CN113113221A - 磁性芯及其制造方法 - Google Patents
磁性芯及其制造方法 Download PDFInfo
- Publication number
- CN113113221A CN113113221A CN202110369915.XA CN202110369915A CN113113221A CN 113113221 A CN113113221 A CN 113113221A CN 202110369915 A CN202110369915 A CN 202110369915A CN 113113221 A CN113113221 A CN 113113221A
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- Prior art keywords
- iron
- temperature
- magnetic core
- epoxy resin
- magnetic powder
- Prior art date
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- Granted
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 21
- 238000000034 method Methods 0.000 title claims description 22
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 106
- 239000006247 magnetic powder Substances 0.000 claims abstract description 53
- 229910052742 iron Inorganic materials 0.000 claims abstract description 46
- 239000002245 particle Substances 0.000 claims abstract description 37
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- 238000000576 coating method Methods 0.000 claims abstract description 29
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- HECLRDQVFMWTQS-RGOKHQFPSA-N 1755-01-7 Chemical group C1[C@H]2[C@@H]3CC=C[C@@H]3[C@@H]1C=C2 HECLRDQVFMWTQS-RGOKHQFPSA-N 0.000 description 1
- VPWNQTHUCYMVMZ-UHFFFAOYSA-N 4,4'-sulfonyldiphenol Chemical compound C1=CC(O)=CC=C1S(=O)(=O)C1=CC=C(O)C=C1 VPWNQTHUCYMVMZ-UHFFFAOYSA-N 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
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- ILRRQNADMUWWFW-UHFFFAOYSA-K aluminium phosphate Chemical compound O1[Al]2OP1(=O)O2 ILRRQNADMUWWFW-UHFFFAOYSA-K 0.000 description 1
- 150000004982 aromatic amines Chemical class 0.000 description 1
- YYXHRUSBEPGBCD-UHFFFAOYSA-N azanylidyneiron Chemical compound [N].[Fe] YYXHRUSBEPGBCD-UHFFFAOYSA-N 0.000 description 1
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- 229910052796 boron Inorganic materials 0.000 description 1
- ZDVYABSQRRRIOJ-UHFFFAOYSA-N boron;iron Chemical compound [Fe]#B ZDVYABSQRRRIOJ-UHFFFAOYSA-N 0.000 description 1
