CN1700369A - High-frequency core and inductance component using the same - Google Patents
High-frequency core and inductance component using the same Download PDFInfo
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- CN1700369A CN1700369A CNA2005100726334A CN200510072633A CN1700369A CN 1700369 A CN1700369 A CN 1700369A CN A2005100726334 A CNA2005100726334 A CN A2005100726334A CN 200510072633 A CN200510072633 A CN 200510072633A CN 1700369 A CN1700369 A CN 1700369A
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- 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
- H01F1/14—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
- H01F1/147—Alloys characterised by their composition
- H01F1/153—Amorphous metallic alloys, e.g. glassy metals
- H01F1/15308—Amorphous metallic alloys, e.g. glassy metals based on Fe/Ni
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- 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
- H01F1/14—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
- H01F1/147—Alloys characterised by their composition
- H01F1/153—Amorphous metallic alloys, e.g. glassy metals
- H01F1/15358—Making agglomerates therefrom, e.g. by pressing
- H01F1/15366—Making agglomerates therefrom, e.g. by pressing using a binder
- H01F1/15375—Making agglomerates therefrom, e.g. by pressing using a binder using polymers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- 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
- H01F1/14—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
- H01F1/147—Alloys characterised by their composition
- H01F1/153—Amorphous metallic alloys, e.g. glassy metals
- H01F1/15316—Amorphous metallic alloys, e.g. glassy metals based on Co
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- 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
- H01F1/14—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
- H01F1/147—Alloys characterised by their composition
- H01F1/153—Amorphous metallic alloys, e.g. glassy metals
- H01F1/15325—Amorphous metallic alloys, e.g. glassy metals containing rare earths
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F17/06—Fixed inductances of the signal type with magnetic core with core substantially closed in itself, e.g. toroid
- H01F17/062—Toroidal core with turns of coil around it
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F2017/048—Fixed inductances of the signal type with magnetic core with encapsulating core, e.g. made of resin and magnetic powder
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/10—Composite arrangements of magnetic circuits
- H01F3/14—Constrictions; Gaps, e.g. air-gaps
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—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
- 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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- Soft Magnetic Materials (AREA)
Abstract
A high-frequency core (1) is a molded body obtained by molding a mixture of a soft magnetic metallic glass powder and a binder in an amount of 10% or less in mass ratio. The powder has an alloy composition represented by (Fe1-aCoa)100-x-y-z-q-r(M1-pM'p)xTyBzCqAlr (0 < a < 0.50, 0 < p < 0.5, 2 atomic% < x < 5 atomic%, 8 atomic% < y < 12 atomic%, 12 atomic% < z < 17 atomic%, 0.1 atomic% < q < 1.0 atomic%, 0.2 atomic% < r < 2.0 atomic% and 25 < (x+y+z+q+r) < 30, M being at least one selected from Zr, Nb, Ta, Hf, Mo, Ti, V, Cr, and W, M' being at least one selected from Zn, Sn, and R (R being at least one element selected from rare earth metals including Y), T being at least one selected from Si and P). An inductance component (101, 102) is formed by the core and a winding (3).
Description
The present invention requires the priority of Japanese patent application JP-2004-146595, and this application disclosure is incorporated into herein as a reference.
Technical field
The inductance element that the present invention relates to a kind of high frequency magnetic core of main use soft magnetic material and use this high frequency magnetic core.
Background technology
Up to now, as the material of high frequency magnetic core, mainly use soft ferrite, high silicon steel, amorphous metal, powder core etc. usually.Use the reason of above-mentioned material as follows.If soft ferrite, then material itself has high ratio resistance.If other metal material, though then material self has low ratio resistance, this material can form thin slice or powder to reduce vortex flow.Above-mentioned material is selected to use according to operating frequency or intended purpose.Therefore it is former because material such as soft ferrite with high specific resistance have low saturation flux density, and material such as high silicon steel with high saturation magnetic flux metric density have low ratio resistance to conclude it.Therefore, can not provide magnetic material so far with high saturation magnetic flux metric density and high specific resistance.
When having obtained following remarkable break-throughs recent years on reducing size and the various electronic functionalities of improvement, inductance element such as coil and transformer need reduce size and need have inductance under big electric current.For satisfying the demand, need improve the saturation flux density and the high-frequency loss performance of core simultaneously.In addition, because the copper loss that winding coil resistance produces, the heat that has caused increasing coil or transformer generates.Therefore, need be provided for suppressing the method that temperature raises.
If soft ferrite then can improve saturation flux density, improve but in fact can not carry out essence.If high silicon steel or amorphous metal, then material self has high saturation flux density.Yet, in order to adapt to high frequency band, the essential thin slice that forms of material when frequency band is higher.Use the multilayer core of such material can reduce space factor, this can cause the reduction of saturation flux density.
In addition, if powder core then can obtain high specific resistance and obtain the high saturation magnetic flux metric density by the high density moulding by insert insulating material between the micro powder particle.Yet there are some problems that are difficult to solve in this.That is, set up at present improve for the method for the saturation magnetization of this soft magnetic powder that uses and when keeping insulating between the powder particle method of formation high density molded body.
In order to correct the problems referred to above, especially be difficult to obtain have the problem of the magnetic material of saturation flux density and high specific resistance, the method for preparing powder core and produce this powder core has been proposed, in this powder core, the metal glass powder is as soft magnetic powder, mix with insulating material, and be not less than the temperature formation molding of normal temperature, to obtain to have the soft magnetic material (, being called patent documentation 1 below) of high magnetic permeability and better frequency properties referring to Japanese unexamined patent publication (JP-A)-2001-189211.
At this, the alloy composition that is called metal glass jointly has a variety of.Yet, being limited to Fe base alloy as the alloy composition of soft magnetic material, this alloy is divided into FePCBSiGa alloy composition and FeSiBM (M is a transition metal) alloy composition usually.
On the other hand, openly winding around and metal dust form the overall structure that size reduces, so that improve DC stacked character (, being called patent documentation 5 and 6 below respectively) referring to Japanese unexamined patent publication (JP-A)-H04-286305 and 2002-305108.
Under above-mentioned soft magnetic material makes situation as high frequency magnetic core, for example under the situation of patent documentation 1 disclosed FePCBSiGa alloy composition, can obtain to comprise the magnetic property of high magnetic permeability and more excellent frequency properties.Yet in this case, need to use expensive metal such as Ga.This can cause such problem: material self cost is very high, so the lifting of commercial Application is suppressed.
On the other hand, open and considers to be applied in the FeSiBM alloy composite of core in patent documentation 4 in patent documentation 2 and 3, material self has the business efficiency of excellence.Yet, in these patent documentations, the technology (this is general because do not find to form the method for powder and the method that formation is applicable to the molding of alloy composition thing, and these methods are suitable for alloy composite) that is used to obtain high specific resistance and high flux density is not shown.Therefore, at present, be difficult to use the material that is used for high frequency magnetic core and uses the inductance element of this high frequency magnetic core.
Patent documentation 5 and 6 discloses reducing of coil dimension.Yet because use existing soft magnetic metallic material, so loss reduces also insufficient.
Summary of the invention
The object of the invention provides a kind of cheap high frequency magnetic core of being made by soft magnetic material and a kind of inductance element that uses this high frequency magnetic core is provided, and described soft magnetic material has high saturation magnetic flux metric density and high specific resistance.
According to an aspect of the present invention, a kind of high frequency magnetic core is provided, it comprises the molding that the mixture by molded soft magnetic metallic glass powder and adhesive obtains, in with the mass ratio of soft magnetic metallic glass powder, the content of adhesive is 10% or littler mass ratio, and described soft magnetic metallic glass powder has the alloy composition of being represented by following general formula: (Fe
1-aCo
a)
100-x-y-z-q-r(M
1-pM '
p)
xT
yB
zC
qAl
r(0<a<0.50,0<p<0.5,2 atom %<x<5 atom %, 8 atom %<y<12 atom %, 12 atom %<z<17 atom %, 0.1 atom %<q<1.0 atom %, 0.2 atom %<r<2.0 atom % and 25<(x+y+z+q+r)<30, M is selected from least a among Zr, Nb, Ta, Hf, Mo, Ti, V, Cr and the W, M ' is for being selected from least a among Zn, Sn and the R (R is at least a element of selecting) from the rare earth metal that comprises Y, T is selected from least a among Si and the P).
