JP2002299113A - Soft magnetic powder and dust core using the same - Google Patents
Soft magnetic powder and dust core using the sameInfo
- Publication number
- JP2002299113A JP2002299113A JP2001105016A JP2001105016A JP2002299113A JP 2002299113 A JP2002299113 A JP 2002299113A JP 2001105016 A JP2001105016 A JP 2001105016A JP 2001105016 A JP2001105016 A JP 2001105016A JP 2002299113 A JP2002299113 A JP 2002299113A
- Authority
- JP
- Japan
- Prior art keywords
- powder
- soft magnetic
- dust core
- thickness
- magnetic
- 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
Links
Classifications
-
- 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
- H01F1/14766—Fe-Si based alloys
- H01F1/14791—Fe-Si-Al based alloys, e.g. Sendust
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、軟磁性粉末および
それを用いた圧粉磁心に関し、さらに詳しくは、成形時
に高密度で充填可能な軟磁性粉末と、それを用いた成形
体よりなり、小型でありながら、高い透磁率、磁束密度
および電気抵抗率を有する圧粉磁心に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a soft magnetic powder and a dust core using the same, and more specifically, a soft magnetic powder which can be filled at a high density during molding and a molded body using the same. The present invention relates to a dust core having high magnetic permeability, magnetic flux density and electric resistivity while being small.
【０００２】[0002]
【従来の技術】軟磁性粉末を圧縮成形することにより得
られる圧粉磁心は、例えば、スイッチング電源における
直流出力側の平滑用チョークコイル、交流入力用ノーマ
ルモードノイズフィルタ、あるいは、インジェクタ用電
磁弁用のコアなどに使用されている。2. Description of the Related Art A powder magnetic core obtained by compression molding soft magnetic powder is used, for example, for a smoothing choke coil on a DC output side of a switching power supply, a normal mode noise filter for an AC input, or a solenoid valve for an injector. It is used for cores.
【０００３】近年、ノート型パソコンなど様々な電子機
器の小型化が進められるに伴い、その部品として圧粉磁
心に対しても小型化と、高性能化すなわち高透磁率と高
磁化すなわち高磁束密度が求められている。このような
高透磁率化を達成するためには、圧粉磁心の密度、すな
わち、軟磁性粉末の体積含有率を増大させることが必要
である。In recent years, with the miniaturization of various electronic devices such as notebook personal computers, the miniaturization of powder magnetic cores as a component and the improvement of high performance, that is, high magnetic permeability and high magnetization, that is, high magnetic flux density Is required. In order to achieve such high magnetic permeability, it is necessary to increase the density of the dust core, that is, the volume content of the soft magnetic powder.
【０００４】一般に、圧粉磁心は次のようにして製造さ
れている。すなわち、まずＦｅ−Ｓｉ−Ａｌ系合金のよ
うな軟磁性合金を、アトマイズ法または機械粉砕法など
により粉末化し、得られた軟磁性粉末と所定のバインダ
成分とを混練してこの粉末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所定の圧力
で圧縮成形して所望形状の成形体とし、さらに、その成
形体に熱処理（焼鈍）を行うことにより圧縮成形時に成
形体内に蓄積された成形歪みを開放すると同時に、バイ
ンダ成分を硬化することにより圧粉磁心が得られる。Generally, a dust core is manufactured as follows. That is, first, a soft magnetic alloy such as an Fe-Si-Al alloy is powderized by an atomizing method or a mechanical pulverizing method, and the obtained soft magnetic powder is kneaded with a predetermined binder component to form a surface of the powder with a binder. Coat with ingredients. Then, after filling the powder into a mold, compression molding is performed under a predetermined pressure to form a molded body having a desired shape, and the molded body is subjected to a heat treatment (annealing) to form a molded body accumulated in the molded body during compression molding. A dust core is obtained by curing the binder component while releasing the strain.
【０００５】このような圧縮工程において、最終的に得
られる磁心中の軟磁性粉末の体積含有率を増大させて、
結果的に高透磁率および高磁束密度を実現するために
は、金型への粉末の充填密度をできる限り高めることが
必要である。In such a compression step, the volume content of the soft magnetic powder in the finally obtained magnetic core is increased,
As a result, in order to achieve high magnetic permeability and high magnetic flux density, it is necessary to increase the packing density of the powder in the mold as much as possible.
