JP2006024844A - Magnetic core and coil component using same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a magnetic core which is not magnetically saturated to show excellent DC current superposition characteristics when used in an area of ≥200A and attains low noise, and a coil component using the same. <P>SOLUTION: The magnetic core 10 is obtained by curing a mixture of magnetic powder, nonmagnetic powder, and resin; and the magnetic powder is nearly spherical powder, and the nonmagnetic powder is nearly spherical powder and has ≥10 relative permeability in a magnetic field of 79.3 kA/m. The compound ratio of the resin to the mixture is 20 to 90 vol.%, the nonmagnetic powder is at least one material selected out of inorganic material powder containing silica powder, alumina powder, titanium oxide powder, quartz glass powder, zirconium powder, calcium carbonate, aluminum hydroxide powder, and a glass fiber. The nonmagnetic powder is spherical powder filled with inert gas and in multi-layered structure. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a magnetic core and a coil component using the same, and more particularly to a magnetic core suitable for use as a reactor in energy control of a storage battery mounted in an electric vehicle or a hybrid car and a wire ring component using the magnetic core. .

  Conventionally, a coil component including a magnetic core made of resin and magnetic powder is known. For example, the coil component of Patent Document 1 includes a magnetic core made of a ferrite sintered body or a powder magnetic core made of metal magnetic powder in addition to a magnetic core made of resin and magnetic powder. The coil is wound around the magnetic core, and another magnetic core made of resin and magnetic powder is provided so as to cover the coil.

  The object of Patent Document 1 is described as providing a magnetic element such as an inductor, a choke coil, or a transformer that is suitable for use in a large current of various electronic devices. What should be noted here is a word having a relative concept of “large current”. Specifically, according to Patent Document 1, the target current range is only several tens of A to several hundreds of A.

  Moreover, as a common sense in the person skilled in the art, the coil component is usually designed to have a DC current superposition characteristic as good as possible in a target region. In other words, coil components are usually designed on the assumption that the relative permeability is as high as possible in the current range used, while the inductance saturates when the target current region is exceeded. ing.

  That is, the coil component described in Patent Document 1 is designed to obtain as large an inductance as possible with respect to a current value of several tens of A to several hundreds of A, while a current value exceeding that range is used. Is a matter predicted from a normal design method that the inductance may be saturated. The reason why such a design method is adopted is to avoid inductance, which is deteriorated even in the target current range, when designing is performed in consideration of the inductance in the current range which is not the target.

  On the other hand, a coil component in a high power system such as an energy control of an electric vehicle or a hybrid battery storage battery may be used in an area of 200 A or more, for example. As understood from the fact that if the current value is different by one digit, the power value is different by two digits, it is not possible to divert the coil component of Patent Document 1 to the energy control of the storage battery of an electric vehicle or a hybrid car. It is considered appropriate.

  In addition, the driving frequency of coil components used for boosting / regeneration in electric vehicles and hybrid cars is from several kHz to several tens of kHz in the audible region, so during driving, between the coil wires and between the coil and the magnetic core. There is a problem that audible noise and beat are generated due to vibrations caused by mutual suction force. In addition, there has been no magnetic core configuration that does not cause magnetic saturation even when a large current of 200 A or more flows, for example, without providing an air gap. In addition to the possibility, vibration may occur between the cores with the gap therebetween.

  A coil component having a magnetic core made of resin and magnetic powder is known (see Patent Document 1). The coil component of Patent Document 1 includes a powder magnetic core made of a ferrite sintered body or metal magnetic powder in addition to a magnetic core made of resin and magnetic powder. The coil is wound around the dust core, and a magnetic core made of resin and magnetic powder is provided so as to cover the coil.

  One of the objects of Patent Document 1 is to provide a magnetic element such as an inductor, a choke coil, or a transformer that can reduce noise generation during driving. However, as will be described below, it is considered that the noise regarded as a problem in Patent Document 1 is caused by a mechanism different from at least the audible noise and the beat which is regarded as a problem in the present application.

  The frequency range targeted by the coil component described in Patent Document 1 is a so-called “high frequency”, which is a frequency region far exceeding the audible frequency. In fact, Patent Document 1 has a description of “several hundred kHz to MHz”, and the term “high frequency” is frequently used as a keyword. Even if the air gap part vibrates at a very high frequency of several hundred kHz to MHz, it will only generate sound that cannot be heard by the human ear, and it is possible that it will result in audible noise and beating as described above. Absent.

  Therefore, it is appropriate to consider a solution for audible noise and beat caused by driving in the audible frequency band, apart from the technique described in Patent Document 1. In addition, the coil component that is the target in Patent Document 1 is a coil component for a low-power system, as is clear from the size illustrated. As a matter of course, withstand voltage performance of several hundred volts or more and withstand pulse current performance of several hundred amperes or more (resistance to unwanted current noise such as surge current) cannot be expected. As described above, it is appropriate to consider that it is inappropriate to use the coil component described in Patent Document 1 for high power / low frequency applications.

JP 2001-185421 A

  Accordingly, the present invention provides a magnetic core that exhibits good DC current superposition characteristics without magnetic saturation even when used in an area of 200 A or more and realizes low noise, and a wire ring part using the same. The purpose is to provide.

  The magnetic core of the present invention is a magnetic core obtained by curing a composite of a magnetic powder, a nonmagnetic powder, and a resin, and the magnetic powder is a substantially spherical powder. The powder is a substantially spherical powder.

  That is, the present invention provides a magnetic core obtained by curing a composite of magnetic powder, nonmagnetic powder, and resin, wherein the magnetic powder is a substantially spherical powder, and the nonmagnetic powder Is a substantially spherical powder, and has a relative magnetic permeability of 10 or more in a magnetic field of 79.3 kA / m, and the blending ratio of the resin in the composite is in the range of 20% by volume to 90% by volume. It is a certain magnetic core.

  In the present invention, the composite of the magnetic powder and the non-magnetic powder has an average particle size of a group A powder formed from the magnetic powder and the non-magnetic powder of 90 μm to 900 μm. The average particle size of the group B powder formed from the magnetic powder and the non-magnetic powder is in the range of 40 μm to 90 μm, and the mixing ratio in the volume ratio of the group A and the group B is The magnetic core is a hybrid in the range of 70:30 to 90:10.

