构。软磁性粉末具有上述组成时,能够进一步降低铁芯损耗。
软磁性粉末的平均粒径优选为10μm~70μm。如果平均粒径过小,则有时难以利用气体雾化法来制造软磁性粉末。如果平均粒径为10μm以上,则可以容易地利用气体雾化法来制作软磁性粉末。另一方面,如果平均粒径过大,则有时球形度小的变形的异形粒子的含量增加,其结果,使用性有可能会变差。如果平均粒径为70μm以下,则能够容易地得到球形度高的粒子,其结果,可以提高使用性。软磁性粉末的平均粒径可以利用干式的激光衍射式粒度分布仪进行测定。
接下来,对于本发明的一个实施方式的软磁性粉末的制造方法进行以下的说明。本实施方式的软磁性粉末的制造方法通过气体雾化法将母合金熔液利用喷射气体粉碎而形成软磁性粉末,其中,将熔液流量(重量基准)除以喷射气体流量(体积基准)而得的值为3.1g/L以下。
首先,准备具有规定组成的母合金。可以将Fe、FeSi合金、FeB合金等的原料在坩埚中熔化,进行冷却而得到具有均匀组成的母合金。母合金优选含有Fe作为主成分,除了Fe以外,还可以含有Co和/或Ni。母合金中的Fe、Co和Fe的合计含量优选为72at.%~85at.%(其中,Co和/或Ni的含量可以为0at.%)。如果母合金具有上述组成,则能够得到作为磁芯材料使用时可降低铁芯损耗的软磁性粉末。
接下来,将气体雾化装置的内部设定为氩气、氮气等非活性气氛。也可以设定为在该非活性气氛中添加有氢气的混合气体气氛。添加氢气时,能够抑制金属(合金)的氧化。气体雾化装置的内部例如可以设定为添加有以分压换算为3%的氢气的氩气的混合气体气氛。
将上述的母合金粉碎至易于熔化的大小5mm左右。将已粉碎的母合金投入到气体雾化装置的坩埚中,利用高频感应加热进行加热使母合金熔化,得到熔液。接着,在上述的混合气体气氛下将喷射气体向熔液喷射而进行粉碎,得到合金粉末。此时,设定熔液流量和喷射气体流量以使将熔液流量MM(重量基准)除以喷射气体流量MJ(体积基准)而得的值MM/MJ为3.1g/L以下。根据本发明人等的研究,认为中空粒子是因未凝固的熔液中卷入高压水或高压气体而产生的。特别是在为了粉碎母合金而使用高压水的情况下,由于水的蒸发而使中空粒子的个数增多。因此,在将使用高压水制造的软磁性粉末作为磁芯材料使用时,铁芯损耗的增大会变得显著。另外,如果与熔液的流量相比喷射气体的流量过大,则容易引起喷射气体被卷入到熔液中,容易形成中空粒子。在本实施方式的软磁性粉末的制造方法中,通过使用喷射气体来粉碎母合金,进一步如上所述地控制熔液流量和喷射气体流量,从而能够抑制喷射气体被卷入到熔液中,能够减少中空粒子的个数。其结果,在将得到的软磁性粉末作为磁芯材料使用时,能够降低铁芯损耗,能够得到优异的软磁特性。将熔液流量MM(重量基准)除以喷射气体流量MJ(体积基准)而得的值MM/MJ优选为0.1g/L~2.0g/L。MM/MJ的值为0.1g/L以上时,能够以低成本制造软磁性粉末。如果MM/MJ的值为2.0g/L以下,则能够进一步减少中空粒子的个数。
对于母合金熔液的流量和喷射气体的流量,只要将熔液流量(重量基准)除以喷射气体流量(体积基准)而得的值为上述范围内,就没有特别限定,可以根据使用的装置而适当地设定。例如,母合金熔液的流量可以为10g/秒~50g/秒,喷射气体的流量可以为10L/秒~50L/秒。在气体雾化装置中配置有多个熔液喷嘴时,与各个熔液喷嘴有关的熔液的流量和喷射气体的流量可以为上述范围。
喷射气体优选含有非活性气体。喷射气体含有非活性气体时,能够抑制金属成分的氧化等不希望的反应。喷射气体例如可以含有Ar和/或N2。另外,喷射气体可以含有以分压换算为0.5%~7%的H2。喷射气体在上述范围内含有H2时,能够有效地抑制金属成分的氧化。
利用喷射气体粉碎母合金熔液后,可以用冷却水进行骤冷。通过用冷却水进行骤冷,能够抑制粗大晶体的生成,能够得到良好的磁特性。通过如上所述进行粉碎以及根据情况进行骤冷,能够得到本实施方式的软磁性粉末。该软磁性粉末可以根据情况过筛(例如网孔53μm的筛)进行整粒。
接下来,对将本发明的软磁性粉末作为磁芯材料使用的线圈部件的一个实施方式进行说明。本实施方式的线圈部件具有磁性体部以及埋设于磁性体部的线圈导体,所述磁性体部含有上述的软磁性粉末和树脂,磁性体部中的软磁性粉末的含量为60vol%以上。本实施方式的线圈部件因为使用减少了中空粒子的含量的本实施方式的软磁性粉末作为磁芯材料,所以具有优异的软磁特性。本实施方式的线圈部件例如可以按照以下说明的顺序进行制造。首先,形成多张含有软磁性粉末和树脂的复合材料的片材。然后,在片材之间配置线圈导体。以在片材之间配置有线圈导体的状态对片材进行热压,由此得到具有磁性体部以及埋设于磁性体部的线圈导体的线圈部件,其中,所述磁性体部含有软磁性粉末和树脂。
