JP2012043971A - Magnetic core manufacturing method - Google Patents

Magnetic core manufacturing method Download PDF

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JP2012043971A
JP2012043971A JP2010183723A JP2010183723A JP2012043971A JP 2012043971 A JP2012043971 A JP 2012043971A JP 2010183723 A JP2010183723 A JP 2010183723A JP 2010183723 A JP2010183723 A JP 2010183723A JP 2012043971 A JP2012043971 A JP 2012043971A
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magnetic
iron
insulating
organic binder
resin
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JP5740113B2 (en
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Yoshiaki Ishii
善明 石井
Takahiro Ogawa
高浩 小川
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Toko Inc
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Abstract

PROBLEM TO BE SOLVED: To provide a cheap magnetic core capable of reducing the number of manufacturing components without needing a special manufacturing process.SOLUTION: A magnetic core manufacturing method forms magnetic core by laminating a plurality of insulative magnetic body layers 31B to 31D including a magnetic powder and an organic binder on an insulative magnetic body layer 31A by repeatedly printing an insulative magnetic body paste including the magnetic power and the organic binder on the insulative magnetic body layer 31A formed by printing the insulative magnetic body paste including the magnetic power and the organic binder on a substrate 30.

Description

本発明は、磁性体粉と有機結合剤を有する磁性体によって形成された磁性体コアの製造方法に関するものである。   The present invention relates to a method for producing a magnetic core formed of a magnetic material having magnetic powder and an organic binder.

近年、通信端末の小型化、多用途化が進み、低中波帯の電波を利用した小型の端末が多く見られる。この様な低中波帯の送信及び受信に使用するコイルアンテナとして、図８に示す様に、偏平状又は針状の軟磁性体粉と有機結合剤を有する磁性体によって形成された磁性体シートを複数枚積層して磁性体コア８１を形成し、この磁性体コア８１に巻線８２を巻回して形成したものがある（例えば、特許文献１を参照。）。   In recent years, communication terminals have become smaller and more versatile, and there are many small terminals using low-medium-band radio waves. As a coil antenna used for transmission and reception in such a low and medium wave band, as shown in FIG. 8, a magnetic material sheet formed of a magnetic material having a flat or needle-like soft magnetic powder and an organic binder. A magnetic core 81 is formed by laminating a plurality of layers, and a winding 82 is wound around the magnetic core 81 (see, for example, Patent Document 1).

特開2005-317674号公報JP 2005-317674 A

この様な従来のコイルアンテナは、偏平状又は針状の軟磁性体粉を用い、この軟磁性体粉の平らな面が磁性体シートの厚み方向と垂直な方向に配列する様に配向した磁性体シートを複数枚積層しているため、磁性体コアの実数部透磁率を高くすることができ、これにより磁性体コアの形状を小さくでき、コイルの出力も大きくできる。しかしながら、この様な従来のコイルアンテナは、磁性体シートの厚みを厚くすると軟磁性体粉の平らな面が磁性体シートの厚み方向と垂直な方向に配列する様に軟磁性体粉を充分に配向することができなかった。そのため、磁性体シートの厚みを薄くする必要があり、所定の厚みのコアを形成するためには、より多くの磁性体シートが必要だった。従って、従来のコイルアンテナは、磁性体シートを形成するための支持体や、コアを形成するための作業工数をより多く必要とし、製造コストが高くなるという問題があった。   Such a conventional coil antenna uses flat or needle-shaped soft magnetic powder, and the magnetic surface is oriented so that the flat surface of the soft magnetic powder is arranged in a direction perpendicular to the thickness direction of the magnetic sheet. Since a plurality of body sheets are laminated, the real part permeability of the magnetic core can be increased, thereby reducing the shape of the magnetic core and increasing the output of the coil. However, such a conventional coil antenna has sufficient soft magnetic powder so that when the thickness of the magnetic sheet is increased, the flat surface of the soft magnetic powder is arranged in a direction perpendicular to the thickness direction of the magnetic sheet. It could not be oriented. Therefore, it is necessary to reduce the thickness of the magnetic sheet, and more magnetic sheets are required to form a core having a predetermined thickness. Therefore, the conventional coil antenna requires a larger number of work steps for forming the support and the core for forming the magnetic sheet, and there is a problem that the manufacturing cost increases.

本発明の磁性体コアの製造方法は、特別な製造工程を必要とせず、製造部品点数を少なくすることができ、安価な磁性体コアを提供することを目的とする。   An object of the method for manufacturing a magnetic core of the present invention is to provide an inexpensive magnetic core that does not require a special manufacturing process and can reduce the number of manufactured parts.

