CN111834075B - 合金粉末组合物、成型体及其制造方法和电感器 - Google Patents

合金粉末组合物、成型体及其制造方法和电感器 Download PDF

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CN111834075B
CN111834075B CN201910582862.2A CN201910582862A CN111834075B CN 111834075 B CN111834075 B CN 111834075B CN 201910582862 A CN201910582862 A CN 201910582862A CN 111834075 B CN111834075 B CN 111834075B
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水嶋隆夫
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Chilisin Electronics Corp
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Abstract

本发明关于一种合金粉末组合物、由该合金粉末组合物制造成型体的方法、由该方法所制得的成型体、以及包含该成型体的电感器。合金粉末组合物包括铁基非晶质合金的粉末及铁基结晶质合金的粉末；其中铁基非晶质合金的粉末在受到20kN的力时，其体积电阻率为1×106Ω·cm以下，铁基结晶质合金的粉末在受到20kN的力时，其体积电阻率为1×106Ω·cm以上；且其中铁基非晶质合金包含Fe、Co、Cr、C、P、及Si。

Description

合金粉末组合物、成型体及其制造方法和电感器
技术领域
本发明关于一种合金粉末组合物、由该合金粉末组合物制造成型体的方法、由该方法所制得的成型体、以及包含该成型体的电感器。
背景技术
电感器包含磁芯材料以及导体，其中磁芯材料可以使用铁氧体磁芯或粉末铁芯。铁氧体是含有镍、锌或锰的化合物，其具有较高的相对磁导率，而且铁氧体化合物的高频铁损小，因此被广泛应用于高频电感器中。然而，铁氧体的缺点在于饱和磁通量密度差，且镍-锌或锰-锌铁氧体制作流程繁杂，例如：煅烧、研磨、造粒、成型、烧结。粉末铁芯则具有高饱和磁通量密度，且粉末铁芯可被压成任意形状；因此电感器的体积可以缩小，以实现小型化、轻量化。
专利文献1(TW200419600A)揭示了一种复合磁性材料，其是将60wt％-90wt％的含铁晶体合金磁粉和40wt％-10wt％的含铁非晶质合金磁粉混合而构成，因而得到复合磁粉，另将重量为混合磁粉的1wt％-10wt％的绝缘连结剂混入混合磁粉。然而，实际上，如专利文献1中图4至图6所示，其转换效率、磁导率以及铁损仍有很大的改善空间。
专利文献2(TW201712699A)则揭示一种压粉磁芯材料，其是含有羰基铁粉及非晶质磁性材料粉末，且上述羰基铁粉的含量相对于上述羰基铁粉的含量与上述非晶质磁性材料粉末的含量总和的质量比率，即第一混合比率，为75质量％以上且95质量％以下，通过使压粉磁芯不仅含有结晶质磁性材料粉末，也含有特定量的非晶质磁性材料粉末，而铁损Pcv容易降低。然而，这样的磁芯材料所得到的磁芯磁导率(专利文献2图10)表现不足，且铁损的降低也存在改善空间，此外，由此得到的电感器的电感转换效率不佳。
发明内容
因此，本发明的目的在于提供一种具有稳定的高磁导率、低铁损(Core loss)的合金粉末组合物，由该合金粉末组合物制造成型体的方法和由该方法所制得的成型体，以及具有高电感转换效率的电感器。