接下来,对将本发明的软磁性粉末作为磁芯材料使用的线圈部件的另一个实施方式进行说明。本实施方式的线圈部件包含磁芯以及卷绕于磁芯的线圈导体。所述磁芯含有上述的软磁性粉末和树脂,磁芯中的软磁性粉末的含量为60vol%以上。本实施方式的线圈部件因为将减少了中空粒子的含量的本实施方式的软磁性粉末作为磁芯材料使用,所以具有优异的软磁特性。本实施方式的线圈部件例如可以按照以下说明的顺序进行制造。首先,混合软磁性粉末和有机硅树脂、环氧树脂、酚醛树脂等树脂得到混合物。以规定的压力对该混合物进行加压成型,形成磁芯。磁芯的形状和尺寸没有特别限定,例如可以为外径13mm、内径8mm、厚度2.5mm的环形磁芯。通过对该磁芯进行热处理而使其固化。将铜线等卷绕于已固化的磁芯,从而可以形成包含磁芯和卷绕于磁芯的线圈导体的线圈部件。
另外,可以使用本发明的软磁性粉末而形成马达的定子铁芯。马达具备:在上述电枢齿上卷绕有线圈导体的线圈部件;可旋转地配置于该线圈部件的内部的转子;以及在同一圆周上以等间隔设有多个电枢齿的定子铁芯。本发明的软磁性粉末具有高饱和磁通密度且低磁损耗,因此通过用本发明的软磁性粉末形成定子铁芯而可以得到功率损耗低的高品质的马达。
实施例
按照以下说明的顺序,制作例1~15的软磁性粉末。首先,准备制备成表1的组成的母合金。将该母合金粉碎成5mm左右的大小。将气体雾化装置的内部设定成添加有以分压换算3%的氢气的氩气的混合气体气氛。将已粉碎的上述的母合金投入到气体雾化装置的坩埚中,利用高频感应加热而加热到1350℃,使母合金熔化,得到熔液。
接下来,在上述的混合气体气氛下将喷射气体向熔液喷射而进行粉碎,得到合金粉末。作为喷射气体使用氩气。在例7、8、14和15中,利用喷射气体将熔液粉碎后,用冷却水进行骤冷(在表2中记载为“并用气体和水的雾化”)。喷射气体的压力PJ和流量MJ以及熔液的流量MM设定为表2中示出的值。将熔液流量(重量基准)除以喷射气体流量(体积基准)而得到值MM/MJ,将该值MM/MJ示于表2。使得到的合金粉末通过网孔53μm的筛,得到例1~15的软磁性粉末。
(中空粒子的个数的测量)
按照以下说明的顺序,进行例1~15的软磁性粉末中含有的中空粒子的个数的测量。首先,将各试样采取2g,相对于软磁性粉末100重量份添加3重量份(相对于软磁性粉末100体积份为17体积份)的有机硅树脂而得到混合物。将该混合物在100MPa的压力进行加压成型,制作外径10mm、厚度2.5mm的圆板。将该圆板以160℃进行1小时热处理而使其固化,得到成型体。这样得到的成型体中的软磁性粉末的体积填充率为75%~77%。应予说明,体积填充率是通过测定成型体的外径和重量而求出密度并将其除以软磁性粉末的真比重而得的值。
将上述的成型体的表面在厚度方向研磨0.5mm而露出截面。利用显微镜以倍率100倍拍摄该截面的照片,随机抽取2.5mm见方(面积6.25mm2)的区域,通过目视对存在于区域内的中空粒子的个数进行计数。中空粒子数的计数就各试样每个在2个区域内实施,算出2个区域中的中空粒子数的平均值。将结果示于表2。另外,将使用例5的软磁性粉末制作的成型体的截面的显微镜照片作为代表而示于图1。
(铁芯损耗测定)
使用例1~15的软磁性粉末作为磁芯材料,按照以下说明的顺序来制作环形磁芯,进行铁芯损耗的测定。首先,将各试样采取2g,相对于软磁性粉末100重量份添加3重量份(相对于软磁性粉末100体积份为17体积份)的有机硅树脂而得到混合物。将该混合物在100MPa的压力下进行加压成型,制作外径13mm、内径8mm、厚度2.5mm的环形磁芯。将该环形磁芯以160℃进行1小时热处理而使其固化。在已固化的环形磁芯上卷绕粗度为0.24mm的铜线,制作具备一次绕组和二次绕组的线圈部件。一次绕组和二次绕组的匝数分别为16匝。使用岩通测量株式会社制的B-H Analyzer SY-8217,在外加磁场30mT、测定频率1MHz下测定线圈部件的铁芯损耗。将结果示于表2。应予说明,在表1和2中带有“*”的例子为比较例。
表1
例 | 组成 |
1 | Fe75.6Si9B10P5Cu0.4 |
2 | Fe75.6Si9B10P5Cu0.4 |
3 | Fe75.6Si9B10P5Cu0.4 |
4 | Fe75.6Si9B10P5Cu0.4 |
