JP2007220747A - 複合磁性シートおよびその製造方法 - Google Patents
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- 238000004519 manufacturing process Methods 0.000 title claims description 38
- 239000000843 powder Substances 0.000 claims abstract description 68
- 239000004810 polytetrafluoroethylene Substances 0.000 claims abstract description 57
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims abstract description 57
- -1 polytetrafluoroethylene Polymers 0.000 claims abstract description 29
- 239000006247 magnetic powder Substances 0.000 claims description 61
- 238000002156 mixing Methods 0.000 claims description 13
- 239000011812 mixed powder Substances 0.000 claims description 12
- 238000000465 moulding Methods 0.000 claims description 11
- 238000003825 pressing Methods 0.000 claims description 4
- 230000035699 permeability Effects 0.000 abstract description 36
- 239000000696 magnetic material Substances 0.000 abstract description 2
- 238000005096 rolling process Methods 0.000 description 41
- 238000000034 method Methods 0.000 description 27
- 230000000052 comparative effect Effects 0.000 description 13
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- 229910052751 metal Inorganic materials 0.000 description 8
- 239000002184 metal Substances 0.000 description 8
- 239000002904 solvent Substances 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 239000011230 binding agent Substances 0.000 description 6
- 238000011156 evaluation Methods 0.000 description 6
- 239000000203 mixture Substances 0.000 description 6
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- 238000000576 coating method Methods 0.000 description 5
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- 229910000859 α-Fe Inorganic materials 0.000 description 5
- 238000001035 drying Methods 0.000 description 4
- XWHPIFXRKKHEKR-UHFFFAOYSA-N iron silicon Chemical compound [Si].[Fe] XWHPIFXRKKHEKR-UHFFFAOYSA-N 0.000 description 4
- 239000003960 organic solvent Substances 0.000 description 4
- 238000005452 bending Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 230000009467 reduction Effects 0.000 description 3
- 239000002002 slurry Substances 0.000 description 3
- 229910000676 Si alloy Inorganic materials 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 238000007373 indentation Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 229920002037 poly(vinyl butyral) polymer Polymers 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910017518 Cu Zn Inorganic materials 0.000 description 1
- 229910017752 Cu-Zn Inorganic materials 0.000 description 1
- 229910017943 Cu—Zn Inorganic materials 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- 229910001030 Iron–nickel alloy Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- KOMIMHZRQFFCOR-UHFFFAOYSA-N [Ni].[Cu].[Zn] Chemical compound [Ni].[Cu].[Zn] KOMIMHZRQFFCOR-UHFFFAOYSA-N 0.000 description 1
- HRZMCMIZSOGQJT-UHFFFAOYSA-N [Zn].[Mn].[Mg] Chemical compound [Zn].[Mn].[Mg] HRZMCMIZSOGQJT-UHFFFAOYSA-N 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