According to a further aspect in the invention, provide a kind of inductance element, it comprises high frequency magnetic core and at least one circle coil around this high frequency magnetic core.
In accordance with a further aspect of the present invention, provide a kind of inductance element, it comprises high frequency magnetic core and at least one circle coil around this high frequency magnetic core.
The accompanying drawing summary
Fig. 1 is the external perspective view that high frequency magnetic core basic structure according to an embodiment of the invention is shown;
Fig. 2 comprises high frequency magnetic core shown in Figure 1 and around the inductance element external perspective view of the coil of high frequency magnetic core;
Fig. 3 is the external perspective view of high frequency magnetic core basic structure according to another embodiment of the invention;
Fig. 4 comprises high frequency magnetic core shown in Figure 3 and around the inductance element external perspective view of the coil of high frequency magnetic core;
Fig. 5 is the external perspective view of the inductance element basic structure of another embodiment according to the present invention.
Embodiment
To describe the present invention in detail below.
As the result of further investigation, if finding following alloy composite, the inventor selects as soft magnetic metallic glass powder with excellent economic benefit, then can obtain to have the powder of excellent magnetic matter and glass formation performance: (Fe
1-aCo
a)
100-x-y-z-q-r(M
1-pM '
p)
xT
yB
zC
qAl
r(0<a<0.50,0<p<0.5,2 atom %<x<5 atom %, 8 atom %<y<12 atom %, 12 atom %<z<17 atom %, 0.1 atom %<q<1.0 atom %, 0.2 atom %<r<2.0 atom % and 25<(x+y+z+q+r)<30, M is selected from least a among Zr, Nb, Ta, Hf, Mo, Ti, V, Cr and the W, M ' is for being selected from least a among Zn, Sn and the R (R is select at least a) from the rare earth metal that comprises Y, T is selected from least a among Si and the P).In the present invention, the group formed by lanthanide series such as La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu and another element Y of " rare earth metal that comprises Y " expression.The inventor also finds if by making powder carry out oxidation or insulation coating, use die head etc. powder to be formed molding then and obtain powder core by suitable method of moulding, then this powder core is a kind of high magnetic permeability powder core that shows at wide band excellent magnetic permeability and the excellent properties that never obtained, thereby can low-cost prepare a kind of high frequency magnetic core that is made of the soft magnetic material with high saturation magnetic flux metric density and high specific resistance.
In addition, find that inductance element by providing high frequency magnetic core with at least one turn coil to obtain is cheap and have before the high-performance that never has.
The inventor also finds, by limiting the granularity of forming the soft magnetic metallic glass powder that general formula represents by above-mentioned, this powder core is in the core loss aspect of performance excellence of high frequency.
In addition, find that inductance element by providing high frequency magnetic core with at least one turn coil to obtain is cheap and have before the high-performance that never has.Also find to obtain to be suitable for the inductance element that the big electric current of high frequency is used by forming with the state compacting that forms internal structure so that coil is imbedded in the magnet.
In order to increase the ratio resistance of molding, molded alloy powder before can carry out oxidizing thermal treatment in atmospheric air.In order to form the high density molded body, can under the temperature that is not less than as the softening point of the resin of adhesive, continue molded.In order to realize the high density of molding, molded can in the sub-cooled liquid temperature scope of alloy powder, carrying out.
Specifically, the soft magnetic metallic glass powder has the alloy composition that following general formula is represented: (Fe
1-aCo
a)
100-x-y-z-q-r(M
1-pM '
p)
xT
yB
zC
qAl
r(0<a<0.50,0<p<0.5,2 atom %<x<5 atom %, 8 atom %<y<12 atom %, 12 atom %<z<17 atom %, 0.1 atom %<q<1.0 atom %, 0.2 atom %<r<2.0 atom % and 25<(x+y+z+q+r)<30, M is selected from least a among Zr, Nb, Ta, Hf, Mo, Ti, V, Cr and the W, M ' is for being selected from least a among Zn, Sn, the R (R is select at least a) from the rare earth metal that comprises Y, T is selected from least a among Si and the P).This molding obtains by the mixture of molded soft magnetic metallic glass powder and scheduled volume adhesive, and described scheduled volume is the mass ratio with respect to the soft magnetic metallic glass powder.
To the alloy composition of soft magnetic metallic glass powder be described herein.Fe as key component is the element that helps magnetic, and is for obtaining the indispensable element of high saturation magnetic flux metric density.Part Fe can replace with the Co of 0~0.5 ratio.This replacement component has improves the effect that glass forms performance, but also expection has the effect that improves saturation flux density.In whole alloy powder, the total amount of Fe and substituted element is being not less than 70 atom % and is being not more than in the scope of 75 atom %.This be because, if this content is not 70 atom % or bigger, then saturation flux density is too low, practicality loss is if this content is greater than 75 atom %, then because crystallization causes the magnetic permeability and the core loss reduction of core.
Element M is to improve glass to form the required transition metal of performance, and it is at least a element of selecting from Zr, Nb, Ta, Hf, Mo, Ti, V, Cr and W.The content of element M is for being not less than 2 atom % and being not more than 5 atom %.
This be because if content less than 2 atom %, the remarkable deterioration of then forming of glass decreased performance, and magnetic permeability and core loss, if this content surpasses 5 atom %, then saturation flux density reduces, and practicality loses.Replace the element M of 0~0.5 ratio by Zn, Sn, R (R is at least a element that is selected from the rare earth metal that comprises Y), then form the ratio that can increase Fe and Co under the situation of performance, so that can improve saturation flux density at deterioration glass not.
Si and B are the necessary element of preparation soft magnetic metallic glass powder.Si content is being not less than 8 atom % and is being not more than in the scope of 12 atom %.B content is being not less than 12 atom % and is being not more than in the scope of 17 atom %.If this be because if Si content less than 8 atom % or greater than 12 atom % or B content less than 12 atom % or greater than 17 atom %, then glass forms performance and reduces, and can not prepare stable soft magnetism glass powder.Herein, Si can replace with P.
As long as Al and C and other component element use in alloy composition scope of the present invention, then when preparing powder by various atomization techniques, Al and C have the effect that powder is formed sphere.As for the amount that is added, if Al content less than 0.2 atom %, the effect that then forms spherical powder is little.If Al content is greater than 2.0 atom %, then amorphous formation performance degradation.Similarly, if C content less than 0.1 atom %, the effect that then forms spherical powder is little.If C content is greater than 1.0 atom %, amorphous formation performance degradation.Al and C can separately or be used in combination.
The soft magnetic metallic glass powder is by water atomization or gas atomization preparation.Preferably at least 50% granularity is for being not less than 10 μ m.Especially, water atomization is thought low cost and is prepared the method for alloy powder in a large number.Can prepare powder by this method very large advantage is arranged on commercial Application.Yet if traditional amorphous compositions, 10 μ m or bigger alloy powder be crystallization, makes the remarkable deterioration of magnetic property.As a result, productive rate seriously descends, thereby has hindered commercial Application.On the other hand, if granularity is 150 μ m or littler, soft magnetic metallic glass powder then according to the present invention is easy to vitrifying (amorphization).Therefore, productive rate height.Therefore from cost consideration, soft magnetic metallic glass powder of the present invention has very big advantage.In addition, preparing in the alloy powder, on powder surface, forming suitable oxide coated film by water atomization.Therefore, by resin being mixed with alloy powder and, being easy to obtain to have the core of high specific resistance with the molded formation molding of mixture.
In in the alloy powder of the alloy powder of water atomization preparation and gas atomization preparation any,, then form more excellent oxidation thing coated film if carry out under the temperature of heat treatment alloy powder crystallization temperature of using He in the atmospheric air not being higher than.At this moment, can improve the ratio resistance of core, so that reduce the core loss of core.
On the other hand, for the inductance element of intending being used for frequency applications, can having very by use, the metal dust of small grain size reduces the vortex flow loss.Yet for alloy composition well known in the art, if average diameter is 30 μ m or littler, the powder oxidation is remarkable in preparation process.Therefore, in powder, be difficult to obtain pre-determined characteristics by common water atomization plant preparation.Yet the metal glass powder has excellent alloy corrosion resistance, so this metal glass powder is advantageous, even because powder is very little, also can be easier to prepare the powder that oxygen content reduces and have excellent properties.