  In the present invention, the composite of the magnetic powder and the non-magnetic powder has an average particle size of Group C powder formed from the magnetic powder and the non-magnetic powder of 15 μm to 40 μm. The average particle size of the D group formed from the magnetic powder and the non-magnetic powder is in the range of 1 μm to 15 μm, and the mixing ratio in the volume ratio of the C group and the D group is 70:30. To 90:10 in the range of a hybrid core.

  In the present invention, the composite of the magnetic powder and the non-magnetic powder has an average particle size of a group A powder formed from the magnetic powder and the non-magnetic powder of 90 μm to 900 μm. The average particle size of the Group B powder formed from the magnetic powder and the nonmagnetic powder is in the range of 40 μm to 90 μm, and the Group C formed from the magnetic powder and the nonmagnetic powder. The magnetic core has a mean particle size of 15 μm or more and 40 μm or less, and a mixing ratio in a volume ratio of the A group, the B group, and the C group is 80: 20: 5.

  In the present invention, the composite of the magnetic powder and the non-magnetic powder has an average particle size of the Group B powder formed from the magnetic powder and the non-magnetic powder of 40 μm to 90 μm. The average particle size of the C group powder formed from the magnetic powder and the nonmagnetic powder is in the range from 15 μm to 40 μm, and the D group formed from the magnetic powder and the nonmagnetic powder. The magnetic core has an average particle diameter in the range of 1 μm to 15 μm, and a mixing ratio of the B group, the C group, and the D group in a volume ratio of 80: 20: 5.

  Moreover, this invention is a magnetic core whose compounding ratio of the said nonmagnetic substance powder and the said resin is 30 volume% or more.

  In the present invention, the non-magnetic powder is selected from silica powder, alumina powder, titanium oxide powder, quartz glass powder, zirconium powder, calcium carbonate powder or aluminum hydroxide powder, and glass fiber. The magnetic core is at least one material.

  Further, in the present invention, the nonmagnetic powder is a magnetic core including a substantially spherical hollow powder whose inside is a vacuum.

  In the present invention, the non-magnetic powder includes a magnetic core including a substantially spherical hollow powder filled with an elastic body.

  Further, in the present invention, the average particle diameter of the Group E powder formed from the nonmagnetic powder is in the range of 90 μm to 900 μm, and the average particle of the Group F powder formed from the nonmagnetic powder is used. By mixing the non-magnetic powder and the resin in which the diameter is in the range of 40 μm to 90 μm and the mixing ratio in the volume ratio of the E group and the F group is in the range of 70:30 to 90:10 The insulator is a magnetic core filled in a region outside the hybrid material or a region around the winding.

  In the present invention, the average particle size of the G group powder formed from the nonmagnetic powder is in the range of 15 μm to 40 μm, and the average particle size of the H group formed from the nonmagnetic powder is 1 μm. From the above, the insulating material by mixing the non-magnetic powder mixed powder in which the mixing ratio in the volume ratio of the G group and the H group is in the range of 70:30 to 90:10 and the resin is 15 μm or less. , A magnetic core filled in a region outside the hybrid or a region around the winding.

  Further, in the present invention, the average particle diameter of the Group E powder formed from the nonmagnetic powder is in the range of 90 μm to 900 μm, and the average particle of the Group F powder formed from the nonmagnetic powder is used. The diameter is in the range of 40 μm to 90 μm, the average particle size of the G group powder formed from the non-magnetic powder is in the range of 15 μm to 40 μm, and the volume of the E group, the F group, and the G group. A magnetic material in which a nonmagnetic powder mixed powder having a mixing ratio of 80: 20: 5 and an insulating material mixed with a resin are filled in a region outside the composite or a region around the windings. The core.

  In the present invention, the average particle size of the F group powder formed from the nonmagnetic powder is in the range of 40 μm to 90 μm, and the average particle size of the G group powder formed from the nonmagnetic powder. The diameter is in the range of 15 μm to 40 μm, the average particle size of the H group formed from the non-magnetic powder is in the range of 1 μm to 15 μm, and the volume ratio of the F group, the G group, and the H group A magnetic core in which a nonmagnetic powder mixed powder having a mixing ratio of 80: 20: 5 and an insulating material mixed with a resin are filled in a region outside the composite or a region around the winding. .

  Further, in the present invention, the non-magnetic powder is a magnetic core containing a substantially spherical hollow powder filled inside with a vacuum or inert gas, or the non-magnetic powder contains an elastic body such as a resin inside. It is a magnetic core containing a substantially spherical hollow powder filled.

  In the present invention, the soft magnetic metal powder is a Fe—Si based powder, and the magnetic core has an average Si content of 11.0% by weight or less.

  In the present invention, the soft magnetic metal powder is an Fe-Si-Al-based powder, the average Si content is 11.0 wt% or less, and the average Al content is 7.0 wt% or less. It is.

  In the present invention, the soft magnetic metal powder is an Fe—Ni-based powder, and the magnetic core has an average Ni content of 30.0 wt% or more and 85.0 wt% or less.

  In the present invention, the soft magnetic metal powder is a magnetic core of Fe-based amorphous powder, and the magnetic core is a magnetic core having an elastic modulus of 3000 MPa or more.

  In the present invention, the elastic modulus of the resin is a magnetic core of 100 MPa or more when the resin is cured alone under the same conditions as those for curing the composite.

  Moreover, this invention is a magnetic core of the cast product obtained by the said magnetic core casting the said hybrid, and the said hybrid is a magnetic core of the material which can be cast without using a solvent.

  Further, the present invention is a wire ring component constituted by the magnetic core and a winding wound around the magnetic core, the wire ring component comprising the magnetic core and the winding, The magnetic core is a wire ring component that is disposed around the winding and forms at least a part of the magnetic path.

  Further, the present invention is a wire ring component comprising the magnetic core and a winding formed by burying at least part of the inside of the magnetic core, the winding except the end of the winding, This is a wire ring part completely surrounded by a magnetic core.

  Further, the present invention is a wire ring component including at least one specific permeability magnetic core member arranged around the winding or in the cavity of the winding.

  Moreover, this invention is a wire ring component with which the said specific-permeability magnetic core member was fixed with respect to the said coil | winding by the said magnetic core which consists of the said composite.

  Further, in the present invention, the specific permeability magnetic core member is an Fe-based amorphous powder, or a powder magnetic core member made of Fe-Si-Al-based, Fe-Si-based, or Fe-Ni-based powder, or This is a wire ring component of an Fe-based laminated magnetic core member.