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- 239000004020 conductor Substances 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
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- 238000000280 densification Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- XUCNUKMRBVNAPB-UHFFFAOYSA-N fluoroethene Chemical group FC=C XUCNUKMRBVNAPB-UHFFFAOYSA-N 0.000 description 1
- 230000005389 magnetism Effects 0.000 description 1
- WJZHMLNIAZSFDO-UHFFFAOYSA-N manganese zinc Chemical compound [Mn].[Zn] WJZHMLNIAZSFDO-UHFFFAOYSA-N 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000002159 nanocrystal Substances 0.000 description 1
- QELJHCBNGDEXLD-UHFFFAOYSA-N nickel zinc Chemical compound [Ni].[Zn] QELJHCBNGDEXLD-UHFFFAOYSA-N 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 238000013001 point bending Methods 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/147—Alloys characterised by their composition
- H01F1/14766—Fe-Si based alloys
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- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
- H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
- H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
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- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/18—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by using pressure rollers
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
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- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/3154—Of fluorinated addition polymer from unsaturated monomers
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Abstract
【解決手段】磁性体粉末10と、ポリテトラフルオロエチレン粉末20とから構成される複合磁性シート1とする。
【選択図】図1
Description
表1に、各実施例および比較例の製造条件および評価結果を示す。
表1に示すように、鉄−珪素を主成分として、粒径が30μm以上250μm以下の範囲である鉄系アモルファス粉末85重量%と、比重2.22、平均粒径約550μmであるPTFE粉末15重量%とを、約200ccの容量を有する回転式V型混合器に投入した。当該混合器の回転速度を120rpmとし、混合時間を30minに設定することにより、均一な混合粉末を得た。次に、二本圧延ロール法により、上記混合物を、異なる回転速度で回転する二本圧延ロールの上方から供給した。一方の圧延ロールの回転速度を10rpmに設定し、他方の圧延ロールの回転速度を15rpmに設定した。これにより、複合磁性シートが成形された。
用いられた磁性体粉末およびPTFE粉末の量を、得られる複合磁性シートに対して、それぞれ、90重量%および10重量%とした以外は、実施例1と同じ条件で製造を行った。
用いられた磁性体粉末およびPTFE粉末の量を、得られる複合磁性シートに対して、それぞれ、93重量%および7重量%とした以外は、実施例1と同じ条件で製造を行った。
用いられた磁性体粉末およびPTFE粉末の量を、得られる複合磁性シートに対して、それぞれ、97重量%および3重量%とした以外は、実施例1と同じ条件で製造を行った。
用いられた磁性体粉末およびPTFE粉末の量を、得られる複合磁性シートに対して、それぞれ、98重量%および2重量%とした以外は、実施例1と同じ条件で製造を行った。
実施例1により得られた複合磁性シートに対して、プレス機を用いて再加圧工程を行った。
実施例2により得られた複合磁性シートに対して、プレス機を用いて再加圧工程を行った。
実施例3により得られた複合磁性シートに対して、プレス機を用いて再加圧工程を行った。
実施例4により得られた複合磁性シートに対して、プレス機を用いて再加圧工程を行った。
実施例5により得られた複合磁性シートに対して、プレス機を用いて再加圧工程を行った。
特許文献2に類似する従来の複合磁性シートとして、磁性体粉末およびポリビニルブチラール系樹脂および溶剤からなる結着剤の量を、得られる複合磁性シートに対して、それぞれ、83重量%および17重量%とし、新規の図に示す従来の製造方法によって複合磁性シートを得た。
比較例1により得られた複合磁性シートに対して、プレス機を用いて再加圧工程を行った。
得られた複合磁性シートの外観および平面度を目視で調べた。また、複合磁性シートを折り曲げることによって、複合磁性シートの可撓性および強度を調べた。外観の評価において、欠陥の全くない状態を「良」とし、使用に問題のない小さい欠陥がある状態を「可」とした。平面度の評価において、ほぼ平面の状態を「良」とし、凹凸が多少あるが使用に問題のない状態を「可」とした。可撓性の評価において、折り曲げによって破損等が無く元の状態に復元できる状態を「良」とし、折り曲げ時に抵抗が多少あるが使用に問題のない状態を「可」とした。強度の評価は、2mm×2mm×20mmの複合磁性シートの角試験片を用意し、両端を固定した上で中心部に荷重をかける3点曲げ試験を行い、3mmまでの押し込みの途中で破損するか否かという観点で評価した。3mmの押し込みで破損しないものは「良」という評価とし、3mmの押し込みにより表面に、磁性コアへの使用に差し障りはないが皺や微小なクラック等の欠陥が生じたものを「可」とした。また、ある寸法を有する複合磁性シートの体積および重量を測って、これらの値から、密度および空孔率を計算した。さらに、複合磁性シートの特性を調べるため、次のような加工処理を行った。まず、得られた複合磁性シートを外径約12mm、内径約6mmの円環状の板を打ち抜き、得られた板状試験片に30ターンの巻線(S1−UEW−0−30−NTL)を施した。これを試験対象として、インピーダンスアナライザ/ゲインフェイズアナライザを用いて、周波数を変化させて透磁率(μ)を測定した。
