CN112351845A - 磁性部件用粉末 - Google Patents
磁性部件用粉末 Download PDFInfo
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- CN112351845A CN112351845A CN201980041737.9A CN201980041737A CN112351845A CN 112351845 A CN112351845 A CN 112351845A CN 201980041737 A CN201980041737 A CN 201980041737A CN 112351845 A CN112351845 A CN 112351845A
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- 239000000843 powder Substances 0.000 title claims abstract description 54
- 239000002245 particle Substances 0.000 claims abstract description 53
- 239000000956 alloy Substances 0.000 claims abstract description 37
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 33
- 239000012535 impurity Substances 0.000 claims abstract description 8
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 8
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 8
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 7
- 238000000576 coating method Methods 0.000 claims description 23
- 239000011248 coating agent Substances 0.000 claims description 20
- 230000035699 permeability Effects 0.000 description 29
- -1 titanium alkoxide Chemical class 0.000 description 19
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 15
- 239000011651 chromium Substances 0.000 description 13
- 239000011572 manganese Substances 0.000 description 12
- 230000001629 suppression Effects 0.000 description 12
- 229910052719 titanium Inorganic materials 0.000 description 11
- 239000010936 titanium Substances 0.000 description 10
- 229910052710 silicon Inorganic materials 0.000 description 9
- 239000000203 mixture Substances 0.000 description 8
- 229920000642 polymer Polymers 0.000 description 8
- 239000010703 silicon Substances 0.000 description 8
- 150000001875 compounds Chemical class 0.000 description 7
- 230000006872 improvement Effects 0.000 description 7
- 229910052751 metal Inorganic materials 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 238000000034 method Methods 0.000 description 6
- 229910000859 α-Fe Inorganic materials 0.000 description 6
- 230000002411 adverse Effects 0.000 description 4
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- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 description 3
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 3
- WEVYAHXRMPXWCK-UHFFFAOYSA-N Acetonitrile Chemical compound CC#N WEVYAHXRMPXWCK-UHFFFAOYSA-N 0.000 description 3
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 3
- XEKOWRVHYACXOJ-UHFFFAOYSA-N Ethyl acetate Chemical compound CCOC(C)=O XEKOWRVHYACXOJ-UHFFFAOYSA-N 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 3
