CN109215917A - 软磁性粉末及其制造方法、以及使用其的压粉磁芯 - Google Patents
软磁性粉末及其制造方法、以及使用其的压粉磁芯 Download PDFInfo
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Abstract
本发明的课题在于提供兼顾高机械强度和高导磁率的压粉磁芯以及构成压粉磁芯的合金粉末。其解决手段是使用在合金粉末的表面具有多个0.1μm以上且5μm以下的柱状的第1突起的软磁性粉末。使用在合金粉末表面具有前端尖锐倾斜的第2突起,所述第2突起的前端的角度小于90°,所述第2突起与所述合金粉末的表面所成的角度小于90°软磁性粉末。使用至少包含80重量%的所述软磁性粉末的压粉磁芯。使用一种软磁性粉末的制造方法,其包括:利用液体急冷法制作软磁性合金薄带的薄带制造工序;和将所述软磁性合金薄带不进行热处理而粉碎,制成0.1μm以上且40μm以下的厚度的粉末的粉碎工序,在所述粉碎工序中,使所述软磁性合金薄带裂开,在所述粉末的表面设置了突起。
Description
技术领域
本发明涉及软磁性粉末及其制造方法、以及使用其的压粉磁芯。特别是,本发明涉及用于扼流线圈、电抗器、变压器等电感器的软磁性粉末及其制造方法、以及使用其的压粉磁芯。
背景技术
近年来,混合动力汽车(HEV)、插电式混合动力汽车(PHEV)、电动汽车(EV)等车辆的电动化快速发展,为了进一步改善油耗而要求系统的小型、轻量化。
受该电动化市场所带动,对各种电子部件也要求小型化和轻量化,其中对使用了在扼流线圈、电抗器、变压器等中使用的软磁性粉末的压粉磁芯也要求具有越来越高的性能。
为了小型化、轻量化,对于材质而言,要求饱和磁通密度高方面优异,磁芯损耗小,还要求直流叠加特性优异。
考虑到这些要求,提出了显示出优异的软磁性特性的、使用了非晶软磁性合金粉末或纳米结晶软磁性合金粉末的压粉磁芯。
例如,专利文献1、专利文献2中记载有使用了非晶软磁性合金粉末的压粉磁芯。
现有技术文献
专利文献
专利文献1:日本特许第4944971号公报
专利文献2:日本特许第6036394号公报
发明内容
发明要解决的问题
然而,如专利文献1中记载那样,使用将非晶软磁性合金薄带粉碎的合金粉末制作压粉磁芯的情况下,难以兼顾高机械强度和高导磁率。
压粉磁芯是利用粘结剂使这些粉末彼此接合而形成的。由于粉末表面平滑,因此粘结剂和粉末无法得到充分的锚定效果而接合。特别是,为了得到高导磁率,若增加压粉磁芯的粉末的填充率,则使粉末彼此接合的粘结剂的量减少,因此压粉磁芯的机械强度显著降低。
另外,由于粉末具有尖锐的边缘,因此若增加填充率,则发生尖锐的边缘深深进入邻接的粉末而短路的不良情况,因此无法实现高填充化。专利文献2中所记载那样的粉末虽不具有尖锐的边缘,但粉末表面平滑,因此无法解决与高填充化相伴的粘接强度降低的问题。
本发明是为解决上述现有的问题而提出的,其目的在于提供兼顾高机械强度和高导磁率的软磁性粉末及使用其的压粉磁芯、以及软磁性粉末的制造方法。
用于解决问题的方案
为了达成上述目的,使用以下的软磁性粉末,即,在合金粉末的表面具有多个0.1μm以上且5μm以下的柱状的第1突起的软磁性粉末。
另外,使用以下的软磁性粉末,即,在合金粉末表面具有前端尖锐倾斜的第2突起,上述第2突起的前端的角度小于90°,上述第2突起与上述合金粉末的表面所成的角度小于90°的软磁性粉末。
使用至少包含80重量%的上述软磁性粉末的压粉磁芯。
另外,使用以下的软磁性粉末的制造方法,其包括:利用液体急冷法制作非晶软磁性合金薄带的薄带制造工序;和将上述非晶软磁性合金薄带不进行热处理而粉碎,制成0.1μm以上且40μm以下的厚度的粉末的粉碎工序,上述粉碎工序中,使上述非晶软磁性合金薄带裂开,在上述粉末的表面设置了突起。
发明效果
