JP2010080978A - Soft magnetic alloy powder and powder magnetic core - Google Patents
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- 239000000843 powder Substances 0.000 title claims abstract description 72
- 229910001004 magnetic alloy Inorganic materials 0.000 title claims abstract description 23
- 239000000428 dust Substances 0.000 claims abstract description 45
- 230000035699 permeability Effects 0.000 claims abstract description 37
- 229910017082 Fe-Si Inorganic materials 0.000 claims abstract description 10
- 229910017133 Fe—Si Inorganic materials 0.000 claims abstract description 10
- 239000002245 particle Substances 0.000 claims abstract description 10
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 7
- 239000012535 impurity Substances 0.000 claims abstract description 5
- 229920002050 silicone resin Polymers 0.000 claims description 16
- 229910052751 metal Inorganic materials 0.000 claims description 13
- 239000002184 metal Substances 0.000 claims description 13
- 229920005989 resin Polymers 0.000 claims description 11
- 239000011347 resin Substances 0.000 claims description 11
- 239000003822 epoxy resin Substances 0.000 claims description 7
- 229920000647 polyepoxide Polymers 0.000 claims description 7
- 239000005011 phenolic resin Substances 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 4
- 229910052760 oxygen Inorganic materials 0.000 claims description 4
- 229910052710 silicon Inorganic materials 0.000 claims description 3
- 238000009689 gas atomisation Methods 0.000 claims description 2
- 238000007664 blowing Methods 0.000 abstract description 8
- 239000011230 binding agent Substances 0.000 abstract description 7
- 238000002156 mixing Methods 0.000 abstract description 2
- 230000001105 regulatory effect Effects 0.000 abstract description 2
- 239000000498 cooling water Substances 0.000 abstract 1
- 239000000155 melt Substances 0.000 abstract 1
- 239000011369 resultant mixture Substances 0.000 abstract 1
- 229910045601 alloy Inorganic materials 0.000 description 11
- 239000000956 alloy Substances 0.000 description 11
- 239000007789 gas Substances 0.000 description 10
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 9
- 230000000694 effects Effects 0.000 description 7
- 229910000702 sendust Inorganic materials 0.000 description 7
- 230000004907 flux Effects 0.000 description 6
- 238000000034 method Methods 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 5
- 230000007423 decrease Effects 0.000 description 5
- 229910052742 iron Inorganic materials 0.000 description 4
- 230000014759 maintenance of location Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 2
- 229910002796 Si–Al Inorganic materials 0.000 description 2
- 238000000354 decomposition reaction Methods 0.000 description 2
- 238000009499 grossing Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 239000012212 insulator Substances 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- 229910052750 molybdenum Inorganic materials 0.000 description 2
- 239000011733 molybdenum Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229910000889 permalloy Inorganic materials 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 235000019353 potassium silicate Nutrition 0.000 description 2
- 150000003377 silicon compounds Chemical class 0.000 description 2
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 229910003296 Ni-Mo Inorganic materials 0.000 description 1
- 235000021355 Stearic acid Nutrition 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229910000905 alloy phase Inorganic materials 0.000 description 1
- CEGOLXSVJUTHNZ-UHFFFAOYSA-K aluminium tristearate Chemical compound [Al+3].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CEGOLXSVJUTHNZ-UHFFFAOYSA-K 0.000 description 1
- 229940063655 aluminum stearate Drugs 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
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- 230000006835 compression Effects 0.000 description 1
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- 238000001816 cooling Methods 0.000 description 1
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- 238000010304 firing Methods 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000006247 magnetic powder Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 description 1
- 229910052982 molybdenum disulfide Inorganic materials 0.000 description 1
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 1
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 229920002545 silicone oil Polymers 0.000 description 1
- 229920002379 silicone rubber Polymers 0.000 description 1
- 239000004945 silicone rubber Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 239000008117 stearic acid Substances 0.000 description 1
- ITRNXVSDJBHYNJ-UHFFFAOYSA-N tungsten disulfide Chemical compound S=[W]=S ITRNXVSDJBHYNJ-UHFFFAOYSA-N 0.000 description 1
- 238000009692 water atomization Methods 0.000 description 1
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- Soft Magnetic Materials (AREA)
Abstract
Description
本発明は、比較的大きな直流が印加されたときであっても比透磁率が大でありかつまたコアロスが小さい圧粉磁芯およびこの圧粉磁芯の素材として適した軟磁性合金粉末に関するものである。 The present invention relates to a dust core having a large relative permeability and a small core loss even when a relatively large direct current is applied, and a soft magnetic alloy powder suitable as a material for the dust core. It is.
