JP2003197415A - Functional member and method of manufacturing functional member - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide functional member having magnetic insulative properties in one part and non-magnetic insulative properties in the other part without reducing the magnetic properties, and a method of manufacturing the member, and to manufacture the functional member at low cost. <P>SOLUTION: Core particles (S1) that consist of a ferromagnetic is magnetized (S3), ferromagnetic insulative granular material is attached to the surface of the core particles 2, and the magnetic insulative particles are manufactured (S5). The surface of the core particles (S6), that consist of non-magnetic substance, is oxidized to form an insulation oxide layer (S7), and non-magnetic insulation particles on which the oxide layer is formed are manufactured (S8). Then the magnetic insulative particles (S5) and the non-magnetic insulative particles (S5) are formed and unified by pressure forming (S10), and the functional member 10, having magnetic insulation property in one part and non- magnetic insulation property in the other part, is manufactured. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a functional member having both a portion that transmits magnetism but shuts off electricity and a portion that shuts off magnetism and electricity, and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, there is a yoke component used in a linear solenoid or the like which has both a portion that transmits magnetism but cuts off electricity and a portion that cuts off magnetism and electricity.

Therefore, taking a linear solenoid as an example,
This will be described below. Generally, in a linear solenoid, yokes (a front yoke and a rear yoke) are arranged from both axial sides of a coil wound around a bobbin. Then, a hole is formed in the front yoke or the rear yoke, a plunger is arranged in the inner diameter of the hole, and the plunger slides along the inner wall of the hole of the front yoke and the rear yoke. In the linear solenoid having such a configuration, the magnetic field generated by the coil is converted into magnetic flux by the front yoke, and the magnetic flux is transmitted from the front yoke to the plunger. The magnetic flux transmitted to the plunger is transmitted to the rear yoke via the air gap and forms a closed loop magnetic circuit returning from the rear yoke to the coil.

In order to efficiently transmit the magnetic flux generated by the magnetic field generated in the coil to the plunger via the front yoke and to efficiently transmit the magnetic flux from the plunger to the rear yoke, the magnetic flux generated in the coil is efficiently transferred in the magnetic circuit. , It is necessary to propagate effectively. For this reason, in order to efficiently propagate the magnetic field, it is necessary to provide a portion between the front yoke and the rear yoke that does not pass magnetism and does not easily pass electricity.

Therefore, conventionally, a structure has been adopted in which a gap (referred to as a collar) between two yokes arranged in the axial direction is filled with a synthetic resin, and the two yoke parts are connected by the filled synthetic resin. However, if the collars are integrated by filling the synthetic resin after making the two yokes separately, there is a problem that the manufacturing cost becomes high.

Therefore, in recent years, various proposals have been made to independently produce such insulating properties and magnetic properties using a composite material. For example, in Japanese Patent Laid-Open No. 64-13705, metal particles of Fe—Al—Si alloy (Sendust) and Fe—Ni alloy (Permalloy) having an average particle diameter of 1 to 5 μm, Mn—Zn ferrite, Ni— A method is disclosed in which insulating particles of Zn ferrite are mixed by stirring to form a composite material having increased electric resistance.

Further, in Japanese Patent Laid-Open No. 5-47541,
Particles having a particle diameter of 5 to 100 μm and made of a sendust alloy, a permalloy alloy, a Sofmax alloy, a permendur alloy, etc. containing a transition metal, and Mn which is a high resistance soft magnetic substance.
-Zn, Mn-Mg, Ni-Zn, Cu-Zn, Ni-
Particle size 0.02 to 10 made of Cu-Zn ferrite, etc.
A method of coating the particles of μm with mechano-fusion and then activating the plasma is adopted. Furthermore, JP-A-5-
According to Japanese Patent No. 326289, by oxidizing Fe-Al alloy powder in the atmosphere, oxides of iron and aluminum are formed on the surface, which are then densely packed under high temperature and high pressure to form various core shapes as blocks. The method of joining to is taken. Furthermore, in Japanese Unexamined Patent Publication (Kokai) No. 6-000101, an iron-based metal particle having a particle size of 70 to 100 μm and an iron-based alloy powder having a particle size of 15 μm or less are used as an organic binder made of polyalkylene oxide. The method of combining with is taken. In addition, in JP-A-8-167519, a soft magnetic metal powder containing iron as a main component is exposed to an air atmosphere at 300 to 800 ° C. to form an oxide film on the surface, and Cr is formed on the surface of the oxide film. Alternatively, it is covered with a glassy insulator containing P. In Japanese Patent Laid-Open No. 11-251131, a magnetic alloy containing iron as a main component is treated with a phosphate to form an insulating coating, a thermosetting resin is mixed with the insulating coating, and then compression molding is performed to form particles. A method is shown in which the phosphate film thickness is 30 to 60 nm, the thermosetting resin particle size is 100 μm or less, and the weight ratio is 1 to 3 wt% to obtain a volume resistivity of 2 Ωcm or more.