【０００６】[0006]
【発明が解決しようとする課題】上記のような工程にお
いて、圧粉磁心中の軟磁性粉末の密度を増大させるため
には、圧縮成形時に高圧成形を行うなどの方法が採用さ
れているが、粉末自体かなり硬度が高いことに起因し
て、加圧時に粉末自身の反発力いわゆる「戻り」が生
じ、高圧成形しても、ある圧力で金型への充填密度が飽
和してしまうため、結果的に密度の向上には限界がある
という問題があった。In the above-mentioned steps, in order to increase the density of the soft magnetic powder in the dust core, a method of performing high-pressure molding at the time of compression molding has been adopted. Because the powder itself is fairly high in hardness, the repulsion of the powder itself during pressurization, the so-called "return", occurs, and even if high-pressure molding is performed, the packing density in the mold is saturated at a certain pressure. There is a problem that there is a limit to the improvement in density.
【０００７】したがって、本発明は上記の問題を解決
し、圧縮成形により圧粉磁心を製造する際に金型への高
密度充填が可能な軟磁性粉末と、その磁性粉末を使用し
て製造された高透磁率で、しかも高い磁束密度を有する
圧粉磁心を提供することを目的とする。Accordingly, the present invention solves the above-mentioned problems, and a soft magnetic powder which can be densely filled in a mold when a dust core is manufactured by compression molding, and a soft magnetic powder manufactured using the magnetic powder. It is another object of the present invention to provide a dust core having high magnetic permeability and high magnetic flux density.
【０００８】[0008]
【課題を解決するための手段】本発明者らは、上記の問
題を解消すべく軟磁性粉末について種々検討した結果、
以下の知見を得た。すなわち、金型への充填密度に影響
を与える第１の要因は、粉末表面に形成されている酸化
皮膜である。軟質磁性粉末をアトマイズ法で製造する際
にも、機械粉砕法により製造する際にも、粉末表面には
不可避的に酸化皮膜が形成される。この酸化皮膜は電気
抵抗値が高いという利点を有するものの、非常に硬度が
高いため、圧縮成形性をさらに悪化させるという問題が
ある。そのため、この酸化皮膜の厚みを所定の厚さ以下
に制御することにより充填密度を増大することができ
る。The present inventors have conducted various studies on soft magnetic powders in order to solve the above-mentioned problems.
The following findings were obtained. That is, the first factor affecting the filling density in the mold is the oxide film formed on the powder surface. An oxide film is inevitably formed on the surface of the powder when the soft magnetic powder is manufactured by the atomization method or when the soft magnetic powder is manufactured by the mechanical pulverization method. Although this oxide film has the advantage of a high electric resistance value, it has a problem that the compression moldability is further deteriorated because of its extremely high hardness. Therefore, the packing density can be increased by controlling the thickness of the oxide film to a predetermined thickness or less.
【０００９】充填密度に影響を与える第２の要因は、粉
末の形状である。すなわち、粉末が異形になるほど充填
密度を向上させることは困難である。したがって、本発
明者らは軟磁性粉末の厚みとアスペクト比に着目して最
適条件を見出した。すなわち、上記の目的を達成するた
めに、本発明によれば、重量％で、Ｓｉ：0.5〜１５
％、Ａｌ：0.5〜１０％、残部実質的にＦｅよりなるＦ
ｅ−Ｓｉ−Ａｌ系合金粉末の、表面に形成されている酸
化皮膜の厚さが0.05μｍ以下、前記粉末の厚さが１０〜
３０μｍ、かつ、前記粉末のアスペクト比が３〜２０で
ある軟質磁性粉末が提供される。[0009] The second factor affecting the packing density is the shape of the powder. That is, it is difficult to improve the packing density as the powder becomes irregular. Therefore, the present inventors have found the optimum conditions by paying attention to the thickness and aspect ratio of the soft magnetic powder. That is, in order to achieve the above object, according to the present invention, Si: 0.5 to 15% by weight.
%, Al: 0.5 to 10%, the balance being substantially composed of Fe
The thickness of the oxide film formed on the surface of the e-Si-Al-based alloy powder is 0.05 μm or less, and the thickness of the powder is 10 to 10 μm.
A soft magnetic powder having a thickness of 30 μm and an aspect ratio of the powder of 3 to 20 is provided.