- 150000004703 alkoxides Chemical group 0.000 description 3
- 238000000889 atomisation Methods 0.000 description 3
- 239000011230 binding agent Substances 0.000 description 3
- 229910052796 boron Inorganic materials 0.000 description 3
- 239000010408 film Substances 0.000 description 3
- 230000004907 flux Effects 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- HEDRZPFGACZZDS-UHFFFAOYSA-N Chloroform Chemical compound ClC(Cl)Cl HEDRZPFGACZZDS-UHFFFAOYSA-N 0.000 description 2
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 2
- LRHPLDYGYMQRHN-UHFFFAOYSA-N N-Butanol Chemical compound CCCCO LRHPLDYGYMQRHN-UHFFFAOYSA-N 0.000 description 2
- IMNFDUFMRHMDMM-UHFFFAOYSA-N N-Heptane Chemical compound CCCCCCC IMNFDUFMRHMDMM-UHFFFAOYSA-N 0.000 description 2
- 239000006057 Non-nutritive feed additive Substances 0.000 description 2
- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical group [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- MVPPADPHJFYWMZ-UHFFFAOYSA-N chlorobenzene Chemical compound ClC1=CC=CC=C1 MVPPADPHJFYWMZ-UHFFFAOYSA-N 0.000 description 2
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- 239000003822 epoxy resin Substances 0.000 description 2
- FKRCODPIKNYEAC-UHFFFAOYSA-N ethyl propionate Chemical compound CCOC(=O)CC FKRCODPIKNYEAC-UHFFFAOYSA-N 0.000 description 2
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- 125000000962 organic group Chemical group 0.000 description 2
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- 239000002243 precursor Substances 0.000 description 2
- 239000011342 resin composition Substances 0.000 description 2
- 125000005372 silanol group Chemical group 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- WYTZZXDRDKSJID-UHFFFAOYSA-N (3-aminopropyl)triethoxysilane Chemical compound CCO[Si](OCC)(OCC)CCCN WYTZZXDRDKSJID-UHFFFAOYSA-N 0.000 description 1
- OCJBOOLMMGQPQU-UHFFFAOYSA-N 1,4-dichlorobenzene Chemical compound ClC1=CC=C(Cl)C=C1 OCJBOOLMMGQPQU-UHFFFAOYSA-N 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- XDTMQSROBMDMFD-UHFFFAOYSA-N Cyclohexane Chemical compound C1CCCCC1 XDTMQSROBMDMFD-UHFFFAOYSA-N 0.000 description 1
- 229910015136 FeMn Inorganic materials 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical group [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 229910002796 Si–Al Inorganic materials 0.000 description 1
- BOTDANWDWHJENH-UHFFFAOYSA-N Tetraethyl orthosilicate Chemical compound CCO[Si](OCC)(OCC)OCC BOTDANWDWHJENH-UHFFFAOYSA-N 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 238000000149 argon plasma sintering Methods 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical group [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