[0008]

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention
Japanese Patent No. 13705 discloses a composite of particles made of an alloy material having a high magnetic permeability and a powder of soft magnetic ferrite. However, since two kinds of unit particles constituting a component are simply mechanically mixed. The composite component has the effect of increasing the electrical resistance to some extent according to the mixing ratio of ferrite. However, in the composite part, the alloy materials are in contact with each other, and sufficient insulation cannot be obtained.

In Japanese Patent Laid-Open No. 5-47541,
A composite is disclosed in which a non-magnetic and electrically insulating film is formed on the surface of particles made of a high-permeability alloy, but in order to form a non-magnetic substance on the surface of magnetic particles,
The magnetic properties of parts made of composite particles are greatly reduced.

In Japanese Patent Laid-Open No. 5-326289, an iron-aluminum alloy is oxidized in the atmosphere to form an oxide of iron and aluminum on the surface of particles.
Although the electrical resistance of the unit particles is increased, in this case, hematite (αFe ₂ O ₃ ) and aluminum oxide (Al ₂ O ₃ ) are formed, and since both oxides are non-magnetic, Fe -The magnetic properties of the Al alloy are greatly deteriorated.

Further, as disclosed in Japanese Patent Application Laid-Open No. 6-10001, metal particles are bonded with a non-magnetic organic binder, and as disclosed in Japanese Patent Application Laid-Open No. 8-167519, magnetic metal particles are bonded with a non-magnetic glass insulator. Coating, JP-A-11-25
As disclosed in Japanese Patent No. 1131, it is used as an insulating coating layer of phosphate and as a binder. However, since all of the thermo-effective resins are non-magnetic substances, a non-magnetic binder or a non-magnetic coating agent is used. The magnetic properties of the magnetic particles are greatly reduced.

Therefore, the present invention has been made in view of the above-mentioned problems, and a portion partially provided with magnetic and insulating properties and a non-magnetic portion in the other portion without deteriorating the magnetic characteristics. It is a technical object to provide a functional member having a portion having an insulating property and a method thereof, and to make the functional member inexpensively.

[0013]

The first technical means taken to solve the above problems is a magnetic insulating property in which a ferromagnetic insulating powder is adhered to the surface of a core particle made of a ferromagnetic material. A magnetic insulating part formed of powder and a nonmagnetic insulating part formed of nonmagnetic insulating powder in which an insulating layer is formed on the surface of a core particle made of a nonmagnetic material are provided. That is what I did.

According to the above-mentioned means, the magnetic insulating powder having the ferromagnetic insulating powder adhered is formed on the surface of the core particle made of the ferromagnetic material, so that the core particle of the ferromagnetic material becomes ferromagnetic. Covering with the insulating powder ensures the insulating property in the magnetic insulating portion. Further, the non-magnetic insulating powder in which the insulating layer is formed on the surface of the non-magnetic core particle covers the non-magnetic core particle, and the insulating property of the non-magnetic insulating portion is secured. As a result, high insulation is obtained between the magnetic insulating portion and the non-magnetic insulating portion.

Further, in the magnetic insulating portion, the ferromagnetic insulating powder is attached to the surface of the core particle made of a ferromagnetic material, so that the core particle and the powder attached to the core particle do not impair the magnetic characteristics. , Can convey magnetism. On the other hand, in the non-magnetic insulating portion, magnetic transfer does not occur. As a result, by forming the magnetic insulating portion and the non-magnetic insulating portion by molding, it is possible to obtain a functional member having a part of the magnetic insulating property and another part of the non-magnetic insulating property.

