JP2005116820A - Dust core - Google Patents
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- JP2005116820A JP2005116820A JP2003349760A JP2003349760A JP2005116820A JP 2005116820 A JP2005116820 A JP 2005116820A JP 2003349760 A JP2003349760 A JP 2003349760A JP 2003349760 A JP2003349760 A JP 2003349760A JP 2005116820 A JP2005116820 A JP 2005116820A
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本発明は圧粉磁心に関し、更に詳しくは、プレス成形後におけるグリーン成形体が高強度であり、成形後のハンドリング時に割れ、欠けなどが発生しにくい圧粉磁心に関する。 The present invention relates to a powder magnetic core, and more particularly to a powder magnetic core in which a green molded body after press molding has high strength and is less likely to be cracked or chipped during handling after molding.
圧粉磁心は、対象製品が小型で複雑な形状であっても高い歩留まりで製造することができ、現在、ＯＡ機器や自動車用部品などの制御用スイッチング電源やＤＣ−ＤＣコンバータのチョークコイルとして多用されている。
この圧粉磁心は、概ね、次のような工程を経て製造されている（特許文献１を参照）。
まず、所定組成の軟磁性合金に対して機械粉砕法やアトマイズ法などを適用して、所望する形状と粒度の軟磁性粉末を製造する。
Dust cores can be manufactured with a high yield even if the target product is small and has a complicated shape, and is currently widely used as a switching power supply for control of OA equipment and automotive parts, and as a choke coil for DC-DC converters. Has been.
The dust core is generally manufactured through the following steps (see Patent Document 1).
First, a mechanical pulverization method, an atomization method, or the like is applied to a soft magnetic alloy having a predetermined composition to produce a soft magnetic powder having a desired shape and particle size.
ついで、この軟磁性粉末と所定量の例えば水ガラスやシリコーン樹脂のような絶縁バインダを混合して、軟磁性粉末の表面を絶縁バインダの皮膜で被覆する。この絶縁皮膜の形成により、製造目的の圧粉磁心は、その電気抵抗率が高くなる。
ついで、この混合物を所定型面の金型に充填し、通常は室温下において所定の圧力でプレス成形する。この過程で、絶縁バインダの結着能により、軟磁性粉末が絶縁皮膜を介して互いに結着して成る目的形状のグリーン成形体が製造される。
Next, this soft magnetic powder is mixed with a predetermined amount of an insulating binder such as water glass or silicone resin, and the surface of the soft magnetic powder is covered with a film of the insulating binder. Due to the formation of the insulating film, the electrical resistivity of the dust core for manufacturing purposes is increased.
Next, this mixture is filled into a mold having a predetermined mold surface, and is usually press-molded at a predetermined pressure at room temperature. In this process, a green molded body having a desired shape is produced, in which soft magnetic powders are bonded to each other through an insulating film due to the binding ability of the insulating binder.
そして最後に、このグリーン成形体に所定温度の熱処理（磁気焼鈍）を行い、プレス成形時に蓄積された成形歪みを解放する。
この一連の製造工程において、工業的な観点で留意すべき問題は、要求特性を満たす圧粉磁心を、高い歩留まりで製造することである。
In this series of manufacturing processes, a problem to be noted from an industrial point of view is to manufacture a dust core satisfying the required characteristics with a high yield.
ところで、アトマイズ法で製造した軟磁性粉末は、当該アトマイズ法の運転条件にもよるが、概して、粉末の形状は球形に近似している。このような粉末を使用すると、前記したプレス成形によって製造されたプレス成形体における充填密度が高くなるものの、他方では各粉末間の結着力は大きくないので、例えば、成形体に割れや欠けなどの発生する機会が多くなる。そして、そのような成形体は欠陥品として工程から排除される。 By the way, although the soft magnetic powder manufactured by the atomizing method depends on the operating conditions of the atomizing method, the shape of the powder generally approximates a spherical shape. When such a powder is used, although the packing density in the press-molded body produced by the above-described press molding is increased, on the other hand, the binding force between the powders is not large. More opportunities to occur. And such a molded object is excluded from a process as a defective article.