- 239000001506 calcium phosphate Substances 0.000 description 1
- 229910000389 calcium phosphate Inorganic materials 0.000 description 1
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- CPSYWNLKRDURMG-UHFFFAOYSA-L hydron;manganese(2+);phosphate Chemical compound [Mn+2].OP([O-])([O-])=O CPSYWNLKRDURMG-UHFFFAOYSA-L 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- UGKDIUIOSMUOAW-UHFFFAOYSA-N iron nickel Chemical compound [Fe].[Ni] UGKDIUIOSMUOAW-UHFFFAOYSA-N 0.000 description 1
- 229910000398 iron phosphate Inorganic materials 0.000 description 1
- XWHPIFXRKKHEKR-UHFFFAOYSA-N iron silicon Chemical compound [Si].[Fe] XWHPIFXRKKHEKR-UHFFFAOYSA-N 0.000 description 1
- WBJZTOZJJYAKHQ-UHFFFAOYSA-K iron(3+) phosphate Chemical compound [Fe+3].[O-]P([O-])([O-])=O WBJZTOZJJYAKHQ-UHFFFAOYSA-K 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 229910001463 metal phosphate Inorganic materials 0.000 description 1
- QMQXDJATSGGYDR-UHFFFAOYSA-N methylidyneiron Chemical compound [C].[Fe] QMQXDJATSGGYDR-UHFFFAOYSA-N 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 125000001624 naphthyl group Chemical group 0.000 description 1
- 229920003986 novolac Polymers 0.000 description 1
- 150000007524 organic acids Chemical class 0.000 description 1
- AFEQENGXSMURHA-UHFFFAOYSA-N oxiran-2-ylmethanamine Chemical compound NCC1CO1 AFEQENGXSMURHA-UHFFFAOYSA-N 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 235000011837 pasties Nutrition 0.000 description 1
- DPTATFGPDCLUTF-UHFFFAOYSA-N phosphanylidyneiron Chemical compound [Fe]#P DPTATFGPDCLUTF-UHFFFAOYSA-N 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
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- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- PJANXHGTPQOBST-UHFFFAOYSA-N stilbene Chemical compound C=1C=CC=CC=1C=CC1=CC=CC=C1 PJANXHGTPQOBST-UHFFFAOYSA-N 0.000 description 1
- 235000021286 stilbenes Nutrition 0.000 description 1
- 150000003512 tertiary amines Chemical class 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- LRXTYHSAJDENHV-UHFFFAOYSA-H zinc phosphate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O LRXTYHSAJDENHV-UHFFFAOYSA-H 0.000 description 1
