JP2001250709A - Magnetic powder for dust core - Google Patents

Magnetic powder for dust core

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Publication number
JP2001250709A
JP2001250709A JP2000058817A JP2000058817A JP2001250709A JP 2001250709 A JP2001250709 A JP 2001250709A JP 2000058817 A JP2000058817 A JP 2000058817A JP 2000058817 A JP2000058817 A JP 2000058817A JP 2001250709 A JP2001250709 A JP 2001250709A
Authority
JP
Japan
Prior art keywords
powder
magnetic
dust core
particle size
weight
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
JP2000058817A
Other languages
Japanese (ja)
Inventor
Satoshi Takemoto
聡 武本
Takanobu Saitou
貴伸 斉藤
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Daido Steel Co Ltd
Original Assignee
Daido Steel Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Daido Steel Co Ltd filed Critical Daido Steel Co Ltd
Priority to JP2000058817A priority Critical patent/JP2001250709A/en
Publication of JP2001250709A publication Critical patent/JP2001250709A/en
Pending legal-status Critical Current

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  • Powder Metallurgy (AREA)
  • Soft Magnetic Materials (AREA)

Abstract

PROBLEM TO BE SOLVED: To provide magnetic powder suitable for manufacturing a dust magnetic core that is high in density, permeability, and direct-current superposition characteristics. SOLUTION: This dust core magnetic powder is a mixture of soft magnetic power covered with a binder component and 150 μm or below in grain diameter as a whole, where powder of grain diameter 106 to 150 μm amount to 25 to 60 wt.%, powder of grain diameter 45 μm or below amount to 20 to 60 wt.%, and preferably soft magnetic powder of 10 to 50 wt.% is contained furthermore.

Description

【発明の詳細な説明】DETAILED DESCRIPTION OF THE INVENTION

【0001】[0001]

【発明の属する技術分野】本発明は磁性粉末に関し、更
に詳しくは、高密度であるため形状の小型化が可能で、
同時に高透磁率で直流重畳特性が向上している圧粉磁芯
の製造に用いて有用な圧粉磁芯用磁性粉末に関する。
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a magnetic powder, and more particularly, to a high-density magnetic powder that can be reduced in size.
At the same time, the present invention relates to a magnetic powder for a dust core which is useful for producing a dust core having a high magnetic permeability and an improved DC superimposition characteristic.

【0002】[0002]

【従来の技術】例えば、スイッチング電源の直流出力側
の平滑用チョークコイルや交流入力側のノーマルモード
用ノイズフィルタ、またインバータ制御器におけるアク
ティブフィルタ用チョークコイルなどには、対象部品が
複雑形状をしていても高い歩留まりで製造できるので、
従来の磁芯の主流であったケイ素鋼板を用いた積層型磁
芯に代わって圧粉磁芯が広く用いられている。
2. Description of the Related Art For example, a target component has a complicated shape such as a smoothing choke coil on a DC output side of a switching power supply, a normal mode noise filter on an AC input side, and an active filter choke coil in an inverter controller. Can be manufactured with a high yield,
Powder magnetic cores are widely used instead of laminated magnetic cores using silicon steel plates, which have been the mainstream of conventional magnetic cores.

【0003】この圧粉磁芯は、一般に、次のようにして
製造されている。まず、所定の粒度分布を有する軟磁性
粉末を用意し、これと水ガラスに代表されるバインダ成
分と混練して当該軟磁性粉末の表面をバインダ成分で被
覆する。ついで、その粉末を金型に充填したのち圧縮成
形して所定形状の成形体にし、その成形体に加熱処理を
行って圧縮成形時の成形歪みを解放するとともにバイン
ダ成分を硬化する。
[0003] This dust core is generally manufactured as follows. First, a soft magnetic powder having a predetermined particle size distribution is prepared, kneaded with a binder component typified by water glass, and the surface of the soft magnetic powder is coated with the binder component. Next, the powder is filled in a mold and then compression-molded into a molded body having a predetermined shape. The molded body is subjected to a heat treatment to release molding distortion during compression molding and to cure the binder component.