従来、スイッチング電源の直流出力側の平滑用チョークコイルや交流入力側のノーマルモード用ノイズフィルタや、アクティブフィルタ用チョークコイルなどには、Ｆｅ−Ｓｉ−Ａｌ系磁性合金（センダスト合金）よりなる圧粉磁芯が多く用いられている。 Conventionally, for a smoothing choke coil on the DC output side of a switching power supply, a normal mode noise filter on an AC input side, and a choke coil for an active filter, etc., a compact made of Fe-Si-Al magnetic alloy (Sendust alloy) Many magnetic cores are used.
このようなセンダスト合金よりなる圧粉磁芯は、Ｆｅ−Ｎｉ−Ｍｏ系合金（モリブデンパーマロイ合金）よりなる圧粉磁芯に比べて原料費が安価であるが、透磁率およびコアロス（電力損失）〉については優れているとはいいがたい。 The dust core made of Sendust alloy has a lower raw material cost than the dust core made of Fe-Ni-Mo alloy (molybdenum permalloy alloy), but permeability and core loss (power loss). > Is not good.
また、チョークコイルやインダクターに使用する磁芯では、コアロスが大きいと磁芯の温度上昇が大きくなって小型化が難しくなる傾向となる。 In addition, in the magnetic core used for the choke coil and the inductor, if the core loss is large, the temperature rise of the magnetic core becomes large, and the miniaturization tends to be difficult.
そこで、センダスト合金よりなる圧粉磁芯のコアロス低減に関しては、例えば、Ｆｅ−Ｓｉ−Ａｌ系磁性合金（センダスト合金）のインゴットを７００〜１１００℃で焼鈍した後粉砕し、ここで得た粉末をプレス成形したあとさらに水素雰囲気中６００〜８００℃で焼成することにより、モリブデンパーマロイよりも高い透磁率と低いコアロスの圧粉磁芯を得る技術もあった（特許文献１）。
しかしながら、センダスト合金よりなる圧粉磁芯をスイッチング電源の平滑用チョークコイルやアクティブフィルタ用チョークコイルなどに使用した場合には、大きな直流が印加された状態で用いられるため、初透磁率は高いとしても、大きな直流磁界が印加されたときには磁芯が飽和し、透磁率が低下してしまうという問題点があった。 However, when a dust core made of sendust alloy is used for a smoothing choke coil or an active filter choke coil of a switching power supply, it is used in a state where a large direct current is applied. However, there is a problem that when a large DC magnetic field is applied, the magnetic core is saturated and the magnetic permeability is lowered.
本発明は、このような従来の課題にかんがみてなされたものであって、大きな直流磁界が印加されたときでも従来のセンダスト合金からなる圧粉磁芯のように透磁率が低下せず、コアロスも小さく、小型化も可能である圧粉磁芯およびこの圧粉磁芯の素材として適した軟磁性合金粉末を提供することを目的としている。 The present invention has been made in view of such a conventional problem, and even when a large DC magnetic field is applied, the magnetic permeability does not decrease as in the case of a dust core made of a conventional Sendust alloy, and the core loss is reduced. An object of the present invention is to provide a dust core that is small and can be miniaturized, and a soft magnetic alloy powder that is suitable as a material for the dust core.
本発明に係わる軟磁性合金粉末は、請求項１に記載しているように、質量％で、Ｓｉ：０．５〜８．０％を含み、Ｏ：０．５％以下に規制し、残部がＦｅおよび不可避的不純物からなる成分組成を有するアトマイズ粉末からなり、粉末の粒子形状を２次元的に観察したときに長軸の長さＬＬと短軸の長さＬＳとの比ＬＬ／ＬＳが平均して１．１から２．１までの間にあるものとしたことを特徴としている。 As described in claim 1, the soft magnetic alloy powder according to the present invention contains, in mass%, Si: 0.5 to 8.0%, O: 0.5% or less, and the balance Is composed of atomized powder having a component composition composed of Fe and inevitable impurities, and the ratio L L between the long axis length L L and the short axis length L S when the particle shape of the powder is observed two-dimensionally / L S is characterized in that it is assumed to be between 1.1 and average 1.3.
そして、本発明に係わる軟磁性合金粉末は、請求項１に記載しているように、アトマイズ粉末は、溶湯のガス噴霧アトマイズ粉末、溶湯のガス噴霧およびこれに続く水噴霧アトマイズ粉末、溶湯のガス噴霧およびこの直後の水冷却アトマイズ粉末の少なくとも１種である。 In the soft magnetic alloy powder according to the present invention, as described in claim 1, the atomized powder is a gas atomized atomized powder of a molten metal, a gas atomized of a molten metal, and a water atomized powder following the atomized powder, a gas of the molten metal. It is at least one of sprayed and water-cooled atomized powder immediately thereafter.
