JP2009070914A - 軟磁性材料、圧粉磁心、軟磁性材料の製造方法、および圧粉磁心の製造方法 - Google Patents
軟磁性材料、圧粉磁心、軟磁性材料の製造方法、および圧粉磁心の製造方法 Download PDFInfo
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- JP2009070914A JP2009070914A JP2007235637A JP2007235637A JP2009070914A JP 2009070914 A JP2009070914 A JP 2009070914A JP 2007235637 A JP2007235637 A JP 2007235637A JP 2007235637 A JP2007235637 A JP 2007235637A JP 2009070914 A JP2009070914 A JP 2009070914A
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- Prior art keywords
- magnetic material
- soft magnetic
- magnetic particles
- insulating film
- metal
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Images
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/02—Cores, Yokes, or armatures made from sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/05—Metallic powder characterised by the size or surface area of the particles
- B22F1/052—Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/102—Metallic powder coated with organic material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/105—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing inorganic lubricating or binding agents, e.g. metal salts
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- C22C38/00—Ferrous alloys, e.g. steel alloys
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- 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
- H01F1/20—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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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
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- 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
- H01F1/26—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 by macromolecular organic substances
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C2202/00—Physical properties
- C22C2202/02—Magnetic
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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
- H01F1/33—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 mixtures of metallic and non-metallic particles; metallic particles having oxide skin
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Chemical & Material Sciences (AREA)
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Abstract
【解決手段】軟磁性材料は、複数の金属磁性粒子10を備え、金属磁性粒子10の粒径の標準偏差(σ)と平均粒径(μ)との比である変動係数Cv(σ/μ)が0.40以下であり、金属磁性粒子10の円形度Sfが0.80以上1以下である。金属磁性粒子10の平均粒径が1μm以上70μm以下であることが好ましい。また、軟磁性材料は、金属磁性粒子10の表面を取り囲む絶縁被膜をさらに備えていることが好ましい。
【選択図】図1
Description
円形度=4π×金属磁性粒子の面積/金属磁性粒子の外周長さの2乗 ・・・(式1)