Then, be described as the method for type molding.Basically, 10% quality is than adhesive such as the silicones and the soft magnetic metallic glass powder of content.Use die head or, can obtain molding by casting.This molding is as high frequency magnetic core, it have 50% or bigger powder fill ratio, 1.6 * 10
4Have 0.5T or bigger magnetic density in the application in A/m magnetic field, and have 1 * 10
4The ratio resistance of cm.Herein, the content of binding agent is 10% or littler mass ratio.This be because, if this content surpasses 10%, then saturation flux density becomes and is equal to or less than ferritic saturation flux density, core loses practicality.
Molding can be by mixing soft magnetic metallic glass powder and adhesive, and use die head this mixture of compression forming and obtain, in the mass ratio of soft magnetic metallic glass powder, the amount of adhesive is 5% or littler mass ratio.In this case, molding have 70% or bigger powder fill ratio, use 1.6 * 10
4Have 0.75T or bigger magnetic density during A/m magnetic field, and have 1 Ω cm or bigger ratio resistance.When magnetic density is 0.75T or bigger and be 1 Ω m or when bigger than resistance, to compare with the Sendust core, the more excellent and practicality of its performance is further improved.
In addition, molding can be by mixing soft magnetic metallic glass powder and adhesive, and under the temperature conditions that is not higher than the adhesive softening point, use die head this mixture of compression forming and obtain, in the mass ratio of soft magnetic metallic glass powder, the amount of adhesive is 3% or littler mass ratio.In this case, molding have 80% or bigger powder fill ratio, use 1.6 * 10
4Have 0.9T or bigger magnetic density during A/m magnetic field, and have 0.1 Ω cm or bigger ratio resistance.When magnetic density is 0.9T or bigger and be 0.1 Ω m or when bigger than resistance, to compare with commercially available any powder core at present, the more excellent and practicality of its performance is further improved.
In addition, molding can be by mixing soft magnetic metallic glass powder and adhesive, and in the sub-cooled liquid temperature scope of soft magnetic metallic glass powder this mixture of compression forming and obtaining, in the mass ratio of soft magnetic metallic glass powder, the amount of adhesive is 1% or littler mass ratio.In this case, molding have 90% or bigger powder fill ratio, use 1.6 * 10
4Have 1.0T or bigger magnetic density during A/m magnetic field, and have 0.01 Ω cm or bigger ratio resistance.When magnetic density is 1.0T or bigger and be 0.01 Ω m or when bigger than resistance, magnetic density is substantially equal to comprise the magnetic density of the multilayer core of amorphous metal and high silicon steel plate in the application region.Yet the molding of Huo Deing has little hysteresis loss and high ratio resistance herein, so core loss character is very excellent.Like this, further improve as the practicality of core.
In addition, after the moulding, can under the temperature conditions that is not higher than as the heat treated Curie point of strain relief, heat-treat as the molding of high frequency magnetic core.In this case, core loss further reduces, and further improves as the usability of core.Here, for keeping interparticle insulating properties, need to comprise SiO in the part intermediate materials between the alloy powder particle at least
2(as selection, all intermediate materials can all be SiO
2).
If desired after forming the gap on the part magnetic circuit, if, then can prepare the product that in the highfield, shows high magnetic permeability and have excellent properties by equipping above-mentioned inductance element with high frequency magnetic core preparation of at least one turn coil.
Below, the present invention is described in further detail with reference to the accompanying drawings.
Fig. 1 is the external perspective view that high frequency magnetic core 1 basic structure according to an embodiment of the invention is shown.Fig. 1 illustrates the state that the high frequency magnetic core 1 that uses above-mentioned soft magnetic metallic glass powder forms annular plate.
Fig. 2 is the external perspective view that has the inductance element 101 that the high frequency magnetic core 1 of coil obtains by equipment.The coil 3 that Fig. 2 illustrates pre-fixing turn has the state that lead-in wire is pulled out the inductance element 101 of part 3a and 3b around high frequency magnetic core 1 winding as annular plate with preparation.
Fig. 3 illustrates the external perspective view of high frequency magnetic core 1 basic structure according to another embodiment of the invention.Fig. 3 illustrates the high frequency magnetic core 1 that uses above-mentioned soft magnetic metallic glass powder and forms annular plate, and forms the state in gap (gap) 2 on the part magnetic circuit.
Fig. 4 has coil 3 and has the external perspective view of inductance element 102 of high frequency magnetic core 1 preparation in gap 2 by equipment.Fig. 4 illustrates the coil 3 that twines pre-fixing turn around the high frequency magnetic core 1 as the annular plate with gap 2 and has the state that lead-in wire is pulled out the inductance element 102 of part 3a and 3b with preparation.
If the mixture by molded soft magnetic metallic glass powder with above-mentioned metal glass composition and adhesive forms powder core, then this powder core shows and have low-down loss character when high frequency, and the excellent properties that never obtained before having, described soft magnetic metallic glass powder has 45 μ m or littler maximum particle size on granularity, have 30 μ m or littler average diameter, and in the mass ratio of soft magnetic metallic glass powder, the content of described adhesive is 10% or littler mass ratio.Have the powder core of coil by equipment, obtain inductance element with excellent Q character.
In addition, the magnet that has embedding coil wherein by press forming can obtain to be applicable to the inductance element of big high-frequency current to form complete structure.
The reason that limits particle size will be described in detail herein.If maximum particle size surpasses 45 μ m on granularity, then in the Q of high-frequency region character deterioration.In addition, if average diameter is not 30 μ m or littler, then 500kHz or higher on Q character can not surpass 40.In addition, if average diameter is not 20 μ m or littler, then 1MHz or higher on the Q value can not be 50 or bigger just.The advantage of metal glass powder is because the ratio resistance of alloy self is 2~10 times of traditional material, even thereby under same particle sizes Q character also high.If identical Q character is abundant, then spendable particle size range broadens, so that has reduced the powder production cost.
Fig. 5 is the external perspective view of the high frequency inductance element basic structure of another embodiment according to the present invention.With reference to figure 5, the inductance element 103 of structure is by obtaining at following state press forming as a whole: be embedded in the magnet 8 by the coil 7 that twines long plate shape material 5 acquisitions that formed by above-mentioned soft magnetic powder.The whole surface of the winding part of board-like material 5 provides insulating coating 6.
Now, in conjunction with the several embodiment of production technology and inductance elements that comparing embodiment is described high frequency magnetic core of the present invention and this high frequency magnetic core of use of comprising.
(embodiment 1~26, comparing embodiment 1~11)
At first, as the powder preparation step, weighing comprises that the simple metal element material of Fe, Si, B, Nb, Al, C and replacement element or various foundry alloys if desired are so that obtain predetermined composition.By using these materials, various soft-magnetic alloy powders prepare by normally used water atomization.Here to notice that mischmetal(l) (mishmetal) is the mixture of rare earth metal.Using 30%La, 50%Ce, 15%Nd and surplus herein, is the mixture of other one or more rare earth elements.
Then, as the molding preparation process, various alloy powders are divided into the alloy powder with 45 μ m or littler powder size.Subsequently, sneak into 4% mass ratio as the organic siliconresin of adhesive.Then, by using band groove and outer dia φ
Outward=27mm, inside diameter φ
InThe die head of=14mm is by at room-temperature applications 1.18Gpa (about 12t/cm
2) pressure and form various moldings, make the molding height equal 5mm.
In addition, various moldings carry out resin solidification.Subsequently, measure the weight and the size of various moldings.Then, provide the coil of the suitable number of turns to prepare various inductance elements (having shape shown in Figure 2).
Then, for each different sample of inductance element, use the LCR meter to obtain magnetic permeability from the inductance value of 100kHz.In addition, by using dc magnetic energy determinator, when using 1.6 * 10
4During the magnetic field of A/m, measure saturation flux density.In addition, the upper and lower surface of each core is all polished, and carries out X-ray diffraction (XRD) and measure to observe phase.The gained result is table 1 illustrate.