A second technical means taken to solve the above problem is a step of obtaining magnetic insulating particles by attaching ferromagnetic insulating powder to the surface of core particles made of a ferromagnetic material. And a step of obtaining a non-magnetic insulating particle having an insulating layer formed on the surface of a magnetic insulating core particle made of a non-magnetic material,
And a step of integrating the magnetic insulating portion made of the magnetic insulating particles and the nonmagnetic insulating portion made of the nonmagnetic insulating particles by pressure molding.

According to the above-mentioned means, the surface of the core particle made of a ferromagnetic material is made strong by the step of adhering the ferromagnetic insulating powder to the surface of the core particle made of a ferromagnetic material to obtain the magnetic insulating particle. The magnetic insulating powder is adhered to the core particles made of a ferromagnetic material to ensure the insulating property. The insulating property of the core particles made of a non-magnetic material is ensured by the step of obtaining the non-magnetic insulating particles having an insulating layer formed on the surface of the core particles made of a non-magnetic material. A function having a magnetic insulating portion and a nonmagnetic insulating portion is obtained by a step of integrating the magnetic insulating portion made of the magnetic insulating particles and the nonmagnetic insulating portion made of the nonmagnetic insulating particles by pressure molding. A member is obtained, the functional member of which has a high insulating property.

Further, since the magnetic insulating particles have a step of attaching the ferromagnetic insulating powder to the surface of the core particles made of a ferromagnetic material, the core particles and the powder attached to the core particles have magnetic characteristics. It can transmit magnetism without damaging it. on the other hand,
No magnetism is transmitted to the non-magnetic insulating portion made of non-magnetic insulating particles. In this way, when the magnetic insulating particles and the nonmagnetic insulating particles are pressure-molded and integrated, a functional member having a magnetic insulating property in one part and a nonmagnetic insulating property in the other part is obtained. A method of manufacturing is provided.

In this case, the core particles made of a ferromagnetic material contain iron, and the powder deposited is made of soft magnetic ferrite,
If the method further comprises a step of magnetizing the core particles made of ferromagnetic material, and the particles are attached by the magnetic attractive force of the magnetized core particles to obtain magnetic insulating particles, by an easy and simple method, Insulation is ensured by attaching soft magnetic ferrite to the core particles by magnetization.

Further, by leaving the non-magnetic core particles in an oxidizing atmosphere and forming an oxide film on the surface to obtain non-magnetic insulating particles, the non-magnetic core particles are Insulation is secured by an inexpensive method.

Further, if the core particle made of a ferromagnetic material is iron, it has a high saturation magnetic flux density and is inexpensive.

If the core particles made of a non-magnetic material are made of aluminum, an oxide film can be easily formed and the core particles can be made stably even in the air atmosphere.

Furthermore, if the soft magnetic ferrite is made of a mixed crystal of a plurality of ferrites containing manganese, for example, a mixture of ferrites containing manganese represented by Mn-Zn ferrite and Mn-Mg ferrite. If soft crystals are used, the saturated magnetic characteristics (saturation magnetic flux density) are excellent, the magnetic permeability is high, and the electrical resistivity is high among the soft magnetic ferrite, so that the magnetic characteristics required as a functional member are secured.

[0024]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 is a process diagram showing a method for manufacturing the functional member 10, and FIG. 2 is a schematic diagram of a single particle of the magnetic insulating particles 5 and the non-magnetic insulating particles 9 used in the process of FIG. Here, the magnetic insulating particles 5 used have the properties of magnetism and insulation that propagates magnetism but blocks electricity, and as shown in FIG.
Iron is used as a ferromagnetic metal in the core particle 2, and the iron particle is magnetized, magnetized, and adhered by its attractive force, so that the ferrite 3 which is a ferromagnetic insulating powder is attached to the surface of the iron particle. Make it adhered.

On the other hand, the non-magnetic insulating particles 9 are magnetic and electric.
It also has non-magnetic and insulating properties that block even
As shown in (b) of FIG.
Aluminum (Al) is used. The surface of this Al particle
Is oxidized to form an oxide film (Al_TwoO _ThreeFilm) 7 on the surface of Al particles
The oxide film 7 is formed magnetically and electrically.
It is in a state where the edges are made.