- 229910000165 zinc phosphate Inorganic materials 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
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- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
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- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
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- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/103—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing an organic binding agent comprising a mixture of, or obtained by reaction of, two or more components other than a solvent or a lubricating agent
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- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/105—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing inorganic lubricating or binding agents, e.g. metal salts
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- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
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- H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
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- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
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- B22F2998/10—Processes characterised by the sequence of their steps
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- H01F3/00—Cores, Yokes, or armatures
- H01F3/08—Cores, Yokes, or armatures made from powder
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Physics & Mathematics (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Inorganic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Health & Medical Sciences (AREA)
- Organic Chemistry (AREA)
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Abstract
本发明提供磁性芯及其制造方法。其是使在粒子表面形成了树脂被膜的铁系软磁性体粉末在压缩成型后热固化而制造的磁性芯,上述铁系软磁性体粉末为对粉末粒子的表面进行了无机绝缘被膜处理的铁系软磁性体粉末,上述树脂被膜为通过在热固化性树脂的软化温度以上且不到热固化开始温度的温度下进行干式混合而形成的未固化树脂被膜,上述压缩成型为使用模具的压缩成型体的制造,上述热固化是在上述热固化性树脂的热固化开始温度以上的温度下使其热固化。
Description
本申请是申请号为201580050143.6、申请日为2015年9月17日、发明名称为“磁性芯及其制造方法”的中国专利申请的分案申请。
技术领域
本发明涉及磁性芯及其制造方法,特别涉及安装于高频淬火装置的加热线圈部的铁系软质磁性芯及其制造方法。
背景技术
磁性芯具有安装于线圈的背面而使磁力线集中于工件、增强功率、促进感应加热的效果、相反地安装于线圈的前面而遮蔽(屏蔽)磁力线、防止不需要淬火的部位的加热的效果,成为了对于高频淬火装置的加热线圈不可缺少的部件。
例如,进行高频淬火的工件的形状复杂,必须调节淬火深度的情况下,通过改变安装的芯的形状、尺寸、数量、方向、位置等,能够使感应加热的状态变化,可以控制工件的淬火深度。对于该芯材料,(1)频率特性良好,即与频率的变化相伴的电感变化小,(2)饱和磁通量密度高,(3)相对磁导率高,(4)铁损小等磁特性变得必要。
另外,为了应对多样的工件的形状,芯部件也多变为多品种少量生产,多通过1个1个地切削应对来生产。因此,需要强度高、富于切削性的材料。
采用粉末冶金法制造的磁性芯,由于原料损失少,量产性优异,因此多用作在高频淬火装置的加热线圈中使用的磁性芯。例如,作为高频淬火线圈用磁性芯,使用了用氟树脂将磁性粉固着的制品、用酚醛树脂将铁硅铝合金粉(センダスト粉)固着的制品等,但它们的材料强度比较低,存在薄壁切削时的开裂发生、线圈安装时的破损等问题。
为了解决上述问题,本申请人提出了使在粒子表面形成了树脂被膜的铁系软磁性体粉末在压缩成型后热固化的磁性芯(专利文献1)。该磁性芯是经济性、磁特性和材料强度优异的、安装于高频淬火装置的加热线圈部的通用性高的磁性芯。
现有技术文献
专利文献
专利文献1:日本特开2014-72482号公报
发明内容
发明要解决的课题
对于安装于高频淬火装置的加热线圈部的磁性芯,从加热线圈的形状、磁性芯的安装方式出发,有时要求作为体积电阻率值为105Ω·cm左右的电绝缘性。
但是,就专利文献1中记载的磁性芯而言,通用性优异,但有关电绝缘性不充分,因使用用途的不同,有时经由磁性芯发生电短路、发热,使磁性芯的耐久性显著地降低。因此,在要求绝缘性的用途中,存在难以开展的问题。
本发明为了应对这样的问题而完成,目的在于作为磁性芯、特别是安装于高频淬火装置的加热线圈部等的软质磁性芯,提供有效利用专利文献1中记载的磁性芯的长处、同时赋予了绝缘性的磁性芯及其制造方法。
用于解决课题的方案
本发明的磁性芯是使在粒子表面形成了树脂被膜的铁系软磁性体粉末在压缩成型后热固化而制造的磁性芯。其特征在于,上述铁系软磁性体粉末为对粉末粒子的表面进行了无机绝缘被膜处理的铁系软磁性体粉末,上述树脂被膜为通过在热固化性树脂的软化温度以上且不到热固化开始温度的温度下进行干式混合而形成的未固化树脂被膜,上述压缩成型为使用模具的压缩成型体的制造,上述热固化是在上述热固化性树脂的热固化开始温度以上的温度下使其热固化。
进行了无机绝缘被膜处理的铁系软磁性体粉末,其特征在于,是通过筛网眼106μm的筛、不通过筛网眼25μm的筛的粒子。另外,其特征在于,在该铁系软磁性体粉末的粒子表面所形成的树脂被膜为包含潜伏性固化剂的环氧树脂。特别地,其特征在于,该潜伏性固化剂为双氰胺,包含该潜伏性固化剂的环氧树脂的软化温度为100-120℃。其特征在于,相对于上述铁系软磁性体粉末和上述包含潜伏性固化剂的环氧树脂的合计量,配合了95-99质量%的上述铁系软磁性体粉末,配合了1-5质量%的上述包含潜伏性固化剂的环氧树脂。
本发明的磁性芯,其特征在于,是在高频淬火线圈中使用的磁性芯。
上述本发明涉及的磁性芯的制造方法,其特征在于,包含:将上述对粉末粒子的表面进行了无机绝缘被膜处理的铁系软磁性体粉末和上述包含潜伏性固化剂的环氧树脂在该环氧树脂的软化温度以上且不到热固化开始温度的温度下进行干式混合的混合工序;将通过上述混合工序生成的凝聚料饼在室温下粉碎而得到复合磁性粉末的粉碎工序;使用模具使上述复合磁性粉末成为压缩成型体的压缩成型工序;和在上述环氧树脂的热固化开始温度以上的温度下使上述压缩成型体热固化的固化工序。特别地,其特征在于,上述压缩成型工序为用98-294MPa的成型压力进行成型。另外,其特征在于,上述固化工序为在固化温度170-190℃下、非活性气体气氛中进行固化。
发明的效果
本发明的磁性芯与专利文献1中记载的磁性芯相比,用体积电阻率表示的电绝缘性提高到105Ω·cm。
附图说明
图1为表示磁性芯和高频线圈的配置关系的图。
图2为磁性芯的立体图。
图3为复合磁性粉末粒子的截面图。
图4为制造工序图。
具体实施方式
等速万向接头的外侧接头构件由圆柱状的原料经过冷锻等锻造过程而制造,然后,进行高频淬火。就该高频淬火而言,为了在外侧接头构件的杯套部分的内外面和轴部调节高频淬火的淬火度,多在高频线圈的前面或背面配置磁性芯而实施。