本发明上下文中所指的磁导率为相对磁导率(relative permeability)的实数部分(real part)。相对磁导率为实际磁导率除以真空磁导率的值。相对磁导率的实数部分(μr’)和感值成正比。此外，由于L∝μr’×N2，在同一感值下，若使用导磁率较大的材料，除了可减少绕线圈数外，也可使用较粗线径，以降低直流电阻值(DC Resistance)。电磁转换效率可分为轻载效率(light-load efficiency)与重载效率(heavy-load efficiency)两类。轻载部分，主要是依赖磁性材料的铁损，铁损越低，可提高轻载效率。重载效率则是为依赖导体的电阻值，低电阻的导体，可改善重载部分的电磁转换效率。因此，高μr’且低铁损的磁性材料可同时提升轻载到重载之间的电磁转换效率。
为了达成本发明目的，发明人发现，通过使用本发明的合金粉末组合物，可以实现高磁导率、低铁损以及高转换效率。特别是，本发明的合金粉末组合物即使在高频下也可以展现优异的软磁性特性。
因此，本发明一方面提供了合金粉末组合物，其包括铁基非晶质合金的粉末及铁基结晶质合金的粉末，其中铁基非晶质合金的粉末在受到20kN的力时，其体积电阻率为1×106Ω·cm以下，铁基结晶质合金的粉末在受到20kN的力时，其体积电阻率为1×106Ω·cm以上；且其中铁基非晶质合金包含Fe、Co、Cr、C、P、和Si以及视情况可另外包含Ni、B、Al中的一种或多种。
本发明另一方面提供了用于制备成型体的方法，其包含根据使本发明的合金粉末组合物与粘结剂混合以形成成型材料，以及加压成型(pressure molding)该成型材料，以形成成型体。
本发明另一方面提供了成型体，其是通过根据本发明的用于制备成型体的方法得到，其中成型体具有1×104Ω·cm以上的体积电阻率以及70％至95％的相对成型密度。
本发明另一方面提供了电感器，其包含根据本发明的成型体。
根据本发明的成型体相较于现有技术具有稳定的高磁导率、显著降低的铁损，且包含本发明的成型体的电感器具有高电感转换效率。
附图说明
图1显示了本发明实施例1-2与比较例的磁导率与频率的关系。
图2显示了本发明实施例1-2与比较例在Bm＝10mT下铁损与频率的关系。
图3显示了本发明实施例1-2与比较例在Bm＝50mT下铁损与频率的关系。
图4显示了本发明实施例1-2与比较例在Bm＝100mT下铁损与频率的关系。
图5显示了本发明实施例1-2与比较例的电感转换效率。
具体实施方式
本发明的合金粉末组合物包括铁基非晶质合金的粉末及铁基结晶质合金的粉末，其中铁基非晶质合金的粉末在受到20kN的力时，其体积电阻率为1×106Ω·cm以下，铁基结晶质合金的粉末在受到20kN的力时，其体积电阻率为1×106Ω·cm以上；且其中铁基非晶质合金的粉末包含Fe、Co、Cr、C、P、和Si以及视情况可另外包含Ni、B、Al中的一种或多种。根据本发明的合金粉末组合物，其中铁基非晶质合金的粉末及铁基结晶质合金的粉末的体积电阻率是根据JIS K6911结合例如粉体阻抗测定系统MCP-PD51来测定，并且是受到20kN的力时的值。
本发明的铁基非晶质合金包含Fe、Co、Cr、C、P、和Si。
在本发明一个具体实例中，铁基非晶质合金可另外包含Ni、B及Al中的一种或多种。
在本发明一个具体实例中，铁基非晶质合金包含Fe、Co、Cr、C、P及Si或由Fe、Co、Cr、C、P及Si所组成。
在本发明一个具体实例中，铁基非晶质合金包含Fe、Co、Cr、C、P、B及Si或由Fe、Co、Cr、C、P、B及Si所组成。
在本发明一个具体实例中，铁基非晶质合金包含Fe、Co、Cr、C、P、Al及Si或由Fe、Co、Cr、C、P、Al及Si所组成。
在本发明一个具体实例中，铁基非晶质合金包含Fe、Co、Ni、P、Cr、C及Si或由Fe、Co、Ni、P、Cr、C及Si所组成。
在本发明一个具体实例中，铁基非晶质合金包含Fe、Co、Ni、P、Cr、C、B及Si或由Fe、Co、Ni、P、Cr、C、B及Si所组成。
在本发明一个具体实例中，铁基非晶质合金包含Fe、Co、Ni、P、Cr、C、Al及Si或由Fe、Co、Ni、P、Cr、C、Al及Si所组成。
在本发明一个具体实例中，铁基非晶质合金可以包含以下原子比例：