In the present embodiment, two different characteristics are used.
4 particles (magnetic insulating particles 5 and non-magnetic insulating particles 9) are pressure-molded to form a magnetic insulating portion by primary molding as shown in FIG. As shown,
The non-magnetic insulating portion is integrated by secondary molding, and the functional member 10 having different characteristics depending on the site is produced by performing multi-step molding into a desired shape. For example, the functional member 10 thus manufactured is not limited to this, but for example, the linear solenoid 2 shown in FIG.
It can be applied to the yoke 0a of 0, etc.

The yoke 10a, which is the functional member 10, is arranged in a cylindrical case 11. The yoke 10a has circumferential flanges extending in the radial direction at both ends in the axial direction, and the bobbin 1 is provided in the central recess formed by the flanges.
A coil 13 wound around 2 is arranged. A through hole having a small diameter hole and a large diameter hole is formed in the center of the yoke 10a.
A bearing is arranged in the small diameter hole, and the plunger 14, one of which is rotatably supported by the bearing, is arranged in the large diameter hole. The plunger 14 can slide along the inner wall of the large diameter hole of the yoke 10a.

The yoke 10a has magnetic and insulating properties so that the magnetic flux passes through the inside thereof, and serves as a magnetic insulating portion. However, the yoke 10a has a magnetic and electrical cutoff at a substantially axial center thereof. The non-magnetic insulating portion (color) 9a is integrally provided. The yoke 10a is prevented from flowing in the axial direction by the collar 9a so that the magnetic flux at both ends of the collar does not flow.

Therefore, the operation of the linear solenoid 20 having the above structure will be briefly described. When the linear solenoid 20 supplies power to the coil 13, the magnetic flux generated by the supply of power to the coil 13 causes the magnetic flux generated from the yoke (for example, the left side in FIG. 5) 10 a through the air gap between the yoke 10 a and the plunger 14 to reach the plunger 14. Be transmitted to. Then, the magnetic flux generated in the coil passes from the plunger 14 through the yoke (for example, the right side shown in FIG. 5) 10a and returns to the coil again to form a closed loop magnetic circuit. In this case, a magnetic flux proportional to the voltage applied to the coil 13 is generated, and its electromagnetic force pulls the plunger 14 in the axial direction (rightward direction shown in FIG. 5) and moves along the inner wall of the large diameter hole of the yoke. .

Here, when the plunger 14 slides along the inner wall of the yoke 10a, the plunger 14 and the yoke 1
If the coaxiality with 0a is not secured, the plunger 14
It is necessary to secure the coaxiality because it will hinder the movement of the. Further, a method will be described below in which the magnetic function of the yoke 10a is sufficiently ensured, the insulation property at the portion of the collar 9a is sufficiently ensured, and the coaxiality can be ensured at low cost.

Therefore, a method of manufacturing a functional member represented by the yoke 10a will be described.

The method for producing the magnetic insulating particles will be described first. A metal or alloy ferromagnetic particle (for example, iron particle) 2 serving as a core material is prepared (S1). Generally, iron is known as an inexpensive magnetic material having excellent magnetic properties. In the present embodiment, iron will be described as an example of the ferromagnetic particles, but the present invention is not limited to this. It has ferromagnetic properties and exhibits ductility and malleability required at the time of pressure molding described later. Any metal material can be used. For example, Fe-Ni alloys, Fe-Si alloys, Fe-Al alloys, etc. containing iron as a main component, which is a low-cost material having a high saturation magnetic flux density, have a dense density due to appropriate elastic / plastic deformation after pressure molding. Is improved, which is desirable. However, from the magnetic characteristics of low coercive force and high saturation magnetic flux density,
Pure iron, which is very cheap and free of impurities, is most desirable. In this case, the iron particles 2 are those made from the waste material of the rolled steel plate,
It is also possible to use a washed and crushed product to remove impurities on the surface. The metal or alloy that is such a ferromagnetic particle has a particle size of 60 to 120 μm.
Should be

After that, the iron particles 2 are magnetized in order to attach the insulating particles to the surface of the iron particles 2 serving as the core particles by a magnetic attraction force. A magnetic attraction force is generated by magnetizing the iron particles 2, and a magnetic gap (magnetic gap) with the particles attached to the surface of the iron particles 2 is formed by attaching the iron particles 2 with the attraction force. Hard to do. In the magnetic gap, the attached insulating particles form a demagnetizing field. Due to the demagnetizing field formed by this magnetic gap, the saturation magnetic flux density of the iron particles is reduced, and for this reason, the magnetic attractive force is used.