【００１０】また、本発明においては、上記の軟質磁性
粉末と電気絶縁性のバインダ成分とを混練した後に圧縮
成形して得られる成形体よりなり、前記電気絶縁性のバ
インダ成分がリン酸塩と水ガラスを主体とするものであ
り、周波数100kHzにおける透磁率が１２５以上、印加磁
界10000Ａ／ｍにおける磁束密度が0.6Ｔ以上、かつ、電
気抵抗率が0.03Ω・ｍ以上である圧粉磁心が提供され
る。The present invention also provides a molded product obtained by kneading the soft magnetic powder and an electrically insulating binder component and then compression-molding the mixture, wherein the electrically insulating binder component is formed of a phosphate and Provided is a powder magnetic core mainly composed of water glass, having a magnetic permeability of 125 or more at a frequency of 100 kHz, a magnetic flux density of 0.6 T or more at an applied magnetic field of 10,000 A / m, and an electric resistivity of 0.03 Ω · m or more. Is done.
【００１１】[0011]
【発明の実施の形態】まず、本発明の軟質磁性粉末につ
いて説明する。この軟磁性粉末は、Ｓｉ：0.5〜１５
％、Ａｌ：0.5〜１０％、残部実質的にＦｅよりなるＦ
ｅ−Ｓｉ−Ａｌ系合金粉末よりなり、その表面に形成さ
れている酸化皮膜の厚さが0.05μｍ以下のものである。
この酸化皮膜は粉末形成時に不可避的に生成されるもの
で、例えば、Ａｌ2Ｏ3，Ｆｅ3Ｏ4、ＳｉＯ2などであ
る。この酸化皮膜の厚さが0.05μｍを超えると、酸化皮
膜の高い硬度に起因して圧縮成形時の充填密度を向上す
ることが困難となる。DESCRIPTION OF THE PREFERRED EMBODIMENTS First, the soft magnetic powder of the present invention will be described. This soft magnetic powder has a Si content of 0.5 to 15
%, Al: 0.5 to 10%, the balance being substantially composed of Fe
It is made of an e-Si-Al-based alloy powder, and the thickness of an oxide film formed on the surface thereof is 0.05 μm or less.
This oxide film is inevitably generated at the time of powder formation, and is, for example, Al 2 O 3 , Fe 3 O 4 , SiO 2 or the like. If the thickness of the oxide film exceeds 0.05 μm, it becomes difficult to improve the packing density during compression molding due to the high hardness of the oxide film.
【００１２】さらに、この軟質磁性粉末自体の厚みは10
〜30μｍであり、アスペクト比は３〜20である。充填密
度を上げるためには粉末の厚さをある程度薄くすること
が必要であるが、極端に薄くしすぎると、すなわち厚み
が10μｍ未満であると逆に圧縮成形後の成形体の見掛け
密度が低下し、金型への充填性が低下してしまう。粉末
の厚さの好ましい範囲は10〜30である。Further, the thickness of the soft magnetic powder itself is 10
3030 μm, and the aspect ratio is 3-20. In order to increase the packing density, it is necessary to reduce the thickness of the powder to some extent, but if it is too thin, that is, if the thickness is less than 10 μm, the apparent density of the compact after compression molding decreases. However, the filling property of the mold decreases. The preferred range of powder thickness is 10-30.
【００１３】一方、圧粉磁心の透磁率を上げるために
は、粉末のアスペクト比を大きくして形状異方性をつけ
ることが有効であり、アスペクト比が３未満であると、
粉末が球形に近くなり充填密度を増大することができな
い。しかし、逆にアスペクト比が大きすぎても、つまり
３０を超えると粉末が過度に長尺になるため、充填時に
粉末同士の絡み合いなどが原因となり見掛け密度を向上
させることが困難となる。好ましいアスペクト比は３〜
20である。On the other hand, in order to increase the magnetic permeability of the dust core, it is effective to increase the powder's aspect ratio to give shape anisotropy.
The powder becomes nearly spherical and the packing density cannot be increased. However, conversely, if the aspect ratio is too large, that is, if it exceeds 30, the powder becomes excessively long, and it becomes difficult to improve the apparent density due to entanglement of the powders at the time of filling. Preferred aspect ratio is 3 to
20.
【００１４】かかる軟質磁性粉末は、所定の組成のＦｅ
−Ｓｉ−Ａｌ合金をアトマイズ法または粉砕法により製
造されるが、粉末の表面の酸化皮膜の厚さの制御性を勘
案するとアトマイズ法や液体超急冷法が好適である。ア
トマイズ法には、水アトマイズ法、ガスアトマイズ法、
遠心アトマイズ法がある。これらのアトマイズ法を使用
する場合には、それぞれの噴霧条件を制御することによ
り表面に形成される酸化皮膜の厚みを所定値に制御す
る。Such a soft magnetic powder is made of Fe having a predetermined composition.