本実施例では、変動係数Cv(σ/μ)が0.40以下で、円形度Sfが0.80以上である金属磁性粒子を備えることの効果を調べた。
実施例1における軟磁性材料は、上述した実施の形態における軟磁性材料の製造方法を用いて製造された軟磁性材料を用いた。具体的には、まず、準備工程(S11)では、鉄粉を水アトマイズ法により鉄が99.6重量%以上含有され、残部が0.3重量%以下のOおよび0.1重量%以下のC、N、P、またはMnなどの不可避的不純物からなる金属磁性粒子を準備した。実施例1〜4の金属磁性粒子の平均粒径は、それぞれ表1に記載の通りとした。また、実施例1〜4の金属磁性粒子の変動係数Cvおよび円形度Sfは、それぞれ表1に記載の通りであった。なお、金属磁性粒子の変動係数Cvは、レーザ散乱回折粒度分布測定法を用いて対象の軟磁性材料(複数の金属磁性粒子)の粒度分布を測定することにより算出した。円形度Sfは、金属磁性粒子の面積と外周長さを測定した金属磁性粒子の投影像から統計的に算出し、上記式(1)に基づいて算出した。
比較例1〜4の軟磁性材料は、基本的には、実施例2の軟磁性材料と同様に製造したが、変動係数Cv、円形度Sf、および平均粒径(μ)を下記の表1に記載のようにそれぞれ変更した点においてのみ異なる。また、比較例1〜4の軟磁性材料は、実施例1と同様に製造した。
実施例1〜4および比較例1〜4の圧粉磁心について、直流重畳特性および渦電流損をそれぞれ測定した。
(鉄損)=(ヒステリシス損係数)×(周波数)+(渦電流損係数)×(周波数)2
(渦電流損)=(渦電流損係数)×(周波数)2
図11および表1に示すように、変動係数Cvが0.4以下で、かつ円形度Sfが0.8以上1.0以下の金属磁性粒子を備えた実施例1〜4は、比較例1〜3に比べて、インダクタンスの低下量が小さく、かつ直流重畳特性に優れていることがわかった。
Claims (14)
- 複数の金属磁性粒子を備え、
前記金属磁性粒子の粒径の標準偏差(σ)と平均粒径(μ)との比である変動係数Cv(σ/μ)が0.40以下であり、前記金属磁性粒子の円形度Sfが0.80以上1以下である、軟磁性材料。 - 前記金属磁性粒子の平均粒径が1μm以上70μm以下である、請求項1に記載の軟磁性材料。
- 金属石鹸および六方晶系の結晶構造を有する無機潤滑剤の少なくとも一方からなる添加剤をさらに備え、
前記添加剤は、複数の前記金属磁性粒子に対して、0.001質量%以上0.2質量%以下含まれる、請求項1または2に記載の軟磁性材料。 - 前記金属磁性粒子の表面を取り囲む絶縁被膜をさらに備える、請求項1〜3のいずれかに記載の軟磁性材料。
- 前記絶縁被膜は、リン酸化合物、ケイ素化合物、ジルコニウム化合物、およびホウ素化合物からなる群より選ばれた少なくとも一種の物質よりなる、請求項4に記載の軟磁性材料。
- 前記絶縁被膜は、一の絶縁被膜であり、
前記金属磁性粒子は前記一の絶縁被膜の表面を取り囲む他の絶縁被膜を有し、
前記他の絶縁被膜は、熱硬化型シリコーン樹脂を含む、請求項4または5に記載の軟磁性材料。 - 請求項1〜6のいずれかに記載の軟磁性材料を用いて作製された、圧粉磁心。
- 複数の金属磁性粒子を準備する準備工程を備え、
前記準備工程では、粒径の標準偏差(σ)と、平均粒径(μ)との比である変動係数Cv(σ/μ)が0.40以下であり、円形度Sfが0.80以上1以下である前記金属磁性粒子を準備する、軟磁性材料の製造方法。 - 前記準備工程では、平均粒径が1μm以上70μm以下の前記金属磁性粒子を準備する、請求項8に記載の軟磁性材料の製造方法。
- 複数の前記金属磁性粒子に対して、0.001質量%以上0.2質量%以下の金属石鹸および六方晶系の結晶構造を有する無機潤滑剤の少なくとも一方からなる添加剤を加える添加工程をさらに備える、請求項8または9に記載の軟磁性材料の製造方法。
- 前記金属磁性粒子の表面に絶縁被膜を形成する絶縁被膜形成工程をさらに備える、請求項8〜10のいずれかに記載の軟磁性材料の製造方法。
- 前記絶縁被膜形成工程では、リン酸化合物、ケイ素化合物、ジルコニウム化合物、およびホウ素化合物からなる群より選ばれた少なくとも一種の物質よりなる絶縁被膜を形成する、請求項11に記載の軟磁性材料の製造方法。
- 絶縁被膜形成工程は、一の絶縁被膜として前記絶縁被膜を形成する一の絶縁被膜形成工程と、
前記一の絶縁被膜の表面を取り囲む他の絶縁被膜を形成する他の絶縁被膜形成工程とを含み、
前記他の絶縁被膜形成工程では、熱硬化型シリコーン樹脂を含む前記他の絶縁被膜を形成する、請求項11または12に記載の軟磁性材料の製造方法。 - 請求項8〜13のいずれかに記載の軟磁性材料の製造方法を用いて軟磁性材料を製造する工程と、
前記軟磁性材料を用いて加圧成形して圧粉磁心を製造する工程とを備えた、圧粉磁心の製造方法。
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CN101578669B (zh) | 2012-11-07 |
ES2537805T3 (es) | 2015-06-12 |
CN101578669A (zh) | 2009-11-11 |
EP2154694A4 (en) | 2010-12-08 |
EP2154694A1 (en) | 2010-02-17 |
EP2154694B1 (en) | 2015-05-13 |
WO2009034894A1 (ja) | 2009-03-19 |
US20100044618A1 (en) | 2010-02-25 |
JP5368686B2 (ja) | 2013-12-18 |
US8123874B2 (en) | 2012-02-28 |
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