The substance attached to the core particles is required to be a ferromagnetic substance because it is attached by magnetic attraction. In this case, as the substance adhered to the core particles, ferrite 3 which is a ferromagnetic substance and an electrical insulator is used, but in the ferrite, the magnetism is easily passed and the soft magnetic ferrite having a high magnetic permeability (soft It is desirable to prepare and use (ferrite) 3 (S3). Specifically, it is possible to use Mn—Zn based ferrite and Ni—Zn based ferrite for the soft ferrite 3,
Alternatively, these soft ferrites 3 may be mixed with Mg ferrite and mixed crystals may be used. The particle size is about 5 μm. The characteristics are shown below.

[0035]

[Table 1] Specifically, Mn-Zn ferrite is the most desirable,
The electrical resistivity becomes small. Therefore, in order to increase the electrical resistivity in order to obtain electrical insulation and to secure the necessary magnetic characteristics, Mn-Zn ferrite and Mn-Zn are used.
A mixed crystal of -Mg ferrite, a mixed crystal of Mn-Zn ferrite and Ni-Zn ferrite, or a mixed crystal of Mn-Zn ferrite and Mn-Mg ferrite or Ni-Zn ferrite is most preferable.

The iron particles 2 are plastically deformed at the time of pressure forming which is a post-process, and it is necessary to give an initial binding force of the pressure formed product by this plastic deformation. In this case, the iron particles 2 are plastically deformed at the time of plastic deformation. In order to prevent the particles of the ferrite 3 (ferrite particles) attached to the particles 2 from falling off, and the iron particles from which the ferrite particles have fallen off the surface contacting each other, the insulation between the iron particles is not impaired. The iron particles 2 are magnetized in advance with a magnetic field required to magnetically saturate the powder.

Magnetization of the iron particles 2 is applied according to the magnitude of the saturation magnetic field of the ferrite 3, but in the case of pure iron, it is 1
A weak magnetic field of about 5.9 to 39.9 A / m is applied. When using Mn-Zn-based or Ni-Zn-based ferrite, a weak magnetic field of about 238 to 399 A / m is externally applied to magnetically saturate the ferrite 3.

Next, in order to attach the ferrite particles of the soft ferrite 3 to the surface of the iron particles 2, the powders of the iron particles 2 and the ferrite 8 are put together in a stirrer until the two particles are sufficiently stirred. (Stir for about 1 to 3 hours), and while supplying a carrier gas such as nitrogen to the inside, the stirrer is rotated until the ferrite particles are uniformly attached to the iron particles. In this case, the rotating speed of the stirrer is such that the ferrite powder adheres to the surface of the iron particles in a single layer, and the second or more layers of ferrite powder lose the centrifugal force due to the rotation of the stirrer and fall off. Adjusted. For example, the weight of Mn—Zn ferrite having a grain size of 5 μm is 2.2 × 10 5.
^If the weight of pure iron having a size of ⁻¹⁶ g and a particle size of 100 μm is 4.1 × 10 ⁻¹² g, theoretically, 1600 Mn—Zn ferrite particles are pure iron particles. It is attached to the surface and coated around pure iron.

Therefore, through the above manufacturing steps, particles of magnetic insulating powder in which the ferrite powder of the soft ferrite 3 is attached in a single layer on the surface of the iron particle 2 can be produced (S5). The surface of this particle is an electrical insulator, and the particle as a whole exhibits a ferromagnetic material.