本発明に係わる圧粉磁芯は、請求項３に記載しているように、請求項１または２に記載のＦｅ−Ｓｉ系軟磁性合金粉末と絶縁剤兼結合剤を配合して圧粉成形した圧粉成形体よりなり、２０Ｏｅのバイアス直流磁界のもとでの微分比透磁率が５０以上であり、５０Ｏｅのバイアス直流磁界のもとでの微分比透磁率が４０以上であり、１００Ｏｅのバイアス直流磁界のもとでの微分比透磁率が３０以上であるものとしたことを特徴としている。 As described in claim 3, the dust core according to the present invention is formed by blending the Fe-Si soft magnetic alloy powder according to claim 1 or 2 and an insulator / binder. The differential relative permeability under a bias direct current magnetic field of 20 Oe is 50 or more, the differential relative permeability under a bias direct current field of 50 Oe is 40 or more, and 100 Oe. The differential relative permeability under a bias direct current magnetic field is 30 or more.
そして、本発明に係わる圧粉磁芯の実施態様においては、請求項４に記載しているように、絶縁剤は、シリコーン樹脂であるものとすることができる。 In the embodiment of the dust core according to the present invention, as described in claim 4, the insulating agent may be a silicone resin.
また、本発明に係わる別の圧粉磁芯は、請求項５に記載しているように、請求項３または４に記載の圧粉成形体に樹脂を含浸してなるものとしたことを特徴としている。 Further, another powder magnetic core according to the present invention is characterized in that, as described in claim 5, the powder molded body according to claim 3 or 4 is impregnated with a resin. It is said.
そして、この圧粉磁芯の実施態様においては、請求項６に記載しているように、樹脂は、シリコーン樹脂、エポキシ系樹脂、フェノール系樹脂のうちから選ばれるものとすることができる。 In the embodiment of the dust core, as described in claim 6, the resin can be selected from silicone resin, epoxy resin, and phenol resin.
本発明による軟磁性合金粉末では、請求項１に記載しているように、重量％で、Ｓｉ：０．５〜８．０％を含み、Ｏ：０．５％以下に規制し、残部がＦｅおよび不可避的不純物からなる成分組成を有するアトマイズ粉末からなり、粉末の粒子形状を２次元的に観察したときに長軸の長さＬＬと短軸の長さＬＳとの比ＬＬ／ＬＳが平均して１．１から２．１までの間にあるものとしたから、比較的大きな直流（磁界）が印加されたときでも比透磁率の低下が小さく、比透磁率を大きな値のものとすることが可能であると共に、コアロスの小さい圧粉磁芯に適した軟磁性合金粉末を提供することが可能であるという著しく優れた効果がもたらされる。 In the soft magnetic alloy powder according to the present invention, as described in claim 1, by weight, Si: 0.5 to 8.0% is included, O: 0.5% or less, the balance is consists atomized powder having a component composition consisting of Fe and unavoidable impurities, the ratio of the length L S of the major axis length L L and a minor axis when observing the powder particle shape in two dimensions L L / since L S is assumed to be between 1.1 and average 1.3, a relatively large direct reduction of relative magnetic permeability even when the (magnetic field) is applied is small, a large value of relative magnetic permeability In addition, it is possible to provide a soft magnetic alloy powder suitable for a dust core having a small core loss.
そして、請求項１に記載しているように、アトマイズ粉末は、溶湯のガス噴霧アトマイズ粉末、溶湯のガス噴霧およびこれに続く水噴霧アトマイズ粉末、溶湯のガス噴霧およびこの直後の水冷却アトマイズ粉末の少なくとも１種であるものとすることによって、密度を高いものにできる圧密性や形状精度を良好なものにできる成形性（ないしは保形性）を考慮した軟磁性合金粉末を提供することが可能であるという著しく優れた効果がもたらされる。 Further, as described in claim 1, the atomized powder is a gas atomized atomized molten metal powder, a gas atomized molten metal and a water atomized atom powder following the atomized powder, a gas atomized molten metal, and a water-cooled atomized powder immediately thereafter. By using at least one kind, it is possible to provide a soft magnetic alloy powder in consideration of formability (or shape retention) capable of achieving high density and good shape accuracy. There is a markedly superior effect.