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- 229920005601 base polymer Polymers 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- FPCJKVGGYOAWIZ-UHFFFAOYSA-N butan-1-ol;titanium Chemical compound [Ti].CCCCO.CCCCO.CCCCO.CCCCO FPCJKVGGYOAWIZ-UHFFFAOYSA-N 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- GSOLWAFGMNOBSY-UHFFFAOYSA-N cobalt Chemical compound [Co][Co][Co][Co][Co][Co][Co][Co] GSOLWAFGMNOBSY-UHFFFAOYSA-N 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- 238000000748 compression moulding Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000005347 demagnetization Effects 0.000 description 1
- 229940117389 dichlorobenzene Drugs 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000002149 energy-dispersive X-ray emission spectroscopy Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- XGZNHFPFJRZBBT-UHFFFAOYSA-N ethanol;titanium Chemical compound [Ti].CCO.CCO.CCO.CCO XGZNHFPFJRZBBT-UHFFFAOYSA-N 0.000 description 1
- NKSJNEHGWDZZQF-UHFFFAOYSA-N ethenyl(trimethoxy)silane Chemical compound CO[Si](OC)(OC)C=C NKSJNEHGWDZZQF-UHFFFAOYSA-N 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000009689 gas atomisation Methods 0.000 description 1
- 238000010191 image analysis Methods 0.000 description 1
- 230000002401 inhibitory effect Effects 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 229910000765 intermetallic Inorganic materials 0.000 description 1
- 239000000696 magnetic material Substances 0.000 description 1
- 239000006247 magnetic powder Substances 0.000 description 1
- 230000007257 malfunction Effects 0.000 description 1
- 229910000734 martensite Inorganic materials 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- ZEIWWVGGEOHESL-UHFFFAOYSA-N methanol;titanium Chemical compound [Ti].OC.OC.OC.OC ZEIWWVGGEOHESL-UHFFFAOYSA-N 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 150000002894 organic compounds Chemical class 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
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- 238000007493 shaping process Methods 0.000 description 1
- 238000003980 solgel method Methods 0.000 description 1
- 238000001694 spray drying Methods 0.000 description 1
- YLQBMQCUIZJEEH-UHFFFAOYSA-N tetrahydrofuran Natural products C=1C=COC=1 YLQBMQCUIZJEEH-UHFFFAOYSA-N 0.000 description 1
- LFQCEHFDDXELDD-UHFFFAOYSA-N tetramethyl orthosilicate Chemical compound CO[Si](OC)(OC)OC LFQCEHFDDXELDD-UHFFFAOYSA-N 0.000 description 1