Next, a method of manufacturing the non-magnetic insulating particles 9 will be described. Aluminum, copper, zinc, and the like are relatively inexpensive materials that have nonmagnetic properties. Among these, an oxidation treatment is used as a method for forming an insulating layer on the entire surface of non-magnetic particles. By using this oxidation treatment method, it is relatively inexpensive and has a suitable ductility and malleability, and after performing pressure molding in a subsequent step, the elastic density and the plastic deformation improve the compactness of the particles, Aluminum is a non-magnetic material whose oxide film is relatively stable in the atmosphere, and aluminum particles 6 are used as the non-magnetic particles in this embodiment (S
6). The aluminum particles 6 used here may have an average particle size of, for example, about 80 to 100 μm, and are magnetically non-magnetic and electrically have a withstand voltage of 10 ⁶ to 10 ⁷ by a gas atomizing method or the like. It is possible to make particles having an insulating property as high as V / cm.

Then, by leaving the aluminum particles 6 in an oxidizing atmosphere, an oxide film 7 having a film thickness of about 10 μm is formed on the surface of the aluminum particles (S).
7). In this case, the rate of progress of the aluminum particles 6 when they are oxidized is determined by the atmospheric temperature and the oxygen partial pressure, and in order to accurately control the film thickness to a desired value, both the atmospheric temperature and the oxygen partial pressure are controlled. I take the. In this way, the oxide film 7 having a desired thickness is formed on the entire surface of the aluminum particles 6.
Is formed. The oxide film 7 formed on the surface of the aluminum particles 6 can be oxidized by known anodic oxidation. Through the steps described above, the non-magnetic insulating particles 9 that are the non-magnetic insulating powder in which the oxide film 7 is formed on the entire surface of the aluminum particles 6 are manufactured (S
8).

After that, two particles 5 and 9 having different characteristics are pressure-molded to be integrated (S9,
S10). When performing pressure molding, these two types of particles 5,
Comparing No. 9, the particles in which the iron particles 2 are the core particles are harder than the particles in which the aluminum particles 6 are the core particles. Therefore, when performing the secondary pressure molding, first the iron particles 2 are pressed by applying a necessary pressure (for example, a pressing force of about 5 ton / cm ² ) in a mold for forming a desired product shape. By molding, a component made of magnetic insulating particles 5 having iron as a core particle is manufactured. In this case, for example, when the yoke 10a is molded as the functional member 10 as shown in FIG. 4, the front yoke and the rear yoke are pressure-molded by primary molding from magnetic insulating powder made of magnetic insulating particles 5, respectively. . Next, the non-magnetic insulating powder composed of the non-magnetic insulating particles 9 is placed between the molded front and rear yokes and placed in a mold, and the required pressure is applied to obtain non-magnetic characteristics. A portion (collar 9a) between the front yoke and the rear yoke in the axial direction is molded by secondary molding. That is, it has magnetic properties and insulation properties
After the next molded product (magnetic insulating part) and the non-magnetic insulating powder are placed in the mold for molding the non-magnetic and insulating part (non-magnetic insulating part) of the secondary molding, the secondary molding is performed. A pressure required for pressure molding (for example, a pressure of about 1 ton / cm ² ton / cm ² ) is applied to the mold to produce a secondary molded product shown in FIG. 4 (b).

By the steps described above, for example, when the yoke 10a of the linear solenoid 20 as shown in FIG. 5 is manufactured, the front yoke, the rear yoke, and the collar are conventionally made of separate parts, but in the present embodiment, By the secondary molding by pressurization, the collar 9 is manufactured by an inexpensive method.
The yoke 10a including a can be integrally formed. In this case, since the aluminum particles 6 are used as the core particles in the portion corresponding to the collar, the pressure applied during the secondary molding may be smaller than that during the primary molding.

Next, in order to ensure the mechanical strength of the secondary molded product, the secondary molded product is
Glass is prepared as a binder (binder) (S12), and the binder is mixed and stirred (S13). In the present embodiment, a low melting point glass powder is used, and 10 to 20% by weight is used with respect to the core particles, and the glass powder is used as an organic solvent (for example, a vinyl-based synthetic resin is an alcohol-based powder). The secondary molded article is dipped in a solution (for example, a solution viscosity of 50 to 100 cp) dispersed with a solvent dissolved in a medium (S11), and the glass 8 is dispersed in the molded article. The method is such that it penetrates into the gaps (shown in (a) the gaps of the magnetic insulating particles 5 and (b) into the gaps of the non-magnetic insulating particles 9). Then, the molded product is taken out of the solution, and the molded product in which the glass 8 is impregnated has a temperature higher than the melting point of the low melting point glass (for example, 20
By heat treatment (0 to 300 ° C.) (S14), the excess solvent is vaporized, the glass 8 is melted, and then the glass 8 is cooled and solidified. As a result, the bonding force of the molded product, that is, the mechanical strength can be secured by the glass 8 that has penetrated into the voids of the molded product.