本発明による圧粉磁芯では、請求項３に記載しているように、請求項１または２に記載のＦｅ−Ｓｉ系軟磁性合金粉末と絶縁剤兼結合剤を配合して圧粉成形した圧粉成形体よりなり、２０Ｏｅのバイアス直流磁界のもとでの微分比透磁率が５０以上であり、５０Ｏｅのバイアス直流磁界のもとでの微分比透磁率が４０以上であり、１００Ｏｅのバイアス直流磁界のもとでの微分比透磁率が３０以上であるものとしたから、比較的大きな直流（磁界）が印加された状態であっても比透磁率が大であり、かつまたコアロスが小さい圧粉磁芯を提供することが可能であるという著しく優れた効果がもたらされる。 In the dust core according to the present invention, as described in claim 3, the Fe-Si soft magnetic alloy powder according to claim 1 or 2 and an insulator / binder are blended and compacted. It consists of a green compact and has a differential relative permeability of 50 or more under a bias DC magnetic field of 20 Oe, a differential relative permeability of 40 or more under a bias DC magnetic field of 50 Oe, and a bias of 100 Oe Since the differential relative permeability under a direct current magnetic field is 30 or more, the relative permeability is large even when a relatively large direct current (magnetic field) is applied, and the core loss is small. The remarkably excellent effect that it is possible to provide a dust core is brought about.
そして、請求項４に記載しているように、絶縁剤は、シリコーン樹脂であるものとすることによって、高温に加熱されたときでも絶縁特性や接合特性が低下せず、周波数特性の良好な圧粉磁芯を提供することが可能であるという著しく優れた効果がもたらされる。 Further, as described in claim 4, the insulating agent is a silicone resin, so that the insulation characteristic and the bonding characteristic are not deteriorated even when heated to a high temperature, and the pressure characteristic is good. The remarkably superior effect that it is possible to provide a powder magnetic core is brought about.
また、本発明に係わる別の圧粉磁芯によれば、請求項５に記載しているように、請求項３または４に記載の圧粉成形体に樹脂を含浸してなるものとしたから、比較的大きな直流（磁界）が印加された状態であっても比透磁率が大であり、かつまたコアロスが小さく、機械的強度にも優れた圧粉磁芯を提供することが可能であるという著大なる効果がもたらされる。 Further, according to another dust core according to the present invention, as described in claim 5, the powder compact formed in claim 3 or 4 is impregnated with a resin. Even when a relatively large direct current (magnetic field) is applied, it is possible to provide a dust core having a high relative magnetic permeability, a small core loss, and an excellent mechanical strength. The remarkable effect is brought about.
そして、請求項６に記載しているように、樹脂は、シリコーン樹脂、エポキシ系樹脂、フェノール系樹脂のうちから選ばれるものとすることによって、機械的強度をかなり高めた圧粉磁芯を提供することが可能であるという著しく優れた効果がもたらされる。 Further, as described in claim 6, the resin is selected from a silicone resin, an epoxy resin, and a phenol resin, thereby providing a dust core having a considerably increased mechanical strength. It is possible to achieve a remarkably excellent effect.
本発明に係わる軟磁性合金粉末は、質量％で、Ｓｉ：０．５〜８．０％を含み、Ｏ：０．５％以下に規制し、残部がＦｅおよび不純物よりなるものであるが、この限定理由について説明する。 The soft magnetic alloy powder according to the present invention includes, in mass%, Si: 0.5 to 8.0%, O: regulated to 0.5% or less, and the balance is made of Fe and impurities. The reason for this limitation will be described.
Ｓｉは磁性合金の透磁率および磁束密度を向上させるのに有用な元素であるが、Ｓｉ含有量が０．５％よりも少ないと純鉄に近くなってコアロス（電力損失）が大きくなるので、０．５％以上、望ましくは１．０％以上、さらに望ましくは２．０％以上とするのが良い。 Si is an element useful for improving the magnetic permeability and magnetic flux density of a magnetic alloy, but if the Si content is less than 0.5%, it becomes close to pure iron and the core loss (power loss) increases. It should be 0.5% or more, preferably 1.0% or more, and more preferably 2.0% or more.
しかしながら、Ｓｉ含有量が多すぎると透磁率が低下し、磁束密度も低下し、直流重畳特性が劣化して大きな直流が印加された状態で使用されたときに透磁率が低下することとなるので、８．０％以下、より好ましくは７．５％以下、さらに望ましくは７．０％以下とするのが良い。 However, if the Si content is too high, the magnetic permeability is lowered, the magnetic flux density is lowered, the direct current superimposition characteristics are deteriorated, and the magnetic permeability is lowered when used in a state where a large direct current is applied. 8.0% or less, more preferably 7.5% or less, and even more preferably 7.0% or less.