また、このような粉末間の結着力が弱い圧粉磁心の場合、それを、例えば激しく振動する部品用の回路基板などに組み込むと、その振動によって欠けや割れなどが発生して回路基板の機能が消失することもある。
一方、機械粉砕法で製造した軟磁性粉末の場合は、その形状の多くは異形であるため、プレス成形後のプレス成形体における各粉末は互いに絡み合い、相互の結着力は比較的大きくなる。そのため、球状粉末を用いた場合の上記した問題は起こりづらい。
In addition, in the case of a powder magnetic core with a weak binding force between such powders, if it is incorporated into a circuit board for a component that vibrates vigorously, for example, chipping or cracking occurs due to the vibration, and the function of the circuit board May disappear.
On the other hand, in the case of the soft magnetic powder produced by the mechanical pulverization method, since many of the shapes are irregular, the powders in the press-molded body after press molding are entangled with each other, and the mutual binding force becomes relatively large. For this reason, the above-described problem in the case of using a spherical powder is difficult to occur.
しかしながら、このような異形粉末の場合、プレス成形体における充填密度は低くなり、その結果、得られた圧粉磁心は低透磁率となり、特性面で難点が生ずる。
本発明は、後述する軟磁性粉末を使用することにより、磁気特性を低下させることなく、プレス成形後のプレス成形体の強度が大きくなり、上記した問題が発生しにくい圧粉磁心の提供を目的とする。
However, in the case of such irregularly shaped powder, the filling density in the press-molded product is low, and as a result, the obtained dust core has a low magnetic permeability, which causes problems in terms of characteristics.
The purpose of the present invention is to provide a powder magnetic core in which the strength of a press-molded body after press molding is increased and the above-described problems are hardly caused by using a soft magnetic powder described later without deteriorating magnetic properties. And
上記した目的を達成するために、本発明においては、見掛密度／真密度の値が０.５９以下である軟磁性粉末を用いた圧粉磁心であって、プレス成形後における圧環強度をＪＩＳ Ｚ２５０７で規定する方法で測定したときの値が、
前記軟磁性粉末がＦｅ−Ｓｉ系粉末である場合は、５MPa以上、
前記軟磁性粉末がＦｅ−Ｓｉ−Ａｌ系粉末である場合は、２MPa以上、
前記軟磁性粉末がＦｅ−Ｃｒ系粉末である場合は、１０MPa以上、
前記軟磁性粉末がＦｅ−Ｎｉ系粉末である場合は、１０MPa以上、
前記軟磁性粉末がＦｅ−Ｃｏ系粉末である場合は、７MPa以上
であることを特徴とする圧粉磁心が提供される。
In order to achieve the above object, in the present invention, a powder magnetic core using a soft magnetic powder having an apparent density / true density value of 0.59 or less, and the crushing strength after press molding is determined according to JIS. The value when measured by the method specified in Z2507 is
When the soft magnetic powder is Fe-Si based powder, 5 MPa or more,
When the soft magnetic powder is Fe-Si-Al-based powder, 2 MPa or more,
When the soft magnetic powder is Fe-Cr powder, 10 MPa or more,
When the soft magnetic powder is Fe-Ni-based powder, 10 MPa or more,
When the soft magnetic powder is an Fe—Co based powder, a dust core having a pressure of 7 MPa or more is provided.
その場合、前記軟磁性粉末は、Ｓ，Ｔｅ，Ｓｅの群から選ばれる少なくとも１種が、総量で０.０１〜０.５質量％含有されていることを好適とする。 In that case, it is preferable that the soft magnetic powder contains at least one selected from the group of S, Te and Se in a total amount of 0.01 to 0.5% by mass.
この圧粉磁心は、見掛密度／真密度の値が０.５９以下の軟磁性粉末を用いて製造されるので、プレス成形後におけるプレス成形体の圧環強度が高くなる。したがって、プレス成形後におけるハンドリング時にあっても、割れや欠けなどは発生しにくくなっており、全体としての製造歩留まりは高くなる。なお、上記した圧環強度は、ＪＩＳ Ｚ２５０７で規定する方法で測定した値のことである。 Since this powder magnetic core is manufactured using a soft magnetic powder having an apparent density / true density value of 0.59 or less, the crushing strength of the press-molded body after press molding is increased. Therefore, even during handling after press molding, cracks and chips are less likely to occur, and the overall manufacturing yield is increased. The crushing strength described above is a value measured by a method defined in JIS Z2507.