In this case, in order to facilitate the permeation of the liquid in which the glass powder is dispersed in the pressure-molded product with the organic solvent, the viscosity of the solution may be adjusted in advance or the sizing may be performed to the required accuracy. In this way, the functional member shown in FIGS. 4 and 5 can be manufactured at low cost without performing complicated steps. Therefore, like the yoke 10a of the linear solenoid 20, in one member, a magnetic insulating portion can be formed by the magnetic insulating particles 5 in a portion where magnetism and insulation are required. Further, a non-magnetic insulating portion can be formed by the non-magnetic insulating particles 9 in other portions where non-magnetic and insulating properties are required.

The yoke 10a manufactured by such a process
The part corresponding to the front yoke and the part corresponding to the rear yoke are made of material characteristics that positively pass magnetism but not electricity. Further, the portion called the collar 9a sandwiched between the two portions has a characteristic that neither magnetic nor electricity is conducted. The front yoke and the rear yoke (magnetic insulating portion) have their insulating properties determined by ferrite.
When Mn-Zn ferrite is used by applying a voltage of 1000 V, the insulation resistance is 10 ³ Ω, Mn-Mg-Zn.
When ferrite is used, it becomes 10 ⁸ Ω.

On the other hand, the collar (nonmagnetic insulating portion) 9a is
The insulating property is determined by aluminum oxide, and the insulation resistance in this case is 10 ¹² Ω to 10 ¹³ Ω, and the magnetic characteristics of the magnetic particles are not reduced even at the component level.

The functional member 10 manufactured by such a process
Is typified by the above-described production of the core by using, as core particles, pressure-molding particles having high rolling and malleability capable of producing the functional member 10 by multi-stage continuous pressure molding. As described above, as compared with the conventional manufacturing method using a plurality of members, high dimensional accuracy (coaxiality) can be easily obtained at the component level.

In the above-mentioned manufacturing method, since inexpensive particles such as iron and aluminum are used as the particles for pressure molding, the method of preparing two kinds of particles is an easy method. In comparison, the manufacturing cost of the functional member becomes low.

Further, in the above-mentioned manufacturing method, when iron is 100 μm and Mn—Zn ferrite is 5 μm in particle diameter, the saturation magnetic flux density at the component level is 1.5.
It becomes Tesla and is a known alloy (for example, JP-A-6-100).
The saturation magnetic flux density of the alloy of No. 01) is higher than 1.1 Tesla, and a saturation magnetic flux density equivalent to the level of stacking iron plates is obtained. Naturally, the function produced by this manufacturing method is higher than that of stacked iron plates. The member will have a high value of insulation resistance.

[0051]

According to the present invention, since the surface of the core particle made of a ferromagnetic material is covered with the magnetic insulating powder, the magnetic insulating portion can ensure the insulating property. In addition, the non-magnetic insulating powder with the insulating layer formed on the surface of the core particles made of non-magnetic material can ensure the insulating property of the non-magnetic insulating portion. You can get sex. In addition, since the magnetic insulating particles adhere to the surface of the core particles made of a ferromagnetic material, the ferromagnetic insulating powder adheres to the core particles and the powder adhered to the core particles can transmit magnetism without impairing the magnetic characteristics. You can On the other hand, since magnetic transfer does not occur in the non-magnetic insulating part, when the magnetic insulating particles and the non-magnetic insulating particles are integrated by pressure molding, they partially have magnetic and insulating properties and other parts Thus, a functional member having non-magnetic and insulating properties can be obtained.

The surface of the core particles made of a ferromagnetic material is made into a ferromagnetic insulating powder by the step of adhering a ferromagnetic insulating powder to the surface of the core particles made of a ferromagnetic material. The core particles made of a ferromagnetic material can be ensured to have an insulating property. Further, the insulating property of the core particles made of a non-magnetic material can be secured by the step of obtaining the non-magnetic insulating particles having an insulating layer formed on the surface of the core particles made of a non-magnetic material. When the magnetic insulating portion made of magnetic insulating particles and the nonmagnetic insulating portion made of nonmagnetic insulating particles are integrated by pressure molding, high insulating properties can be obtained.