【0004】ところで、圧粉磁芯の嵩密度とその透磁率
や直流重畳特性との間には相関関係があり、通常、圧粉
磁芯を高密度化すると、その透磁率や直流重畳特性は向
上する。また、圧粉磁芯を高密度化することにより、当
該圧粉磁芯の高強度化が可能になるとともに、所望する
磁気特性を確保した状態で形状の小型化を実現すること
ができるという効果が得られる。
By the way, there is a correlation between the bulk density of a dust core and its magnetic permeability and DC superimposition characteristics. Generally, when the dust core is densified, its magnetic permeability and DC superimposition characteristics become higher. improves. In addition, by increasing the density of the dust core, the strength of the dust core can be increased, and the size of the dust core can be reduced while securing desired magnetic properties. Is obtained.

【0005】したがって、高透磁率で直流重畳特性が向
上した圧粉磁芯を得る場合には、上記した一連の製造工
程において、成形体を高密度化することが必要になる。
Therefore, in order to obtain a dust core having a high magnetic permeability and an improved direct current superposition characteristic, it is necessary to increase the density of the compact in the above-described series of manufacturing steps.

【0006】[0006]

【発明が解決しようとする課題】成形体を高密度化する
ためには、例えば、圧縮形成時における成形圧を高める
こと、そのために機械プレスに代えて油圧プレスを用い
ること、また成形温度を高めることなどの手段を講じる
ことの有効性が考えられる。しかしながら、上記したよ
うな諸手段を講じるということは、設備費を高め、また
生産性の点で問題があり、結局、製造された圧粉磁芯の
コスト上昇を引き起こすことになり、工業的には得策で
あるとはいいがたい。
In order to increase the density of a molded article, for example, it is necessary to increase the molding pressure during compression forming, to use a hydraulic press instead of a mechanical press, and to increase the molding temperature. It is considered effective to take such measures. However, taking the above-mentioned various measures increases equipment costs and has a problem in productivity, and eventually causes an increase in the cost of the manufactured dust core, and industrially, Is not a good idea.

【0007】本発明は、上記した問題を解決し、成形条
件は従来の場合と同等であっても、高密度であり、した
がって高透磁率で直流重畳特性も向上している圧粉磁芯
の製造に用いて有効な圧粉磁芯用磁性粉末の提供を目的
とする。
[0007] The present invention solves the above-mentioned problems, and provides a high-density, high-permeability, and improved DC superposition characteristic of a dust core, even though the molding conditions are the same as in the conventional case. An object of the present invention is to provide a magnetic powder for a dust core effective for use in production.

【0008】[0008]

【課題を解決するための手段】本発明者らは上記した目
的を達成するために鋭意研究を重ねる過程で、所定の粒
度分布を有する軟磁性粉末をバインダ成分で被覆する
と、得られた粉末の粒度分布は混練時に凝集または造粒
して当初(バインダ成分との混練前)の粒度分布と大幅
に異なってくるとの知見を得、また、その粉末を用いて
製造した成形体の嵩密度は、当初の粒度分布から予測さ
れる嵩密度と異なった値になるという事実を見出した。
Means for Solving the Problems In the course of intensive studies to achieve the above-mentioned object, the present inventors coated a soft magnetic powder having a predetermined particle size distribution with a binder component. The knowledge that the particle size distribution is agglomerated or granulated at the time of kneading and significantly differs from the initial (before kneading with the binder component) particle size distribution has been obtained. And the fact that the bulk density differs from the bulk density predicted from the initial particle size distribution.