70at％＜Fe＜83at％；
0at％＜Co＜1at％；
1at％＜Cr＜4at％；
7at％＜C＜11at％；
9at％＜P＜12at％；
0at％＜Si＜1at％；
Ni不存在或为5at％＜Ni＜7at％；
0at％≤B＜3at％；且
0at％≤Al＜1at％。
在本发明一个具体实例中，铁基非晶质合金中的Fe量例如在＞70at％至＜83at％的范围内，或＞70at％至＜81at％的范围内，或＞70at％至＜79at％的范围内，或＞70at％至＜78at％的范围内。
在本发明一个具体实例中，铁基非晶质合金的含氧量等于或小于2500ppm、或等于或小于2300ppm、或等于或小于2000ppm。
在本发明一个具体实例中，铁基非晶质合金的粉末的中值粒径(mediandiameter)D50为4μm至14μm、或5μm至12μm，其是通过雷射绕射法量测。
本发明的铁基结晶质合金的实例包含Fe-Ni系合金、Fe-Co系合金、Fe-V系合金、Fe-Si-Cr系合金、Fe-Al系合金、Fe-Si系合金及Fe-Si-Al系合金，这些合金可以单独使用或以混合物使用。本发明优选使用Fe-Si-Cr系合金。
在本发明一个具体实例中，铁基结晶质合金的粉末具有1μm至15μm、2μm至10μm、或2.5μm至6μm的中值粒径，其是通过雷射绕射法量测。
在本发明一个具体实例中，铁基结晶质合金为Fe-Si-Cr系合金。
在本发明一个优选的具体实例中，铁基结晶质合金为Fe-Si-Cr系合金，且其中Cr浓度为等于或大于4wt％。
在本发明一个具体实例中，铁基非晶质合金的粉末具有≥3.5g/cm3的振实密度(tap density)，铁基结晶质合金的粉末具有≥2g/cm3的振实密度，振实密度是例如根据ISO 3953，使粉末在量筒内经过一定次数的振动，体积不再变化时的堆积密度；铁基非晶质合金的粉末具有0.15m2/g至0.30m2/g的BET比表面积，铁基结晶质合金的粉末具有0.5m2/g至2.5m2/g的BET比表面积，其中BET比表面积系根据例如ISO 9277测定。
根据本发明的合金粉末组合物，铁基非晶质合金的粉末和铁基结晶质合金的粉末的混合比例以重量计是介于20∶80至95∶5、30∶70至95∶5、40∶60至95∶5、50∶50至95∶5、60∶40至95∶5、70∶30至95∶5、80∶20至95∶5、90∶10至95∶5。在本发明的优选具体实例中，铁基非晶质合金的粉末和铁基结晶质合金的粉末的混合比例以重量计为90∶10。
本发明的铁基非晶质合金的粉末可以例如通过雾化法制造。雾化法是以快速运动的流体(雾化介质)冲击或其他方式将合金液体破碎为细小液滴，然后使液滴冷却为固体粉末。
本发明另一方面为用于制备成型体的方法，其包含使根据本发明的合金粉末组合物与粘结剂混合以形成成型材料，以及加压成型该成型材料，以得到成型体。成型压力并不设限，依据田岛伸等人刊登于日本粉体与粉末冶金协会志第51卷第7号的“采用模具润滑温压成形法所制备的高密度压粉磁芯(HDMC)的特性”，随着成型压力的增加，体积电阻率会下降。本领域技术人员可以依照所添加的铁基非晶质合金的粉末的比例并考虑所得到的成型体的机械强度视情况调整以得到具有1×104Ω·cm以上的体积电阻率的成型体。在加压成型过程中，可视情况加热。本发明所使用的粘结剂的实例为环氧树脂、聚硅氧树脂、丙烯酸树脂、酚醛树脂或聚乙烯醇。本发明方法所使用的粘结剂的量，基于合金粉末组合物与粘结剂的总重量计为1wt％至4wt％，或者1wt％至3wt％，又或者2wt％至3wt％。
本发明的另一方面为成型体，其包含根据本发明的合金粉末组合物，其中成型体具有1×104Ω·cm以上的体积电阻率以及70％至95％的相对成型密度。
根据本发明的成型体具有70％至95％的相对成型密度，或者是75至92％的相对成型密度，或者是80％至90％的相对成型密度。相对成型密度的定义如下式
Figure BDA0002112937830000061