- ZUEKXCXHTXJYAR-UHFFFAOYSA-N tetrapropan-2-yl silicate Chemical compound CC(C)O[Si](OC(C)C)(OC(C)C)OC(C)C ZUEKXCXHTXJYAR-UHFFFAOYSA-N 0.000 description 1
- VXUYXOFXAQZZMF-UHFFFAOYSA-N titanium(IV) isopropoxide Chemical compound CC(C)O[Ti](OC(C)C)(OC(C)C)OC(C)C VXUYXOFXAQZZMF-UHFFFAOYSA-N 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- CPUDPFPXCZDNGI-UHFFFAOYSA-N triethoxy(methyl)silane Chemical compound CCO[Si](C)(OCC)OCC CPUDPFPXCZDNGI-UHFFFAOYSA-N 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000009692 water atomization Methods 0.000 description 1
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- C22C—ALLOYS
- C22C45/00—Amorphous alloys
- C22C45/008—Amorphous alloys with Fe, Co or Ni as the major constituent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/06—Metallic powder characterised by the shape of the particles
- B22F1/065—Spherical particles
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/102—Metallic powder coated with organic material
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- B22F1/16—Metallic particles coated with a non-metal
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- C22C33/0285—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with Cr, Co, or Ni having a minimum content higher than 5%
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- C22C33/0292—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with more than 5% preformed carbides, nitrides or borides
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Abstract
提供适于能够在频率为100kHz至20MHz的区域中抑制噪声的磁性部件的粉末。该磁性部件用粉末包含多个粒子(2)。该粒子(2)的主要部分为合金制。该合金包含B。该合金中的B的含有率为5.0质量％以上且8.0质量％以下。该合金可以还包含选自Cr、Mn、Co及Ni中的1种或2种以上的元素。这些元素的含有率为0质量％以上且25质量％以下。该合金的余量为Fe及不可避免的杂质。该合金包含Fe2B相。合金中的Fe2B相的面积率为20％以上且80％以下。
Description
技术领域
本发明涉及磁性部件用粉末。具体而言，涉及分散于磁性片、磁性环等部件中的粉末。
背景技术
移动电话、笔记本型电脑、平板型电脑等便携用电子设备在近年来得到普及。最近，这些设备的小型化及高性能化不断推进。伴随着设备的小型化，对设备内的电路零件而言，小型化及高性能化的要求也提高。对于实现了小型化及高性能化的设备而言，安装于电路中的电子零件的密度高。因此，由于从该电子零件放射出的电波噪声，容易产生电子零件彼此间的电波干扰、及电子电路彼此间的电波干扰。电波干扰会导致电子设备的误动作。
出于抑制电波干扰的目的，有时在电子设备中插入噪声抑制片。该噪声抑制片将放出的放射电波(噪声)转换为磁力，防止向电子电路外放出电波。噪声抑制片的加工容易，且该片材的形状自由度高。
在典型的现有的噪声抑制片中，称为铁氧体的氧化物被用作磁性材料。该铁氧体的导磁率在高频区域中小。具体而言，在频率为100kHz至20Mz的区域中，导磁率小。因此，该频率区域中的从电波转换为磁力的转换效率不充分。
提出了不包含铁氧体而包含导磁率高的软磁性金属粉末的磁性片及磁性环。专利文献1(日本特开2017-208416号公报)中公开了使用有FeMn合金粉末的噪声抑制片。专利文献2(日本特开2011-108775号公报)中公开了使用有Fe-Si-Al系的扁平粉末的噪声抑制片。
现有技术文献
专利文献
专利文献1：日本特开2017-208416号公报
专利文献2：日本特开2011-108775号公报
发明内容
对于专利文献1所公开的粉末而言，出于降低退磁系数的目的，粒子进行了扁平化。该粒子的合金不适于以球状进行使用。此外，该粒子不适于基于与树脂的混合而使用。
对于专利文献2所记载的噪声抑制片而言，粉末进行了扁平化，因此，在较高的频率区域，也可实现高的导磁率。然而，对于具有Fe-Si-Al系的组成的粉末而言，在接近20MHz的高频率区域下的噪声抑制不充分。