本発明の磁性体コアの製造方法は、磁性体粉と有機結合剤を含有する絶縁性磁性体ペーストを印刷して形成された絶縁性磁性体層上に、磁性体粉と有機結合剤を含有する絶縁性磁性体ペーストを繰り返し印刷して、絶縁性磁性体層上に磁性体粉と有機結合剤を有する絶縁性磁性体層が複数層積層されて磁性体のコアが形成される。   The method for producing a magnetic core according to the present invention includes a magnetic powder and an organic binder on an insulating magnetic layer formed by printing an insulating magnetic paste containing magnetic powder and an organic binder. The insulating magnetic paste is repeatedly printed, and a plurality of insulating magnetic layers having magnetic powder and an organic binder are laminated on the insulating magnetic layer to form a magnetic core.

本発明の磁性体コアの製造方法は、磁性体粉と有機結合剤を含有する絶縁性磁性体ペーストを印刷して形成された絶縁性磁性体層上に、磁性体粉と有機結合剤を含有する絶縁性磁性体ペーストを繰り返し印刷して、絶縁性磁性体層上に磁性体粉と有機結合剤を有する絶縁性磁性体層が複数層積層されて磁性体のコアが形成されるので、特別な製造工程を必要とせず、製造部品点数を少なくすることができ、安価な磁性体コアを提供することができる。   The method for producing a magnetic core according to the present invention includes a magnetic powder and an organic binder on an insulating magnetic layer formed by printing an insulating magnetic paste containing magnetic powder and an organic binder. Insulating magnetic paste is repeatedly printed, and a plurality of insulating magnetic layers having magnetic powder and organic binder are laminated on the insulating magnetic layer to form a magnetic core. Thus, no manufacturing process is required, the number of manufactured parts can be reduced, and an inexpensive magnetic core can be provided.

本発明に係る磁性体コアを示す分解斜視図である。It is a disassembled perspective view which shows the magnetic body core which concerns on this invention. 本発明に係る磁性体コアを示す斜視図である。It is a perspective view which shows the magnetic body core which concerns on this invention. 本発明の磁性体コアの製造方法における製造工程を示す断面図である。It is sectional drawing which shows the manufacturing process in the manufacturing method of the magnetic body core of this invention. 本発明の磁性体コアの製造方法における製造工程を示す斜視図である。It is a perspective view which shows the manufacturing process in the manufacturing method of the magnetic body core of this invention. 本発明に係る磁性体コアを用いたコイルアンテナの斜視図である。It is a perspective view of the coil antenna using the magnetic body which concerns on this invention. 本発明に係る別の磁性体コアを示す斜視図である。It is a perspective view which shows another magnetic body core which concerns on this invention. 本発明に係る磁性体コアを用いた無接点充電装置を示す斜視図である。It is a perspective view which shows the non-contact charging device using the magnetic body core which concerns on this invention. 従来のコイルアンテナを示す斜視図である。It is a perspective view which shows the conventional coil antenna.