—Si—Al alloy is produced by an atomizing method or a pulverizing method, and in consideration of the controllability of the thickness of the oxide film on the surface of the powder, the atomizing method and the liquid rapid quenching method are preferable. The atomization method includes water atomization, gas atomization,
There is a centrifugal atomization method. When these atomizing methods are used, the thickness of the oxide film formed on the surface is controlled to a predetermined value by controlling the respective spray conditions.
【００１５】なお、液体アトマイズ法を使用する場合
は、得られた粉末が球形に近くなるので、その後、粉末
の扁平化処理を行うことが好ましい。具体的には、乾式
アトライターおよび湿式アトライター処理をする。次
に、本発明の圧粉磁心について説明する。本発明の圧粉
磁心は上記により得られた軟質磁性粉末の成形体よりな
り、周波数100kHzにおける透磁率が125以上、かつ、印
加磁界10000Ａ／ｍにおける磁束密度が0.6Ｔ以上、なら
びに、電気抵抗率が0.03Ω・ｍ以上という特性を有する
ものである。When the liquid atomizing method is used, since the obtained powder has a shape close to a sphere, it is preferable to flatten the powder thereafter. Specifically, a dry attritor and a wet attritor treatment are performed. Next, the dust core of the present invention will be described. The dust core of the present invention is made of the soft magnetic powder obtained above, and has a magnetic permeability of 125 or more at a frequency of 100 kHz, a magnetic flux density of 0.6 T or more at an applied magnetic field of 10,000 A / m, and an electric resistivity. Has a characteristic of 0.03 Ω · m or more.
【００１６】この圧粉磁心は次のようにして製造され
る。すなわち、まず上記のようにして得られた軟磁性粉
末を電気絶縁性のバインダ成分と共に混練して粉末表面
に絶縁皮膜を形成する。この電気絶縁性のバインダ成分
に要求される性質としては、第１に、軟磁性粉末とこの
バインダ成分との混合物の成形時に、印加される圧力に
よって粉末表面に形成されている絶縁皮膜が破損して原
料粉末が相互に接触し、原料粉末間の電気絶縁性が破壊
されてしまうことのないものであることが必要である。This dust core is manufactured as follows. That is, first, the soft magnetic powder obtained as described above is kneaded with an electrically insulating binder component to form an insulating film on the powder surface. The property required of the electrically insulating binder component is that, first, when a mixture of the soft magnetic powder and the binder component is molded, the insulating film formed on the powder surface is damaged by the applied pressure. It is necessary that the raw material powders do not come into contact with each other and the electrical insulation between the raw material powders is not destroyed.
【００１７】また、第２に、後述する成形体の焼鈍工程
で例えば600〜700℃における熱処理により、電気絶縁性
の皮膜中の例えばバインダ成分が熱分解して当該皮膜が
収縮したり、あるいは、原料粉末の熱膨張によってその
表面の皮膜が破損したりして、結果的に原料粉末の直接
的な接触が起こり、電気絶縁性が破壊されることを防止
できるものであることが必要である。Secondly, in the annealing step of the molded body described later, for example, by heat treatment at 600 to 700 ° C., for example, the binder component in the electrically insulating film is thermally decomposed and the film shrinks, or It is necessary that the raw material powder can be prevented from being damaged due to thermal expansion of the raw material powder, resulting in direct contact of the raw material powder and destruction of electric insulation.
【００１８】具体的には、リン酸塩と水ガラス（珪酸ソ
ーダ）を主体としたものが使用される。リン酸塩として
は、例えば、リン酸マグネシウム、リン酸カルシウム、
リン酸亜鉛、リン酸マンガン、リン酸カドミウムなどか
ら選ばれる１種または２種以上を使用することができ
る。これらは当初からリン酸塩として添加してもよい
し、あるいは、リン酸と、ＭｇＯ，ＣａＯ，ＺｎＯ，Ｍ
ｎＯ，ＣｄＯから選択された１種または２種以上を同時
に添加してもよい。なお、このバインダ成分にホウ酸を
添加するとリン酸塩と水ガラスよりなる系が安定化され
るので好ましい。Specifically, a material mainly composed of a phosphate and water glass (sodium silicate) is used. As the phosphate, for example, magnesium phosphate, calcium phosphate,
One or more selected from zinc phosphate, manganese phosphate, cadmium phosphate and the like can be used. These may be added as a phosphate from the beginning, or may be added with phosphoric acid, MgO, CaO, ZnO, M
One or more selected from nO and CdO may be added simultaneously. It is preferable to add boric acid to the binder component, since the system composed of phosphate and water glass is stabilized.