  The magnetic core of the present invention has a low relative magnetic permeability in a zero magnetic field compared to the relative magnetic permeability of small coil components used in electronic devices driven at a high frequency. The characteristics do not suddenly saturate, and the relative permeability of the magnetic core of the present invention can maintain a relatively large value even in a high magnetic field.

  Further, according to the present invention, even when used in an area of 200 A or more, a magnetic core that exhibits good DC current superposition characteristics without magnetic saturation and realizes low noise, and a wire using the same Wheel parts can be provided.

  The magnetic core according to the embodiment of the present invention is composed of a mixture of magnetic powder, nonmagnetic powder and resin, and an insulator made of nonmagnetic powder and resin. The magnetic core of the present invention is a cast product formed by casting the above hybrid. Here, when the size is large, such as a coil component for high power use, considering the case where the coil component has a certain height, it is preferable that the composite is made of a material that can be cast without adding a solvent. .

  Casting is basically performed without pressure or under reduced pressure. Once the casting is performed, pressure may be applied to improve the filling rate (density of the magnetic core 80). There is no particular limitation on the mold for casting the hybrid, and therefore any shape can be considered as the shape of the magnetic core made of the hybrid. The insulator is formed on an outer portion or a peripheral portion of the hybrid.

  The magnetic powder according to the present embodiment is a substantially spherical powder. When the substantially spherical magnetic powder is used in this way, the filling rate of the magnetic powder in the hybrid can be improved. Such a substantially spherical magnetic substance powder is obtained, for example, by a gas atomizing method. According to the gas atomization method, the particle size and shape of the magnetic powder have a certain distribution, but as a guide, the most standard particle size (average particle size) of the magnetic powder is 900 μm or less. Desirable yield, characteristics, and performance cannot be obtained.

  The magnetic powder in the present embodiment is a soft magnetic powder, specifically an Fe-based soft magnetic metal powder. More specifically, the soft magnetic metal powder is a powder selected from the group consisting of Fe-Si powder, Fe-Si-Al powder, Fe-Ni powder, and Fe amorphous powder. Here, the average Si content in the Fe—Si based powder is preferably 11.0% by weight or less. The average Si content in the Fe—Si—Al-based powder is preferably 11.0% by weight or less, and the average Al content is preferably 7.0% by weight or less. Further, the average Ni content in the Fe—Ni-based powder is preferably 30.0 wt% or more and 85.0 wt% or less.

  The blending ratio of the resin in the hybrid is in the range of 20% by volume to 90% by volume. When the resin content is less than 20% by volume, it becomes difficult to mix the magnetic powder and the resin, and when the resin content exceeds 90% by volume, the amount of the magnetic powder decreases, resulting in a decrease in magnetic properties. It is because it ends.

  Furthermore, the blending ratio of the resin in the hybrid is preferably in the range of 40% by volume to 70% by volume.

  The resin is a curable resin, and the curable resin is a thermosetting resin. For example, an epoxy resin or a silicone resin is used as the resin.

  In the magnetic core of the present invention, the composite of the magnetic substance powder and the nonmagnetic substance powder has an average particle diameter of 90 μm or more of the Group A powder formed from the magnetic substance powder and the nonmagnetic substance powder. To 900 μm or less, the average particle size of Group B powder formed from magnetic powder and non-magnetic powder is in the range of 40 μm to 90 μm, and mixing in the volume ratio of Group A and Group B Hybrids with a ratio in the range of 70:30 to 90:10.

  Here, when the mixing ratio in the volume ratio is less than 70:30 (mixing ratio 3), the volume ratio of the powder of the group B increases, and the phenomenon that the powders adsorb to each other occurs and the density decreases. In addition, when the mixing ratio by volume ratio exceeds 90:10 (mixing ratio 9), the volume ratio of the powder of Group A increases, and the particle size of the powder is large, so that high-density filling is difficult. This is because the density decreases.

  In the magnetic core of the present invention, the composite of the magnetic substance powder and the nonmagnetic substance powder has an average particle diameter of the group C powder formed from the magnetic substance powder and the nonmagnetic substance powder from 15 μm or more. The average particle size of the D group formed from the magnetic powder and the non-magnetic powder is in the range of 1 μm to 15 μm, and the mixing ratio in the volume ratio of the C group and the D group is 70 μm or less. It is a hybrid that ranges from 30 to 90.

  Here, when the mixing ratio in the volume ratio is less than 70:30 (mixing ratio 3), the volume ratio of the powder of the D group increases, and the phenomenon that the powders adsorb to each other occurs and the density decreases. In addition, when the mixing ratio by volume ratio exceeds 90:10 (mixing ratio 9), the volume ratio of the powder of Group C increases and the particle size of the powder is large, so it is difficult to fill with high density. This is because the density decreases.

  In the magnetic core of the present invention, the composite of the magnetic powder and the non-magnetic powder has an average particle diameter of the group A powder formed from the magnetic powder and the non-magnetic powder from 90 μm or more. The range is 900 μm or less, and the average particle size of Group B powders formed from magnetic powder and non-magnetic powder is in the range of 40 μm to 90 μm, and is formed from magnetic powder and non-magnetic powder. The average particle size of the powder of Group C is in the range of 15 μm to 40 μm, and the magnetic core has a mixing ratio of 80: 20: 5 in the volume ratio of Group A, Group B, and Group C.

  In the magnetic core of the present invention, the composite of the magnetic substance powder and the nonmagnetic substance powder has an average particle diameter of the group B powder formed from the magnetic powder and the nonmagnetic substance powder of 40 μm or more to 90 μm. The average particle size of the group C powder formed from the magnetic powder and the nonmagnetic powder is in the range of 15 μm to 40 μm, and the D formed from the magnetic powder and the nonmagnetic powder. The average particle diameter of the group is in the range of 1 μm to 15 μm, and the magnetic core has a mixing ratio of 80: 20: 5 in the volume ratio of the B group, the C group, and the D group.

  The wire ring component of the present invention is a wire ring component composed of a magnetic core and a winding wound around the magnetic core, and the magnetic core is disposed around the winding, and is at least magnetic. It is a wire ring part that forms part of the road.

  Moreover, the wire ring component of the present invention is a wire ring component including a magnetic core and a winding formed by burying at least a part inside the magnetic core.