对于用于近年来的电子设备的磁性部件，要求抑制在高频率区域下的噪声。本发明的目的在于，提供适于能够在频率为100kHz至20MHz的区域中抑制噪声的磁性部件的粉末。
本发明的磁性部件用粉末包含多个粒子。这些粒子各自的主要部分是合金制，所述合金包含：
B：5.0质量％以上且8.0质量％以下、以及
余量：Fe及不可避免的杂质。
该合金包含Fe2B相。
根据其他观点，本发明的磁性部件用粉末包含多个粒子。这些粒子各自的主要部分是合金制，所述合金包含：
B：5.0质量％以上且8.0质量％以下、
选自Cr、Mn、Co及Ni中的1种或2种以上：0质量％以上且25质量％以下、以及
余量：Fe及不可避免的杂质。
该合金包含Fe2B相。
优选的是，合金中的Fe2B相的面积率PS为20％以上且80％以下。
优选的是，合金的、bHc相对于各元素所具有的电子数的加权平均N之比(bHc/N)为500A/(m·个)以上且700A/(m·个)以下。
粒子也可以具有位于主要部分的表面的绝缘包覆。
优选的是，粒子具有球形形状。
对于使用了本发明的粉末的磁性部件而言，在频率为100kHz至20MHz的区域中，能够抑制噪声。
附图说明
图1是示出本发明的一个实施方式的磁性部件用粉末的粒子的截面图。
图2是示出分散有图1的粉末的磁性片的一部分的截面图。
图3是示出本发明的其他实施方式的磁性部件用粉末的粒子的截面图。
具体实施方式
以下，适当参照附图，并基于优选的实施方式对本发明详细地进行说明。
[第一实施方式]
本发明的磁性部件用粉末是多个粒子的集合体。各粒子优选具有球形形状。图1是该粒子2的截面图。图2是示出分散有该粉末的磁性部件(磁性片4)的截面图。
为了得到该磁性片4，首先将粉末与各种化学药品一同混炼至树脂及橡胶这样的基材聚合物中从而得到聚合物组合物。混炼可以采用已知的方法。例如，可以利用密闭式混炼机、开放式辊等来进行混炼。作为化学药品，可例示润滑材料及粘合剂这样的加工助剂。
接下来，由该聚合物组合物来成形磁性片4。成形可以采用已知的方法。可以利用压缩成形法、注射成形法、挤出成形法、压延法等来进行成形。
磁性部件的形状不限于片状。可以采用环状、立方体状、长方体状、圆筒状等形状。从加工容易的观点出发，也可以在组合物中配合润滑材料、粘合剂等加工助剂。
作为表示磁性部件的性能的指标，有导磁率μ、实部导磁率μ’及虚部导磁率μ”。实部导磁率μ’表示电磁波屏蔽特性的优劣。虚部导磁率μ”表示电磁波吸收特性的优劣。导磁率μ可以由下述数式来算出。
μ＝μ’+jμ”
该数式中，“j”表示虚数单位。换言之，“j”的平方为-1。需要说明的是，本申请中，导磁率μ、实部导磁率μ’及虚部导磁率μ”各自以作为与真空导磁率之比的比导磁率的形式表示。高频下的磁损耗tanδ以该虚部导磁率μ”与实部导磁率μ’之比来表示。换言之，磁损耗tanδ由下述数式算出。
tanδ＝μ”/μ’
由该数式可知，若由于涡流损耗、磁共振等而导致μ’降低且μ”提高，则损耗tanδ提高。
包含金属的磁性粉末的饱和磁通密度比铁氧体的饱和磁通密度高。这是金属粉末的优点。另一方面，对于现有的金属粉末而言，与铁氧体相比，因磁共振导致的损耗在低频区域内发生。因此，该金属粉末对于高频区域(频率为100kHz至20MHz的范围)下的损耗降低而言不适合。
粉末的扁平化对于确保高导磁率是有用的。然而，经扁平化的粉末在与聚合物的混炼性方面差。
发明人们进行了研究，结果发现：具有规定的组成及组织的金属粉末适合于磁性部件。对于本发明的粉末而言，能够在高频区域中抑制损耗。
该粒子2的主要部分为合金制。此处，所谓主要部分，是指粒子2在其表面具有绝缘性覆膜的情况下，除去该覆膜的部分。该合金包含B。该合金中的B的含有率为5.0质量％以上且8.0质量％以下。该合金可以还包含选自Cr、Mn、Co及Ni中的1种或2种以上的元素。这些元素的含有率为0质量％以上且25质量％以下。该合金的余量为Fe及不可避免的杂质。以下，对各元素的作用进行详细说明。
[硼(B)]
B与Fe结合，生成金属间化合物。生成了金属间化合物的合金包含Fe2B相。对于包含含有该合金的粒子的磁性片4而言，在频率为100kHz至20MHz的区域中的损耗小。对于该磁性片4而言，在频率为100kHz至20MHz的区域中，可以抑制噪声。从噪声抑制的观点出发，B的含有率优选为5.0质量％以上、特别优选为5.5质量％以上。过剩的Fe2B相使饱和磁通密度降低。从饱和磁通密度的观点出发，B的含有率优选为8.0质量％以下、特别优选为7.5质量％以下。
[铬(Cr)]
Cr在Fe中固溶，有助于矫顽力的提高。矫顽力与磁共振频率相关。矫顽力大的合金，磁共振频率高。Cr还可以有助于粉末的耐腐蚀性。从这些观点出发，Cr的含有率优选为1.0质量％以上、特别优选为2.0质量％以上。矫顽力与导磁率为负相关关系。Cr的过剩添加对导磁率的提高产生不良影响。从该观点出发，Cr的含有率优选为15.0质量％以下、特别优选为10.0质量％以下。Cr的含有率根据“JIS G 1256”的规定来测定。
[锰(Mn)]
Mn在Fe中固溶，有助于矫顽力的提高。矫顽力与磁共振频率相关。矫顽力大的合金，磁共振频率高。从该观点出发，Mn的含有率优选为1.0质量％以上、特别优选为2.0质量％以上。矫顽力与导磁率为负相关关系。Mn的过剩添加对导磁率的提高产生不良影响。从该观点出发，Mn的含有率优选为5.0质量％以下。Mn的含有率根据“JIS G 1256”的规定来测定。
[钴(Co)]
Co在Fe中固溶，有助于矫顽力的提高。矫顽力与磁共振频率相关。矫顽力大的合金，磁共振频率高。从该观点出发，Co的含有率优选为1.0质量％以上、特别优选为2.0质量％以上。矫顽力与导磁率为负相关关系。Co的过剩添加对导磁率的提高产生不良影响。从该观点出发，Co的含有率优选为5.0质量％以下。Co的含有率根据“JIS G 1256”的规定来测定。
[镍(Ni)]