【００１９】上記の絶縁性バインダ成分の組成は、水ガ
ラス１〜５重量％、リン酸塩（リン酸＋金属酸化物）0.
1〜1.5重量％、および、必要に応じてホウ酸0.05〜0.5
重量％に設定することが好ましい。上記のバインダ成分
と軟磁性粉末とは例えばミキサを用いて混練する。この
混練過程で、軟磁性粉末の表面が電気絶縁性のバインダ
成分で被覆される。このときの混練方法は、軟磁性粉末
と水ガラスとリン酸塩とを同時に混練してもよく、ま
た、あらかじめ水ガラスとリン酸塩とを混合してバイン
ダ成分とし、これと軟磁性粉末とを混練してもよく、さ
らには、あらかじめ軟磁性粉末とリン酸塩とを混合し、
その混合粉末に水ガラスを添加して全体を混練してもよ
い。The composition of the above-mentioned insulating binder component is as follows: 1 to 5% by weight of water glass, phosphate (phosphoric acid + metal oxide) 0.
1-1.5% by weight and, if necessary, boric acid 0.05-0.5
It is preferable to set the weight%. The binder component and the soft magnetic powder are kneaded using, for example, a mixer. During the kneading process, the surface of the soft magnetic powder is coated with an electrically insulating binder component. The kneading method at this time may be to knead the soft magnetic powder, the water glass and the phosphate at the same time, or to mix the water glass and the phosphate in advance as a binder component, May be further kneaded, and further, the soft magnetic powder and the phosphate are mixed in advance,
Water glass may be added to the mixed powder and the whole may be kneaded.
【００２０】なかでも好ましい工程は、まず、リン酸と
金属酸化物、または、リン酸と金属酸化物とホウ酸の水
溶液もしくは水分散液を軟磁性粉末と混合することによ
り、軟磁性粉末の表面にリン酸塩の皮膜を形成し、つい
で、この軟磁性粉末と水ガラスとを混合するものであ
る。混合するバインダ成分の比率は、軟磁性粉末の重量
に対して、１〜５重量％の範囲に設定することが好まし
い。Among the preferred steps, first, an aqueous solution or aqueous dispersion of phosphoric acid and a metal oxide or phosphoric acid and a metal oxide and boric acid is mixed with a soft magnetic powder to form a surface of the soft magnetic powder. Then, a phosphate film is formed, and then the soft magnetic powder and water glass are mixed. The ratio of the binder component to be mixed is preferably set in the range of 1 to 5% by weight based on the weight of the soft magnetic powder.
【００２１】続いて、上記により得られた軟磁性粉末を
所定の形状の金型に充填し、圧縮成形する。このときの
加圧力は、例えば、1000〜2500MPaに設定される。軟磁
性粉末として上記のような形状、酸化皮膜の厚さのもの
を使用することにより、金型への充填密度が向上し、し
かも、高圧成形時にも粉末の硬度に起因して生じる、い
わゆる「戻り」がないため、高密度の成形体を得ること
が可能となる。Subsequently, the soft magnetic powder obtained as described above is filled in a mold having a predetermined shape, and is subjected to compression molding. The pressing force at this time is set to, for example, 1000 to 2500 MPa. By using the soft magnetic powder having the above-mentioned shape and the thickness of the oxide film, the filling density in the mold is improved, and the so-called “soft” powder is generated due to the hardness of the powder even during high-pressure molding. Since there is no "return", a high-density molded body can be obtained.