  The wire ring component of the present invention is a wire ring component in which a winding is completely surrounded by the magnetic core except for an end portion of the winding.

  Moreover, the wire ring component of the present invention is a wire ring component including at least one specific permeability magnetic core member arranged around the winding or in the cavity of the winding.

  Moreover, the wire ring component of the present invention is a wire ring component in which the specific permeability magnetic core member is fixed to the winding by the magnetic core made of the hybrid.

  Here, the specific permeability magnetic core member is an Fe-based amorphous powder, or a powder magnetic core member made of Fe-Si-Al-based, Fe-Si-based, or Fe-Ni-based powder, or An Fe-based laminated magnetic core member is used.

  The wire ring component of the present invention is a wire ring component having a high magnetic resistance member embedded in the magnetic core and having a higher magnetic resistance than the magnetic core. Here, the high magnetic resistance member is made of a material containing the same resin as the resin in the hybrid.

  The high magnetic resistance member is disposed in the cavity of the winding, and the high magnetic resistance member forms a region having a relative permeability of 20 or less in the magnetic core.

  The magnetic powder according to the present embodiment is a substantially spherical powder. When the substantially spherical magnetic powder is used in this way, the filling rate of the magnetic powder in the hybrid can be improved. Such a substantially spherical magnetic substance powder is obtained, for example, by a gas atomizing method. According to the gas atomization method, the particle size and shape of the magnetic powder have a certain distribution, but as a guide, the most standard particle size (average particle size) of the magnetic powder is 900 μm or less. Desirable yield, characteristics, and performance cannot be obtained.

  According to the gas atomization method, a non-spherical powder can be intentionally formed in addition to the substantially spherical powder as described above. Moreover, according to the water atomization method, an amorphous powder can also be obtained. In the present invention, non-spherical powder, amorphous powder, and other shapes of powder obtained by the above method can be used instead of the substantially spherical powder employed in the embodiment. As a reason for adopting a magnetic powder other than a substantially spherical shape, for example, anisotropy due to its shape is used. More specifically, for example, non-spherical, flat, or needle-shaped magnetic powder is mixed with a resin, and a predetermined magnetic field is applied before the resin is cured to perform anisotropic orientation of the powder group. The use method of hardening the resin after that can be considered.

  The resin in the present embodiment is an epoxy resin. In the present embodiment, since there is a demand for liquidity and low viscosity with respect to the epoxy resin, compatibility with additives, curing agents and catalysts, and storage stability are also considered in the specific epoxy resin selection. It is an important property to be. In view of the above, it is preferable to use an epoxy resin such as bisphenol A type, bisphenol F type or polyfunctional type as the main agent, and aromatic polyamine type, carboxylic acid anhydride type, latent curing agent as the curing agent. It is preferable to use a system. In this embodiment, a combination of a bisphenol A type epoxy resin and a solvent-free low viscosity liquid aromatic amine curing agent is used.

  The resin in the hybrid may be another thermosetting resin such as a silicone resin. Further, other curable resins such as a chemically reactive curable resin, a photocurable resin, and an ultraviolet curable resin may be used.

  The blending ratio of the resin in the hybrid product needs to be 20% by volume or more and 90% by volume or less in consideration of fluidity. Preferably, the compounding ratio of the resin in the hybrid is 40% by volume or more and 70% by volume or less.

  The elastic modulus of the magnetic core made of the hybrid is set to 3000 MPa or more. In order to realize the elastic modulus of the magnetic core, the resin has an elastic modulus of 100 MPa or more when the resin is cured alone under the same conditions as those obtained when the composite is cured to obtain the magnetic core. So that it is selected. The elastic modulus of the magnetic core or the cured resin is a value measured according to JIS-K6911 (General Thermosetting Plastic Test Method).

  In the present embodiment, the elastic modulus of the magnetic core made of the hybrid is 15000 MPa, and the elastic modulus of the resin alone cured under the same curing conditions is 1500 MPa. When the elastic modulus of the magnetic core is 15000 MPa or more, the thermal conductivity is improved to 2 W / (K · m) or more compared to the case where the thermal conductivity is less than that. Therefore, the elastic modulus of the magnetic core is preferably 15000 MPa or more. In the magnetic core of the present invention, the blending ratio of the non-magnetic powder and the resin in the composite is 100% to 30% by volume or more, thereby realizing magnetic characteristics that do not decrease μ even in a high magnetic field.

  Further, in the magnetic core insulator of the present invention, the average particle size of the E group powder formed from the non-magnetic powder is in the range of 90 μm to 900 μm, and the F group formed from the non-magnetic powder. Non-magnetic powder in which the average particle size of the powder is in the range of 40 μm to 90 μm, and the mixing ratio in the volume ratio of the E group and the F group is in the range of 70:30 to 90/10 It is an insulator made by mixing resin and resin. Here, when the mixing ratio in the volume ratio is less than 70:30 (mixing ratio 3), the volume ratio of the powder of the F group increases, and a phenomenon in which the powders adsorb to each other occurs and the density decreases. In addition, when the mixing ratio by volume ratio exceeds 90:10 (mixing ratio 9), the volume ratio of the powder of Group E increases, and the powder particle size is large, so that high-density filling becomes difficult, Density decreases.

  Further, in the magnetic core insulator of the present invention, the average particle size of the G group powder formed from the nonmagnetic powder is in the range of 15 μm to 40 μm, and the H group formed from the nonmagnetic powder. A non-magnetic powder mixed powder having an average particle size of 1 to 15 μm and a mixing ratio in a volume ratio of the G group and the H group of 70 to 30 to 90 to 10, and a resin. It is an insulator by mixing. Here, when the mixing ratio in the volume ratio is less than 70:30 (mixing ratio 3), the volume ratio of the powder of the G group increases, and a phenomenon in which the powders adsorb to each other occurs, resulting in a decrease in density. In addition, when the mixing ratio by volume ratio exceeds 90:10 (mixing ratio 9), the volume ratio of the H group powder increases, and the powder particle size is large, so that high-density filling becomes difficult, Density decreases.

  Further, in the magnetic core insulator of the present invention, the average particle size of the E group powder formed from the non-magnetic powder is in the range of 90 μm to 900 μm, and the F group formed from the non-magnetic powder. The average particle size of the powder of G is in the range of 40 μm to 90 μm, the average particle size of the G group powder formed from the non-magnetic powder is in the range of 15 μm to 40 μm, and the E group and F It is an insulator obtained by mixing a non-magnetic powder mixed powder in which the mixing ratio of the group G and the group G is 80: 20: 5 and a resin.