如上所示,根据本发明中公开的方案,能够使合金粉末高填充化,且合金粉末彼此之间以充分的强度接合,因此可以提供兼顾高导磁率和高机械强度的、非晶软磁性合金粉末或纳米结晶软磁性合金粉末、及使用其的压粉磁芯。
附图说明
图1是将本实施方式1的软磁性合金薄带进行了粉碎的合金粉末的电子显微镜照片。
图2(a)~图2(b)是示出本实施方式1的合金粉末的突起形状的示意图。
图3是示出本实施方式1的合金粉末的截面的电子显微镜照片。
图4是示出本实施方式1的合金粉末的形状的示意图。
图5(a)~图5(d)是对本实施方式1的制造合金粉末的工序进行说明的图。
具体实施方式
一边参照附图,一边对以下本发明的实施方式进行说明。
(实施方式1)
图1是本实施方式的合金粉末的电子显微镜照片。合金粉末1的材料为非晶软磁性合金或纳米结晶软磁性合金,可以得到高饱和磁通密度和损耗小的优异的磁特性。
合金粉末包括Fe基非晶软磁性合金、Fe基纳米结晶软磁性合金、Co基非晶软磁性合金等。非晶软磁性合金包括一部分发生纳米结晶化的合金。
作为Fe基非晶软磁性合金、Fe基纳米结晶软磁性合金,除Fe-Si-B合金以外,可以是向其中添加了Nb、Cu、P、C等元素的Fe-Si-B系合金、Fe-Cr-P系合金、Fe-Zr-B系合金、铁硅铝系合金等。
作为Co基非晶软磁性合金,为Co-Fe-Si-B系合金等,可以将各种公知的软磁性合金的非晶粉末、纳米结晶粉末单独或混合使用。
<突起2>
如图1所示,在合金粉末1的表面形成有多个突起2。压粉磁芯是利用粘结剂使合金粉末1彼此接合而形成的。因为有突起2,所以合金粉末1和粘结剂的接合变强。这是因为,由于合金粉末1的突起2,粘结剂容易得到粘接的锚定效果。其结果是,压粉磁芯的机械强度也变强。
图2(a)、图2(b)是示出本实施方式的合金粉末1的突起2的形状的截面示意图。突起2大部分为图2(a)和图2(b)的形状。
突起2有山状或柱状的第1突起2a、和翘起皮状或前端尖锐倾斜的突起状的第2突起2b。
图2(a)中,第1突起2a的高度H优选为0.1μm以上且5μm以下。若高度H为0.1μm以下,则第1突起2a过小,无法得到充分的锚定效果。另外,若高度H大于5μm,则第1突起2a过大,在形成压粉磁芯时,合金粉末1之间彼此无法接近,导磁率劣化。第1突起2a的大致全周的侧面与合金粉末表面所成的角度4为90度以上。
在此,突起为山状或柱状表示角度4为90度以上且前端不尖锐的情况。
如图2(b)所示,第2突起2b的前端的角度3更优选小于90度。这是因为前端的角度小于90度的情况下,更能够得到与粘结剂的锚定效果,能够得到强的粘接力。
特别优选角度3为15度以上且60度以下。这是因为:若为60度以下,则能够得到更强的锚定效果,粘接强度变强;另一方面,若角度3小于15度,则第2突起2b的厚度变薄、强度变弱、容易折断,因此相伴于此,粘接强度也变弱。
另外,优选第2突起2b与合金粉末表面所成的角度4小于90°。这是因为:第2突起2b的前端不朝上方,因此在形成压粉磁芯时,能够防止刺穿邻接的合金粉末而发生短路。
第2突起2b的高度为第1突起2a的高度水平。第2突起2b与第1突起2a为山脉或刀刃的形状。图2(a)、图2(b)为截面,该形状有进深即有长度。
合金粉末1具有第1突起2a和第2突起2b中的至少一种。合金粉末1优选具有第1突起2a和第2突起2b二者的合金粉末1。
图3是示出本实施方式的合金粉末1的截面的电子显微镜照片。
如图3所示,第1突起2a形成突状的突起,第2突起2b为以下形状:第2突起2b的前端的角度3小于90°,第2突起2b与合金粉末表面所成的角度4小于90°。
如图1和图3所示,作为合金粉末1的整体的结构,为不具有锐利的角的呈圆形的结构。
优选合金粉末1的磨圆度(円磨度)为0.6以上。合金粉末1不具有锐利的角,因此容易进行高填充,以使得压粉磁芯能够具有高导磁率。这是因为:能够防止高填充时由于锐利的边缘深深进入邻接的合金粉末1而导致的合金粉末之间互通的不良。磨圆度利用Krumbein的磨圆度印象图进行判断。