Table 1-1
Alloy composition | 1.6 * 10 4Magnetic density during A/m | Magnetic permeability at 100kHz | XRD determining | |
Comparing embodiment | ||||
1 | ??Fe 72.5Si 9B 14.5Nb 2.5Al 1.0C 0.5 | ??0.85/T | ??22 | |
Embodiment | ||||
1 | ??Fe 72Si 9B 14.5Nb 3Al 1.0C 0.5 | ??0.82 | ??31 | |
Embodiment | ||||
2 | ??Fe 71Si 9B 14.5Nb 4Al 1.0C 0.5 | ??0.77 | ??33 | |
Embodiment | ||||
3 | ??Fe 70Si 9B 14.5Nb 5Al 1.0C 0.5 | ??0.72 | ??35 | Glassy |
Comparing embodiment | ||||
2 | ??Fe 69Si 9B 14.5Nb 6Al 1.0C 0.5 | ??0.67 | ??37 | Glassy |
Comparing embodiment | ||||
3 | ??Fe 74.3Si 7.7B 13.5Nb 3Al 1.0C 0.5 | ??0.92 | ??19 | Crystalline phase |
Embodiment 4 | ??Fe 74Si 8B 13.5Nb 3Al 1.0C 0.5 | ??0.91 | ??30 | Glassy phase |
Embodiment 5 | ??Fe 72Si 10B 13.5Nb 3Al 1.0C 0.5 | ??0.82 | ??32 | Glassy phase |
Embodiment 6 | ??Fe 70Si 12B 13.5Nb 3Al 1.0C 0.5 | ??0.72 | ??34 | Glassy phase |
Comparing embodiment 4 | ??Fe 69.5Si 12.5B 13.5Nb 3Al 1.0C 0.5 | ??0.69 | ??21 | Crystalline phase |
Comparing embodiment 5 | ??Fe 75.5Si 8.5B 11.5Nb 3Al 1.0C 0.5 | ??0.94 | ??20 | Crystalline phase |
Embodiment 7 | ??Fe 75Si 8.5B 12Nb 3Al 1.0C 0.5 | ??0.93 | ??33 | Glassy phase |
Embodiment 8 | ??Fe 72Si 8.5B 15Nb 3Al 1.0C 0.5 | ??0.82 | ??35 | Glassy phase |
Embodiment 9 | ??Fe 70Si 8.5B 17Nb 3Al 1.0C 0.5 | ??0.72 | ??37 | Glassy phase |
Comparing embodiment 6 | ??Fe 69.5Si 8.5B 17.5Nb 3Al 1.0C 0.5 | ??0.70 | ??23 | Crystalline phase |
Embodiment 10 | ??(Fe 0.9Co 0.1) 73Si 9B 14.5Nb 2Al 1.0C 0.5 | ??0.87 | ??31 | Glassy phase |
Embodiment 11 | ??(Fe 0.7Co 0.3) 73Si 9B 14.5Nb 2Al 1.0C 0.5 | ??0.89 | ??33 | Glassy phase |
Embodiment 12 | ??(Fe 0.5Co 0.5) 73Si 9B 14.5Nb 2Al 1.0C 0.5 | ??0.87 | ??35 | Glassy phase |
Comparing embodiment 7 | ??(Fe 0.4Co 0.6) 73Si 9B 14.5Nb 2Al 1.0C 0.5 | ??0.85 | ??37 | Glassy phase |
Embodiment 13 | ??(Fe 0.7Co 0.3) 73Si 9B 14.5Ta 2Al 1.0C 0.5 | ??0.88 | ??34 | Glassy phase |
Embodiment 14 | ??(Fe 0.7Co 0.3) 73Si 9B 14.5Mo 2Al 1.0C 0.5 | ??0.87 | ??35 | Glassy phase |
Embodiment 15 | ??Fe 73Si 8B 14.5Nb 2.0Zn 1.0Al 1.0C 0.5 | ??0.86 | ??37 | Glassy phase |
Embodiment 16 | ??Fe 73Si 8B 14.5Nb 1.5Zn 1.5Al 1.0C 0.5 | ??0.86 | ??35 | Glassy phase |
Table 1-2
Alloy composition | 1.6 * 10 4Magnetic density during A/m | Magnetic permeability at 100k Hz | XRD determining result | |
Comparing embodiment 8 | ??Fe 73Si 8B 14.5Nb 1.0Zn 2.0Al 1.0C 0.5 | ??0.86 | ??19 | Crystalline phase |
Embodiment 17 | ??Fe 73.5Si 8B 14.5Nb 2Zn 0.5Al 1.0C 0.5 | ??0.89 | ??33 | Glassy phase |
Embodiment 18 | ??Fe 71Si 8B 14.5Nb 4.5Zn 0.5Al 1.0C 0.5 | ??0.77 | ??37 | Glassy phase |
Comparing embodiment 9 | ??Fe 70.5Si 8B 14.5Nb 5Zn 0.5Al 1.0C 0.5 | ??0.74 | ??35 | Crystalline phase |
Embodiment 19 | ??Fe 74Si 8B 14.5Nb 1.5Sn 0.5Al 1.0C 0.5 | ??0.91 | ??35 | Glassy phase |
Embodiment 20 | ??Fe 74Si 8B 14.5Nb 1.5(mischmetal(l)) 0.5Al 1.0C 0.5 | ??0.90 | ??35 | Glassy phase |
Embodiment 21 | ??(Fe 0.7Co 0.3) 74Si 8B 14.5Nb 1.5Zn 0.5Al 1.0C 0.5 | ??0.93 | ??33 | Glassy phase |
Embodiment 22 | ??(Fe 0.7Co 0.3) 74Si 8B 14.5Ta 1.5Zn 0.5Al 1.0C 0.5 | ??0.92 | ??32 | Glassy phase |
Embodiment 23 | ??(Fe 0.7Co 0.3) 74Si 8B 14.5Mo 1.5Zn 0.5Al 1.0C 0.5 | ??0.91 | ??34 | Glassy phase |
Embodiment 24 | ??Fe 71.5Si 9B 14.5Nb 3Al 1.0C 1.0 | ??0.79 | ??33 | Glassy phase |
Comparing embodiment 10 | ??Fe 71.3Si 9B 14.5Nb 3Al 1.0C 1.2 | ??0.77 | ??16 | Crystalline phase |
Embodiment 25 | ??Fe 71.5Si 9B 14.5Nb 3Al 1.5C 0.5 | ??0.79 | ??33 | Glassy phase |
Embodiment 26 | ??Fe 71Si 9B 14.5Nb 3Al 2.0C 0.5 | ??0.79 | ??33 | Glassy phase |
Comparing embodiment 11 | ??Fe 70.8Si 9B 14.5Nb 3Al 2.2C 0.5 | ??0.76 | ??15 | Crystalline phase |
Table 1 illustrates the ratio of components of sample.In addition, if the XRD figure case that obtains by XRD determining only is found to be the broad peak of glassy phase feature then is judged as glassy phase, if the spike owing to crystallization can be observed with broad peak, then be judged as (glass+crystallization) phase, if do not have the broad peak value to observe spike then be judged as crystalline phase.
Have the composition sample of glassy phase for those, confirm that as the glass transition temperature of the hot assay determination of DSC and crystallization temperature the sub-cooled liquid temperature range delta Tx for all samples is 30K or higher.Herein, Δ Tx=Tx-Tg, wherein Tx represents crystallization temperature, and Tg represents glass transition temperature.Measure the ratio resistance of molding (core) by the two ends DC measurement.As a result, confirm that all samples shows the excellence that is not less than 1 Ω cm and compares resistance.
The temperature increase rate of DSC is 40K/min.Find out from embodiment 1~3 and comparing embodiment 1 and 2, can infer,, then can obtain to have the core of glassy phase if Nb content is 3~6%.
Yet, find at Nb content to be that magnetic density is low to moderate 0.70T or littler in 6% the comparing embodiment 2.
From embodiment 4~9 and comparing embodiment 3~6, can think if Si content is 8~12, B content is 12~17, Fe content is 70~75, then can obtain to have the core of glassy phase.
From embodiment 10~14 and comparing embodiment 7, can think with Co instead of part Fe, even Nb content is 2%, also can obtain the metal glass powder.Yet, surpass 0.5, the effect of the magnetic density that can not be improved if find the replacement amount.Also think and use Ta or Mo to replace Nb can obtain similar effect.
From embodiment 15 and 16 and comparing embodiment 8, can think by replacing Nb can improve saturation flux density with Zn, if but replace ratio to surpass 0.5, then can not form glassy phase.
As for the total amount of Zn and Nb, from embodiment 17 and 18 and comparing embodiment 9 can infer 5% or be suitable more for a short time.Can infer from embodiment 19 and 20,, can obtain type effect if add Sn or mischmetal(l) replacement Zn.