  In addition, the insulator of the magnetic core according to the present invention has an average particle diameter of the F group powder formed from the nonmagnetic powder in the range of 40 μm to 90 μm, and the G group formed from the nonmagnetic powder. The average particle size of the powder is 15 μm or more and 40 μm or less, the average particle size of the H group formed from the non-magnetic powder is 1 μm or more and 15 μm or less, the F group, the G group, and the H group. It is an insulator obtained by mixing a nonmagnetic powder mixed powder having a mixing ratio of 80 to 20 to 5 in volume ratio of a group and a resin.

  The insulator of the magnetic core of the present invention is a magnetic core containing a substantially spherical hollow powder filled with a vacuum or an inert gas inside the nonmagnetic powder, and the inside of the nonmagnetic powder is a resin. A magnetic core containing a substantially spherical hollow powder filled with an elastic body such as.

  FIG. 2 is an explanatory diagram of the coil component according to the first embodiment of the present invention. 2A is an external view of the coil component, and FIG. 2B is an explanatory diagram of a mixed state of the magnetic powder and the non-magnetic powder of the coil component of FIG. 2 (c) is an explanatory view of a mixed state of the non-magnetic powder of the insulator 25 of the coil component of FIG. 2 (a). A coil component 100 shown in FIG. 2 is wound around the toroidal type magnetic core 10 made of the above-mentioned hybrid, the insulator 25 disposed on one surface thereof, and the magnetic core 10 and the insulator 25. And winding 20.

  As shown in FIG. 2 (b), a magnetic powder A with an average particle size of 120 μm, a magnetic powder B with an average particle size of 60 μm, a hollow nonmagnetic powder A1 with an average particle size of 120 μm, and an average particle size The non-magnetic powder B1 having a hollow shape of 50 μm is mixed and mixed so as to have the highest density.

  As shown in FIG. 2 (c), the insulator 25 has an average particle diameter of the group E powder formed from the nonmagnetic powder of 120 μm, and the group F powder formed from the nonmagnetic powder. This is an insulator obtained by mixing a mixed powder of non-magnetic material powder having an average particle diameter of 50 μm and a mixing ratio of the E group and the F group in a volume ratio of 80 to 20, and a resin.

  The nonmagnetic powder is silica, and is a substantially spherical hollow powder filled with an inert gas. Alternatively, the non-magnetic powder may be silica, and may be a substantially spherical hollow powder filled with an elastic body. As shown in FIG. 2 (c), a non-spherical powder F of a substantially spherical hollow powder whose inside is a vacuum with a small size is provided around a non-spherical powder E of a substantially spherical hollow powder whose inside is a vacuum. It has entered. With such a composition, sound waves of noise are reflected and absorbed in the non-magnetic hollow powder and attenuated, and the insulator 25 prevents noise from the magnetic core 10.

  FIG. 3 is a comparison diagram of the noise characteristics of the coil component according to the first embodiment of the present invention and the noise characteristics of the conventional magnetic core. In the present invention, the noise is improved by about 20 dB.

  FIG. 1 is a graph showing DC current superposition characteristics of a coil component according to Example 1 of the present invention. In FIG. 1, the magnetic core of the present invention (magnetic core obtained from a mixture obtained by mixing 50% by volume of Fe—Si based powder and epoxy resin) and the conventional magnetic core (Fe—Si based powder magnetic core). ) Shows the DC current superposition characteristics. As shown in FIG. 1, the relative magnetic permeability of the magnetic core made of the hybrid in the present embodiment does not suddenly saturate and has a relatively high relative magnetic permeability of 10 or more even in a magnetic field of 79.3 kA / m. is doing.

  The magnetic core can be appropriately changed as long as it is 10 or more in a magnetic field having a relative permeability of 79.3 kA / m. For example, in order to slightly increase the initial permeability, a high permeability thin film layer may be formed on the surface of the magnetic powder. An example of the high magnetic permeability thin film is an Fe—Ni thin film. In order to avoid an electrical short circuit due to the magnetic powder, the magnetic powder may be coated with one or more insulating layers before being mixed with the resin. When a high permeability thin film is formed on the surface of the magnetic powder, an insulating layer is coated on the formed high permeability thin film. Furthermore, a nonmagnetic filler may be added to the composite of magnetic powder and resin in order to ensure a high relative permeability in a higher magnetic field.

  Examples of the nonmagnetic filler include a group consisting of silica powder, alumina powder, titanium oxide powder, quartz glass powder, zirconium powder, calcium carbonate powder or aluminum hydroxide powder, glass fiber, and granular resin. One filler selected from Instead of non-magnetic filler, a spherical hollow powder made of silicon oxide filled with vacuum, resin, or inert gas is used, or by increasing the specific surface area, a multi-layer structure of different density can be used for It is good also as the magnetic core selected for the part. This is used to enhance the sound insulation effect. Further, in order to extend the direct current superposition characteristics well into a higher magnetic field, permanent magnet powder may be added to apply a magnetic bias to the magnetic core.

  Here, the driving frequency assumed as the DC-DC converter is 1 kHz to 100 MHz. Assuming a driving frequency up to 100 kHz, the combination of magnetic powders is a higher performance combination, the average particle size of group A is 120 μm, the average particle size of group B is 60 μm, and the mixing ratio of groups A and B The best characteristics were obtained when was 80:20.

  FIG. 8 is a characteristic diagram of the relationship between the mixing ratio and density in the magnetic core of the present invention. As shown in FIG. 8, the density is maximum when the mixing ratio is 80:20 (mixing ratio 4).

  In addition, assuming a driving frequency up to several MHz, the combination of magnetic powders is a higher performance combination, and up to 10 MHz, the average particle size of group C is 30 μm, the average particle size of group D is 10 μm, The best characteristics were obtained when the mixing ratio of Group B was 80:20. As an application of the second embodiment, when the average particle size of group B is 60 μm and the average particle size of group C is 30 μm, it is natural that the mixing ratio of group B and group C is 80:20. However, it can be easily estimated.