将磁性芯和高频线圈的配置关系示于图1中。图1(a)为表示将磁性芯嵌入环状或矩形状线圈的框内而使用的方式的情形的图,图1(b)为表示将磁性芯安装于线圈的一端而使用的方式的情形的图。
如图1(a)和图1(b)中所示那样,线圈2由电阻低的铜的管、板等构成,为了提高加热效率、调整加热部位,配置了控制磁通量的磁性芯1。该磁性芯1能够使通过线圈电流3a流过而产生的磁通量集中于工件,或者通过相反地屏蔽该磁通量而使感应加热的状态变化。图1(a)的情况下,如果使用绝缘耐力低的磁性芯1,则有时泄漏电流3b经由磁性芯1内流动,磁性芯1引起绝缘破坏,发生熔损·短路等,磁性芯1的耐久性显著地降低。相对于此,图1(b)的情况下,由于不发生经由磁性芯1的电短路,因此未必需要高的绝缘耐力。
为了提高绝缘耐力,考虑用绝缘材料被覆成为磁性芯的原料的磁性粉表面,从而制成体积电阻率大的磁性芯。将有机绝缘材料或无机材料各自单独地被覆,但体积电阻率没有大幅地提高。但是,通过使有机绝缘材料与无机材料成为复层,与各自单独层的情形相比,发现了10万倍以上的体积电阻率的提高。本发明基于这样的认知。
将磁性芯的立体图的一例示于图2,将成为原料的复合磁性粉末粒子的截面图示于图3。磁性芯1通过使复合磁性粉末粒子4压缩成型·加热固化而得到。复合磁性粉末粒子4在铁系软磁性体粉末粒子4a的表面被覆无机绝缘被膜4b,进而在该无机绝缘被膜4b表面被覆了未固化的树脂被膜4c。磁性芯1通过对复合磁性粉末粒子4进行压缩成型,然后使树脂被膜4c热固化而制造。然后,根据需要进行切削加工、滚筒加工和防锈处理等后处理。根据高频线圈的形状、大小、场所等,所配置的磁性芯的形状等也可以适当地改变。图2中所示的磁性芯1为嵌入环状或矩形状线圈的框内使用的磁性芯的例子。
作为本发明中能够使用的铁系软磁性体粉末,能够使用纯铁、铁-硅系合金、铁-氮系合金、铁-镍系合金、铁-碳系合金、铁-硼系合金、铁-钴系合金、铁-磷系合金、铁-镍-钴系合金和铁-铝-硅系合金(铁硅铝合金)等的粉末。
上述铁系软磁性体粉末中,优选纯铁,特别优选在粉末冶金中使用的还原铁粉或雾化铁粉。更优选为得到的磁性芯的机械特性优异的还原铁粉。还原铁粉为将炼铁厂中产生的氧化铁等用焦炭等还原、接下来在氢气氛进行热处理而制造的铁粉,在粒子内具有孔隙。另外,雾化铁粉为将熔钢用高压水进行粉化·冷却、然后在氢气氛中热处理而制造的铁粉,粒子内无孔隙。在还原铁粉的断面照片中,在表面发现大量的凹凸,认为该凹凸使环压强度降低。
用无机绝缘体被覆铁系软磁性体粉末粒子的表面。对无机绝缘材料的种类并无特别限定,能够使用以往在压粉磁心中使用的无机绝缘材料。作为优选的绝缘材料的例子,可列举出磷酸铁、磷酸锰、磷酸锌、磷酸钙、磷酸铝等磷酸金属盐、氧化硅、氧化镁、氧化铝、氧化钛、氧化锆等金属氧化物。另外,也可以使用其他矿物。作为无机绝缘材料,可使用1种材料,也可将2种以上的材料并用。作为用无机绝缘体被覆的铁系软磁性体粉末的市售品,可列举出ヘガネス社制商品名:Somaloy。
上述表面经无机绝缘被膜处理的铁系软磁性体粉末优选为通过筛网眼为106μm的筛、不通过筛网眼为25μm的筛的粒子。优选的范围是通过90μm、不通过38μm的粒子。就通过25μm的微粉而言,在铁粒子表面的树脂被膜的形成变得困难,不通过106μm的铁粉的铁损变大。
本发明中能够使用的环氧树脂为能够作为粘接用环氧树脂使用的树脂,优选软化温度为100-120℃的树脂。例如,只要是室温下为固体,但在50-60℃下成为糊状,在130-140℃下成为流动性,如果进一步继续加热,则开始固化反应的环氧树脂,就能够使用。该固化反应即使在120℃附近也开始,但作为在实用的固化时间、例如2小时以内固化反应就结束的温度,优选为170-190℃。如果为该温度范围,则固化时间为45-80分钟。
作为环氧树脂的树脂成分,例如可以列举出双酚A型环氧树脂、双酚F型环氧树脂、双酚S型环氧树脂、氢化双酚A型环氧树脂、氢化双酚F型环氧树脂、均二苯乙烯型环氧树脂、含有三嗪骨架的环氧树脂、含有芴骨架的环氧树脂、脂环式环氧树脂、酚醛清漆型环氧树脂、丙烯酸系环氧树脂、缩水甘油基胺型环氧树脂、三酚酚甲烷型环氧树脂、烷基改性三酚甲烷型环氧树脂、联苯型环氧树脂、含有双环戊二烯骨架的环氧树脂、含有萘骨架的环氧树脂、芳基亚烷基型环氧树脂等。
环氧树脂的固化剂成分为潜伏性环氧固化剂。通过使用潜伏性环氧固化剂,能够将软化温度设定在100-120℃,另外,能够将固化温度设定在170-190℃,能够进行对经无机绝缘被膜处理的铁粉粉末的有机绝缘性涂膜的形成以及其后的压缩成型和热固化。
作为潜伏性环氧固化剂,可列举出双氰胺、三氟化硼-胺络合物、有机酸酰肼等。这些中,优选适合上述固化条件的双氰胺。
另外,可以与潜伏性环氧固化剂一起包含叔胺、咪唑、芳香族胺等固化促进剂。