本発明の磁性体コアの製造方法は、まず、支持体上に球状の磁性体粉と有機結合剤を含有する絶縁性磁性体ペーストを印刷して絶縁性磁性体層が形成される。この絶縁性磁性体層上に球状の磁性体粉と有機結合剤を含有する絶縁性磁性体ペーストを繰り返し印刷して、支持体上に形成された絶縁性磁性体層上に、球状の磁性体粉と有機結合剤を有する絶縁性磁性体層が複数層積層される。これらの絶縁性磁性体層の積層体を支持体から剥離し、各々に切断して磁性体コアが形成される。球状の磁性体粉は、鉄アルミ珪素合金、鉄ニッケル、鉄コバルト合金、鉄コバルトシリコン合金、鉄シリコンバナジューム合金、鉄コバルトボロン合金、鉄クロムシリコン合金、コバルト系アモルファス合金、鉄系アモルファス合金、酸化物磁性粉、カーボニル鉄、モリブデンパーマロイ、純鉄圧粉の磁性材料のうち少なくとも１種類以上を含有する。また、有機結合剤は、ポリエステル系樹脂、ポリ塩化ビニル系樹脂、ポリビニルブチラール樹脂、ポリウレタン樹脂、セルロース系樹脂、ニトリル−ブタン系ゴム、スチレン−ブタジエン系ゴム等の熱可塑性樹脂あるいはそれらの共重合体、エポキシ樹脂、フェノール樹脂、アミド系樹脂、イミド系樹脂等の熱硬化性樹脂、あるいは有機系難燃剤であるハロゲン化物、臭素化ポリマーのうち少なくとも１種類以上を含有する。この時、この磁性体コアは、可撓性を有する様に、球状の磁性体粉と有機結合剤の材質及び比率が選択される。
また、本発明の磁性体コアの製造方法は、まず、支持体上に偏平状又は針状の磁性体粉と有機結合剤を含有する絶縁性磁性体ペーストを印刷して絶縁性磁性体層が形成される。この絶縁性磁性体層上に偏平状又は針状の磁性体粉と有機結合剤を含有する絶縁性磁性体ペーストを繰り返し印刷して、支持体上に形成された絶縁性磁性体層上に、偏平状又は針状の磁性体粉と有機結合剤を有する絶縁性磁性体層が複数層積層される。これらの絶縁性磁性体層の積層体を支持体から剥離し、各々に切断して磁性体コアが形成される。偏平状又は針状の磁性体粉は、鉄アルミ珪素合金、鉄ニッケル、鉄コバルト合金、鉄コバルトシリコン合金、鉄シリコンバナジューム合金、鉄コバルトボロン合金、鉄クロムシリコン合金、コバルト系アモルファス合金、鉄系アモルファス合金、酸化物磁性粉、カーボニル鉄、モリブデンパーマロイ、純鉄圧粉の磁性材料のうち少なくとも１種類以上を含有する。また、有機結合剤は、ポリエステル系樹脂、ポリ塩化ビニル系樹脂、ポリビニルブチラール樹脂、ポリウレタン樹脂、セルロース系樹脂、ニトリル−ブタン系ゴム、スチレン−ブタジエン系ゴム等の熱可塑性樹脂あるいはそれらの共重合体、エポキシ樹脂、フェノール樹脂、アミド系樹脂、イミド系樹脂等の熱硬化性樹脂、あるいは有機系難燃剤であるハロゲン化物、臭素化ポリマーのうち少なくとも１種類以上を含有する。この時、この磁性体コアは、可撓性を有する様に、偏平状又は針状の磁性体粉と有機結合剤の材質及び比率が選択される。
従って、本発明の磁性体コアの製造方法は、絶縁性磁性体層を印刷する印刷機に取り付けられた支持体上において複数の絶縁性磁性体層が印刷により積み重ねられ、しかも、磁性体粉として偏平状又は針状の磁性体粉を用いた場合でも、絶縁性磁性体層上に磁性体粉と有機結合剤を含有する絶縁性磁性体ペーストを印刷する際のスキージに加える圧力によって磁性体粉の平らな面が絶縁性磁性体層の厚み方向と垂直な方向に配列する様に配向される。これにより、支持体の使用枚数を減らすことができると共に、磁性体コア内の磁性体粉を均一に配向することができる。
また、本発明の磁性体コアの製造方法は、支持体上に複数の絶縁性磁性体層が印刷により積み重ねられるので、磁性体シートを形成する場合の様に、溶媒の添加量を考慮する必要がなく、絶縁性磁性体ペーストの溶媒の添加量の自由度を大きくできる。 In the method for producing a magnetic core of the present invention, an insulating magnetic layer is first formed by printing an insulating magnetic paste containing spherical magnetic powder and an organic binder on a support. On this insulating magnetic layer, an insulating magnetic paste containing spherical magnetic powder and an organic binder is repeatedly printed, and the spherical magnetic material is formed on the insulating magnetic layer formed on the support. A plurality of insulating magnetic layers having powder and an organic binder are laminated. A laminate of these insulating magnetic layers is peeled from the support and cut into each to form a magnetic core. Spherical magnetic powder is iron aluminum silicon alloy, iron nickel, iron cobalt alloy, iron cobalt silicon alloy, iron silicon vanadium alloy, iron cobalt boron alloy, iron chromium silicon alloy, cobalt amorphous alloy, iron amorphous alloy, oxidation It contains at least one kind of magnetic materials such as physical magnetic powder, carbonyl iron, molybdenum permalloy, and pure iron powder. The organic binder is a thermoplastic resin such as polyester resin, polyvinyl chloride resin, polyvinyl butyral resin, polyurethane resin, cellulose resin, nitrile-butane rubber, styrene-butadiene rubber, or a copolymer thereof. And at least one of thermosetting resins such as epoxy resins, phenol resins, amide resins, imide resins, and the like, halides that are organic flame retardants, and brominated polymers. At this time, the material and ratio of the spherical magnetic powder and the organic binder are selected so that the magnetic core has flexibility.
In the method for producing a magnetic core according to the present invention, first, an insulating magnetic layer containing a flat or needle-like magnetic powder and an organic binder is printed on a support to form an insulating magnetic layer. It is formed. On this insulating magnetic layer, by repeatedly printing an insulating magnetic paste containing a flat or needle-like magnetic powder and an organic binder, on the insulating magnetic layer formed on the support, A plurality of insulating magnetic layers having a flat or needle-like magnetic powder and an organic binder are laminated. A laminate of these insulating magnetic layers is peeled from the support and cut into each to form a magnetic core. Flat or needle-shaped magnetic powders are iron aluminum silicon alloy, iron nickel, iron cobalt alloy, iron cobalt silicon alloy, iron silicon vanadium alloy, iron cobalt boron alloy, iron chromium silicon alloy, cobalt-based amorphous alloy, iron-based It contains at least one or more of magnetic materials of amorphous alloy, oxide magnetic powder, carbonyl iron, molybdenum permalloy, and pure iron powder. The organic binder is a thermoplastic resin such as polyester resin, polyvinyl chloride resin, polyvinyl butyral resin, polyurethane resin, cellulose resin, nitrile-butane rubber, styrene-butadiene rubber, or a copolymer thereof. And at least one of thermosetting resins such as epoxy resins, phenol resins, amide resins, imide resins, and the like, halides that are organic flame retardants, and brominated polymers. At this time, the material and ratio of the flat or needle-like magnetic powder and the organic binder are selected so that the magnetic core has flexibility.
Therefore, in the method for producing a magnetic core according to the present invention, a plurality of insulating magnetic layers are stacked by printing on a support attached to a printing machine that prints the insulating magnetic layers, and as magnetic powder. Even when flat or needle-like magnetic powder is used, the magnetic powder is applied by pressure applied to the squeegee when printing the insulating magnetic paste containing the magnetic powder and the organic binder on the insulating magnetic layer. These flat surfaces are oriented so as to be arranged in a direction perpendicular to the thickness direction of the insulating magnetic layer. As a result, the number of supports used can be reduced, and the magnetic powder in the magnetic core can be uniformly oriented.
Further, in the method for producing a magnetic core of the present invention, since a plurality of insulating magnetic layers are stacked on a support by printing, it is necessary to consider the amount of solvent added as in the case of forming a magnetic sheet. Therefore, the degree of freedom of the amount of solvent added to the insulating magnetic paste can be increased.