また、プレス成形体を磁気焼鈍して得られた圧粉磁心の強度も高くなるので、この圧粉磁心を例えば振動の激しい箇所で使用しても、割れや欠けなどが発生することもなく、安心して使用することができる。 In addition, since the strength of the powder magnetic core obtained by magnetically annealing the press-molded body is increased, even if this powder magnetic core is used in a place where vibration is intense, for example, cracks and chips do not occur, Can be used with confidence.
本発明の圧粉磁心は、用いる軟磁性粉末が、Ｆｅ−６.５％Ｓｉ，Ｆｅ−３％Ｓｉ，Ｆｅ−１％ＳｉのようなＦｅ−Ｓｉ系粉末；Ｆｅ−９.５％Ｓｉ−５.５％Ａｌ，Ｆｅ−３％Ｓｉ−２％ＡｌのようなＦｅ−Ｓｉ−Ａｌ系粉末；Ｆｅ−９％Ｃｒ，Ｆｅ−９％Ｃｒ−２％Ｓｉ，Ｆｅ−１３％Ｃｒ，Ｆｅ−１７％ＣｒのようなＦｅ−Ｃｒ系粉末；Ｆｅ−４５％Ｎｉ，Ｆｅ−５０％Ｎｉ，Ｆｅ−８０％ＮｉのようなＦｅ−Ｎｉ系粉末；Ｆｅ−５０％Ｃｏ，Ｆｅ−３５％Ｃｏ，Ｆｅ−５０％Ｃｏ−２％ＶのようなＦｅ−Ｃｏ系粉末のいずれかである。 In the dust core of the present invention, the soft magnetic powder used is Fe-Si based powder such as Fe-6.5% Si, Fe-3% Si, Fe-1% Si; Fe-9.5% Si- Fe-Si-Al-based powders such as 5.5% Al, Fe-3% Si-2% Al; Fe-9% Cr, Fe-9% Cr-2% Si, Fe-13% Cr, Fe- Fe-Cr powder such as 17% Cr; Fe-Ni powder such as Fe-45% Ni, Fe-50% Ni, Fe-80% Ni; Fe-50% Co, Fe-35% Co, Any of Fe-Co based powders such as Fe-50% Co-2% V.
そして、これら組成の異同に関係なく、粉末の見掛密度をＡＤとし、真密度をＤとしたとき、ＡＤ／Ｄ値が０.５９以下の粉末が用いられる。
ここで、ＡＤ値は、軟磁性粉末の粉末形状を示す指標であって、これは、ＪＩＳ Ｚ２５０４で規定する見掛密度試験法で測定した値とする（ただし、漏斗のオリフィスの口径は２.５mmとする）。
Regardless of the difference in composition, when the apparent density of the powder is AD and the true density is D, a powder having an AD / D value of 0.59 or less is used.
Here, the AD value is an index indicating the powder shape of the soft magnetic powder, and this is a value measured by an apparent density test method defined in JIS Z2504 (however, the orifice diameter of the funnel is 2. 5mm).
このＡＤ値が大きい場合は、その粉末形状が球形状に近く、逆にＡＤ値が小さい粉末は、その形状が異形であることを示している。
なお、このＡＤ値は、例えばアトマイズ法で製造する粉末の場合は、その運転条件を、また機械粉砕法で製造する粉末の場合はその粉砕条件を適宜に選定することによって調整することができる。
When the AD value is large, the powder shape is close to a spherical shape, and conversely, the powder with a small AD value indicates that the shape is irregular.
The AD value can be adjusted, for example, by appropriately selecting the operating conditions in the case of powder produced by the atomizing method and the pulverizing conditions in the case of powder produced by the mechanical pulverization method.
一方、Ｄ値は粉末材料の真密度であって、粉末と同一の成分組成から成る溶製材の密度とする。
したがって、ＡＤ／Ｄ値は、用いる軟磁性粉末における材質の見掛密度に対する影響を消去した因子であって、成分組成が異なっていても各軟磁性粉末の見掛密度の大小を比較できるように規格化した値である。
On the other hand, the D value is the true density of the powder material and is the density of the melted material having the same component composition as the powder.