Can infer from embodiment 21~23, Fe is replaced by Co as fruit part, then can obtain similar effect, and if Ta or Mo be used to replace Nb, then can obtain type effect.Shown in embodiment 24~26 and comparing embodiment 11 and 12, Al can with 2.0 or lower ratio add, and C can with 1.0 or lower ratio add.Yet,, form the remarkable variation of ability of impalpable structure if addition is bigger.
(embodiment 27)
Has (Fe by the water atomization preparation
0.8Co
0.2)
73Si
9B
14.5Nb
2Al
1.0C
0.5The alloy powder of forming.The powder of Huo Deing is divided into the powder with 75 μ m or smaller szie like this.Carry out XRD determining, determined broad peak as the glassy phase feature.
Then, carry out DSC heat and analyze, thereby determine that Δ Tx is 35K with mensuration glass transition temperature and crystallization temperature.Then, this powder is at atmospheric air and be lower than 450 ℃ of heat treatments 0.5 hour of glass transition temperature, thereby forms oxide on powder surface.Then, this powder and 10%, 5%, 2.5%, 1% and 0.5% silicones mix.By using the die head of φ 27 * φ 14, these powder in room temperature, be higher than carry out under 550 ℃ of these three kinds of conditions in 150 ℃ of the resin softening temperature and the sub-cooled liquid temperature scope at this metal glass powder molded.Magnetic density and the direct current of measure powder filling ratio, measuring by dc magnetic matter compare resistance.The gained result is table 2 illustrate.
Table 2
Sample number | Resin content (%) | Molding temperature | Powder is filled ratio (%) | 1.6 * 10 4Magnetic density during A/m | Than resistance Ω cm |
??1 | ??0.5% | Room temperature | ??69.5 | ??0.93 | ??>100 |
??2 | ??1% | Room temperature | ??70.3 | ??0.95 | ??>100 |
??3 | ??2.5% | Room temperature | ??71.1 | ??0.97 | ??>100 |
??4 | ??5% | Room temperature | ??70.5 | ??0.97 | ??>100 |
??5 | ??10% | Room temperature | ??52.1 | ??0.66 | ??>10 4 |
??6 | ??0.5% | ??150℃ | ??81.3 | ??1.12 | ??5 |
??7 | ??1% | ??150℃ | ??81.9 | ??1.14 | ??10 |
??8 | ??2.5% | ??150℃ | ??82.5 | ??1.16 | ??15 |
??9 | ??5% | ??150℃ | ??71.0 | ??0.95 | ??>100 |
??10 | ??10% | ??150℃ | ??52.6 | ??0.67 | ??>10 4 |
??11 | ??0.5% | ??550℃ | ??96.0 | ??1.37 | ??0.1 |
??12 | ??1% | ??550℃ | ??92.8 | ??1.31 | ??0.5 |
??13 | ??2.5% | ??550℃ | ??83.0 | ??1.15 | ??10 |
??14 | ??5% | ??550℃ | ??71.4 | ??0.97 | ??>100 |
??15 | ??10% | ??550℃ | ??52.3 | ??0.67 | ??>10 4 |
As seen from Table 2, when the content of adhesive surpasses 5%, compare with the ratio resistance of ferrite core, it has up to 〉=10 than resistance
4Value.Even also do not obtain special-effect, be enough therefore in the room temperature mold pressing because molding temperature raises.Secondly, when the amount of adhesive equals 5%, obtain, and be enough in the room temperature mold pressing up to 100 Ω cm or higher ratio resistance.Secondly, can infer, when binder content equaled 2.5%, if carry out mold pressing at 150 ℃, then the powder ratio of filling was significantly improved, the magnetic density height, and obtain 10 Ω cm or higher ratio resistance.Secondly, can infer, when the content of adhesive was 1% and 0.5%, if carry out mold pressing at 550 ℃, then the powder ratio of filling was significantly improved, the saturation flux density height, and obtain 0.1 Ω cm or higher ratio resistance.
(embodiment 28)
In embodiment 28, has Fe by the water atomization preparation
72Si
9B
14.5Nb
3Al
1.0C
0.5The alloy powder of forming.Subsequently, the powder that obtains like this is divided into and has the 75 μ m or the powder of small grain size more.Then, carry out XRD determining to determine broad peak as the glassy phase feature.
In addition, carry out DSC heat and analyze, thereby determine that vitrifying initial temperature scope or sub-cooled liquid temperature range delta Tx are 35K with mensuration glass transition temperature and crystallization temperature.Then, this powder keeps also heat treatment 0.5 hour at atmospheric air and 450 ℃ of temperature conditions that are lower than glass transition temperature, to form oxide on powder surface.
Then, the silicones as adhesive of this powder and 10%, 5%, 2.5%, 1% and 0.5% mass ratio mixes.Has outer dia φ by use
Outward=27mm * inside diameter φ
InThe band groove die head of=14mm, these powder three kinds of condition of different temperatures promptly in room temperature, be higher than under 150 ℃ of the resin softening temperature and 550 ℃ of these three kinds of conditions, by using 1.18Gpa (about 12t/cm in the sub-cooled liquid temperature scope of this soft magnetic metallic glass powder
2) pressure carries out moldedly as molding pressure, make highly to equal 5mm.Like this, prepare various moldings.
Then, the molding that obtains like this carries out resin solidification.Subsequently, measure the weight and the size of each molding.Then, twine the coil of the suitable number of turns to prepare various inductance elements (having shape shown in Figure 2).
Then, for each different sample (numbering 1~15) of inductance element, measure powder and fill ratio %, pass through the magnetic density of dc magnetic matter measurement (1.6 * 10
4A/m) and direct current than resistance Ω cm.The gained result is table 3 illustrate.
Table 3
Sample number | Resin content (%) | Molding temperature | Powder is filled ratio (%) | 1.6 * 10 4Magnetic density during A/m | Than resistance Ω cm |
??1 | ??0.5% | Room temperature | ??69.1 | ??0.84 | ??>100 |
??2 | ??1.0% | Room temperature | ??69.9 | ??0.85 | ??>100 |
??3 | ??2.5% | Room temperature | ??70.9 | ??0.86 | ??>100 |
??4 | ??5.0% | Room temperature | ??70.4 | ??0.85 | ??>100 |
??5 | ??10% | Room temperature | ??51.6 | ??0.56 | ??>10 4 |
??6 | ??0.5% | ??150℃ | ??80.9 | ??1.04 | ??5 |
??7 | ??1.0% | ??150℃ | ??81.6 | ??1.06 | ??10 |
??8 | ??2.5% | ??150℃ | ??82.3 | ??1.08 | ??15 |
??9 | ??5.0% | ??150℃ | ??70.7 | ??0.86 | ??>100 |
??10 | ??10% | ??150℃ | ??52.1 | ??0.58 | ??>10 4 |
??11 | ??0.5% | ??550℃ | ??95.8 | ??1.26 | ??0.1 |
??12 | ??1.0% | ??550℃ | ??92.5 | ??1.21 | ??0.5 |
??13 | ??2.5% | ??550℃ | ??82.6 | ??1.08 | ??10 |
??14 | ??5.0% | ??550℃ | ??71.1 | ??0.87 | ??>100 |
??15 | ??10% | ??550℃ | ??51.8 | ??0.58 | ??>10 4 |
As shown in table 3, when the content (resin content) of adhesive surpasses 5%, to compare with the ratio resistance of ferrite core, it has up to 〉=10 than resistance
4Value.Can infer, even molding temperature raises, can not obtain special effect, the molded condition about room temperature is enough.In addition, can infer, when resin content equals 5%, obtain up to 100 Ω cm or higher ratio resistance, and molded in room temperature be enough.
In addition, can infer, when resin content equaled 2.5%, if carry out moldedly at 150 ℃, then the powder ratio of filling was significantly improved, the magnetic density height, and obtain 10 Ω cm or higher ratio resistance.In addition, can infer, when the content of adhesive was 1% and 0.5%, if carry out mold pressing at 550 ℃, then the powder ratio of filling was significantly improved, the saturation flux density height, and obtain 0.1 Ω cm or higher ratio resistance.