以下、本発明の磁性体コアの製造方法の実施例を図１乃至図７を参照して説明する。
図１は本発明に係る磁性体コアを示す分解斜視図、図２は本発明に係る磁性体コアを示す斜視図である。
絶縁性磁性体層１１Ａ〜１１Ｅは、球状の磁性体粉と有機結合剤を有する絶縁性磁性体を用いて形成される。球状の磁性体粉としては、例えば鉄とクロムとシリコンを含有した鉄クロムシリコン合金が用いられる。また、有機結合剤としては、例えばポリウレタン樹脂と難燃剤を組み合わせたものが用いられる。この有機結合剤は、鉄クロムシリコン合金に対して、ポリウレタン樹脂が４〜１０重量部と難燃剤が０．４〜２重量部添加される。
この絶縁性磁性体層１１Ａ乃至絶縁性磁性体層１１Ｅは、球状の磁性体粉と有機結合剤を有する絶縁性磁性体ペーストを繰り返し印刷することにより順次形成され、図２に示す様な磁性体コア１１が形成される。この磁性体コア１１は、可撓性を有する様に、球状の磁性体粉と有機結合剤の比率が選択され、縦が例えば５０ｍｍ、横が例えば７ｍｍ、厚みが例えば０．５ｍｍに形成される。 Hereinafter, an embodiment of a method for producing a magnetic core according to the present invention will be described with reference to FIGS.
FIG. 1 is an exploded perspective view showing a magnetic core according to the present invention, and FIG. 2 is a perspective view showing the magnetic core according to the present invention.
The insulating magnetic layers 11A to 11E are formed using an insulating magnetic material having a spherical magnetic powder and an organic binder. As the spherical magnetic powder, for example, an iron-chromium-silicon alloy containing iron, chromium, and silicon is used. As the organic binder, for example, a combination of a polyurethane resin and a flame retardant is used. In this organic binder, 4 to 10 parts by weight of polyurethane resin and 0.4 to 2 parts by weight of flame retardant are added to the iron-chromium silicon alloy.
The insulating magnetic layer 11A to the insulating magnetic layer 11E are sequentially formed by repeatedly printing a spherical magnetic powder and an insulating magnetic paste having an organic binder, as shown in FIG. A core 11 is formed. The magnetic core 11 is formed such that the ratio of the spherical magnetic powder and the organic binder is selected so as to be flexible, and the vertical length is, for example, 50 mm, the horizontal length is, for example, 7 mm, and the thickness is, for example, 0.5 mm. .