5 | Fe75.6Si9B10P5Cu0.4 |
6 | Fe75.6Si9B10P5Cu0.4 |
7 | Fe75.6Si9B10P5Cu0.4 |
8 | Fe75.6Si9B10P5Cu0.4 |
9 | Fe70Ni6Si9B9P6 |
10 | Fe70Co6Si9B9P6 |
11 | Fe78.3Si5.3B6.8P8.9Cu0.7 |
12* | Fe75.6Si9B10P5Cu0.4 |
13* | Fe75.6Si9B10P5Cu0.4 |
14* | Fe75.6Si9B10P5Cu0.4 |
15* | Fe75.6Si9B10P5Cu0.4 |
[表2]
如表2所示,在将熔液流量除以喷射气体流量而得的值MM/MJ为3.1g/L以下的例1~11的软磁性粉末中,存在于2.5mm见方的区域的中空粒子的个数为40以下。与此相对,在MM/MJ的值大于3.1g/L的例12~15的软磁性粉末中,存在于2.5mm见方的区域的中空粒子的个数大于40。根据该结果,可知通过将MM/MJ的值控制为3.1g/L以下,能够减少存在于软磁性粉末中的中空粒子的个数。
另外,如表2所示,使用中空粒子的个数为40以下的例1~11的软磁性粉末制作的线圈部件的铁芯损耗为2000kW/m3以下的低值。与此相对,使用中空粒子的个数大于40的例12~15的软磁性粉末制作的线圈部件的铁芯损耗为高于2000kW/m3的值。根据该结果,可知通过减少存在于软磁性粉末中的中空粒子的个数,能够降低线圈部件的铁芯损耗,能够得到优异的软磁特性。
产业上的可利用性
本发明的软磁性粉末在作为磁芯材料使用时能够降低铁芯损耗,所以能够在可用于要求高性能的电子设备的线圈部件中应用。
Claims (11)
1.一种软磁性粉末,其含有不具有中空部的粒子作为主成分,在将所述软磁性粉末压粉成型以使体积填充率为75%~77%而得到的成型体的截面中,存在于2.5mm见方的区域的中空粒子的个数为40以下。
2.根据权利要求1所述的软磁性粉末,其中,所述软磁性粉末包含含有Fe作为主成分的合金组合物,所述合金组合物中的Fe、Co和Ni的含量合计为72at.%~85at.%,其中,Co和/或Ni的含量可以为0at.%,并且,所述软磁性粉末含有非晶结构。
3.根据权利要求1或2所述的软磁性粉末,其中,所述软磁性粉末的平均粒径为10μm~70μm。
4.一种软磁性粉末的制造方法,通过气体雾化法将母合金熔液利用喷射气体粉碎而形成软磁性粉末,其中,将重量基准熔液流量除以体积基准喷射气体流量而得的值为3.1g/L以下。
5.根据权利要求4所述的方法,其中,将所述母合金熔液利用喷射气体粉碎后,用冷却水进行骤冷。
6.根据权利要求4或5所述的方法,其中,所述母合金含有Fe作为主成分,该母合金中的Fe、Co和Ni的含量的合计为72at.%~85at.%,其中,Co和/或Ni的含量可以为0at.%。
7.根据权利要求4~6中任一项所述的方法,其中,所述喷射气体含有非活性气体。
8.根据权利要求7所述的方法,其中,所述喷射气体含有Ar和/或N2。
9.根据权利要求7或8所述的方法,其中,所述喷射气体含有以分压换算为0.5%~7%的H2。
10.一种线圈部件,具有磁性体部以及埋设于该磁性体部的线圈导体,所述磁性体部含有权利要求1~3中任一项所述的软磁性粉末和树脂,所述磁性体部中的所述软磁性粉末的含量为60vol%以上。
11.一种线圈部件,含有磁芯以及卷绕于该磁芯的线圈导体,所述磁芯含有权利要求1~3中任一项所述的软磁性粉末和树脂,所述磁芯中的所述软磁性粉末的含量为60vol%以上。
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CN112533712A (zh) * | 2019-02-04 | 2021-03-19 | 三菱动力株式会社 | 金属粉末制造装置及其气体喷射器 |
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JP7473424B2 (ja) * | 2019-10-31 | 2024-04-23 | Tdk株式会社 | 磁性体コアおよびコイル部品 |
JP2023045961A (ja) * | 2021-09-22 | 2023-04-03 | 株式会社トーキン | 合金粉末 |
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