(embodiment 29)
Use sample number into spectrum 12 among the embodiment 27, with various core material comparative measurements inductive.In addition, the core by using the preparation of identical alloy powder and identical production technology blanket of nitrogen and 500 ℃ of heat treatment 0.5 hour to obtain another sample.The inductive nature of this sample also is illustrated.For making the inductance value standardization, the gained magnetic permeability is used for comparison.The core material that is compared is sendust (Sendust), 6.5% silicon steel and iron-based amorphous metal.
Table 4
The sample name | 1.6 * 10 4Magnetic density/T during A/m | Than resistance Ω cm | Magnetic permeability | Core loss 20KHz 0.1T |
The present invention | ??1.31 | ??0.5 | ??150 | ??50/mW/cc |
The present invention's (heat treatment) | ??1.33 | ??0.4 | ??200 | ??30 |
The MnZn ferrite | ??0.55 | ??>10 4 | ??100 * | ??10 |
??Sendust | ??0.65 | ??100 | ??80 | ??100 |
6.5% silicon steel | ??1.0 | ??100μ | ??100 * | ??250 |
The iron-based amorphous metal | ??1.3 | ??150μ | ??100 * | ??400 |
Annotate)
*To the energy specification (power specification) that is embedded in the gap on the part magnetic circuit
Find out that from last table 4 inductance element of the present invention has the magnetic density that equates with the inductance element magnetic density of using amorphous metal, and show than the low core loss character of inductance element core loss character of using Sendust.Therefore inductance element of the present invention can be as very excellent inductance element.Confirm that in the inductance element that uses heat treated core, magnetic permeability and core loss further improve.
(embodiment 30)
In embodiment 30, by using the material preparation inductance element of sample number into spectrum 12 correspondences among the embodiment 28.In addition, by using identical alloy powder and identical production technology, and prepared another inductance element in 0.5 hour 500 ℃ of blanket of nitrogen heat treatments.In addition, be relatively, prepare inductance element (comprising the structure that on the part magnetic circuit, has the gap as shown in Figure 4) as core material by using sendust (Sendust), 6.5% silicon steel and iron-based amorphous metal respectively.For those inductance elements, measure the magnetic density of measuring by dc magnetic matter (1.6 * 10
4A/m), direct current than resistance Ω cm, be used for standardized magnetic permeability of inductance value and core loss (20kHz 0.1T).Result shown in the acquisition table 5.
Table 5
The sample name | 1.6 * 10 4Magnetic density/T during A/m | Than resistance Ω cm | Magnetic permeability | Core loss 20KHz 0.1T |
The present invention | ??1.21 | ??0.5 | ??160 | ??50/mW/cc |
The present invention (heat treated) | ??1.23 | ??0.4 | ??220 | ??25 |
The MnZn ferrite | ??0.55 | ??>10 4 | ??100 * | ??9 |
??Sendust | ??0.65 | ??100 | ??80 | ??100 |
6.5% silicon steel | ??1.0 | ??100μ | ??100 * | ??250 |
The iron-based amorphous metal | ??1.3 | ??150μ | ??100 * | ??400 |
As seen from Table 5, inductance element of the present invention has the magnetic density that equates with the magnetic density of using Fe base amorphous metal as the inductance element of core, and shows than using Sendust as the low core loss of the core loss of the inductance element of core.Therefore inductance element of the present invention has very excellent character.Confirm that in the inductance element that uses heat treated core, magnetic permeability and core loss further improve, and obtain more excellent performance.
(embodiment 31)
In embodiment 31, has Fe by the water atomization preparation
72Si
9B
14.5Nb
3Al
1.0C
0.5The alloy powder of forming.The powder that obtains is divided into and has the 45 μ m or the powder of small grain size more subsequently.Then, carry out the XRD test to determine broad peak as the glassy phase feature.
In addition, carry out DSC heat and analyze, thereby determine that sub-cooled liquid temperature range delta Tx is 35K with mensuration glass transition temperature and crystallization temperature.Then, obtain by water atomization and powder with following table 6 expression alloy compositions is filtered into 20 μ m or littler powder by the standard sieve.These powder are with the mixed shown in the table 6.
In addition, use the powder that obtains like this, mix with the silicones as adhesive of 1.5% quality than content.Has outer dia φ by use
Outward=27mm * inside diameter φ
InThe band groove die head of=14mm, these powder use 12t/cm in room temperature
2Pressure carries out molded, so that highly equal 5mm.Like this, prepare different types of molding.After molded, in 500 ℃ Ar atmosphere, heat-treat.
Then, the various moldings that obtain like this carry out resin solidification.Subsequently, measure the weight and the size of each molding.Then, twine the coil of the suitable number of turns to prepare various inductance elements (having shape shown in Figure 2).
Then, for each different sample of inductance element, measure powder and fill ratio %, magnetic permeability and core loss (20kHz 0.1T).Result shown in the acquisition table 6.
Table 6
Sample number into spectrum | Alloy composition | Add proportion of powder (quality %) | Powder is filled ratio (volume %) | Magnetic permeability at 100 kHz | The core loss of 20kHz 0.1T | |
Comparing embodiment | ??- | ??- | ??71.9 | ??36 | ??25kW/m 3 | |
The present invention | ??1 | ??3%SiFe | ??5 | ??72.5 | ??39 | ??30 |
??2 | ??3%SiFe | ??10 | ??73.1 | ??41 | ??40 | |
??3 | ??3%SiFe | ??20 | ??73.7 | ??42 | ??60 | |
??4 | ??3%SiFe | ??30 | ??74.4 | ??43 | ??70 | |
??5 | ??3%SiFe | ??40 | ??74.9 | ??44 | ??80 | |
??6 | ??3%SiFe | ??50 | ??75.4 | ??46 | ??90 | |
??7 | ??3%SiFe | ??60 | ??75.6 | ??46 | ??200 | |
??8 | Sendust | ??30 | ??73.1 | ??40 | ??80 | |
??9 | The Mo permalloy | ??30 | ??75.4 | ??45 | ??85 | |
??10 | Pure iron powder | ??30 | ??76.9 | ??50 | ??95 |
As seen from Table 6, thereby inductance element of the present invention improves happy powder filling ratio by the littler soft magnetic powder of granularity is added in the metal glass powder, thereby has improved magnetic permeability.On the other hand,, then improve deleterious if institute's addition surpasses 50%, and the remarkable deterioration of core loss.Therefore, can infer, addition is preferably 50% or littler.
(embodiment 32)
In embodiment 32, has Fe7 by the water atomization preparation
3.5-q-rSi
9B
14.5Nb
3C
qAl
rThe alloy powder of forming, q has different variations with r in this composition.Like this, prepare the powder shown in the table 7 with length-width ratio.The powder that obtains is divided into and has the 45 μ m or the powder of small grain size more subsequently.Then, carry out the XRD test to determine broad peak as the glassy phase feature.In addition, carry out DSC heat and analyze, thereby determine that sub-cooled liquid temperature range delta Tx is 35K with mensuration glass transition temperature and crystallization temperature.
In addition, use the powder that obtains like this, mix with the silicones as adhesive of 3.0% quality than content.Has outer dia φ by use
Outward=27mm * inside diameter φ
InThe band groove die head of=14mm, these powder use 1.47GPa (15t/cm in room temperature
2) pressure carry out molded so that highly equal 5mm.Like this, prepare different types of molding.After molded, in 500 ℃ Ar atmosphere, heat-treat.
Then, the various moldings that obtain like this carry out resin solidification.Subsequently, measure the weight and the size of each molding.Then, twine the coil of the suitable number of turns to prepare various inductance elements (having shape shown in Figure 2).
Then, for each different sample of inductance element, measure powder and fill ratio % and magnetic permeability.Result shown in the acquisition table 7.
Table 7
Sample | Length-width ratio | Powder is filled ratio (volume %) | Magnetic permeability at 100kHz | |
At 0 (Oe) | At 50 (Oe) | |||
??Fe 71.3Si 9B 14.5Nb 3C 0.7Al 1.5 | ??1.1 | ??70 | ??26 | ??24 |
??Fe 71.5Si 9B 14.4Nb 3C 0.5Al 1.5 | ??1.3 | ??68 | ??29 | ??24 |
??Fe 72.0Si 9B 14.5Nb 3C 0.5Al 1.0 | ??1.5 | ??67 | ??32 | ??25 |
??Fe 73.2Si 9B 14.5Nb 3C 0.1Al 0.2 | ??1.9 | ??66 | ??37 | ??25 |
??Fe 73.3Si 9B 14.5Nb 3C 0.05Al 0.15 | ??2.2 | ??65 | ??42 | ??23 |
As shown in table 7, inductance element of the present invention improves magnetic permeability by the length-width ratio that increases the metal glass powder.On the other hand, if length-width ratio surpasses 2, initial permeability height then, but in DC stacked magnetic permeability variation down.Therefore, can infer, the length-width ratio of powder is preferably 2 or littler.