また、酸素含有量が多いと保磁力が増大し、その結果としてコアロスが増大するので、酸素量は少ない方が望ましく、０．５％以下、好ましくは０．４％以下、さらに好ましくは０．３％以下とするのが良い。 Further, when the oxygen content is high, the coercive force is increased, and as a result, the core loss is increased. It should be 3% or less.
本発明に係わる上記成分組成のＦｅ−Ｓｉ系軟磁性合金粉末は、アトマイズ粉末よりなるものであって、
・ガス噴霧アトマイズ粉末（溶湯流にガスを吹きつけてアトマイズ化する手法であって、比較的丸い（アスペクト比が１に近い）形状で圧密性の良好な粉末を得る方法)
・ガス噴霧およびこれに続く水噴霧アトマイズ粉末(溶湯流にガスを吹きつけたのち水を吹きつけてアトマイズ化する手法であって、比較的小径のものは丸い（アスペクト比が１に近い）形状にすると共に比較的大径のものはやや不規則な（アスペクト比が２〜４の）形状に変えて凝固させることによって全体としてアスペクト比が１〜４程度の成形性（保形性）および圧密性が共に良好な粉末を得る方法）
・ガス噴霧およびこの直後の水冷却アトマイズ粉末（溶湯流にガスを吹きつけたのち水中で冷却する手法であって、比較的小径のものは丸い(アスペクト比が１に近い）形状にすると共に比較的大径のものはやや不規則な（アスペクト比が２〜４の）形状にして凝固させることによって全体としてアスペクト比が１〜４程度で成形性（保形性）および圧密性が共に良好な粉末を得る方法)が用いられる。
The Fe—Si based soft magnetic alloy powder of the above component composition according to the present invention is made of atomized powder,
・ Gas spray atomized powder (A method of atomizing by blowing gas into the molten metal flow, and obtaining a powder with good roundness (aspect ratio close to 1) and good compactness)
-Gas atomization and subsequent water atomization atomized powder (A method of atomizing by blowing water to a molten metal stream and then atomizing water, with a relatively small diameter having a round shape (with an aspect ratio close to 1) In addition, a relatively large-diameter one having a relatively irregular shape (with an aspect ratio of 2 to 4) is solidified and solidified to formability (shape retention) and compaction with an aspect ratio of about 1 to 4 as a whole. To obtain powder with good properties)
・ Gas spraying and water-cooled atomized powder immediately after this (a method of cooling in water after gas is blown into a molten metal stream, and comparatively small ones with a round shape (with an aspect ratio close to 1) A large-diameter material having a moderately irregular shape (with an aspect ratio of 2 to 4) is solidified to have an aspect ratio of about 1 to 4 as a whole, and both formability (shape retention) and compactness are good. A method of obtaining a powder) is used.
そして、本発明に係わる軟磁性合金粉末は、より好ましくは、上記の手法により得られるアトマイズ粉末からなり、粉末の粒子形状を二次元的に観察したときに長軸の長さＬＬと短軸の長さＬＳとの比（アスペクト比）ＬＬ／ＬＳが平均して１．１から２．１までの間にあるものとする。 The soft magnetic alloy powder according to the present invention is more preferably composed of an atomized powder obtained by the above method, and the major axis length L L and minor axis when the particle shape of the powder is observed two-dimensionally. assumed to be between from the length L ratio of S (aspect ratio) L L / L S is on average 1.1 to 2.1.
この場合、ＬＬ／ＬＳの値が１．０〜３．５の適度のものであれば、良好なる成形性を有するものとなり、このＬＬ／ＬＳの値が大きいと、透磁率は大きいものになりやすいが、この比が大きすぎる（すなわち、偏平なものが多くなりすぎる）と成形性が低下するので、２．１以下となっているものとするのが良い。 In this case, if the value of L L / L S is a moderate value of 1.0 to 3.5, it has good moldability, and when the value of L L / L S is large, the magnetic permeability is Although it tends to be large, if this ratio is too large (that is, too many flat ones), the moldability deteriorates, so it should be 2.1 or less.