【0009】したがって、成形体の嵩密度は、バインダ
成分による処理前の軟磁性粉末の粒度分布ではなく、バ
インダ成分で表面が被覆された粉末の粒度分布によって
規定されるとの着想を抱き、この着想に基づいて更に研
究を重ねた結果、成形体、ひいては圧粉磁芯の高密度化
を実現することができる本発明の磁性粉末を開発するに
至った。
Therefore, the idea is that the bulk density of the compact is determined not by the particle size distribution of the soft magnetic powder before the treatment with the binder component but by the particle size distribution of the powder whose surface is coated with the binder component. As a result of further research based on the idea, the inventors have developed a magnetic powder of the present invention that can realize a high density of a compact, and thus a dust core.

【0010】すなわち、本発明の圧粉磁芯用磁性粉末
は、バインダ成分で被覆された軟磁性粉末の混合物であ
って、全体は粒径150μm以下の粉末から成り、その
うち、粒径106〜150μmの粉末の重量割合が25
〜60重量%であり、かつ、粒径45μm以下の粉末の
重量割合が20〜60重量%であることを特徴とする。
That is, the magnetic powder for a dust core of the present invention is a mixture of a soft magnetic powder coated with a binder component, and is entirely composed of a powder having a particle size of 150 μm or less. Powder weight ratio is 25
To 60% by weight, and the weight ratio of the powder having a particle size of 45 μm or less is 20 to 60% by weight.

【0011】[0011]

【発明の実施の形態】本発明の磁性粉末は、粒径が異な
り、かつ、その表面がバインダ成分で被覆されている軟
磁性粉末を、後述の重量割合で混合したものである。そ
の場合、磁性粉末は、全体として100メッシュ(タイ
ラー篩)を通過する粒径、すなわち150μm以下にな
っている。
BEST MODE FOR CARRYING OUT THE INVENTION The magnetic powder of the present invention is obtained by mixing soft magnetic powders having different particle diameters and the surfaces of which are coated with a binder component in a weight ratio described later. In this case, the magnetic powder has a particle size that passes through a 100 mesh (Tyler sieve) as a whole, that is, 150 μm or less.

【0012】そして、そのうち、100〜140メッシ
ュのタイラー篩で分級される粒径、すなわち、106〜
150μmの粉末(粉末A)が25〜65重量%の割合
を占め、同時に、330メッシュのタイラー篩を通過す
る粒径、すなわち、45μm以下の粉末(粉末B)が2
0〜60重量%の割合を占めている。上記した条件を満
たしていない磁性粉末は、理由は明確ではないが、それ
を用いた成形体の嵩密度はそれほど高くならない。
[0012] Among them, the particle size classified by a 100-140 mesh Tyler sieve, ie, 106-140 mesh
150 μm powder (powder A) occupies a proportion of 25 to 65% by weight, while at the same time the particle size passing through a 330 mesh Tyler sieve, ie powder of 45 μm or less (powder B) is 2%.
It accounts for 0-60% by weight. The reason for the magnetic powder that does not satisfy the above conditions is not clear, but the bulk density of a molded body using the same does not become so high.

【0013】この磁性粉末は図1で示したプロセスを経
て製造される。まず、各種粒径の軟磁性粉末の混合物で
ある素材粉をバインダ成分と混練する。用いるバインダ
成分としては、有機質、無機質のいずれを用いてもよい
が、成形体は最後に700℃程度の温度で加熱処理され
ることを考えると、比較的耐熱度が高い無機質のバイン
ダ成分であることが好ましい。具体的には、水ガラスが
好適である。
This magnetic powder is manufactured through the process shown in FIG. First, raw material powder, which is a mixture of soft magnetic powders of various particle sizes, is kneaded with a binder component. As the binder component to be used, any of an organic material and an inorganic material may be used. However, considering that the molded body is finally heat-treated at a temperature of about 700 ° C., it is an inorganic binder component having a relatively high heat resistance. Is preferred. Specifically, water glass is suitable.