  FIG. 4 is an explanatory diagram of the coil component 120 according to the second embodiment of the present invention. 4A is an external view of the coil component 120, and FIG. 4B is an explanation of a mixed state of the nonmagnetic powders E and F of the insulator 26 of the coil component 120 of FIG. 4A. FIG. A coil component 120 shown in FIG. 4 is one of other modifications of the toroidal coil component, and further includes a specific permeability magnetic core member 30 in addition to the winding 20. The winding 20 is completely embedded in the insulator 26 except for the end portions 21 and 22.

  Further, in the coil component 120, the specific permeability magnetic core member 30 is also completely embedded in the insulator 26. The winding 20 is wound around the specific permeability core member 30 inside the insulator 26. The specific permeability magnetic core member 30 may be disposed anywhere as long as it forms a part of a magnetic path related to the winding 20. For example, the specific permeability magnetic core member 30 may be disposed around the insulator 26 or in the cavity. In addition, the cavity part of a coil may be called a magnetomotive force part.

  Preferably, the specific permeability magnetic core member 30 is fixed to the winding 20 by an insulator 26. Preferably, the specific permeability magnetic core member 30 is a powder magnetic core member made of Fe-based amorphous powder, or Fe-Si-Al-based, Fe-Si-based, or Fe-Ni-based powder. Or it is a Fe-type laminated magnetic core member.

  In the insulator 26, the average particle size of the Group E powder formed from the non-magnetic powder is 120 μm, the average particle size of the Group F powder formed from the non-magnetic powder is 50 μm, It is an insulator formed by mixing a mixed powder of non-magnetic material powder and a resin in which the mixing ratio of the group and the F group is in the range of 80 to 20.

  As shown in FIG. 4B, a non-spherical hollow powder non-magnetic powder F having a small size inside is vacuum around a non-spherical powder E having a substantially spherical hollow powder whose inside is vacuum. It has entered. Here, the non-magnetic powder is silica. With such a composition, the insulator 26 prevents noise generated from the specific permeability magnetic core member 30. FIG. 3 is a comparison diagram between the noise characteristics of the coil component according to the present invention and the noise characteristics of the conventional magnetic core. In the coil component 120 of the present invention, the noise is improved by about 20 dB.

  FIG. 5 is an explanatory diagram of the coil component 160 according to the third embodiment of the present invention. FIG. 5A is an external view of the coil component 160, and FIG. 5B is an illustration of a mixed state of the non-magnetic powders of the insulators 26a and 27 of the coil component 160 of FIG. 5A. . Here, the insulator 26 a is formed around the winding 20, and the insulator 26 a and the winding 20 constitute a winding part 60. The insulator 27 covers the entire outer periphery of the magnetic core 50.

  As shown in FIG. 5, the winding 20 may be completely surrounded by the insulator 26a, and insulation between adjacent coil wires may be ensured. In this way, since each winding 20 is completely insulated from the surroundings, when two or more windings 20 are connected to form one coil, insulation between the plurality of windings 20 is also ensured. be able to.

  The insulators 26a and 27 have an average particle size of the E group powder formed from the nonmagnetic powder of 150 μm, and the average particle size of the F group powder formed of the nonmagnetic powder is 50 μm. The insulating material is obtained by mixing a mixed powder of non-magnetic powder and a resin in which the mixing ratio in the volume ratio of the E group and the F group is in the range of 80:20.

  As shown in FIG. 4 (b), a substantially spherical hollow powder non-magnetic powder E filled with an inert gas inside has a small spherical shape and a substantially spherical shape filled with an inert gas inside. The non-magnetic powder F of hollow powder has entered. The non-magnetic powder is silica. With such a composition, the insulators 26 and 27 prevent noise generated from the magnetic core 50.

  FIG. 6 is an explanatory diagram of the coil component 140 according to the fourth embodiment of the present invention. 6A is an external view of the coil component, and FIG. 6B is an explanatory diagram of a mixed state of the non-magnetic powders of the insulators 28 and 29 of the coil component of FIG. 6A.

  The coil component 140 shown in FIG. 6 further includes cases 80a and 80b. The case 80a in the coil component 140 has a rectangular parallelepiped shape. The case 80b has a plate shape. The winding 20 is formed by vertically winding a rectangular conducting wire. The winding 20 is disposed in the case 80a, and the magnetic core 10 made of a hybrid fills the space between the winding 20 and the case 80a and encloses the winding 20 inside the magnetic core 10. Examples of the case 80a include those made of a metal such as an aluminum alloy or an Fe—Ni alloy. Thus, when case 80a is metal, it is preferable to form an insulating layer on the inner surface. The case 80a may be a ceramic case such as an alumina molded body, for example. The insulator 28 is disposed inside the case 80a, and the insulator 29 is disposed on the bottom surface of the case 80b.

  The magnetic core 10 made of a hybrid is a cast product obtained by casting the hybrid described in the embodiment. Here, when the size is large as in the case of a coil component for high power use, particularly when considering the case where the coil component has a certain height or more, the composite material may be made of a material that can be cast without adding a solvent. preferable.

  In addition, casting is basically performed with no pressure or reduced pressure. Once the casting is performed, pressure may be applied to improve the filling rate (magnetic core density). There is no restriction | limiting in particular about the type | mold shape at the time of casting a hybrid, Therefore All shapes can be considered as a shape of the magnetic core which consists of a hybrid. Here, as shown in FIG. 6B, the insulator 28 and the insulator 29 are filled with a nonmagnetic powder F around the nonmagnetic powder E and filled with a resin (not shown). It has a structured.

  In the insulator 26, the average particle diameter of the E group powder formed from the nonmagnetic powder is in the range of 120 μm, and the average particle diameter of the F group powder formed from the nonmagnetic powder is in the range of 50 μm. It is an insulator obtained by mixing a nonmagnetic powder mixed powder having a volume ratio of E group and F group of 80:20 and a resin. Here, the nonmagnetic powders E and F are silica and are hollow powders filled with an inert gas. With such a composition, the insulators 28 and 29 prevent noise generated from the coil component 140.

  FIG. 3 is a comparison diagram between the noise characteristics of the coil component 140 of the present invention and the noise characteristics of a conventional magnetic core. In the coil component 120 of the present invention, the noise is improved by about 20 dB.