Therefore, the AD / D value is a factor that eliminates the influence on the apparent density of the material in the soft magnetic powder to be used, so that the magnitude of the apparent density of each soft magnetic powder can be compared even if the component composition is different. This is a standardized value.
このＡＤ／Ｄ値が０.５９より大きい粉末を用いると、その粉末の形状は球形に近くなっているため、プレス成形後のプレス成形体における粉末間の結着力は弱くなり、その後のハンドリングに難点が生ずる。
また、ＡＤ／Ｄ値が小さくなればなるほど、プレス成形体の強度は高くなってハンドリング時の割れ、欠けなどの発生頻度は減少するが、他方では空隙が多くなり、粉末の充填密度が低下して透磁率の低下が引き起こされる。このようなことから、ＡＤ／Ｄ値の下限は０.４程度に設定することが好ましい。
When a powder having an AD / D value greater than 0.59 is used, the shape of the powder is close to a sphere, so that the binding force between the powders in the press-molded body after press molding becomes weak, and subsequent handling is difficult. Difficulties arise.
In addition, the smaller the AD / D value, the higher the strength of the press-molded body and the less frequent the occurrence of cracks and chips during handling, but on the other hand, the voids increase and the powder packing density decreases. This causes a decrease in permeability. For this reason, the lower limit of the AD / D value is preferably set to about 0.4.
本発明の圧粉磁心は、そのプレス成形体の圧環強度をＪＩＳ Ｚ２５０７で規定する方法で測定したときに、次のような値になっている。
すなわち、用いた軟磁性粉末がＦｅ−Ｓｉ系粉末の場合には、５MPa以上、Ｆｅ−Ｓｉ−Ａｌ系粉末の場合には、２MPa以上、Ｆｅ−Ｃｒ系粉末の場合には、１０MPa以上、Ｆｅ−Ｎｉ系粉末の場合には、１０MPa以上、Ｆｅ−Ｃｏ系粉末の場合には、７MPa以上の値である。
The dust core of the present invention has the following values when the crushing strength of the press-molded product is measured by a method defined in JIS Z2507.
That is, when the soft magnetic powder used is Fe-Si powder, it is 5 MPa or more, when it is Fe-Si-Al powder, it is 2 MPa or more, and when it is Fe-Cr powder, it is 10 MPa or more. In the case of -Ni-based powder, the value is 10 MPa or more, and in the case of Fe-Co-based powder, the value is 7 MPa or more.
それぞれの軟磁性粉末を用いて成形したプレス成形体の圧環強度が上記した値より小さい場合には、その後のハンドリング時に割れや欠けの発生頻度が多くなり、また磁気焼鈍後の圧粉磁心の強度も低くなる。
本発明の圧粉磁心は次のようにして製造される。
まず、ＡＤ／Ｄ≦０.５９の関係を満たす軟磁性粉末を用意する。その時、粉末を例えば水素中で熱処理することにより、粉末の製造時に蓄積される歪みを取り除き、粒子内の結晶粒径を粗大化させて軟磁性特性を向上させておくことが好ましい。
If the crushing strength of the press-molded body formed using each soft magnetic powder is smaller than the above value, the frequency of occurrence of cracks and chips increases during the subsequent handling, and the strength of the dust core after magnetic annealing Also lower.
The dust core of the present invention is manufactured as follows.
First, a soft magnetic powder satisfying the relationship of AD / D ≦ 0.59 is prepared. At that time, it is preferable to improve the soft magnetic characteristics by heat treating the powder in hydrogen, for example, to remove distortion accumulated during the production of the powder and to increase the crystal grain size in the particles.
ついで、粉末と絶縁バインダを混合して当該粉末の表面を絶縁皮膜で被覆する。このとき、絶縁バインダの混合量が少なすぎると、後段のプレス成形時に型崩れなどが起こりやすく、また混合量が多すぎると、プレス成形体の成形密度が低下して、圧粉磁心は低透磁率になるので、通常、粉末１００質量部に対し、０.１〜１０質量部にすることが好ましい。 Next, the powder and the insulating binder are mixed and the surface of the powder is covered with an insulating film. At this time, if the mixing amount of the insulating binder is too small, mold collapse or the like is likely to occur during the subsequent press forming, and if the mixing amount is too large, the molding density of the press-molded body is lowered and the dust core has a low permeability. Since it becomes a magnetic susceptibility, it is usually preferable to set it as 0.1-10 mass parts with respect to 100 mass parts of powder.