包含本发明中能够使用的上述潜伏性固化剂的环氧树脂以成为160℃下2小时、170℃下80分钟、180℃下55分钟、190℃下45分钟、200℃下30分钟的固化条件的方式配合潜伏性固化剂。
就表面经无机绝缘被膜处理的铁系软磁性体粉末与环氧树脂的配合比例而言,相对于它们的合计量,铁系软磁性体粉末为95-99质量%,包含潜伏性固化剂的环氧树脂为1-5质量%。这是因为:如果环氧树脂不到1质量%,绝缘被膜的形成困难,如果超过5质量%,发生磁特性的降低和富含树脂的粗大的凝聚体。
就本发明的磁性芯而言,通过在100-120℃的温度下对上述表面经无机绝缘被膜处理的铁系软磁性体粉末、和上述环氧树脂进行干式混合,从而在铁系软磁性体粉末表面形成了的无机绝缘被膜上形成未固化树脂被膜。该未固化树脂被膜也为绝缘被膜,热固化后成为无机绝缘被膜与树脂被膜的复合绝缘被膜。由于被膜的绝缘性显著提高,因此能够作为要求电绝缘性的领域中的磁芯利用。
对于在表面形成了绝缘被膜的铁系软磁性体粉末,通过使用模具的压缩成型而成为成型体,然后在环氧树脂的热固化开始温度以上的温度下使其热固化,从而得到一体化了的磁性芯。
就本发明的磁性芯而言,电绝缘性优异,同时磁特性和环压强度等机械特性优异。另外,成型后切削加工性优异。因此,能够容易地制造薄型的磁性芯、特殊形状的磁性芯。因此,能够利用于等速万向接头的外侧接头构件等。
通过图4对上述磁性芯的制造方法进行说明。图4为制造工序图。
分别准备上述的在表面形成了无机绝缘被膜的铁系软磁性体粉末和上述的已配合了潜伏性固化剂的环氧树脂。将铁系软磁性体粉末预先通过分级机调整为通过筛网眼106μm的筛、没有通过25μm的筛的粒子。
通过混合工序,在该环氧树脂的软化温度以上且不到热固化开始温度的温度下对无机绝缘铁系软磁性体粉末和环氧树脂进行干式混合。在该混合工序中,最初在室温下使用掺混机等将无机绝缘铁系软磁性体粉末和环氧树脂充分地混合。接下来,将经混合的混合物投入捏合机等混合机中,在环氧树脂的软化温度(100-120℃)下加热混合。通过该加热混合的工序,在无机绝缘铁系软磁性体粉末的表面形成环氧树脂的绝缘被膜。在该阶段中,环氧树脂为未固化。
使用捏合机等混合机加热混合了的内容物成为了凝聚的饼状。粉碎工序是通过在室温下将该凝聚料饼粉碎并进行筛分,从而得到在表面形成了环氧树脂的绝缘膜的复合磁性粉末的工序。粉碎优选亨舍尔混合机,筛分优选制成通过60目(250μm)的筛的粒子。
压缩成型工序中所使用的模具只要是能够施加98-294MPa的成型压力的模具即可。这是因为:如果成型压力不到98MPa,则磁特性、强度低,如果超过294MPa,环氧树脂固着于模具内壁,或者由于树脂被膜的破坏,绝缘性降低。
将从模具取出的成型品在170-190℃的温度下加热固化45-80分钟。这是因为:如果不到170℃,则固化需要长时间,如果超过190℃,则开始劣化。加热固化优选在氮气氛中进行。
加热固化后,根据需要进行切削加工、滚筒加工、防锈处理等,得到磁性芯。
实施例
实施例1
将粒子表面用无机绝缘被膜覆盖的铁粉粒子97.0g、包含双氰胺作为固化剂的环氧树脂粉末3.0g用掺混机在室温下混合了10分钟。使用的铁粉粒子使用了通过筛网眼106μm的筛、没有通过25μm的筛的粒子。将混合物投入捏合机中,在110℃下加热混炼了15分钟。从捏合机将凝聚的料饼取出,冷却后,用粉碎机粉碎。接下来,使用模具以200MPa的成型压力进行了压缩成型。将压缩成型品从模具中取出,在180℃的温度下在氮气氛中使其固化了1小时。进而实施切削加工,制造了磁性芯。
另外,在上述条件下制作磁特性测定用圆环(トロイダル)状的试验片,测定了磁特性。就试验片而言,制成内径7.6mmφ、外径12.6mmφ、厚5.7mm的平圆筒状的磁性芯,在该磁性芯卷绕一次侧卷线和二次侧卷线,得到了圆环状的供试试验片。对一次侧卷线通直流电,测定使磁化力(A/m)变化时的二次侧卷线的磁通量密度,测定了饱和磁通量密度。另外,对上述磁性芯分别调节卷线的卷绕数以致电感成为10μH,将1kHz下的电感设为100%,测定了使频率变化时的电感和相对磁导率。使用上述磁性芯在表1中所示的条件下测定了铁损和温度特性(电感变化率)。进而,测定了上述磁性芯的环压强度。就测定而言,对磁性芯连续施加其直径方向的载荷直至发生破坏,测定了破坏时的载荷。将测定结果示于表1中。
另外,作为表面硬度、体积电阻、表面电阻、密度测定用试验片,制作了10mm×25mm×3mm厚的试验片。表面硬度采用洛氏硬度试验法测定,体积电阻和表面电阻采用四探针法测定,密度采用水中法测定。将测定结果示于表1中。
比较例1
除了作为铁粉粒子,粒子表面没有用无机绝缘被膜覆盖以外,使用与实施例1同样的铁粉粒子,采用与实施例1同样的方法制造了磁性芯。将采用与实施例1同样的方法评价的结果示于表1中。
比较例2