この様な磁性体コアは次の様にして製造される。図３は本発明の磁性体コアの製造方法の実施例を示す製造工程の断面図、図４は本発明の磁性体コアの製造方法の実施例を示す製造工程の斜視図である。
まず、印刷機の印刷台に配置された支持体上にマスクを配置し、このマスク上の絶縁性磁性体ペーストをスキージで捌いて、支持体の表面に絶縁性磁性体ペーストを印刷し、これを乾燥することにより、支持体３０上に絶縁性磁性体層３１Ａが形成される。絶縁性磁性体ペーストは、鉄クロムシリコン合金にポリウレタン樹脂４〜１０重量部と、難燃剤０．４〜２重量部を添加し、さらに溶媒を添加して攪拌機で混合分散してペースト状にして形成される。また、支持体３０上に形成された絶縁性磁性体層３１Ａは、プレス機によってプレスされる。
次に、支持体３０に形成された絶縁性磁性体層３１Ａ上にマスクを配置し、マスク上の絶縁性磁性体ペーストをスキージで捌いて、絶縁性磁性体層３１Ａの表面に絶縁性磁性体ペーストを印刷し、これを乾燥することにより、図３（Ａ）に示す様に、絶縁性磁性体層３１Ａ上に絶縁性磁性体層３１Ｂが形成される。絶縁性磁性体層３１Ｂはプレス機によってプレスされる。
続いて、この絶縁性磁性体層３１Ｂ上にマスクを配置し、マスク上の絶縁性磁性体ペーストをスキージで捌いて、絶縁性磁性体層３１Ｂの表面に絶縁性磁性体ペーストを印刷し、これを乾燥することにより、図３（Ｂ）に示す様に、絶縁性磁性体層３１Ｂ上に絶縁性磁性体層３１Ｃが形成される。絶縁性磁性体層３１Ｃはプレス機によってプレスされる。
さらに、この絶縁性磁性体層３１Ｃ上にマスクを配置し、マスク上の絶縁性磁性体ペーストをスキージで捌いて、絶縁性磁性体層３１Ｃの表面に絶縁性磁性体ペーストを印刷し、これを乾燥することにより、図３（Ｃ）に示す様に、絶縁性磁性体層３１Ｃ上に絶縁性磁性体層３１Ｄが形成される。絶縁性磁性体層３１Ｄはプレス機によってプレスされる。
続いて、この絶縁性磁性体層３１Ｄ上にマスクを配置し、マスク上の絶縁性磁性体ペーストをスキージで捌いて、絶縁性磁性体層３１Ｄの表面に絶縁性磁性体ペーストを印刷し、これを乾燥することにより、図４（Ａ）に示す様に、絶縁性磁性体層３１Ｄ上に絶縁性磁性体層３１Ｅが形成される。絶縁性磁性体層３１Ｅはプレス機によってプレスされる。
さらに、この様にして支持体３０上に形成された絶縁性磁性体層３１Ａ〜３１Ｅの積層体３１は、支持体３０から剥離し、刃型、プレス金型、カッターの様な刃物等を用いて、所定の大きさになる様、図４（Ｂ）に示す点線の部分で切断されて、図２に示す様な磁性体コア１１が形成される。
この磁性体コアは、コイルアンテナとして用いられる場合、図５に示される様に、磁性体コア５１の外周に巻線５２が巻回される。 Such a magnetic core is manufactured as follows. FIG. 3 is a cross-sectional view of a manufacturing process showing an embodiment of a method for manufacturing a magnetic core of the present invention, and FIG. 4 is a perspective view of the manufacturing process showing an embodiment of a method of manufacturing a magnetic core of the present invention.
First, a mask is placed on a support placed on a printing stand of a printing press, the insulating magnetic paste on the mask is squeezed with a squeegee, and the insulating magnetic paste is printed on the surface of the support. Is dried, the insulating magnetic layer 31A is formed on the support 30. Insulating magnetic paste is made of iron-chromium silicon alloy with 4-10 parts by weight of polyurethane resin and 0.4-2 parts by weight of flame retardant. It is formed. Further, the insulating magnetic layer 31A formed on the support 30 is pressed by a press.
Next, a mask is disposed on the insulating magnetic layer 31A formed on the support 30, and the insulating magnetic paste on the mask is squeezed with a squeegee, so that the insulating magnetic material is formed on the surface of the insulating magnetic layer 31A. By printing the paste and drying it, an insulating magnetic layer 31B is formed on the insulating magnetic layer 31A as shown in FIG. The insulating magnetic layer 31B is pressed by a press.
Subsequently, a mask is disposed on the insulating magnetic layer 31B, the insulating magnetic paste on the mask is spread with a squeegee, and the insulating magnetic paste is printed on the surface of the insulating magnetic layer 31B. As shown in FIG. 3B, the insulating magnetic layer 31C is formed on the insulating magnetic layer 31B. The insulating magnetic layer 31C is pressed by a press.
Further, a mask is disposed on the insulating magnetic layer 31C, the insulating magnetic paste on the mask is squeezed with a squeegee, and the insulating magnetic paste is printed on the surface of the insulating magnetic layer 31C. By drying, an insulating magnetic layer 31D is formed on the insulating magnetic layer 31C as shown in FIG. The insulating magnetic layer 31D is pressed by a press.
Subsequently, a mask is disposed on the insulating magnetic layer 31D, the insulating magnetic paste on the mask is squeezed with a squeegee, and the insulating magnetic paste is printed on the surface of the insulating magnetic layer 31D. As shown in FIG. 4A, an insulating magnetic layer 31E is formed on the insulating magnetic layer 31D. The insulating magnetic layer 31E is pressed by a press.
Further, the laminated body 31 of the insulating magnetic layers 31A to 31E formed on the support 30 in this manner is peeled off from the support 30 and a blade tool, a press die, a cutter such as a cutter, or the like is used. Then, the magnetic core 11 as shown in FIG. 2 is formed by cutting along the dotted line shown in FIG.
When this magnetic core is used as a coil antenna, a winding 52 is wound around the outer periphery of the magnetic core 51 as shown in FIG.