ついで、上記混合物を金型に充填したのち定温下でプレス成形する。
このとき、プレス成形や金型からの離型を円滑に進めるために、例えばステアリン酸亜鉛のような潤滑剤を粉末１００質量部に対し０.１〜１０質量部程度添加することが好ましい。プレス成形圧が低すぎると、得られたプレス成形体は低密度化するとともに、前記した圧環強度を実現することができず、また圧が高すぎると、金型の破損などを招くので、通常、２００〜２０００MPa程度でプレス成形を行えばよい。
Next, the mixture is filled in a mold and press-molded at a constant temperature.
At this time, it is preferable to add about 0.1 to 10 parts by mass of a lubricant such as zinc stearate with respect to 100 parts by mass of the powder in order to facilitate press molding and mold release from the mold. If the press molding pressure is too low, the resulting press-molded body will have a lower density and the above-mentioned crushing strength cannot be realized. If the pressure is too high, the mold will be damaged. The press molding may be performed at about 200 to 2000 MPa.
このようにして得られたプレス成形体を、次に、磁気焼鈍することにより本発明の圧粉磁心が得られる。
なお、本発明で用いる軟磁性粉末は、上記した成分組成のものであるが、更に、Ｓ，Ｓｅ，Ｔｅの１種または２種以上を含有しているものであることが好ましい。
これらの成分が含有されている組成の軟磁性合金は、例えばその溶湯をアトマイズして粉末を製造する場合、当該溶湯の表面張力が低下するので得られる粉末は球形になりづらい、すなわち異形になりやすい。そのため、この粉末のＡＤ／Ｄ値は小さくなり、それを用いたプレス成形体の強度が高くなる。
The pressed core thus obtained is then magnetically annealed to obtain the dust core of the present invention.
The soft magnetic powder used in the present invention has the above-described component composition, but preferably further contains one or more of S, Se, and Te.
For example, when a soft magnetic alloy having a composition containing these components is manufactured by atomizing the molten metal, the surface tension of the molten metal decreases, so that the obtained powder is difficult to be spherical, that is, deformed. Cheap. Therefore, the AD / D value of this powder becomes small, and the strength of a press-molded body using the powder becomes high.
また、これら成分を含有させると、アトマイズ後の粉末における結晶粒は大きくなるので、製造された圧粉磁心の保持力が低減し、低コアロスになるという効果も得られる。
その場合、これら成分の含有量が多すぎると、これらの成分が粉末内部に固溶したり、介在物として存在するようになり、圧粉磁心のヒステリシス損を増大させるので、これら成分の含有量は、総量で、０.０１〜０.５質量％に設定することが好ましい。
Further, when these components are contained, the crystal grains in the powder after atomization become large, so that the holding power of the produced powder magnetic core is reduced and the effect of low core loss is also obtained.
In that case, if the content of these components is too large, these components will be dissolved in the powder or will be present as inclusions, increasing the hysteresis loss of the dust core. Is preferably set to 0.01 to 0.5 mass% in total.
実施例１〜１２、比較例１〜４
表１で示した組成の各種溶湯を溶製し、それらにつき、水−ガスアトマイズ法で、見掛密度が異なり、粒度が１００メッシュ下の各種の軟磁性粉末を製造した。これらの粉末につき、その見掛密度を測定した。真密度はそれぞれの溶製材から測定した。ついで、これらの粉末を、水素雰囲気下において温度９５０℃で３時間の熱処理を行ったのち、各粉末１００質量部に対しシリコーン樹脂１質量部を均一に混合し、更にステアリン酸亜鉛０.５質量部を添加した。
Examples 1-12, Comparative Examples 1-4
Various melts having the compositions shown in Table 1 were melted, and various soft magnetic powders having different apparent densities and particle sizes of 100 mesh or less were produced by the water-gas atomization method. The apparent density of these powders was measured. The true density was measured from each melted material. Next, after heat-treating these powders at a temperature of 950 ° C. for 3 hours in a hydrogen atmosphere, 1 part by mass of a silicone resin is uniformly mixed with 100 parts by mass of each powder, and further 0.5 parts by mass of zinc stearate. Parts were added.