【0014】また、バインダ成分の使用量は、そのバイ
ンダ成分が素材粉の表面を略全体に亘って被覆でき、同
時に素材粉を相互に結着することができるような量に設
定される。なお、このときに、Al23粉,SiO
2粉,MgO粉,Fe23粉,TiO2粉,CaO粉,K
2O粉,Na23粉のような絶縁酸化物の粉末を適量同
時に添加すると、この絶縁酸化物の作用で粉末相互間の
絶縁性が確保され、製造された圧粉磁芯のコアロスを小
さくすることができるので好適である。
The amount of the binder component used is set so that the binder component can cover almost the entire surface of the material powder and can simultaneously bind the material powder to each other. At this time, Al 2 O 3 powder, SiO 2
2 powder, MgO powder, Fe 2 O 3 powder, TiO 2 powder, CaO powder, K
When an appropriate amount of insulating oxide powder such as 2 O powder and Na 2 O 3 powder is added at the same time, insulation between the powders is secured by the action of the insulating oxide, and the core loss of the manufactured dust core is reduced. This is preferable because it can be reduced.

【0015】この混練過程を経て、素材粉の表面はバイ
ンダ成分で被覆される。ついで、得られた混練物を大気
中で乾燥し、軽く解砕したのち、例えばタイラー篩で分
級する。具体的には、下から順に、330メッシュの
篩、140メッシュの篩、100メッシュの篩を重ね合
わせ、100メッシュの篩の上に混練物の粉末をいれ
て、全体に振動を与える。そして、330メッシュの篩
を通過したものを分取して粉末Bとし、また140メッ
シュの篩の上に残っている粉末を分取して粉末Aとす
る。そして、330メッシュの篩の上に残っている粉も
粉末Cとして分取しておく。
Through the kneading process, the surface of the material powder is coated with the binder component. Next, the obtained kneaded material is dried in the air, crushed lightly, and then classified using, for example, a Tyler sieve. Specifically, a 330-mesh sieve, a 140-mesh sieve, and a 100-mesh sieve are superimposed sequentially from the bottom, and the kneaded material powder is put on the 100-mesh sieve to give vibrations to the whole. The powder passing through the 330-mesh sieve is collected as powder B, and the powder remaining on the 140-mesh sieve is collected as powder A. The powder remaining on the 330-mesh sieve is also fractionated as powder C.

【0016】ついで、これら3種類の粉末を混合して、
本発明の磁性粉末が製造される。具体的には、粉末A
(粒径106〜150μm)の重量割合が25〜60重
量%、粉末B(粒径45μm以下)の重量割合が20〜
60重量%、残余が粉末C(粒径45〜106μm)と
なるように混合する。なお、このときに、粉末Bの一部
として、粒径が20μm以下である微粉を、10〜50
重量%(したがって、粒径20〜45μmの粉末の重量
割合は0〜50重量%になっている)添加しておくと、
得られた圧粉磁芯は更に高密度化するので好適である。
Next, these three kinds of powders are mixed,
The magnetic powder of the present invention is produced. Specifically, powder A
(Particle size: 106 to 150 μm) by weight is 25 to 60% by weight, and powder B (particle size: 45 μm or less) is 20 to 20% by weight.
60% by weight, with the balance being powder C (particle size 45-106 μm). At this time, a fine powder having a particle size of 20 μm or less was
% By weight (therefore, the weight ratio of the powder having a particle size of 20 to 45 μm is 0 to 50% by weight)
The obtained dust core is suitable because it has a higher density.

【0017】[0017]

【実施例】実施例1〜6,比較例1〜12 ガスアトマイズ法により、センダストから成る軟磁性粉
末を製造した。そして、このセンダスト粉末100重量
部に対し、水ガラス3重量部、Al23粉1重量部を添
加して全体を混練した。
EXAMPLES Examples 1 to 6 and Comparative Examples 1 to 12 Soft magnetic powders of Sendust were produced by gas atomization. Then, 3 parts by weight of water glass and 1 part by weight of Al 2 O 3 powder were added to 100 parts by weight of this sendust powder, and the whole was kneaded.