进而,磨圆度为0.75以上为宜。这是因为:容易进行更高填充,以使得压粉磁芯能够具有更高的导磁率。另外,在与粒径大的合金粉末组合而形成压粉磁芯时,也容易进入大的粒子的隙间,可以得到更高的导磁率的压粉磁芯。
首先,合金粉末1是将片状的薄带粉碎而制作的。以下对形状进行说明。
图4是本实施方式的合金粉末1的示意图。如图4所示,将合金粉末1近似为椭圆柱形状的情况下,厚度5小于被粉碎的薄带的厚度。需要说明的是,合金粉末1在以下进行说明,是将薄带粉碎而制作的。需要比该薄带的厚度薄,即需要进行粉碎。
合金粉末1的突起2是将薄带粉碎时,使薄带裂开而形成的。需要说明的是,裂开是指通过粉碎工序使表面层状地剥离。
厚度5不薄于薄带的厚度的情况下,在椭圆形状的两主面,薄带未充分裂开,因此在合金粉末1的表面无法得到充分的突起。
对于推定机理进行具体叙述。通过将薄带粉碎而得到粉末。这是因为:合金粉末1的厚度不薄于薄带的情况表示:合金粉末1的两主面以薄带的表面部分未被粉碎的状态残留。即,表示由粉碎得到的突起在合金粉末1的两主面部未形成。
合金粉末1的厚度5优选为0.1μm以上且40μm以下。这是因为:薄带的厚度大于40μm的情况下,成为原料的薄带无法得到良好的磁性特性。薄带的厚度小于0.1μm时,粉碎导致的损伤变大,合金粉末1的磁特性劣化。
进而,厚度5优选为10μm以上且30μm以下。其原因是,直至30μm为止,粉碎比较容易进行,若小于10μm,则需要长时间的粉碎,优选为10μm以上且30μm以下是为了性能与生产率的平衡良好。
优选合金粉末1发生纳米结晶化为宜。其原因是,能够得到更高的导磁率。再者,通过使合金粉末1发生纳米结晶化,粉末表面变硬而优选。由此,进入至合金粉末1的突起的粘结剂难以脱落,使锚定效果变强,因此能够进一步增强粘接强度而优选。
<合金粉末1的制造>
首先,对于本实施方式的合金粉末1的制造方法,用以下的例子进行说明。
(1)利用液体急冷法制作非晶软磁性合金薄带(Fe-Si-B-Cu-Nb)。可以使用单辊式的非晶制造装置、双辊式的非晶制造装置制作。冷却速度例如以约100万℃/秒进行。
(2)接着,不进行热处理,将薄带粉碎而进行粉末化。薄带的粉碎可以使用通常的粉碎装置。例如可以使用球磨机、捣碎机、行星磨机、旋风磨机、喷磨机、旋转磨机等。
粉末的厚度5粉碎至成为薄带的厚度以下。薄带的表面部分也进行粉碎,用于形成突起2。若薄带的厚度厚于40μm,则难以得到良好的磁特性。其结果是,粉碎进行至粉末的厚度为40μm以下为止。
粉碎至平均粒径为50μm以下,优选粉碎至平均粒径为10μm以下。这是因为,在平均粒径为50μm以下,开始发生突起2,在平均粒径为10μm以下,可以得到充分的突起2。
<粉碎的详细情况>
非晶软磁性合金薄带在粉碎前不进行基于热处理的脆性化处理。这是因为:通过不进行脆性化处理,从而粉碎时容易裂开。若为了脆性化而进行热处理,则薄带的硬度变高,反而难以粉碎。即,难以发生裂开。另外,若在进行作为脆性化处理的热处理之后进行粉碎,则粉碎粉末成为具有锐利的边缘的结构,无法成为上述合金粉末1的磨圆度为0.6以上的形状。
若合金粉末1为具有锐利的边缘的结构,则使合金粉末1高填充时,该锐利的边缘深深进入邻接的粒子。由此发生合金粉末1的粒子之间互通的不良。若将非晶软磁性合金薄带进行热处理后进行粉碎,则非晶薄带为硬且脆的状态,因此在粉碎时,该断裂部成为具有锐利的边缘的结构,不适宜。
接着,对进行粉碎的程度进行叙述。需要进行至合金粉末1的厚度,即,呈近似椭圆形状时的厚度比所粉碎的薄带的厚度薄。这是因为:合金粉末1的突起2是在将薄带粉碎时由于薄带裂开而形成的。若合金粉末1的厚度厚于薄带的厚度的情况下,在椭圆形状的两主面,薄带未充分裂开。
图5(a)~图5(d)是示出形成合金粉末1的工序的图。
第1粉碎工序中,图5(a)所示的薄带7被粉碎,成为图5(b)所示的粗粉碎而成的块体8。