In this case, the ferromagnetic core particles contain iron, and the powder to be adhered is made of soft magnetic ferrite, further comprising a step of magnetizing the ferromagnetic core particles. If the magnetic insulating particles are obtained by a magnetic attractive force, the soft magnetic ferrite can be attached to the core particles by magnetizing for insulation by an easy and simple method.

If the non-magnetic insulating particles are obtained by leaving the non-magnetic core particles in an oxidizing atmosphere and forming an oxide film on the surface, the non-magnetic core particles can be compared with the non-magnetic core particles. Insulation can be secured by an inexpensive method.

Further, if the core particle made of a ferromagnetic material is iron, it has a high saturation magnetic flux density and can be made inexpensive.

If the core particles made of a non-magnetic material are made of aluminum, an oxide film can be easily formed, and the core particles can be produced in a stable state even in the atmosphere.

Furthermore, if the soft magnetic ferrite is composed of a mixed crystal of a plurality of ferrites containing manganese, the saturated magnetic characteristics are excellent among the soft magnetic ferrites, the magnetic permeability is high, and the electric resistance is high. The rate is increased, and the required magnetic characteristics can be secured.

[Brief description of drawings]

FIG. 1 is a process drawing showing a method for manufacturing a functional member according to an embodiment of the present invention.

FIG. 2 is a schematic diagram showing a configuration of a single core particle of the magnetic insulating particles and the non-magnetic insulating particles shown in FIG.

FIG. 3 is a schematic diagram showing that when glass as a binder is impregnated in the aggregate of particles shown in FIG. 2, the glass enters the gap between the particles.

FIG. 4 is a schematic view (half-sectional view) showing a functional member manufactured by the manufacturing method of FIG.

5 is a cross-sectional view of a linear solenoid when the functional member produced by the manufacturing method of FIG. 1 is applied to a yoke of a linear solenoid.

[Explanation of symbols]

1 Functional Member 2 Core Particle (Fe Particle) 3 Ferrite 5 Magnetic Insulating Particle 6 Core Particle (Al Particle) 7 Oxide Film (Al ₂ O ₃ Film) 9 Nonmagnetic Insulating Particle 9a Color (Nonmagnetic Insulating Part) 10 Functional member 10a Core (magnetic insulating part)

Claims (7)

[Claims] 1. A magnetic insulating part, in which a magnetic insulating powder having a ferromagnetic insulating powder adhered to the surface of a core particle made of a ferromagnetic material is formed, and a surface of the core particle made of a non-magnetic material. A functional member comprising a non-magnetic insulating portion formed by molding a non-magnetic insulating powder having an insulating layer formed thereon. 2. A step of adhering a ferromagnetic insulating powder to the surface of a core particle made of a ferromagnetic material to obtain magnetic insulating particles, and an insulating layer on the surface of a magnetic insulating core particle made of a non-magnetic material. And a step of obtaining a non-magnetic insulating particles formed, a step of integrating a magnetic insulating portion made of the magnetic insulating particles and a non-magnetic insulating portion made of the non-magnetic insulating particles by pressure molding, A method of manufacturing a functional member, comprising: 3. The magnetized core, wherein the ferromagnetic core particle contains iron, and the powder to be adhered is made of soft magnetic ferrite, further comprising a step of magnetizing the ferromagnetic core particle. The method of manufacturing a functional member according to claim 2, wherein the magnetic insulating particles are attached by magnetic attraction of the particles. 4. The non-magnetic core particles are left in an oxidizing atmosphere to form an oxide film on the surface,
The method for producing a functional member according to claim 2, wherein nonmagnetic insulating particles are obtained. 5. The method for manufacturing a functional member according to claim 2, wherein the core particle made of ferromagnetic material is iron. 6. The method for producing a functional member according to claim 2, wherein the non-magnetic core particle is aluminum. 7. The method for manufacturing a functional member according to claim 2, wherein the soft magnetic ferrite is composed of a mixed crystal of a plurality of ferrites containing manganese.