(embodiment 33)
At first, as the powder preparation step, the weighing material is to obtain Fe
72.0Si
9B
14.5Nb
3C
0.5Al
1.0Composition.Use this material, by hydraulic atomized preparation median particle magnetically soft alloy micro powder inequality.
Secondly, as the molding preparation process, the alloy powder of Huo Deing filters to obtain the powder shown in the table 8 by the variety classes standard screen like this.Subsequently, the silicones as adhesive mixes with the amount of 3% mass ratio.Then, use the die head of 10mm * 10mm, with every kind of powder with have outer dia φ
Outward=8, inside diameter φ
InThe coil of=4mm and 2mm height carries out molded and arranges, so that the coil after molded is positioned at the accurate center of molding, by use the pressure of 490MPa in room temperature, so that highly be 4mm.Like this, just formed molding.
Then, carry out resin solidification at 150 ℃.As for sample number 5, also pass through the another kind of sample of this inductance element of heat treatment preparation in 0.5 hour in 500 ℃ blanket of nitrogen.
Then, for each different sample of inductance element, use the LCR meter to measure inductance and resistance at different frequency.Draw from mensuration, inductance value can obtain peak frequency Q and peak value Q when 1MHz.The result that obtains table 8 illustrate.
Then, for the same sample of inductance element, the evaluation kit that is used for typical DC/DC transducer is measured energy conversion efficiency.The gained result is as follows.Condition determination is 12V input, 5V output, 300kHz driving frequency and 1A output current.
Table 8
Sample number | Mesh particle diameter μ m | Average diameter | At the L of 1MHZ (μ H) | Q peak frequency | The Q peak value | Energy conversion |
Comparing embodiment | ||||||
1 | ??45 | ??33 | ??0.58 | ??300kHz | ??32 | ??79.6% |
??1 | ??45 | ??28 | ??0.61 | ??600kHz | ??44 | ??83.1 |
??2 | ??45 | ??23 | ??0.64 | ??800kHz | ??47 | ??83.7 |
??3 | ??45 | ??18 | ??0.67 | ??1.5MHz | ??62 | ??85.2 |
??4 | ??45 | ??15 | ??0.65 | ??2.5MHz | ??67 | ??85.4 |
??5 | ??45 | ??10 | ??0.63 | ??3.5MHz | ??77 | ??85.7 |
5 (heat treated) | ??45 | ??10 | ??0.70 | ??3.0MHz | ??82 | ??87.3 |
Comparing | ??63 | ??28 | ??0.67 | ??400kHz | ??35 | ??79.8 |
As seen from Table 8, in inductance element of the present invention, when the mesh particle diameter is that 45 μ m or littler and average diameter are 30 μ m or more hour, Q peak frequency is 500kHz or bigger, and the Q peak value is 40 or bigger.Simultaneously, energy conversion efficiency is very excellent, is 80% or bigger.When the mesh particle diameter is that 45 μ m or littler and average diameter are 20 μ m or more hour, Q peak frequency is 1MHz or bigger, and the Q peak value is 50 or bigger.Simultaneously, energy conversion efficiency is very excellent, is 85% or bigger.In addition, can infer,, can further improve transformation efficiency by this inductance element of heat treatment.
As mentioned above, in high frequency magnetic core according to the present invention, the alloy composition of following general formula is selected as the soft magnetic metallic glass powder with excellent economic benefit: (Fe
1-aCo
a)
100-x-y-z-q-r(M
1-pM '
p)
xT
yB
zC
qAl
r(0<a<0.50,0<p<0.5,2 atom %<x<5 atom %, 8 atom %<y<12 atom %, 12 atom %<z<17 atom %, 0.1 atom %<q<1.0 atom %, 0.2 atom %<r<2.0 atom % and 25<(x+y+z+q+r)<30, M is selected from least a among Zr, Nb, Ta, Hf, Mo, Ti, V, Cr and the W, M ' is for being selected from least a among Zn, Sn and the R (R is at least a element of selecting) from the rare earth metal that comprises Y, T is selected from least a among Si and the P).This makes can obtain to have the excellent magnetic energy, glass forms performance and powder filling capacity.In addition, powder carries out oxidation or insulation coating, and is molded to obtain molding by using die head etc. and using suitable method of moulding to carry out.By this way, preparation powder core.Thereby, obtain the high magnetic permeability powder core that shows excellent magnetic permeability character and never know at wide frequency ranges.Therefore, can produce soft magnetic material high frequency magnetic core economically with high saturation magnetic flux metric density and high specific resistance.In addition, obtain to comprise high frequency magnetic core and at least one circle inductance element around the coil of this high frequency magnetic core, it is a kind of economic and high performance product that never obtained.Therefore, the present invention is very useful in commercial Application.
In the present invention, if use on granularity, have 45 μ m or littler maximum particle size and have 30 μ m or littler, better be the metal glass powder of 20 μ m or littler average diameter, the powder core that then obtains when high frequency, to have very low-loss character.Comprise that high frequency magnetic core and at least one circle have excellent Q performance around the inductance element of the coil of this high frequency magnetic core, so that can improve the energy efficiency of supply.Therefore, the present invention is very useful in commercial Application.
In addition, in the present invention, on granularity, have 45 μ m or littler maximum particle size and have 30 μ m or littler, better be 20 μ m or littler average diameter the metal glass powder be embedded in coil in the magnet and carry out compression molding to form complete structure.In this case, except that excellent core performance, passed the metal magnet by radiation from the heat that the electric current that flows through coil produces as the metal glass phase character.By thermal-radiating synergy, can obtain the inductance element that rated current increases for identical shaped.Herein, the strain relief heat treatment temperature of metal glass powder is lower than temperature more than 600 ℃, described more than 600 ℃ temperature think the copper cash that in coil, uses and the upper limit of coating material allowable temperature.Therefore, by in the heat treatment that is not higher than 600 ℃ of temperature, can obtain the coil that loss significantly reduces.Therefore, have the powder of coil and the integrally-built core of powder as formation, alloy composite of the present invention is very suitable.
As mentioned above, high frequency magnetic core of the present invention has the soft magnetic metallic glass material of high saturation magnetic flux metric density and high specific resistance by use and obtains economically.In addition, have inductance element that the core of coil obtains by equipment and have in my innocent life excellent magnetic energy at high frequency band.Therefore, can prepare the high magnetic permeability powder core of with low cost and excellent performance in my innocent life, this powder core is applicable to energy feed element such as the choking-winding and the transformer of various electronic installations.
Use the high frequency magnetic core that obtains by molded powder in the present invention, can prepare the high-performance inductance element on high frequency with small granularity.In addition, in the high frequency magnetic core that obtains by molded small granularity powder, the coil that is embedded in the magnet is carried out compression molding to form overall structure.Therefore, it is little and be applicable to the inductance element of big electric current to obtain size, and this inductance element is suitable for the inductance element of doing such as choking-winding and transformer.
Claims (20)
1. high frequency magnetic core, it comprises the molding that the mixture by molded soft magnetic metallic glass powder and adhesive obtains, in with the mass ratio of soft magnetic metallic glass powder, described binder content is 10% or littler, and described soft magnetic metallic glass powder has the alloy composition of being represented by following general formula: (Fe
1-aCo
a)
100-x-y-z-q-r(M
1-pM '
p)
xT
yB
zC
qAl
r(0<a<0.50 wherein, 0<p<0.5,2 atom %<x<5 atom %, 8 atom %<y<12 atom %, 12 atom %<z<17 atom %, 0.1 atom %<q<1.0 atom %, 0.2 atom %<r<2.0 atom % and 25<(x+y+z+q+r)<30, M is selected from least a among Zr, Nb, Ta, Hf, Mo, Ti, V, Cr and the W, M ' is for being selected from least a among Zn, Sn and the R (R is at least a element of selecting) from the rare earth metal that comprises Y, T is selected from least a among Si and the P).