本发明的成型体的形状并没有限制，可以是例如E字型、T字型或工字鼓形。
本发明的另一方面为电感器，电感器包含根据本发明的成型体以及导体，例如附绝缘层的导线或总线(bus bar)。本发明的电感器可以是例如绕线式电感器(wire woundinductor)或一体成型电感器(molded inductor)。
在本发明一个具体实例中，电感器为绕线式电感器，电感器的附绝缘层的导线是缠绕于成型体上。本发明的绕线式电感器是通过将附绝缘层的导线缠绕于本发明的成型体上，由外侧覆盖磁封胶加以密封。
在本发明一个具体实例中，电感器为一体成型电感器，电感器的导体是埋设于成型体内部。一体成型电感器的制造方法已揭示于美国专利第US6204744B1、US 6198375B1号中。本发明的电感器是例如通过以下方法制造：将导体的一端焊接至引线框架；卷绕导体；将导体的另一端焊接至引线框架；将导体置放于模穴中；混合本发明的合金粉末组合物与粘结剂的混合物以形成成型材料；将成型材料倒入模穴中；加压成型；加热以固化粘结剂。本发明所使用的粘结剂的实例为环氧树脂、聚硅氧树脂、丙烯酸树脂、酚醛树脂或聚乙烯醇。成型材料可视情况添加填料及/或润滑剂。在加压成型步骤中，对成型材料施加适当的压力，以压缩导体周围的成型材料。
实施例
实施例1
使用具有如表1所示性质的铁基非晶质合金的粉末与铁基结晶质合金的粉末。混合90wt％的Fe77.27Co0.1P10.8C9.31Cr2Si0.52粉末以及10wt％的Fe88.6Cr6.7Si4.7粉末后，添加丙烯酸树脂作为粘结剂以形成成型材料，随后在成型压力为20t/cm2下经过加压成型得到具有大于104Ω·cm的体积电阻率以及相对成型密度为82％的成型体；其中Fe77.27Co0.1P10.8C9.31Cr2Si0.52粉末的含氧量为1300～1400ppm，Fe88.6Cr6.7Si4.7粉末的Cr浓度为4.5wt％，且丙烯酸树脂粘结剂的使用量基于合金粉末组合物和粘结剂的总重量计为2wt％。
[表1]实施例1所使用的铁基非晶质合金与铁基结晶质合金的性质
Figure BDA0002112937830000071
实施例2
使用具有如表2所示性质的铁基非晶质合金的粉末与铁基结晶质合金的粉末。混合90wt％的Fe70.97Co0.1Ni5.96Cr1.99P10.74C7.75B1.99Si0.5粉末以及10wt％的Fe88.6Cr6.7Si4.7粉末后，添加丙烯酸树脂作为粘结剂以形成成型材料，随后在成型压力为20t/cm2下经过加压成型得到具有大于104Ω·cm的体积电阻率以及相对成型密度为82％的成型体；其中Fe70.97Co0.1Ni5.96Cr1.99P10.74C7.75B1.99Si0.5粉末的含氧量为1300～1400ppm，Fe88.6Cr6.7Si4.7粉末的Cr浓度为4.5wt％，且丙烯酸树脂粘结剂的使用量基于合金粉末组合物和粘结剂的总重量计为2wt％。
[表2]实施例2所使用的铁基非晶质合金与铁基结晶质合金的性质
Figure BDA0002112937830000072
比较例
使用具有如表3所示性质的铁基非晶质合金的粉末与铁基结晶质合金的粉末。混合30wt％的Fe73Si11B10.8Cr2.3C2.9粉末以及70wt％的羰基铁粉(CIP)后，添加环氧树脂作为粘结剂以形成成型材料，随后在成型压力为20t/cm2下经过加压成型得到具有大于104Ω·cm的体积电阻率以及相对成型密度为87％的成型体，其中环氧树脂粘结剂的使用量基于合金粉末组合物和粘结剂的总重量计为4.5wt％。需留意者，比较例中为了得到具有大于104Ω·cm的体积电阻率的成型体，需要添加较多的粘结剂，因此造成软磁性质不佳。
[表3]比较例所使用的铁基非晶质合金与铁基结晶质合金的性质
Figure BDA0002112937830000081
对于根据实施例1-2及比较例的成型体测定磁导率μr’以及铁损PCV，结果显示在图1及图2-4中。