  FIG. 7 is an explanatory diagram of the coil component 150 according to the fifth embodiment of the present invention. FIG. 7A is an external view of the coil component, and FIG. 7B is an explanatory diagram of a mixed state of the nonmagnetic powder in the insulator 84 of the coil component of FIG. 7A. A coil component 150 illustrated in FIG. 7 includes a case 82. The case 82 has a spherical shape. The magnetic core 10 according to the present embodiment has an advantage that it can be applied to any shape. Since the case 82 is spherical, the shape of the magnetic core 10 formed therein is also spherical. As a result, when the axis of the coil 20 is the center, a uniform magnetic flux distribution can be obtained in any orientation.

  The case 82 is a metal case made of an aluminum alloy or an Fe—Ni alloy, and an insulator 84 is formed on the inner surface to prevent an electrical short circuit with the outside due to the magnetic powder in the hybrid. Has been. By using silica spherical hollow powder filled with inert gas for the insulator 84, it is possible to enhance the sound insulation effect by the thickness of this layer and to control the sound absorption performance by the elastic sealing layer. Easy to do. For example, in order to double the sound insulation of a wall of weight M and thickness T, the wall thickness must be quadrupled, that is, the manufacturing cost must be quadrupled. This is intended to increase the sound insulation efficiency and prevent resonance by making the wall an intermediate elastic layer (composite material) having a multilayer structure. Here, as shown in FIG. 7B, the insulator 84 has a structure in which the nonmagnetic powder F enters the periphery of the nonmagnetic powder E and is filled with a resin (not shown). It has become.

  In the insulator 26, the average particle size of the Group E powder formed from the non-magnetic powder is in the range of 150 μm, and the average particle size of the Group F powder formed from the non-magnetic powder is in the range of 50 μm. It is an insulator obtained by mixing a non-magnetic powder mixed powder having a volume ratio of the E group and the F group in the range of 80:20 and a resin. Here, the non-magnetic powders E and F are silica and are substantially spherical hollow powders filled with an inert gas. With such a composition, the insulator 84 attenuates the sound wave of noise reflected and absorbed in the non-magnetic hollow powder, thereby preventing noise generated from the coil component 150.

  FIG. 3 is a comparison diagram between the noise characteristics of the coil component 150 of the present invention and the noise characteristics of a conventional magnetic core. In the coil component 150 of the present invention, the noise is improved by about 20 dB.

  In all the coil components 100, 120, 140, 150, and 160 described above, the magnetic core 10 made of a hybrid constitutes a magnetic path loop that passes through the center of the winding 20. The magnetic core 10 is arranged around the winding 20 and forms at least a part of the magnetic path.

  Application examples of magnetic cores and coil parts that have been described with specific examples include, for example, coil parts for voltage increase control and coils for voltage drop control used in electric vehicles, solar power generation, wind power generation, etc. There are parts. FIG. 9 is an explanatory diagram of the relationship between power and frequency of coil components. The coil component of the present invention is particularly suitable for an electric vehicle.

The graph which shows the direct current superimposition characteristic of the coil components by Example 1 of this invention. Explanatory drawing of the coil components of Example 1 of this invention. FIG. 2A is an external view of the coil component. FIG.2 (b) is explanatory drawing of the mixed state of the magnetic body powder of the magnetic core of the coil component of Fig.2 (a), and a nonmagnetic body powder. FIG.2 (c) is explanatory drawing of the mixed state of the nonmagnetic powder of the insulator of the coil components of Fig.2 (a). The comparison figure of the noise characteristic of the coil components of this invention and the noise characteristic of the conventional magnetic core. Explanatory drawing of the coil components of Example 2 of this invention. FIG. 4A is an external view of the coil component. FIG.4 (b) is explanatory drawing of the mixed state of the nonmagnetic material powder of the insulator of the coil components of Fig.4 (a). Explanatory drawing of the coil components of Example 3 of this invention. FIG. 5A is an external view of a coil component. FIG.5 (b) is explanatory drawing of the mixed state of the magnetic body powder of the magnetic core of the coil component of Fig.5 (a), and a nonmagnetic body powder. FIG.5 (c) is explanatory drawing of the mixed state of the nonmagnetic material powder of the insulator of the coil components of Fig.5 (a). Explanatory drawing of the coil components of Example 4 of this invention. FIG. 6A is an external view of a coil component. FIG. 6B is an explanatory diagram of a mixed state of the non-magnetic powder of the insulator of the coil component of FIG. Explanatory drawing of the coil components of Example 5 of this invention. FIG. 7A is an external view of the coil component. FIG.7 (b) is explanatory drawing of the mixed state of the nonmagnetic material powder of the insulator of the coil components of Fig.7 (a). The characteristic view of the relationship between the mixing ratio and density in the magnetic core of this invention. Explanatory drawing of the relationship of the electric power versus frequency of a coil component.

Explanation of symbols

10, 50 Magnetic core 20 Winding 21, 22 End 25, 26, 26a, 27, 28, 29, 84 Insulator 30 Specific permeability magnetic core member 40 High magnetic resistance member 60 Winding portion 61 Groove
62 Line insulation
70 Cover 80a, 80b, 82 Case 100, 120, 140, 150, 160 Coil parts A, B Magnetic powder E, F, A1, B1 Hollow non-magnetic powder

Claims (30)