Ni是奥氏体形成元素。Ni抑制δ铁素体相的生成。进而，Fe中的富Ni相有助于导磁率提高。从该观点出发，Ni的含有率优选为1.0质量％以上、特别优选为2.0质量％以上。Ni的过剩添加会有阻碍马氏体相变，对磁特性产生不良影响的情况。从该观点出发，Ni的含有率优选为5.0质量％以下。Ni的含有率根据“JIS G 1256”的规定来测定。
若Cr、Mn、Co及Ni的合计含有率过剩，则无法生成充分的Fe2B相，无法在频率为100kHz至20MHz的区域中抑制噪声。从该观点出发，该合计含有率优选为25质量％以下、特别优选为20质量％以下。Cr、Mn、Co及Ni的合计含有率优选为3.0质量％以上、特别优选为5.0质量％以上。合计含有率也可以为零。换言之，Cr、Mn、Co及Ni不是必需的成分。
[余量]
该合金的余量为Fe及不可避免的杂质。该合金中，允许含有作为不可避免的杂质的元素。
[Fe2B相的面积率PS]
合金中的Fe2B相的面积率(以下、称为“面积率PS”)优选为20％以上且80％以下。利用包含含有该面积率PS为上述范围内的合金的粉末的磁性片4，在频率为100kHz至20MHz的区域中，可以抑制噪声。若面积率PS增加，则由Fe2B相导致的噪声抑制效果增加。从该观点出发，该面积率PS更优选为30％以上、特别优选为40％以上。过大的面积率PS导致导磁率的降低，阻碍噪声抑制。从该观点出发，面积率PS更优选为70％以下、特别优选为60％以下。关于面积率PS的测定，首先用SEM观察粒子2的截面，利用能量色散型X射线分析(EDS)来确定Fe2B相。进而对该截面实施图像分析，算出面积率PS。对于随机抽出的10个粒子2测定面积率，对其取平均值。
[bHc/N]
合金的、bHc相对于各元素所具有的电子数的加权平均N之比(bHc/N)优选为500A/(m·个)以上。利用包含含有比(bHc/N)为500A/(m·个)以上的合金的粉末的磁性片4，在频率为100kHz至20MHz的区域中，可抑制噪声。从该观点出发，比(bHc/N)更优选为530A/(m·个)以上、特别优选为550A/(m·个)以上。比(bHc/N)优选为700A/(m·个)以下。
例如，Fe-3质量％B的情况下，Fe的电子数为26，B的电子数为5，因此，加权平均N由下述的数式算出。
5×0.03+26×(1-0.03)＝25.37
例如，Fe-2质量％Cr-5质量％B的情况下，Fe的电子数为26，Cr的电子数为24，B的电子数为5，因此，加权平均N由下述的数式算出。
24×0.02+5×0.05+26×(1-0.02-0.05)＝24.91
bHc由振动试样型磁力计来测定。测定时的施加磁场为120000A/m。通过分析磁性体的磁滞回线，从而导出bHc。作为振动试样型磁力计的一例，可举出Lake Shore公司的AGM2900。
[平均粒径]
该粉末的平均粒径D50优选为20μm以上且150μm以下。平均粒径D50为20μm以上的粉末，流动性优异，因此可以与粘合剂等容易地混合。从该观点出发，平均粒径D50更优选为25μm以上、特别优选为30μm以上。由平均粒径D50为150μm以下的粉末，可得到厚度小的磁性片4。该磁性片4可以应用于小型的电子设备。从该观点出发，平均粒径D50更优选为120μm以下、特别优选为100μm以下。
平均粒径D50是在以粉体的总体积作为100％来求出累积曲线时，该累积曲线达到50％的点的粒径。粒径利用激光衍射/散射式粒径分布测定装置来测定。在该装置的测量单元内，粉末与纯水一起流入，基于粒子2的光散射信息，检测平均粒径。作为该装置的一例，可举出日机装公司的“Microtrac MT3000”。
该粉末可以利用雾化来制造。作为优选的雾化，可举出气体雾化法及水雾化法。
[第二实施方式]
图3是示出本发明的其他的实施方式的磁性部件用粉末的粒子6的截面图。该粒子6具有球状的主要部分8和绝缘性覆膜10。换言之，粒子6具有位于主要部分8的表面的(由绝缘性覆膜10构成的)绝缘包覆。主要部分8的材质、性状、尺寸等与图1所示的粒子2相同。该粒子6可以通过在图1所示的粒子2的表面附着绝缘性覆膜10而得到。
粒子6的主要部分8与邻接于该粒子6的其他粒子6的主要部分8的直接的接触被绝缘性覆膜10防止。由此，涡流损耗得以抑制。从该观点出发，覆膜10的厚度优选为20nm以上、特别优选为30nm以上。从不易阻碍主要部分8所具有的磁特性的观点出发，覆膜10的厚度优选为500nm以下、特别优选为100nm以下。
由具有绝缘性覆膜10的粒子6制作的片材的体积电阻值β相对于由不具有绝缘性覆膜10的粒子制作的片材的体积电阻值α之比(β/α)为100以上。
如图3所示那样，覆膜10覆盖主要部分8的整体。覆膜10也可以部分地覆盖主要部分8。
粒子6也可以在主要部分8与覆膜10之间具有其他覆膜。粒子6也可以在覆膜10的外侧具有其他覆膜。
覆膜10优选含有包含钛醇盐类及硅醇盐类的聚合物。该聚合物可以由钛醇盐类与硅醇盐类的混合物的聚合反应得到。钛醇盐类是在1个分子中具有的钛原子上键合有至少1个醇盐基的化合物。硅醇盐类是在1个分子中具有的硅原子上键合有至少1个醇盐基的化合物。醇盐基是有机基团与带有负电荷的氧键合而得的化合物。有机基团是包含有机化合物的基团。
钛醇盐类包括钛醇盐的单体、多个该单体聚合而形成的低聚物、及生成钛醇盐之前的阶段的化合物(也称为前体。)。硅醇盐类包括硅醇盐的单体、多个该单体聚合而形成的低聚物、及生成硅醇盐之前的阶段的化合物(也称为前体。)。
作为钛醇盐的具体例，可举出四甲氧基钛、四乙氧基钛、四异丙氧基钛、四丁氧基钛、四-2-乙基己氧基钛及异丙基三(十二烷基苯磺酰基)钛酸酯。
作为硅醇盐的具体例，可举出四乙氧基硅烷、四甲氧基硅烷、甲基三乙氧基硅烷、四异丙氧基硅烷、乙烯基三甲氧基硅烷、γ-氨基丙基三乙氧基硅烷及N-(β-氨基乙基)-γ-氨基丙基甲基二甲氧基硅烷。
覆膜10向主要部分8的附着可以采用各种涂敷方法。作为涂敷方法的具体例，可举出混合法、溶胶-凝胶法、喷雾干燥法及旋转式流化床法。