图1显示了磁导率与频率的关系，图1所示的磁导率μr’为相对磁导率的实数部分，其是使用依据实施例1-2及比较例的成型材料制作成尺寸为外径13.5mm、内径7.6mm、高5mm的磁环量测时的相对磁导率的实数部分。从图1可以发现，实施例1及2的成型体的磁导率远高于比较例，且在高频区也具有稳定的磁导率；图2-4则揭示了在不同的最大磁通密度(Bm＝10、50、100mT)下铁损与频率的关系，实施例1及2的成型体皆具有显著较低的铁损。
电感转换效率进一步被分析，结果显示于图5。从图5可以发现，从实施例1及2的成型体得到的电感的转换效率明显优于比较例。
以上虽已参照图式来详细说明本发明优选实施方式，但本发明不限于上述实施方式。本发明所属技术领域的技术人员应当可在权利要求书所记载的范围内做各种变化，也可任意组合说明书中所揭示的各种具体实例，并且可明了这些当然也属于本发明的保护范围。

Claims (16)

1.一种合金粉末组合物，其包括铁基非晶质合金的粉末及铁基结晶质合金的粉末，其中该铁基非晶质合金的粉末在受到20kN的力时，其体积电阻率为1×106Ω·cm以下，该铁基结晶质合金的粉末在受到20kN的力时，其体积电阻率为1×106Ω·cm以上；其中该铁基非晶质合金包含以下的原子比例：
70at％＜Fe＜83at％；
0at％＜Co＜1at％；
1at％＜Cr＜4at％；
7at％＜C＜11at％；
9at％＜P＜12at％；
0at％＜Si＜1at％；
5at％＜Ni＜7at％；
0at％≤B＜3at％；且
0at％＜Al＜1at％。
2.如权利要求1所述的合金粉末组合物，其中该铁基非晶质合金的原子比例为：70at％＜Fe＜78at％。
3.如权利要求1所述的合金粉末组合物，其中该铁基非晶质合金的含氧量等于或小于2500ppm。
4.如权利要求1所述的合金粉末组合物，其中该铁基结晶质合金的粉末是选自由Fe-Ni系合金、Fe-Co系合金、Fe-V系合金、Fe-Si-Cr系合金、Fe-Al系合金、Fe-Si系合金及Fe-Si-Al系合金所组成的组中之一或多者，且其具有2.5μm至6μm的中值粒径D50。
5.如权利要求4所述的合金粉末组合物，其中该铁基结晶质合金为Fe-Si-Cr系合金。
6.如权利要求5所述的合金粉末组合物，其中该Fe-Si-Cr系合金的Cr含量为等于或大于4wt％。
7.如权利要求1所述的合金粉末组合物，其中该铁基非晶质合金的粉末具有≥3.5g/cm3的振实密度，且该铁基结晶质合金的粉末具有≥2g/cm3之振实密度。
8.如权利要求1所述的合金粉末组合物，其中该铁基非晶质合金的粉末具有0.15m2/g至0.30m2/g的BET比表面积，且该铁基结晶质合金的粉末具有0.5m2/g至2.5m2/g的BET比表面积。
9.如权利要求1所述的合金粉末组合物，其中该铁基非晶质合金的粉末具有4μm至14μm的中值粒径D50。
10.如权利要求1所述的合金粉末组合物，其中该铁基非晶质合金的粉末和该铁基结晶质合金的粉末的混合比例以重量计是介于20∶80至95∶5。
11.一种用于制备成型体的方法，其包含混合如权利要求1至10任一项所述的合金粉末组合物与粘结剂以形成成型材料，以及加压成型该成型材料。
12.如权利要求11所述的方法，其中粘结剂为环氧树脂、聚硅氧树脂、丙烯酸树脂、酚醛树脂或聚乙烯醇。
13.如权利要求11或12所述的方法，其中粘结剂的使用量基于该合金粉末组合物和粘结剂的总重量计为1wt％至4wt％。
14.一种成型体，其通过权利要求11至13中任一项所述的方法得到，其中该成型体具有1×104Ω·cm以上的体积电阻率以及70％至95％的相对成型密度。
15.一种电感器，其包含如权利要求14所述的成型体。
16.如权利要求15所述的电感器，其包含导体，其中该导体是埋设于该成型体内部或缠绕于该成型体外部。
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