図６は本発明に係る別の磁性体コアを示す斜視図である。
絶縁性磁性体層は、球状の磁性体粉と有機結合剤を有する絶縁性磁性体を用いて形成される。球状の磁性体粉としては、例えば鉄とクロムとシリコンを含有した鉄クロムシリコン合金が用いられる。また、有機結合剤としては、例えばポリウレタン樹脂と難燃剤を組み合わせたものが用いられる。この有機結合剤は、鉄クロムシリコン合金に対して、ポリウレタン樹脂が４〜１０重量部と難燃剤が０．４〜２重量部添加される。
絶縁性磁性体層は、球状の磁性体粉と有機結合剤を有する絶縁性磁性体ペーストを繰り返し印刷することにより順次形成され、図６に示す様な磁性体コア６１が形成される。この磁性体コア６１は、可撓性を有する様に、球状の磁性体粉と有機結合剤の比率が選択され、縦が例えば５０ｍｍ、横が例えば５０ｍｍ、厚みが例えば１ｍｍに形成される。
この様な磁性体コアは前述のものと同様にして製造される。この磁性体コアは、無接点充電装置として用いられる場合、図７に示される様に、磁性体コア７１の表面に、巻線を巻回した空芯コイル７２が配置される。 FIG. 6 is a perspective view showing another magnetic core according to the present invention.
The insulating magnetic layer is formed using an insulating magnetic material having a spherical magnetic powder and an organic binder. As the spherical magnetic powder, for example, an iron-chromium-silicon alloy containing iron, chromium, and silicon is used. As the organic binder, for example, a combination of a polyurethane resin and a flame retardant is used. In this organic binder, 4 to 10 parts by weight of polyurethane resin and 0.4 to 2 parts by weight of flame retardant are added to the iron-chromium silicon alloy.
The insulating magnetic layer is sequentially formed by repeatedly printing an insulating magnetic paste having a spherical magnetic powder and an organic binder to form a magnetic core 61 as shown in FIG. The magnetic core 61 is formed such that the ratio of the spherical magnetic powder and the organic binder is selected so as to be flexible, and the length is, for example, 50 mm, the width is, for example, 50 mm, and the thickness is, for example, 1 mm.
Such a magnetic core is manufactured in the same manner as described above. When this magnetic core is used as a non-contact charging device, an air-core coil 72 wound with a winding is disposed on the surface of the magnetic core 71 as shown in FIG.