使用模具、以900MPa的成型压力将实施例1中使用的、粒子表面被无机绝缘被膜覆盖的铁粉粒子压缩成型。将压缩成型品从模具中取出,在530℃的温度下在空气气氛中热处理20分钟。进而,实施切削加工,制造了磁性芯。将采用与实施例1同样的方法评价的结果示于表1中。
比较例3和比较例4
将用聚四氟乙烯使铁粉固着的磁性芯(比较例3)、用酚醛树脂使铁硅铝合金粉固着的磁性芯(比较例4)制成与上述试验片相同的形状,进行了与实施例1相同的评价。在切削加工的工序中,比较例3和比较例4的磁性芯的机械强度弱,如果可以进行薄壁部的切削,则产生开裂、裂纹。将结果示于表1中。
[表1]
实施例1的磁性芯与比较例1和比较例2的磁性芯相比,电绝缘性提高了105倍以上。
产业上的可利用性
本发明的磁性芯由于经济性、磁特性和材料强度优异,同时体积电阻率、表面电阻等电特性优异,因此能够作为通用的磁性芯利用。特别地,能够特别有效地在将磁性芯嵌入环状或矩形状线圈的框内而使用的磁性芯中利用。另外,能够作为需要复杂的形状、例如安装于高频淬火装置的加热线圈部的软质磁性芯利用。
附图标记的说明
1 磁性芯
2 线圈
3 电流
4 复合磁性粉末粒子
Claims (11)
1.磁性芯的制造方法,其特征在于,所述磁性芯是使用于高频淬火线圈的磁性芯,
所述制造方法包含:
将对粉末粒子的表面进行了无机绝缘被膜处理的铁系软磁性体粉末和包含潜伏性固化剂的环氧树脂在该环氧树脂的软化温度以上且不到热固化开始温度的温度下进行干式混合,得到在上述铁系软磁性体粉末的表面形成了上述环氧树脂的未固化树脂被膜的状态的凝聚料饼的混合工序,
将通过上述混合工序生成的上述凝聚料饼在室温下粉碎而得到复合磁性粉末的粉碎工序,
使用模具使上述复合磁性粉末成为压缩成型体的压缩成型工序,和
在上述环氧树脂的热固化开始温度以上的温度下使上述压缩成型体热固化的固化工序,
上述压缩成型工序是在98-294MPa的成型压力下进行成型。
2.根据权利要求1所述的磁性芯的制造方法,其特征在于,上述固化工序是在固化温度170-190℃下、非活性气体气氛中进行固化。
3.根据权利要求1所述的磁性芯的制造方法,其特征在于,上述潜伏性固化剂为双氰胺,上述环氧树脂的软化温度为100-120℃。
4.根据权利要求1所述的磁性芯的制造方法,其特征在于,相对于上述铁系软磁性体粉末和上述环氧树脂的合计量,配合了95-99质量%的上述铁系软磁性体粉末,配合了1-5质量%的上述环氧树脂。
5.根据权利要求1所述的磁性芯的制造方法,其特征在于,上述高频淬火线圈为环状或矩形状,上述磁性芯嵌入该线圈的环状或矩形状的框内而使用。
6.磁性芯,其是使在粒子表面形成了树脂被膜的铁系软磁性体粉末在压缩成型后热固化而制造的磁性芯,其特征在于,
上述磁性芯是使用于高频淬火线圈的磁性芯,上述高频淬火线圈为环状或矩形状,在使用中,上述磁性芯装入环状或矩形状的框内,
上述铁系软磁性体粉末具有在粒子表面形成了的树脂被膜,此处,该粒子表面被无机绝缘体被覆,该无机绝缘体位于该铁系软磁性体粉末和该树脂被膜之间,形成铁系软磁性体粉末无机绝缘体被覆粒子,
上述无机绝缘体被覆粒子是通过筛网眼106μm的筛、不通过筛网眼25μm的筛的粒子,
上述树脂被膜为将上述铁系软磁性体粉末和软化温度为100-120℃的包含潜伏性固化剂的热固化性环氧树脂、通过在该热固化性树脂的软化温度以上且不到该树脂的热固化开始温度的温度下进行干式混合而形成的未固化树脂被膜,
上述压缩成型为使用模具的压缩成型体的制造,
上述热固化是在上述热固化性树脂的热固化开始温度以上的温度下使其热固化。
7.根据权利要求6所述的磁性芯,其特征在于,上述潜伏性固化剂为双氰胺。
8.根据权利要求6所述的磁性芯,其特征在于,相对于上述铁系软磁性体粉末和上述包含潜伏性固化剂的环氧树脂的合计量,配合了95-99质量%的上述铁系软磁性体粉末,配合了1-5质量%的上述包含潜伏性固化剂的环氧树脂。
9.磁性芯的制造方法,其是权利要求6所述的磁性芯的制造方法,其特征在于,包含:
将上述对粉末粒子的表面进行了无机绝缘被膜处理的铁系软磁性体粉末和上述包含潜伏性固化剂的环氧树脂在该环氧树脂的软化温度以上且不到热固化开始温度的温度下进行干式混合的混合工序,
将通过上述混合工序生成的凝聚料饼在室温下粉碎而得到复合磁性粉末的粉碎工序,
使用模具使上述复合磁性粉末成为压缩成型体的压缩成型工序,和
在上述环氧树脂的热固化开始温度以上的温度下使上述压缩成型体热固化的固化工序。
10.根据权利要求9所述的磁性芯的制造方法,其特征在于,上述压缩成型工序是在98-294MPa的成型压力下进行成型。
11.根据权利要求9所述的磁性芯的制造方法,其特征在于,上述固化工序是在固化温度170-190℃下、非活性气体气氛中进行固化。
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