表1に示すように、実施例1で得られた複合磁性シートの密度および1MHzにおける透磁率(μ)は、それぞれ3.4g/cm3および8.7であった。また、当該シートの外観、可撓性、強度および平面度は、「良」であった。
また、実施例6〜10と実施例1〜5を対比すると明らかなように、同じ組成の磁性体粉末およびPTFE粉末を用いた場合でも、再加圧成形の工程を採用することによって、複合磁性シート内に残存する空気溜まりを最大で約36%低減できることがわかった。つまり、磁性体粉末の混合比が低い複合磁性シートである程、再加圧成形処理を行うことによる密度および透磁率(μ)を効果的に向上させることができる。このことは、本発明に係る複合磁性シートの密度や透磁率(μ)が、万一、所望の値からはずれている場合に、プレス機による再加圧成形を行うという極めて簡素な処置によって、所望の値に調整が可能であるという大きな利点となる。
10 磁性体粉末
20 ポリテトラフルオロエチレン(PTFE)粉末
Claims (2)
- 磁性体粉末と、
ポリテトラフルオロエチレン粉末と、
から構成されることを特徴とする複合磁性シート。 - 磁性体粉末とポリテトラフルオロエチレン粉末とを混合する粉末混合工程と、
上記粉末混合工程後の混合粉末を加圧して成形する加圧成形工程と、
を含むことを特徴とする複合磁性シートの製造方法。
Priority Applications (6)
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JP2006037004A JP4808506B2 (ja) | 2006-02-14 | 2006-02-14 | 複合磁性シート、コイル用複合磁性シートおよびそれらの製造方法 |
KR1020060113830A KR100933523B1 (ko) | 2006-02-14 | 2006-11-17 | 복합 자성 시트 및 그 제조 방법 |
CN2006101727485A CN101022053B (zh) | 2006-02-14 | 2006-12-30 | 复合磁性薄板及其制造方法 |
TW096100468A TW200735137A (en) | 2006-02-14 | 2007-01-05 | Composite magnetic sheet and production method thereof |
US11/672,796 US7976720B2 (en) | 2006-02-14 | 2007-02-08 | Composite magnetic sheet and production method thereof |
EP20070002817 EP1818950B1 (en) | 2006-02-14 | 2007-02-09 | Production method of a composite magnetic sheet |
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JP2006037004A JP4808506B2 (ja) | 2006-02-14 | 2006-02-14 | 複合磁性シート、コイル用複合磁性シートおよびそれらの製造方法 |
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JP2007220747A true JP2007220747A (ja) | 2007-08-30 |
JP2007220747A5 JP2007220747A5 (ja) | 2009-02-19 |
JP4808506B2 JP4808506B2 (ja) | 2011-11-02 |
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US (1) | US7976720B2 (ja) |
EP (1) | EP1818950B1 (ja) |
JP (1) | JP4808506B2 (ja) |
KR (1) | KR100933523B1 (ja) |
CN (1) | CN101022053B (ja) |
TW (1) | TW200735137A (ja) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2009252961A (ja) * | 2008-04-04 | 2009-10-29 | Kobe Steel Ltd | 圧粉磁心用軟磁性材および圧粉磁心 |
JP2009295985A (ja) * | 2008-06-05 | 2009-12-17 | Tridelta Weichferrite Gmbh | 軟磁性材料、およびこの軟磁性材料から構成される物品の製造方法 |
JP2011058058A (ja) * | 2009-09-10 | 2011-03-24 | Nec Tokin Corp | 非晶質軟磁性合金粉末及びその製造方法、並びに非晶質軟磁性合金粉末を用いた圧粉磁心、インダクタ及び磁性シート |
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Also Published As
Publication number | Publication date |
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TW200735137A (en) | 2007-09-16 |
EP1818950A1 (en) | 2007-08-15 |
KR100933523B1 (ko) | 2009-12-23 |
US20070190360A1 (en) | 2007-08-16 |
CN101022053A (zh) | 2007-08-22 |
JP4808506B2 (ja) | 2011-11-02 |
KR20070082014A (ko) | 2007-08-20 |
US7976720B2 (en) | 2011-07-12 |
CN101022053B (zh) | 2010-12-08 |
EP1818950B1 (en) | 2012-08-29 |
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