以上、本発明の磁性体コアの製造方法の実施例を述べたが、本発明はこれらの実施例に限定されるものではない。例えば、実施例では絶縁性磁性体層を一層ごとにプレス機でプレスしているが、複数の絶縁性磁性体層を積層した後に全体をプレス機でプレスしてもよい。
また、球状の磁性体粉としては、鉄アルミ珪素合金、鉄ニッケル、鉄コバルト合金、鉄コバルトシリコン合金、鉄シリコンバナジューム合金、鉄コバルトボロン合金、コバルト系アモルファス合金、鉄系アモルファス合金、酸化物磁性粉、カーボニル鉄、モリブデンパーマロイ、純鉄圧粉の磁性材料のうち少なくとも１種類以上を含有する磁性材料を用いてもよい。さらに、有機結合剤としては、ポリエステル系樹脂、ポリ塩化ビニル系樹脂、ポリビニルブチラール樹脂、ポリウレタン樹脂、セルロース系樹脂、ニトリル−ブタン系ゴム、スチレン−ブタジエン系ゴム等の熱可塑性樹脂あるいはそれらの共重合体、エポキシ樹脂、フェノール樹脂、アミド系樹脂、イミド系樹脂等の熱硬化性樹脂、あるいは有機系難燃剤であるハロゲン化物、臭素化ポリマーのうち少なくとも１種類以上を含有するものを用いてもよい。またさらに、磁性体粉として、鉄アルミ珪素合金、鉄ニッケル、鉄コバルト合金、鉄コバルトシリコン合金、鉄シリコンバナジューム合金、鉄コバルトボロン合金、鉄クロムシリコン合金、コバルト系アモルファス合金、鉄系アモルファス合金、酸化物磁性粉、カーボニル鉄、モリブデンパーマロイ、純鉄圧粉の磁性材料のうち少なくとも１種類以上を含有する偏平又は針状の磁性体粉が用いられてもよい。
さらに、絶縁性磁性体層１１Ａ〜１１Ｄを球状の磁性体粉と有機結合剤を含有する絶縁性磁性体ペーストを印刷して形成し、絶縁性磁性体層１１Ｅを偏平状又は針状の磁性体粉と有機結合剤を含有する絶縁性磁性体ペーストを印刷して形成することにより、磁性体のコアが、球状の磁性体粉と有機結合剤を有する絶縁性磁性体によって形成された第１磁性体部と、偏平状又は針状の磁性体粉と有機結合剤を有する絶縁性磁性体によって形成された第２磁性体部を有する様に形成してもよい。 As mentioned above, although the Example of the manufacturing method of the magnetic body core of this invention was described, this invention is not limited to these Examples. For example, in the embodiment, the insulating magnetic layer is pressed by a press machine for each layer, but the whole may be pressed by a press machine after laminating a plurality of insulating magnetic layers.
In addition, spherical magnetic powder includes iron aluminum silicon alloy, iron nickel, iron cobalt alloy, iron cobalt silicon alloy, iron silicon vanadium alloy, iron cobalt boron alloy, cobalt amorphous alloy, iron amorphous alloy, oxide magnetic You may use the magnetic material containing at least 1 or more types among the magnetic materials of powder | flour, a carbonyl iron, molybdenum permalloy, and a pure iron compact. Furthermore, as the organic binder, thermoplastic resins such as polyester resins, polyvinyl chloride resins, polyvinyl butyral resins, polyurethane resins, cellulose resins, nitrile-butane rubbers, styrene-butadiene rubbers, A thermosetting resin such as a coalescence, epoxy resin, phenol resin, amide resin, imide resin, or the like, or a halide or brominated polymer that is an organic flame retardant may be used. . Furthermore, as magnetic powder, iron aluminum silicon alloy, iron nickel, iron cobalt alloy, iron cobalt silicon alloy, iron silicon vanadium alloy, iron cobalt boron alloy, iron chromium silicon alloy, cobalt amorphous alloy, iron amorphous alloy, A flat or needle-like magnetic powder containing at least one of magnetic materials such as oxide magnetic powder, carbonyl iron, molybdenum permalloy, and pure iron powder may be used.
Further, the insulating magnetic layers 11A to 11D are formed by printing an insulating magnetic paste containing spherical magnetic powder and an organic binder, and the insulating magnetic layer 11E is formed into a flat or needle-like magnetic body. The magnetic core is formed by printing an insulating magnetic paste containing powder and an organic binder, whereby the magnetic core is formed of an insulating magnetic material having a spherical magnetic powder and an organic binder. You may form so that it may have a 2nd magnetic body part formed with the body part and the insulating magnetic body which has a flat or acicular magnetic body powder, and an organic binder.