【0018】ついで、この混練物を大気中で乾燥したの
ち、330メッシュのタイラー篩、140メッシュのタ
イラー篩、100メッシュタイラー篩を用いて分級し、
粉末A、粉末Bおよび粉末Cを分取した。ついで、これ
らの粉末を表1で示した割合で混合し、更にその混合粉
末100重量部に対して0.5重量部のステアリン酸亜
鉛を添加し、それを金型に充填したのち成形圧13ton
/cm2で圧縮成形し、外径25mm、内径20mm、厚み5m
mのリング状の成形体にした。
Then, the kneaded material is dried in the air, and then classified using a 330-mesh Tyler sieve, a 140-mesh Tyler sieve, and a 100-mesh Tyler sieve.
Powder A, powder B and powder C were separated. Then, these powders were mixed at the ratio shown in Table 1, and 0.5 part by weight of zinc stearate was added to 100 parts by weight of the mixed powder, and the mixture was filled in a mold.
/ Cm 2 compression molding, outer diameter 25mm, inner diameter 20mm, thickness 5m
m shaped into a ring.

【0019】そして、この成形体に、温度700℃のA
r雰囲気中で1時間の熱処理を行って、圧粉磁芯を製造
した。各圧粉磁芯については、その嵩密度を測定し、ま
たLCRメータを用いて周波数100kHzにおける初透
磁率を測定した。更に、これら圧粉磁芯に直流バイアス
電流を流しながらLCRメータで透磁率を測定してい
き、磁界が6400A/mになったときの透磁率を測定
して直流重畳特性を判定した。このときの透磁率が高い
ほど直流重畳特性は優れている。
[0019] Then, this molded body is treated with A at a temperature of 700 ° C.
Heat treatment was performed for 1 hour in an r atmosphere to produce a dust core. The bulk density of each dust core was measured, and the initial permeability at a frequency of 100 kHz was measured using an LCR meter. Further, the magnetic permeability was measured with an LCR meter while a DC bias current was passed through these dust cores, and the magnetic permeability when the magnetic field reached 6400 A / m was measured to determine the DC superimposition characteristics. The higher the magnetic permeability at this time, the better the DC superposition characteristics.

【0020】[0020]

【表1】 [Table 1]

【0021】表1から明らかなように、実施例の磁性粉
末を用いて製造した圧粉磁芯は、いずれも、比較例の磁
性粉末を用いて製造した圧粉磁芯に比べて、その嵩密度
は2〜8.5%程度高く、高密度化しており、そのこと
により初透磁率も高く、磁界が6400A/mのときの
透磁率も高く直流重畳特性に優れている。これは、圧粉
磁芯の製造に用いる粉末において、粉末A(粒径106
〜150μm)の重量割合を25〜60重量%、粉末B
の重量割合を20〜60重量%に設定することの有効性
を示している。
As is clear from Table 1, each of the dust cores manufactured using the magnetic powders of the examples has a larger volume than the dust cores manufactured using the magnetic powder of the comparative example. The density is as high as about 2 to 8.5%, and the density is increased. As a result, the initial magnetic permeability is high, the magnetic permeability is high when the magnetic field is 6,400 A / m, and the DC superimposition characteristics are excellent. This is because powder A (particle size 106
25 to 60% by weight, powder B
Is set to 20 to 60% by weight.

【0022】実施例7〜11,比較例13〜18 実施例1〜6で用いた粉末Bにつき、更に625メッシ
ュのタイラー篩を用いて分級し、その篩を通過した粒径
20μm以下の粉末を粉末B2として分取した。そし
て、この篩の上に残っている粉末(粒径20〜45μ
m)を粉末B1として分取した。
Examples 7 to 11 and Comparative Examples 13 to 18 The powder B used in Examples 1 to 6 was further classified using a 625 mesh Tyler sieve, and the powder having a particle size of 20 μm or less passed through the sieve. It was collected as powder B2. Then, the powder remaining on the sieve (particle size: 20 to 45 μm)
m) was collected as powder B1.