  A magnetic core obtained by curing a mixture of a magnetic powder, a non-magnetic powder, and a resin, wherein the magnetic powder is a substantially spherical powder, and the non-magnetic powder is a substantially spherical powder. And having a relative permeability of 10 or more in a magnetic field of 79.3 kA / m, and the blending ratio of the resin in the hybrid is in the range of 20% by volume to 90% by volume. Magnetic core.   The composite of the magnetic powder and the non-magnetic powder has an average particle diameter of the group A powder formed from the magnetic powder and the non-magnetic powder in the range of 90 μm to 900 μm, and the magnetic powder The average particle size of the Group B powder formed from the nonmagnetic powder is in the range of 40 μm to 90 μm, and the mixing ratio in the volume ratio of the Group A and the Group B is 70:30 to 90:10. The magnetic core according to claim 1, wherein the magnetic core is a hybrid that falls within the range.   The composite of the magnetic substance powder and the nonmagnetic substance powder has a powder average particle size of group C formed from the magnetic substance powder and the nonmagnetic substance powder in the range of 15 μm to 40 μm, and the magnetic powder And the average particle size of the D group formed from the non-magnetic powder is in the range of 1 μm to 15 μm, and the mixing ratio in the volume ratio of the C group and the D group is in the range of 70:30 to 90:10. The magnetic core according to claim 1, wherein the magnetic core is a hybrid.   The composite of the magnetic powder and the non-magnetic powder has an average particle diameter of the group A powder formed from the magnetic powder and the non-magnetic powder in the range of 90 μm to 900 μm, and the magnetic powder The average particle size of the Group B powder formed from the non-magnetic powder and the average particle size of the Group C powder formed from the magnetic powder and the non-magnetic powder is from 40 μm to 90 μm. The magnetic core according to claim 1, wherein the mixing ratio in the volume ratio of the A group, the B group, and the C group is 80: 20: 5.   The composite of the magnetic powder and the non-magnetic powder has an average particle diameter of the group B powder formed from the magnetic powder and the non-magnetic powder in the range of 40 μm to 90 μm, and the magnetic powder And the average particle size of Group C powder formed from non-magnetic powder is from 15 μm to 40 μm, and the average particle size of Group D formed from magnetic powder and non-magnetic powder is from 1 μm or more. 2. The magnetic core according to claim 1, wherein a mixing ratio in a volume ratio of the group B, the group C, and the group D is 80: 20: 5 in a range of 15 μm or less.   The magnetic core according to claim 1, wherein a blending ratio of the non-magnetic powder and the resin is 30% by volume or more.   The non-magnetic powder is at least one material selected from silica powder, alumina powder, titanium oxide powder, quartz glass powder, zirconium powder, calcium carbonate powder or aluminum hydroxide powder, and glass fiber. The magnetic core according to claim 1, wherein the magnetic core is provided.   The magnetic core according to claim 1, wherein the nonmagnetic powder includes a substantially spherical hollow powder filled with a vacuum or an inert gas.   The magnetic core according to claim 1, wherein the non-magnetic powder includes a substantially spherical hollow powder filled with an elastic body.   The average particle size of the Group E powder formed from the nonmagnetic powder is in the range from 90 μm to 900 μm, and the average particle size of the Group F powder formed from the nonmagnetic powder is from 40 μm to 90 μm. An insulating material obtained by mixing a non-magnetic powder mixed powder having a volume ratio of 70 to 30 to 90 to 10 and a resin in the following range, wherein the mixing ratio in a volume ratio of the E group and the F group is 70:30. A magnetic core filled in a region outside the hybrid material according to any one of 1 to 5 or a region around a winding.   The average particle size of Group G powder formed from nonmagnetic powder is in the range of 15 μm to 40 μm, and the average particle size of Group H formed of nonmagnetic powder is in the range of 1 μm to 15 μm. And an insulating material obtained by mixing a non-magnetic powder mixed powder having a volume ratio of the G group and the H group in a range of 70:30 to 90:10 and a resin. A magnetic core that is filled in a region outside the hybrid material according to any one of the above or a region around the winding.   The average particle size of the Group E powder formed from the nonmagnetic powder is in the range from 90 μm to 900 μm, and the average particle size of the Group F powder formed from the nonmagnetic powder is from 40 μm to 90 μm. The average particle size of the G group powder formed from the non-magnetic powder is in the range of 15 μm to 40 μm, and the mixing ratio in the volume ratio of the E group, the F group, and the G group is An insulator formed by mixing a non-magnetic powder mixed powder of 80: 20: 5 and a resin is an outer region of the composite according to any one of claims 1 to 5, or a region around a winding A magnetic core characterized by being filled in.   The average particle size of the F group powder formed from the nonmagnetic powder is in the range of 40 μm to 90 μm, and the average particle size of the G group powder formed from the nonmagnetic powder is from 15 μm to 40 μm. The average particle size of the H group formed from the nonmagnetic powder is in the range of 1 μm to 15 μm, and the mixing ratio in the volume ratio of the F group, the G group, and the H group is 80 pairs. An insulating material obtained by mixing a non-magnetic powder mixed powder of 20 to 5 and a resin is filled in a region outside the hybrid material according to any one of claims 1 to 5 or a region around the winding. A magnetic core characterized by that.   14. The magnetic core according to claim 10, wherein the non-magnetic powder includes a substantially spherical hollow powder filled with a vacuum or an inert gas.   14. The magnetic core according to claim 10, wherein the non-magnetic powder includes a substantially spherical hollow powder filled with an elastic body.   The magnetic core according to any one of claims 1 to 9, wherein the soft magnetic metal powder is an Fe-Si based powder, and an average Si content is 11.0 wt% or less.   The soft magnetic metal powder is Fe-Si-Al-based powder, the average Si content is 11.0 wt% or less, and the average Al content is 7.0 wt% or less. 16. The magnetic core according to 16.   The magnetic core according to claim 16, wherein the soft magnetic metal powder is Fe—Ni-based powder, and an average Ni content is 30.0 wt% or more and 85.0 wt% or less.   The magnetic core according to claim 16, wherein the soft magnetic metal powder is an Fe-based amorphous powder.   The magnetic core according to claim 1, wherein the magnetic core has an elastic modulus of 3000 MPa or more.   20. The elastic modulus of the resin when the resin is cured alone under the same conditions as those for curing the hybrid is 100 MPa or more. Magnetic core.   The magnetic core according to claim 1, wherein the magnetic core is a cast product obtained by casting the composite.   The magnetic core according to claim 22, wherein the hybrid is made of a material that can be cast without using a solvent.   A wire ring component comprising the magnetic core according to any one of claims 1 to 23 and a winding wound around the magnetic core.   24. A wire ring component comprising the magnetic core according to claim 1 and a winding, wherein the magnetic core is disposed around the winding and forms at least a part of a magnetic path. Wire ring parts characterized by   A wire ring component comprising: the magnetic core according to any one of claims 1 to 23; and a winding formed by burying at least a part inside the magnetic core.   26. The wire ring component according to claim 24, wherein the winding is completely surrounded by the magnetic core except for an end portion of the winding.   The wire ring component according to any one of claims 24 to 25, further comprising at least one specific permeability magnetic core member arranged around the winding or in a hollow portion of the winding.   The wire ring component according to claim 28, wherein the specific permeability magnetic core member is fixed to the winding by the magnetic core made of the hybrid.   The specific permeability magnetic core member is a powder magnetic core member made of Fe-based amorphous powder, Fe-Si-Al-based, Fe-Si-based, or Fe-Ni-based powder, or an Fe-based laminate. The wire ring component according to claim 29, wherein the wire ring component is a magnetic core member.

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