本発明による圧粉磁芯は、上記したＦｅ−Ｓｉ系軟磁性合金粉末と絶縁剤（ないしは結合剤）をプレス成形等により圧粉成形した圧粉成形体よりなるものであるが、この場合の絶縁剤（ないしは結合剤）としては水ガラスを使用することも可能ではあるが、この水ガラスは接着強度が低いと共に高温に加熱した場合に絶縁特性が低下する傾向となって圧粉磁芯の周波数特性を劣化させる可能性があるので、シリコーン樹脂を用いるのが好ましい。 The dust core according to the present invention is composed of a dust compact formed by compacting the above-described Fe-Si soft magnetic alloy powder and an insulating agent (or binder) by press molding or the like. It is possible to use water glass as the insulating agent (or binder), but this water glass has low adhesive strength and tends to deteriorate the insulation properties when heated to high temperatures. Since there is a possibility of deteriorating frequency characteristics, it is preferable to use a silicone resin.
そして、この場合のシリコーン樹脂としては、広義におけるシリコーンオイルやシリコーンゴムなども含まれる。そして、このシリコーン樹脂は０．５〜５．０重量％程度の配合量とすることができ、０．５重量％よりも少ないと絶縁剤、結合剤としての十分な作用を得ることが困難な傾向となり、５．０重量％よりも多いと透磁率が低下する傾向となる。 In this case, the silicone resin includes silicone oil and silicone rubber in a broad sense. And this silicone resin can be made into the compounding quantity of about 0.5 to 5.0 weight%, and when less than 0.5 weight%, it is difficult to obtain sufficient effect | action as an insulating agent and a binder. If it exceeds 5.0% by weight, the magnetic permeability tends to decrease.
また、圧粉成形の際の潤滑剤として、ステアリン酸、ステアリン酸亜鉛、ステアリン酸アルミニウム、ワックス、二硫化モリブデン、二硫化タングステンなどを０．１〜１．０重量％程度用いることもできる。 In addition, as a lubricant for compacting, stearic acid, zinc stearate, aluminum stearate, wax, molybdenum disulfide, tungsten disulfide, or the like can be used in an amount of about 0.1 to 1.0% by weight.
そして、圧粉磁芯に対しては適度な温度範囲、例えば、５００〜１０００℃での熱処理を行うことにより、圧縮歪が解放され、合金相が安定化し、シリコ一ン樹脂の分解に伴う体積収縮によって磁性粉末の充填率が向上し、高飽和磁束密度を有する高比透磁率の圧粉磁芯とすることが可能となる。 Then, by performing a heat treatment at an appropriate temperature range, for example, 500 to 1000 ° C., on the dust core, the compression strain is released, the alloy phase is stabilized, and the volume associated with the decomposition of the silicone resin. The packing rate of the magnetic powder is improved by the shrinkage, and a powder core having a high relative magnetic permeability and a high saturation magnetic flux density can be obtained.
このとき、シリコーン樹脂の分解に伴ってシリコン化合物が残存することとなるが、このシリコン化合物は基本的に強い結合力を有するため、圧粉磁芯の十分な強度を確保することができることとなる。 At this time, the silicon compound remains with the decomposition of the silicone resin, but since this silicon compound basically has a strong binding force, sufficient strength of the dust core can be secured. .
さらに、本発明による圧粉磁芯においては、前記圧粉成形体中の気孔部分に、樹脂を含浸させることによってその強度をさらに増大させたものとすることも必要に応じて望ましく、この際の樹脂としては、シリコーン樹脂やエポキシ系樹脂やフェノール系樹脂などの液状樹脂を用いることができ、エポキシ系樹脂やフェノール系樹脂では２００℃程度で熱分解するが、シリコーン樹脂を用いた場合には８００〜９００℃程度の高温であっても十分な機械的強度を確保できるものとなる。 Furthermore, in the dust core according to the present invention, it is desirable that the strength is further increased by impregnating a resin in the pore portion in the dust compact, if necessary. As the resin, a liquid resin such as a silicone resin, an epoxy resin, or a phenol resin can be used. The epoxy resin or the phenol resin is thermally decomposed at about 200 ° C. However, when the silicone resin is used, the resin is 800. Sufficient mechanical strength can be secured even at a high temperature of about ~ 900 ° C.
そして、本発明に係わる圧粉磁芯は、２０Ｏｅのバイアス直流磁界のもとでの微分比透磁率が５０以上であり、５０Ｏｅのバイアス直流磁界のもとでの微分比透磁率が４０以上であり、１００Ｏｅのバイアス直流磁界のもとでの微分比透磁率が３０以上であるものであって、大きな直流磁界が印加されたときでも透磁率がさほど低下しないことを特徴とするものである。 The dust core according to the present invention has a differential relative permeability of 50 or more under a bias DC magnetic field of 20 Oe and a differential relative permeability of 40 or more under a bias DC magnetic field of 50 Oe. In other words, the differential relative permeability under a bias DC magnetic field of 100 Oe is 30 or more, and the magnetic permeability does not decrease so much even when a large DC magnetic field is applied.