【0023】ついで、粉末A、粉末B1、粉末B2およ
び粉末Cを表2で示した割合で混合したことを除いて
は、実施例1〜6と同じようにして圧粉磁芯を製造し
た。そして、これら圧粉磁芯の嵩密度、初透磁率、直流
重畳特性を同様にして測定した。その結果を表2に示
す。
Then, a dust core was manufactured in the same manner as in Examples 1 to 6, except that the powder A, the powder B1, the powder B2, and the powder C were mixed at the ratios shown in Table 2. Then, the bulk density, initial magnetic permeability, and direct current superposition characteristics of these dust cores were measured in the same manner. Table 2 shows the results.

【0024】[0024]

【表2】 [Table 2]

【0025】表1の実施例と表2を対比して明らかなよ
うに、水ガラスで被覆された粒径20μm以下の微粉が
添加されている粉末を用いると、製造された圧粉磁芯の
嵩密度はより一層高くなり、そのことに伴って初透磁率
と直流重畳特性の更なる向上が認められる。
As is clear from the comparison between the examples in Table 1 and Table 2, when the powder coated with water glass and added with a fine powder having a particle size of 20 μm or less is used, the produced dust core is The bulk density is further increased, and a further improvement in the initial magnetic permeability and the direct current superimposition characteristics is recognized.

【0026】[0026]

【発明の効果】以上の説明で明らかなように、本発明の
磁性粉末は、それを用いて製造した圧粉磁芯を高密度化
し、そのことに伴って初透磁率を高め、直流重畳特性を
向上せしめるので、その工業的価値は極めて大である。
As is evident from the above description, the magnetic powder of the present invention provides a powder magnetic core manufactured using the same with a high density, thereby increasing the initial magnetic permeability and the direct current superposition characteristic. Therefore, its industrial value is extremely large.

【図面の簡単な説明】[Brief description of the drawings]

【図1】本発明の磁性粉末の製造工程を示す概略図であ
る。
FIG. 1 is a schematic view showing a production process of a magnetic powder of the present invention.

Claims (2)

【特許請求の範囲】[Claims] 【請求項1】 バインダ成分で被覆された軟磁性粉末の
混合物であって、全体は粒径150μm以下の粉末から
成り、そのうち、粒径106〜150μmの粉末の重量
割合が25〜60重量%であり、かつ、粒径45μm以
下の粉末の重量割合が20〜60重量%であることを特
徴とする圧粉磁芯用磁性粉末。
1. A mixture of soft magnetic powders coated with a binder component, the whole of which is a powder having a particle size of 150 μm or less, of which a weight ratio of a powder having a particle size of 106 to 150 μm is 25 to 60% by weight. A magnetic powder for a dust core, wherein the weight ratio of the powder having a particle size of 45 μm or less is 20 to 60% by weight.
【請求項2】 粒径が20μm以下で、かつ、バインダ
成分で被覆されている軟磁性粉末が、更に10〜50重
量%含まれている請求項1の圧粉磁芯用磁性粉末。
2. The magnetic powder for a dust core according to claim 1, further comprising 10 to 50% by weight of a soft magnetic powder having a particle size of 20 μm or less and coated with a binder component.
JP2000058817A 2000-03-03 2000-03-03 Magnetic powder for dust core Pending JP2001250709A (en)

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JP2006024844A (en) * 2004-07-09 2006-01-26 Nec Tokin Corp Magnetic core and coil component using same
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JP2007200962A (en) * 2006-01-24 2007-08-09 Nec Tokin Corp Composite material, method for manufacturing the same, magnetic core, and coil component
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