【００２２】さらに、この成形体を焼鈍して、圧縮成形
時に成形体内に蓄積された成形歪みを除去する。焼鈍
は、例えば、真空もしくはＡｒのような不活性ガス雰囲
気中で行われ、このときの熱処理温度は、通常、600〜9
50℃に設定される。こうして得られた本発明の圧粉磁心
は、密度、すなわち、磁心中の軟磁性粉末の体積含有率
が非常に高く、周波数100kHzにおける透磁率が125以
上、印加磁界10000Ａ／ｍにおける磁束密度が0.6Ｔ以上
と非常に優れた磁気特性を有する。しかも、粉末表面の
絶縁被膜が圧縮成形時、および焼鈍時に剥離などが生じ
ないものであるため、0.03Ω・ｍ以上の高い電気抵抗率
を保有することが可能である。Further, the compact is annealed to remove molding distortion accumulated in the compact during compression molding. The annealing is performed, for example, in a vacuum or in an inert gas atmosphere such as Ar, and the heat treatment temperature at this time is usually 600 to 9
Set to 50 ° C. The thus obtained dust core of the present invention has a very high density, that is, a very high volume content of soft magnetic powder in the core, a magnetic permeability of 125 or more at a frequency of 100 kHz, and a magnetic flux density of 0.60 at an applied magnetic field of 10,000 A / m. It has excellent magnetic properties of T or more. In addition, since the insulating film on the powder surface does not peel off during compression molding and annealing, it can have a high electrical resistivity of 0.03 Ω · m or more.
【００２３】[0023]
【実施例】実施例１〜７、比較例１〜８ （１）軟磁性粉末の製造 単ロール法を使用した液体超急冷法により、表１に示し
た寸法形状のＦｅ−9.5Ｓｉ−5.5Ａｌ粉末を製造した。
各粉末の厚さはロール速度を変化させることにより、ま
た、アスペクト比は粉砕により制御した。また、各粉末
表面には、Ａｌ 2Ｏ3の酸化皮膜が形成されており、その
厚さは粉末を粉砕後に大気中で熱処理することにより制
御した。また、酸化皮膜の厚さはオージェ分析により測
定した。EXAMPLES Examples 1 to 7 and Comparative Examples 1 to 8 (1) Production of soft magnetic powders
Thus, Fe-9.5Si-5.5Al powder having the following dimensions and shapes was manufactured.
The thickness of each powder can be adjusted by changing the roll speed.
The aspect ratio was controlled by pulverization. Also, each powder
Al on the surface TwoOThreeOxide film is formed.
Thickness is controlled by heat treatment in air after grinding the powder.
I controlled. The thickness of the oxide film is measured by Auger analysis.
Specified.
【００２４】（２）圧粉磁心の製造 絶縁性バインダ成分として、リン酸、マグネシア（Ｍｇ
Ｏ）およびホウ酸を重量比６：１：１で混合したものを
用意し、これを各粉末重量に対して0.5重量％添加した
後、大気中、２００℃で１時間乾燥した。その後、水ガ
ラスを磁性粉末重量に対して３重量％添加したのち混練
し、金型に充填したのち室温下で成形圧2000MPaで圧縮
成形し、外径２８mm、内径２０mm、高さ５mmのリング状
の成形体とした。(2) Manufacture of dust cores As insulating binder components, phosphoric acid, magnesia (Mg)
A mixture of O) and boric acid in a weight ratio of 6: 1: 1 was prepared, and 0.5% by weight based on the weight of each powder was added, followed by drying at 200 ° C. for 1 hour in the air. Thereafter, water glass was added in an amount of 3% by weight based on the weight of the magnetic powder, kneaded, filled in a mold, and compression-molded at room temperature at a molding pressure of 2000 MPa to form a ring having an outer diameter of 28 mm, an inner diameter of 20 mm, and a height of 5 mm. Molded article.
【００２５】なお、比較例６〜８は絶縁性バインダ成分
として、水ガラス、シリコーン、およびリン酸塩をそれ
ぞれ単独で使用した。しかるのち、各成形体に真空中、
６５０℃で１時間の焼鈍を行って、圧粉磁心を製造し
た。得られた各圧粉磁心の密度を寸法と重量から算出
し、結果を表１に示した。In Comparative Examples 6 to 8, water glass, silicone, and phosphate were used alone as insulating binder components. After that, each molded body is vacuumed,
Annealing was performed at 650 ° C. for 1 hour to produce a dust core. The density of each of the obtained dust cores was calculated from the size and weight, and the results are shown in Table 1.
【００２６】（３）圧粉磁心の特性評価 各圧粉磁心に対して、LCRメータにより周波数100kHzに
おける透磁率、B-Hトレーサーにより10000Ａ／ｍの印加
磁界における磁束密度、ならびに、２端子法により電気
抵抗率をそれぞれ測定し、結果を表１に示した。(3) Characteristic evaluation of dust cores For each dust core, the magnetic permeability at a frequency of 100 kHz by an LCR meter, the magnetic flux density at an applied magnetic field of 10,000 A / m by a BH tracer, and the electric resistance by a two-terminal method The ratios were measured, and the results are shown in Table 1.