ついで、各混合物を金型に充填し、室温下において、１９６０MPaの圧力でプレス成形して、外径２８mm、内径２０mm、厚み５mmのリングコアを成形した。比較のために、ガスアトマイズ法で製造した粉末についても、同様にしてリングコアを成形してこれらを比較例とした。
得られたリングコアにつき、圧環強度を測定した。以上の結果を一括して表１に示した。
Next, each mixture was filled in a mold and press molded at a pressure of 1960 MPa at room temperature to form a ring core having an outer diameter of 28 mm, an inner diameter of 20 mm, and a thickness of 5 mm. For comparison, a ring core was molded in the same manner for the powder produced by the gas atomization method, and these were used as comparative examples.
The crushing strength of the obtained ring core was measured. The above results are collectively shown in Table 1.
表１から明らかなように、粉末のＡＤ／Ｄ値が０.５９以下であると、圧環強度は、Ｆｅ−Ｓｉ系粉末の場合には、５MPa以上、Ｆｅ−Ｓｉ−Ａｌ系粉末の場合には、２MPa以上、Ｆｅ−Ｃｒ系粉末の場合には、１０MPa以上、Ｆｅ−Ｎｉ系粉末の場合には、１０MPa以上、Ｆｅ−Ｃｏ系粉末の場合には７MPa以上になっている。
そして、各系統の粉末において、Ｓ，Ｔｅ，Ｓｅを含有する組成の粉末を用いると、そのプレス成形体の圧環強度は、これら成分を含有しない組成の粉末を用いたプレス成形体の圧環強度よりも大きな値になっていて、強度的には優れたものになっている。
As is clear from Table 1, when the AD / D value of the powder is 0.59 or less, the crushing strength is 5 MPa or more in the case of Fe-Si powder, and in the case of Fe-Si-Al powder. Is 2 MPa or more, 10 MPa or more in the case of Fe—Cr powder, 10 MPa or more in the case of Fe—Ni powder, and 7 MPa or more in the case of Fe—Co powder.
And in the powder of each system, when the powder having the composition containing S, Te, Se is used, the crushing strength of the press-molded body is more than the crushing strength of the press-molded body using the powder having the composition not containing these components. Is also a large value and is excellent in strength.
以上の説明で明らかなように、本発明の圧粉磁心は、その製造工程におけるプレス成形体の強度が高いので、後工程でのハンドリング時にあっても割れや欠けが発生しにくく、高い歩留まりで製造することができる。 As is clear from the above description, the powder magnetic core of the present invention has high strength of the press-molded body in the production process, so that cracking and chipping are not likely to occur even during handling in the subsequent process, and the yield is high. Can be manufactured.
Claims (2)
前記軟磁性粉末がＦｅ−Ｓｉ系粉末である場合は、５MPa以上、
前記軟磁性粉末がＦｅ−Ｓｉ−Ａｌ系粉末である場合は、２MPa以上、
前記軟磁性粉末がＦｅ−Ｃｒ系粉末である場合は、１０MPa以上、
前記軟磁性粉末がＦｅ−Ｎｉ系粉末である場合は、１０MPa以上、
前記軟磁性粉末がＦｅ−Ｃｏ系粉末である場合は、７MPa以上
であることを特徴とする圧粉磁心。 A powder magnetic core using a soft magnetic powder having an apparent density / true density value of 0.59 or less, and the value when the crushing strength after press molding is measured by a method defined in JIS Z2507,
When the soft magnetic powder is Fe-Si based powder, 5 MPa or more,
When the soft magnetic powder is Fe-Si-Al-based powder, 2 MPa or more,
When the soft magnetic powder is Fe-Cr powder, 10 MPa or more,
When the soft magnetic powder is Fe-Ni-based powder, 10 MPa or more,
When the soft magnetic powder is Fe-Co powder, the dust core is 7 MPa or more.
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| JP2007035826A (en) * | 2005-07-26 | 2007-02-08 | Nec Tokin Corp | Composite magnetic material, and dust core and magnetic element using the same |
| JP2008147405A (en) * | 2006-12-08 | 2008-06-26 | Sumitomo Electric Ind Ltd | Manufacturing method of soft magnetic composite material |
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