2. high frequency magnetic core as claimed in claim 1, wherein said molding have 50% or bigger powder fill ratio, when using 1.6 * 10
4Have 0.5T or bigger magnetic density during the magnetic field of A/m, and have 1 * 10
4Ω cm or bigger ratio resistance.
3. high frequency magnetic core as claimed in claim 1, wherein said molding by preparation soft magnetic metallic glass powder and adhesive mixture and use compression molded this mixture of die head to obtain, in with the mass ratio of soft magnetic metallic glass powder, the amount of described adhesive is 5% or littler, described molding have 70% or bigger powder fill ratio, when using 1.6 * 10
4Have 0.70T or bigger magnetic density during the magnetic field of A/m, and have 1 Ω cm or bigger ratio resistance.
4. high frequency magnetic core as claimed in claim 1, wherein said molding by preparation soft magnetic metallic glass powder and adhesive mixture and use die head to obtain at molded this mixture of the temperature conditions lower compression that is not less than the binding agent softening point, in with the mass ratio of soft magnetic metallic glass powder, the amount of described adhesive is 3% or littler, described molding have 80% or bigger powder fill ratio, when using 1.6 * 10
4Have 0.9T or bigger magnetic density during the magnetic field of A/m, and have 0.1 Ω cm or bigger ratio resistance.
5. high frequency magnetic core as claimed in claim 1, wherein said molding by the mixture of preparation soft magnetic metallic glass powder and adhesive and in the sub-cooled liquid temperature scope of soft magnetic metallic glass powder compression molded this mixture obtain, in with the mass ratio of soft magnetic metallic glass powder, the amount of described adhesive is 1% or littler, described molding have 90% or bigger powder fill ratio, when using 1.6 * 10
4Have 1.0T or bigger magnetic density during the magnetic field of A/m, and have 0.01 Ω cm or bigger ratio resistance.
6. high frequency magnetic core as claimed in claim 1, wherein the soft magnetic metallic glass powder produces by water atomization or gas atomization, and at least 50% powder particle has the size that is not less than 10 μ m.
7. high frequency magnetic core as claimed in claim 1 wherein has than the soft magnetic metal alloy powder of littler average diameter of the average diameter of soft magnetic metallic glass powder and the soft amount with 5~50% volume ratios and adds.
8. high frequency magnetic core as claimed in claim 1, wherein said soft magnetic metallic glass powder have the length-width ratio in 1~2 scope (major axis/minor axis) basically.
9. high frequency magnetic core as claimed in claim 1, wherein molded after, described molding is heat-treated in the temperature that is not less than the alloy powder Curie point, SiO
2At least be included in the part intermediate materials between the powder particle of alloy powder.
10. inductance element, it comprises the coil that the described high frequency magnetic core of claim 1 and at least one circle twine around this high frequency magnetic core.
11. inductance element as claimed in claim 10 wherein forms the gap on the part magnetic circuit of high frequency magnetic core.
12. high frequency magnetic core as claimed in claim 1, wherein said soft magnetic metallic glass powder have 45 μ m or littler maximum particle size and have 30 μ m or littler average diameter on the grid granularity.
13. high frequency magnetic core as claimed in claim 12 wherein has than the soft magnetic metal alloy powder of littler average diameter of the average diameter of soft magnetic metallic glass powder and the soft amount with 5~50% volume ratios and adds.
14. high frequency magnetic core as claimed in claim 12, wherein said soft magnetic metallic glass powder have the length-width ratio in 1~2 scope (major axis/minor axis) basically.
15. high frequency magnetic core as claimed in claim 12, wherein powder filling ratio is 50% or bigger, and is 40 or bigger at 500kHz or bigger Q peak value.
16. high frequency magnetic core as claimed in claim 12, wherein said soft magnetic metallic glass powder has 45 μ m or littler maximum powder granularity and has 20 μ m or littler average diameter on the grid granularity, and 1MHz or when bigger the Q peak value of high frequency magnetic core be 50 or bigger.
17. an inductance element, it comprises the coil that the described high frequency magnetic core of claim 12 and at least one circle twine around high frequency magnetic core.
18. inductance element as claimed in claim 17, wherein said coil are embedded in the magnet and by compression molding and become overall structure to form.
19. inductance element as claimed in claim 17, wherein said molding forms at least one turn coil, and described coil is embedded in the magnet and by compression molding and forms overall structure.
20. inductance element as claimed in claim 17, wherein heat treatment is carried out in the temperature that is not higher than 600 ℃.
Applications Claiming Priority (6)
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JP2005-136958 | 2005-05-10 | ||
JP2005136958A JP2006032907A (en) | 2004-05-17 | 2005-05-10 | High-frequency core and inductance component using the same |
JP2005136958 | 2005-05-10 |
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CN1700369A true CN1700369A (en) | 2005-11-23 |
CN1700369B CN1700369B (en) | 2010-05-12 |
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US (1) | US20050254989A1 (en) |
EP (1) | EP1598836B1 (en) |
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Cited By (7)
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CN100457955C (en) * | 2007-04-16 | 2009-02-04 | 安泰科技股份有限公司 | Ferrum-base block non-crystalline alloy material |
CN102509603A (en) * | 2011-12-31 | 2012-06-20 | 青岛云路新能源科技有限公司 | Iron-based amorphous state soft magnetic material and preparation method thereof |
CN101896982B (en) * | 2007-12-12 | 2012-08-29 | 松下电器产业株式会社 | Inductance part and method for manufacturing the same |
CN103794327A (en) * | 2006-02-02 | 2014-05-14 | Nec东金株式会社 | Amorphous soft magnetic alloy and inductance component using the same |
CN104021910A (en) * | 2014-06-26 | 2014-09-03 | 天津理工大学 | Magnetically soft alloy having high initial magnetic conductivity and used under high-frequency condition |
CN104036905A (en) * | 2014-05-28 | 2014-09-10 | 浙江大学 | Soft magnetic composite material and preparation method thereof |
CN110192257A (en) * | 2017-01-10 | 2019-08-30 | Lg伊诺特有限公司 | Magnetic core and coil block including the magnetic core |
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EP1610348B1 (en) * | 2003-08-22 | 2011-08-10 | Nec Tokin Corporation | High-frequency magnetic core and inductive component using the same |
DE102006032517B4 (en) | 2006-07-12 | 2015-12-24 | Vaccumschmelze Gmbh & Co. Kg | Process for the preparation of powder composite cores and powder composite core |
US11355276B2 (en) * | 2009-02-27 | 2022-06-07 | Cyntec Co., Ltd. | Choke |
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Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
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US205295A (en) * | 1878-06-25 | Improvement in milk-coolers | ||
JPS6074412A (en) * | 1983-09-28 | 1985-04-26 | Toshiba Corp | Multi-output common choke coil |
JP2611994B2 (en) * | 1987-07-23 | 1997-05-21 | 日立金属株式会社 | Fe-based alloy powder and method for producing the same |
US5252148A (en) * | 1989-05-27 | 1993-10-12 | Tdk Corporation | Soft magnetic alloy, method for making, magnetic core, magnetic shield and compressed powder core using the same |
US6594157B2 (en) * | 2000-03-21 | 2003-07-15 | Alps Electric Co., Ltd. | Low-loss magnetic powder core, and switching power supply, active filter, filter, and amplifying device using the same |
EP1610348B1 (en) * | 2003-08-22 | 2011-08-10 | Nec Tokin Corporation | High-frequency magnetic core and inductive component using the same |
-
2005
- 2005-05-09 EP EP05010020A patent/EP1598836B1/en not_active Expired - Fee Related
- 2005-05-09 US US11/125,747 patent/US20050254989A1/en not_active Abandoned
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Also Published As
Publication number | Publication date |
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US20050254989A1 (en) | 2005-11-17 |
EP1598836A1 (en) | 2005-11-23 |
DE602005012020D1 (en) | 2009-02-12 |
EP1598836B1 (en) | 2008-12-31 |
CN1700369B (en) | 2010-05-12 |
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Address after: Japan's Miyagi Prefecture Co-patentee after: Northeastern University Patentee after: Tokin Corporation Address before: Japan's Miyagi Prefecture Co-patentee before: Northeastern University Patentee before: NEC Tokin Corp. |
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CF01 | Termination of patent right due to non-payment of annual fee | ||
CF01 | Termination of patent right due to non-payment of annual fee |
Granted publication date: 20100512 Termination date: 20210516 |