【００２７】[0027]
【表１】 [Table 1]
【００２８】表１の結果からも明らかなように、本発明
の軟磁性粉末を使用して製造された圧粉磁心は、高密度
で高い透磁率および磁束密度を有し、さらに電気抵抗値
も高いという事実が確認された。一方、酸化皮膜の厚さ
が厚すぎるもの（比較例３）は、磁心の密度が低く充分
な透磁率および磁束密度を得ることができない。また、
粉末の厚さが薄すぎるもの（比較例１）、および、厚す
ぎるもの（比較例２）も、ともに磁心の密度が低いため
透磁率および磁束密度が低い。As is clear from the results shown in Table 1, the dust core manufactured using the soft magnetic powder of the present invention has a high density, a high magnetic permeability and a high magnetic flux density, and also has an electric resistance value. The fact that it was high was confirmed. On the other hand, when the thickness of the oxide film is too large (Comparative Example 3), the density of the magnetic core is low and sufficient magnetic permeability and magnetic flux density cannot be obtained. Also,
Both the powder having a too thin thickness (Comparative Example 1) and the powder having a too thick thickness (Comparative Example 2) have low magnetic permeability and magnetic flux density due to low core density.
【００２９】また、アスペクト比が小さすぎるもの（比
較例４）は、粉末が球形に近いため密度が充分ではな
く、透磁率、磁束密度共に低く、逆にアスペクト比が大
きすぎるもの（比較例５）は粉末が長尺になりすぎるた
め、かえって密度を増大することができず、透磁率およ
び磁束密度が低くなってしまう。さらに、絶縁性バイン
ダとして、水ガラス、シリコーンおよびリン酸塩をそれ
ぞれ単独で使用したもの（比較例６〜８）は、磁心の密
度は高くなるものの、絶縁皮膜が加圧成形時もしくは焼
鈍時に剥離してしまうため、透磁率が低いことに加え
て、電気抵抗率が著しく低下してしまうことが確認され
た。On the other hand, those having an aspect ratio that is too small (Comparative Example 4) have insufficient density because the powder is close to spherical, and have low magnetic permeability and magnetic flux density, and conversely have an aspect ratio that is too large (Comparative Example 5). In (2), since the powder becomes too long, the density cannot be increased and the magnetic permeability and the magnetic flux density decrease. Furthermore, in the case of using water glass, silicone and phosphate alone as the insulating binder (Comparative Examples 6 to 8), the density of the magnetic core was increased, but the insulating film was peeled off during pressure molding or annealing. Therefore, it was confirmed that, in addition to the low magnetic permeability, the electrical resistivity was significantly reduced.
【００３０】[0030]
【発明の効果】以上の説明から明らかなように、本発明
の軟磁性粉末は、その表面の酸化皮膜の厚さと粉末自体
の厚さおよびアスペクト比を規制したことにより、磁心
製造時に金型への充填密度が向上し、しかも、絶縁性バ
インダとしてリン酸塩と水ガラスを同時に使用すること
により、加圧成形時に絶縁皮膜が剥離することなく、結
果として得られる圧粉磁心は、高透磁率、高磁束密度で
あると同時に高い電気抵抗率を有するものであり、その
工業的価値は極めて大である。As is apparent from the above description, the soft magnetic powder of the present invention is formed into a mold at the time of manufacturing a magnetic core by regulating the thickness of the oxide film on the surface thereof and the thickness and aspect ratio of the powder itself. By using phosphate and water glass at the same time as the insulating binder, the insulating film does not peel off during pressure molding, and the resulting dust core has high magnetic permeability. It has a high magnetic flux density and a high electrical resistivity, and its industrial value is extremely large.
───────────────────────────────────────────────────── フロントページの続き Ｆターム(参考） 4K018 AA26 AB01 AB06 AC01 BA15 BA16 BB01 CA02 CA11 FA08 KA44 5E041 AA04 CA02 HB17 NN01 NN14 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4K018 AA26 AB01 AB06 AC01 BA15 BA16 BB01 CA02 CA11 FA08 KA44 5E041 AA04 CA02 HB17 NN01 NN14
Claims (2)
0.5〜１０％、残部実質的にＦｅよりなるＦｅ−Ｓｉ−
Ａｌ系合金粉末であって、前記粉末表面に形成されてい
る酸化皮膜の厚さが0.05μｍ以下、前記粉末の厚さが１
０〜３０μｍ、かつ、前記粉末のアスペクト比が３〜２
０であることを特徴とする軟磁性粉末。1% by weight of Si: 0.5 to 15%, Al:
Fe—Si— consisting of 0.5 to 10%, with the balance being substantially Fe
An Al-based alloy powder, wherein the thickness of an oxide film formed on the surface of the powder is 0.05 μm or less, and the thickness of the powder is 1 μm or less.