本発明による圧粉磁芯では、上記したように、磁束密度の高いＦｅ−Ｓｉ系合金を用いることによって、大きな直流が印加された状態でも高い微分比透磁率を得ることができるものであり、直流重畳性がかなり良好なものである。 In the dust core according to the present invention, as described above, by using a Fe-Si alloy having a high magnetic flux density, a high differential relative permeability can be obtained even when a large direct current is applied, DC superimposition is quite good.
本発明に係わる圧粉磁芯は、上述した構成としたものであるが、その形状はとくに限定されるものではなく、いわゆるＥＥ型、ＥＩ型、ＥＲ型、ＥＰＣ型、カップ型、ポット型、ドラム型、ロイダル型等々のものとして適用することができる。 The dust core according to the present invention has the above-described configuration, but the shape is not particularly limited, so-called EE type, EI type, ER type, EPC type, cup type, pot type, It can be applied as a drum type, a roidal type, or the like.
以下、本発明の実施例について比較例とともに説明するが、本発明はこのような実施例にのみ限定されないことはいうまでもない。 Examples of the present invention will be described below together with comparative examples, but it is needless to say that the present invention is not limited to such examples.
表１に示すようにＳｉ含有量を変化させたＦｅ−Ｓｉ系合金の溶湯を溶製したのち、同じく表１に示す噴霧方法でアトマイズ化した。 As shown in Table 1, after melting a molten Fe-Si alloy having a different Si content, it was atomized by the spraying method also shown in Table 1.
次いで、ここで得た各アトマイズ粉末を１００メッシュ以下の大きさにふるい分けした後、各粉末粒子（各々約１０００個）を二次元に投影した際の長軸方向の長さＬＬと短軸方向の長さＬＳとの比（アスペクト比）ＬＬ／ＬＳを測定し、その平均を求めたところ、同じく表１に示す結果であった。このように、各粉末の粒子径の比（ＬＬ／ＬＳ）は、最大で３．１となっており、各粒子は成形性が低下するほどには偏平化していないものであった。 Next, each atomized powder obtained here is screened to a size of 100 mesh or less, and then the length L L in the major axis direction and the minor axis direction when each powder particle (each about 1000 particles) is projected two-dimensionally. the length L ratio of S (aspect ratio) L L / L S were measured, and was determined the average, it was also the result shown in Table 1. Thus, the particle diameter ratio (L L / L S ) of each powder was 3.1 at the maximum, and each particle was not flattened to such an extent that formability was lowered.
また、各粉末におけるＳｉ含有量およびＯ含有量を測定したところ、同じく表１に示す結果であった。 Moreover, when Si content and O content in each powder were measured, it was the result similarly shown in Table 1.
次いで、各アトマイズ粉末に対し、真空中１０００℃で１時間の歪取り熱処理を施したのち、絶縁剤（兼結合剤）としてシリコーン樹脂を４．０重量％混合して撹拌した後乾燥し、さらに潤滑剤としてステアリン酸亜鉛を０．５重重％混合し、次いで、室温にて圧力１３tonf/cm2でプレス成形することによって、外径が２８mm、内径が２０mm、高さが５mmのリング形状をなす圧粉磁芯を作製した。そして、得られた各圧粉磁芯に対して真空中８００℃で１時間の熱処理を施した。 Next, each atomized powder was subjected to a heat treatment for removing strain for 1 hour at 1000 ° C. in a vacuum, and then mixed with 4.0% by weight of a silicone resin as an insulating agent (cum binder), stirred and dried. 0.5 wt% zinc stearate as a lubricant is mixed and then press-molded at room temperature with a pressure of 13 tonf / cm 2 to form a ring shape with an outer diameter of 28 mm, an inner diameter of 20 mm, and a height of 5 mm. A dust core was prepared. The obtained dust cores were heat-treated at 800 ° C. for 1 hour in a vacuum.
さらに、実施例１〜４、比較例１〜４の圧粉磁芯に対しては、圧粉成形体中の気孔内にシリコーン樹脂またはエポキシ系樹脂の含浸処理を行い、シリコーン樹脂の含浸を行った圧粉成形体に対しては真空中８００℃で１時間の硬化処理を施し、エポキシ系樹脂の含浸を行った圧粉成形体に対しては大気中１５０℃で１時間の硬化処理を施した。 Furthermore, with respect to the dust cores of Examples 1 to 4 and Comparative Examples 1 to 4, the silicone resin or the epoxy resin is impregnated into the pores in the dust compact, and the silicone resin is impregnated. The compacted green body was subjected to a curing treatment at 800 ° C. for 1 hour in a vacuum, and the green compact body impregnated with an epoxy resin was subjected to a curing treatment at 150 ° C. for 1 hour in the atmosphere. did.