也可以将包含钛醇盐类及硅醇盐类的聚合物用溶剂稀释，并供于涂敷。作为优选的溶剂，可例示丙酮、甲基乙基酮、乙腈、甲醇、乙醇、异丙醇、正丁醇、苯、甲苯、己烷、庚烷、环己烷、氯仿、氯苯、二氯苯、乙酸乙酯、丙酸乙酯及四氢呋喃。
覆膜10在包含钛醇盐类及硅醇盐类的聚合物的基础上，也可以包含其他的化合物。覆膜10也可以由除了包含钛醇盐类及硅醇盐类的聚合物以外的化合物形成。
实施例
以下，本发明的效果基于实施例而明确，但不应基于该实施例的记载对本发明进行限定性的解释。
[实施例1]
利用雾化，制作具有下述的表1所示的组成的实施例1的粉末。该粉末中的各粒子的形状为球形。将该粉体用小型混合机在100℃的温度下与环氧树脂进行混炼，得到粉末均匀地分散于树脂基体中的树脂组合物。环氧树脂与粉末的体积比为5比2。将该树脂组合物在压力为4MPa、温度为200℃的条件下进行5分钟热压处理，得到厚度为0.1mm的磁性片。
[实施例2～30及比较例1～16]
组成如下述的表1～3所示，除此之外，与实施例1同样地操作，制作实施例2～30及比较例1～16的粉末。与实施例1同样地操作，由这些粉末得到磁性片。
[磁性片的评价]
在温度为25℃的条件下改变频率，测定磁性片的导磁率及tanδ。测定利用安捷伦科技(Agilent Technologies)公司制的商品名“Vector Network Analyzer N5245A”来进行。求出该10MHz的实部导磁率μ’及tanδ超过0.02的频率区域的下限值FL。进而，基于该实部导磁率μ’及下限值FL，根据下述的基准，对各粉末进行分级。
A：μ’为4.0以上、并且FL为100MHz以上
B：μ’为4.0以上、并且FL超过40MHz且不足100MHz
C：μ’为4.0以上、并且FL为10MHz以上且40MHz以下
F：μ’不足4.0、或FL不足10MHz
这些结果示于下述的表1～3。
[表1]
[表2]
[表3]
由表1～3所示的评价结果可知本发明的优越性。
本发明的粉末适用于各种磁性部件。
Claims (6)
1.一种磁性部件用粉末，其包含多个粒子，
所述粒子各自的主要部分是合金制，所述合金包含：
B：5.0质量％以上且8.0质量％以下、以及
余量：Fe及不可避免的杂质，
所述合金包含Fe2B相。
2.一种磁性部件用粉末，其包含多个粒子，
所述粒子各自的主要部分是合金制，所述合金包含：
B：5.0质量％以上且8.0质量％以下、
选自Cr、Mn、Co及Ni中的1种或2种以上：0质量％以上且25质量％以下、以及
余量：Fe及不可避免的杂质，
所述合金包含Fe2B相。
3.根据权利要求1或2所述的磁性部件用粉末，其中，所述合金中的Fe2B相的面积率PS为20％以上且80％以下。
4.根据权利要求1～3中任一项所述的磁性部件用粉末，其中，所述合金的、bHc相对于各元素所具有的电子数的加权平均N之比即bHc/N为500A/(m·个)以上且700A/(m·个)以下。
5.根据权利要求1～4中任一项所述的磁性部件用粉末，其中，所述粒子具有位于所述主要部分的表面的绝缘包覆。
6.根据权利要求1～5中任一项所述的磁性部件用粉末，其中，所述粒子具有球形形状。
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| JP2018179174A JP7288294B2 (ja) | 2018-09-25 | 2018-09-25 | 磁性部材用粉末 |
| JP2018-179174 | 2018-09-25 | ||
| PCT/JP2019/036505 WO2020066779A1 (ja) | 2018-09-25 | 2019-09-18 | 磁性部材用粉末 |
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| KR20100138657A (ko) * | 2009-06-25 | 2010-12-31 | 주식회사 비아이티범우연구소 | 자용합금 분말 및 그 제조방법과 제조를 위한 조립체 |
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2018
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2019
- 2019-09-18 US US17/279,122 patent/US11920226B2/en active Active
- 2019-09-18 WO PCT/JP2019/036505 patent/WO2020066779A1/ja active Application Filing
- 2019-09-18 KR KR1020207034134A patent/KR20210065896A/ko unknown
- 2019-09-18 CN CN201980041737.9A patent/CN112351845A/zh active Pending
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| CN1689733A (zh) * | 2004-04-22 | 2005-11-02 | 阿尔卑斯电气株式会社 | 非晶软磁性合金粉末以及使用它的压粉铁心和电波吸收体 |
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| KR20210065896A (ko) | 2021-06-04 |
| US20210398719A1 (en) | 2021-12-23 |
| JP7288294B2 (ja) | 2023-06-07 |
| WO2020066779A1 (ja) | 2020-04-02 |
| JP2020050896A (ja) | 2020-04-02 |
| US11920226B2 (en) | 2024-03-05 |
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