0 to 30 μm, and the aspect ratio of the powder is 3 to 2
0. A soft magnetic powder characterized by being 0.
性のバインダ成分とを混練した後に圧縮成形して得られ
る成形体よりなる圧粉磁心であって、前記電気絶縁性の
バインダ成分がリン酸塩と水ガラスを主体とするもので
あり、周波数１００kHzにおける透磁率が１２５以上、
印加磁界10000Ａ／ｍにおける磁束密度が0.6Ｔ以上、か
つ、電気抵抗率が0.03Ω・ｍ以上であることを特徴とす
る圧粉磁心。2. A powder magnetic core comprising a compact obtained by kneading the soft magnetic powder according to claim 1 and an electrically insulating binder component and then compression molding, wherein the electrically insulating binder component is provided. Is mainly composed of phosphate and water glass, has a magnetic permeability of 125 or more at a frequency of 100 kHz,
A dust core having a magnetic flux density of 0.6 T or more at an applied magnetic field of 10,000 A / m and an electric resistivity of 0.03 Ω · m or more.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001105016A JP2002299113A (en) | 2001-04-03 | 2001-04-03 | Soft magnetic powder and dust core using the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001105016A JP2002299113A (en) | 2001-04-03 | 2001-04-03 | Soft magnetic powder and dust core using the same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JP2002299113A true JP2002299113A (en) | 2002-10-11 |
Family
ID=18957785
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2001105016A Pending JP2002299113A (en) | 2001-04-03 | 2001-04-03 | Soft magnetic powder and dust core using the same |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP2002299113A (en) |
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2008063650A (en) * | 2006-09-11 | 2008-03-21 | Kobe Steel Ltd | Dust core, and iron based powder for dust core |
| KR101187350B1 (en) | 2011-04-27 | 2012-10-02 | 다이요 유덴 가부시키가이샤 | Magnetic material and coil component using the same |
| CN103578680A (en) * | 2013-10-28 | 2014-02-12 | 任静儿 | Soft-magnetic inductive iron core material |
| CN103996479A (en) * | 2014-05-22 | 2014-08-20 | 吴娟 | Manufacturing method of sendust core with magnetic permeability mue 200 |
| CN104934180A (en) * | 2015-06-19 | 2015-09-23 | 浙江大学 | Preparation method of soft magnetic composite material with high saturation magnetic flux density and high magnetic conductivity |
| JP2020017690A (en) * | 2018-07-27 | 2020-01-30 | 日本特殊陶業株式会社 | Dust core |
| JP7337112B2 (en) | 2021-03-23 | 2023-09-01 | 株式会社タムラ製作所 | Soft magnetic powder and dust core |
-
2001
- 2001-04-03 JP JP2001105016A patent/JP2002299113A/en active Pending
Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2008063650A (en) * | 2006-09-11 | 2008-03-21 | Kobe Steel Ltd | Dust core, and iron based powder for dust core |
| JP4723442B2 (en) * | 2006-09-11 | 2011-07-13 | 株式会社神戸製鋼所 | Powder cores and iron-based powders for dust cores |
| KR101187350B1 (en) | 2011-04-27 | 2012-10-02 | 다이요 유덴 가부시키가이샤 | Magnetic material and coil component using the same |
| CN103578680A (en) * | 2013-10-28 | 2014-02-12 | 任静儿 | Soft-magnetic inductive iron core material |
| CN103996479A (en) * | 2014-05-22 | 2014-08-20 | 吴娟 | Manufacturing method of sendust core with magnetic permeability mue 200 |
| CN104934180A (en) * | 2015-06-19 | 2015-09-23 | 浙江大学 | Preparation method of soft magnetic composite material with high saturation magnetic flux density and high magnetic conductivity |
| JP2020017690A (en) * | 2018-07-27 | 2020-01-30 | 日本特殊陶業株式会社 | Dust core |
| JP7133381B2 (en) | 2018-07-27 | 2022-09-08 | 日本特殊陶業株式会社 | dust core |
| JP7337112B2 (en) | 2021-03-23 | 2023-09-01 | 株式会社タムラ製作所 | Soft magnetic powder and dust core |
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