第2粉碎工序中,如图5(c)至图5(d)所示,粗粉碎而成的块体8的表面裂开,微粉末9被刮掉,成为表面具有突起2的合金粉末1。
由于裂开而形成突起2,因此突起2的形状的特征是,如图2(a)所示那样呈微小突状和如图2(b)所示那样朝向合金粉末1的缺口沿斜横方向延伸,突起2的前端朝向斜横方向(横向倾斜)。由此,可以更充分地得到与粘结剂的锚定效果。
作为具体的粉碎方法,利用旋转磨机以转速为1000rpm~3000rpm、粉碎时间为5分钟~30分钟对薄带进行粉碎处理,由此可以得到表面具有因裂开导致的突起2的合金粉末1。
(3)接着,根据需要,使非晶软磁性体合金粉末发生纳米结晶化。将粉碎非晶薄带而成的合金粉末1以纳米结晶析出的温度以上且纳米结晶粗大化的温度以下进行热处理,使其纳米结晶化,制成纳米结晶软磁性合金粉末。
热处理装置例如可以使用热风炉、热压机、灯、覆套式(sheath)金属加热器、陶瓷加热器、回转窑等。合金粉末通过进行纳米结晶化能够得到更高的导磁率,因此根据设备特性要求,使其纳米结晶化。
另外,合金粉末通过进行纳米结晶化而使粉末表面变硬。由此,进入至合金粉末的突起的粘结剂难以脱落,使锚定效果变强,因此能够进一步提高粘接强度。
<压粉磁芯的制作>
(1)本实施方式的压粉磁芯的制作是将合金粉末1和酚醛树脂或有机硅树脂等绝缘性良好且耐热性高的粘结剂混合而制作造粒粉。
(2)接着,将造粒粉填充至具有所期望的形状的耐热性高的模具中,进行加压成形而得到压粉体。
(3)随后,在粘结剂加热固化且纳米结晶不发生粗大化的温度以下进行热处理,从而能够得到可获得高饱和磁通密度且优异的软磁特性的压粉磁芯。
若压粉磁芯中含有的经粉碎的合金粉末1的比例至少为80重量%以上,则可以得到兼顾高机械强度和高导磁率的压粉磁芯。
基于本实施方式的压粉磁芯与现有例相比,导磁率提高1.3倍以上。作为导磁率的值,基于本实施方式的压粉磁芯为24,现有例为15~19。
基于本实施方式的压粉磁芯与现有例相比,机械强度提高1.6倍以上。
利用压力机对压粉磁芯进行加压,测定压粉磁芯被破坏的力。
基于本实施方式的压粉磁芯为30MPa,现有例为14MPa~18MPa。
产业上的可利用性
根据本实施方式,可以提供兼顾高机械强度和高导磁率的软磁性粉末和使用其的压粉磁芯。
附图标记说明
1 合金粉末
2 突起
2a 第1突起
2b 第2突起
3 角度
4 角度
5 厚度
7 薄带
8 块体
9 微粉末
Claims (10)
1.一种软磁性粉末,其中,在合金粉末的表面具有多个0.1μm以上且5μm以下的柱状的第1突起。
2.如权利要求1所述的软磁性粉末,其中,
在所述合金粉末表面具有前端尖锐倾斜的第2突起,
所述第2突起的前端的角度小于90°,所述第2突起与所述合金粉末的表面所形成的角度小于90°。
3.如权利要求1或2所述的软磁性粉末,其具有所述第1突起和所述第2突起。
4.如权利要求1所述的软磁性粉末,其中,所述合金粉末的磨圆度为0.6以上。
5.如权利要求1所述的软磁性粉末,其中,所述合金粉末的厚度为0.1μm以上且40μm以下。
6.如权利要求1所述的软磁性粉末,其中,所述合金粉末为Fe基的软磁性粉末或纳米结晶软磁性合金粉末、或者Co基的软磁性粉末。
7.如权利要求1所述的软磁性粉末,其中,所述合金粉末中析出有纳米结晶。
8.一种压粉磁芯,其至少包含80重量%的权利要求1所述的软磁性粉末。
9.一种软磁性粉末的制造方法,其包括:
薄带制造工序,利用液体急冷法制作软磁性合金薄带;和
粉碎工序,将所述软磁性合金薄带不进行热处理而粉碎,制成0.1μm以上且40μm以下的厚度的粉末,
在所述粉碎工序中,使所述软磁性合金薄带裂开,在所述粉末的表面设置了突起。
10.一种软磁性粉末的制造方法,其包括:在权利要求9所述的粉碎工序之后,对所述合金粉末进行热处理而使其纳米结晶化的工序。
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