１１ 磁性体コア 11 Magnetic core

Claims (6)

磁性体粉と有機結合剤を含有する絶縁性磁性体ペーストを印刷して形成された絶縁性磁性体層上に、磁性体粉と有機結合剤を含有する絶縁性磁性体ペーストを繰り返し印刷して、該絶縁性磁性体層上に磁性体粉と有機結合剤を有する絶縁性磁性体層が複数層積層されて磁性体のコアが形成されたことを特徴とする磁性体コアの製造方法。   Insulating magnetic paste containing magnetic powder and organic binder is repeatedly printed on the insulating magnetic layer formed by printing insulating magnetic paste containing magnetic powder and organic binder. A method for producing a magnetic core, wherein a plurality of insulating magnetic layers having magnetic powder and an organic binder are laminated on the insulating magnetic layer to form a magnetic core. 前記磁性体粉が球状の磁性体粉である請求項１に記載の磁性体コアの製造方法。   The method of manufacturing a magnetic core according to claim 1, wherein the magnetic powder is a spherical magnetic powder. 前記磁性体粉が偏平又は針状の磁性体粉である請求項１に記載の磁性体コアの製造方法。   The method of manufacturing a magnetic core according to claim 1, wherein the magnetic powder is flat or needle-shaped magnetic powder. 前記磁性体のコアが、球状の磁性体粉と有機結合剤を有する絶縁性磁性体によって形成された第１磁性体部と、偏平状又は針状の磁性体粉と有機結合剤を有する絶縁性磁性体によって形成された第２磁性体部を有する請求項１に記載の磁性体コアの製造方法。   The magnetic core has a first magnetic body portion formed of an insulating magnetic body having a spherical magnetic powder and an organic binder, and an insulating material having a flat or needle-like magnetic powder and an organic binder. The manufacturing method of the magnetic body core of Claim 1 which has a 2nd magnetic body part formed with the magnetic body. 前記磁性体粉は、鉄アルミ珪素合金、鉄ニッケル、鉄コバルト合金、鉄コバルトシリコン合金、鉄シリコンバナジューム合金、鉄コバルトボロン合金、鉄クロムシリコン合金、コバルト系アモルファス合金、鉄系アモルファス合金、酸化物磁性粉、カーボニル鉄、モリブデンパーマロイ、純鉄圧粉の磁性材料のうち少なくとも１種類以上を含有する請求項１乃至請求項４のいずれかに記載の磁性体コアの製造方法。   The magnetic powder is iron aluminum silicon alloy, iron nickel, iron cobalt alloy, iron cobalt silicon alloy, iron silicon vanadium alloy, iron cobalt boron alloy, iron chrome silicon alloy, cobalt amorphous alloy, iron amorphous alloy, oxide The method for producing a magnetic core according to any one of claims 1 to 4, comprising at least one of magnetic materials such as magnetic powder, carbonyl iron, molybdenum permalloy, and pure iron compact. 前記有機結合剤は、ポリエステル系樹脂、ポリ塩化ビニル系樹脂、ポリビニルブチラール樹脂、ポリウレタン樹脂、セルロース系樹脂、ニトリル−ブタン系ゴム、スチレン−ブタジエン系ゴム等の熱可塑性樹脂あるいはそれらの共重合体、エポキシ樹脂、フェノール樹脂、アミド系樹脂、イミド系樹脂等の熱硬化性樹脂、あるいは有機系難燃剤であるハロゲン化物、臭素化ポリマーのうち少なくとも１種類以上を含有する請求項１乃至請求項５のいずれかに記載の磁性体コアの製造方法。   The organic binder is a thermoplastic resin such as polyester resin, polyvinyl chloride resin, polyvinyl butyral resin, polyurethane resin, cellulose resin, nitrile-butane rubber, styrene-butadiene rubber, or a copolymer thereof. The thermosetting resin such as an epoxy resin, a phenol resin, an amide resin, an imide resin, or the like, or a halide or brominated polymer that is an organic flame retardant, contains at least one kind. The manufacturing method of the magnetic body core in any one.
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