次いで、各圧粉磁芯について、周波数ｆ＝１００ｋＨｚでかつ２０Ｏｅのバイアス直流磁界のもとでの微分比透磁率μ'、同周波数(f:１００kHz)でかつ５００Ｏｅのバイアス直流磁界のもとでの微分比透磁率μ'、同周波数（ｆ＝１００ｋＨｚ）でかつ１００Ｏｅのバイアス直流磁界のもとでの微分比透磁率μ'をそれぞれ測定したところ、同じく表１に示す結果であった。 Next, for each dust core, the differential relative permeability μ ′ at a frequency f = 100 kHz and a bias DC magnetic field of 20 Oe, the same frequency (f: 100 kHz) and a bias DC magnetic field of 500 Oe. The differential relative permeability μ ′ and the differential relative permeability μ ′ at the same frequency (f = 100 kHz) and under a bias DC magnetic field of 100 Oe were measured, and the results are also shown in Table 1.
さらに、各圧粉磁芯について、周波数ｆ＝１００ｋＨｚ、磁束密度Ｂｍ＝３００Ｇでのコアロス（鉄損）Ｐｃを測定したところ、同じく表１に示す結果であった。 Further, for each dust core, the core loss (iron loss) Pc at a frequency f = 100 kHz and a magnetic flux density Bm = 300 G was measured.
さらにまた、各圧粉磁芯の圧環強度を調べたところ、同じく表１に示す結果であった。なお、このときの圧環強度は、圧粉磁芯を径方向に立てた状態にして上方から圧力を加えたときに、圧粉磁心が破壊したときの荷重として調べた。この結果を同じく表１に示す。 Furthermore, when the crushing strength of each dust core was examined, the results shown in Table 1 were obtained. The crushing strength at this time was examined as a load when the dust core was broken when pressure was applied from above with the dust core standing in the radial direction. The results are also shown in Table 1.
表１に示した結果より明らかなごとく、本発明実施例１〜６の各圧粉磁芯では、大きな直流磁界が印加されたときでも、透磁率の低下が小さく、直流重畳掛生が良好であると共に、コアロスもさほど大きくなく、圧環強度にも優れたものであることが認められた。 As is clear from the results shown in Table 1, in each of the dust cores of Examples 1 to 6 of the present invention, even when a large DC magnetic field is applied, the decrease in the magnetic permeability is small and the DC superposition effect is good. In addition, it was recognized that the core loss was not so large and the crushing strength was excellent.
これに対して、表１に示す比較例１の圧粉磁芯では、Ｓｉ含有量が少なすぎるため純鉄に近くなってコアロスがかなり大きいものとなっており、比較例２の圧粉磁芯では、Ｓｉ含有量が多すぎるため比透磁率がかなり低いものとなっており、比較例３のセンダスト合金に相当する圧粉磁芯では２０Ｏｅのバイアス直流磁界のもとでの比透磁率は良好な値を示すものの直流磁界の強さが増大すると磁束密度が低いため飽和してしまうことから比透磁率の低下がかなり大きいものとなっており、実施例５，６および参考例３の圧粉磁芯では磁気特性は良好であるものの樹脂の含浸処理がないため圧環強度が低いものとなっていて、ある程度の圧環強度が要求される場合には適していないものとなっていた。 On the other hand, in the dust core of Comparative Example 1 shown in Table 1, since the Si content is too small, it is close to pure iron and the core loss is considerably large. However, since the Si content is too high, the relative magnetic permeability is considerably low. With the dust core corresponding to the Sendust alloy of Comparative Example 3, the relative magnetic permeability under a bias DC magnetic field of 20 Oe is good. However, when the strength of the DC magnetic field increases, the magnetic flux density is low and the saturation occurs, so that the relative permeability decreases considerably. The dusts of Examples 5 and 6 and Reference Example 3 The magnetic core has good magnetic properties, but has no crushing strength due to the absence of resin impregnation, and is not suitable when a certain level of crushing strength is required.
さらに、比較例４の圧粉磁芯ではＯ含有量が多すぎるためコアロスがかなり大きいものとなっていた。 Further, in the dust core of Comparative Example 4, the core loss was considerably large because the O content was too large.
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| CN108711482A (en) * | 2018-04-13 | 2018-10-26 | 浙江工业大学 | Preparation method of organic-inorganic composite material insulation coated iron powder core |
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