JP2013145866A - 軟磁性合金粉末、圧粉体、圧粉磁芯および磁性素子 - Google Patents
軟磁性合金粉末、圧粉体、圧粉磁芯および磁性素子 Download PDFInfo
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Abstract
【解決手段】
Fe、Ni、Co及びSiの合計質量に対して、前記Niを38〜48質量%、前記Coを1.0〜15質量%、かつ前記Siを1.2〜10質量%を含み、残部が前記FeであるFe−Ni系粒子を含有する軟磁性合金粉末から成る、圧粉体を備える圧粉磁心及び磁性素子を提供する。前記Fe−Ni系粒子の平均粒子径は1〜10μmである事が望ましい軟磁性合金粉末である。
【選択図】図1
Description
本発明に係るFe−Ni系合金粉末におけるCoの組成比は、Fe、Ni、Co及びSiの合計質量に対して、1.0〜15質量%である。Coの組成比が上記範囲より小さいと、圧粉磁心の透磁率が低くなり、Coの組成比が上記範囲より大きいと、圧粉磁心の損失が大きくなる。
インダクタンス素子100は、図1に示すように各面が互いに直角に連続する六面体状をなして一体成形されたコア110と、このコア110に埋設され、両端部のみが露出されているコイル120とを備えている。
まず、Fe−Ni合金、Fe単体、Ni単体、Co単体及びSi単体のインゴット、チャンク(塊)、又はショット(粒子)を準備した。次にそれらを、表1、に示す組成となるよう混合して、水アトマイズ装置内に配置されたルツボに収容した。次いで、不活性雰囲気中、ルツボ外部に設けたワークコイルを用いて、ルツボを高周波誘導により1500℃以上まで加熱し、ルツボ中のインゴット、チャンク又はショットを溶融、混合して融液を得た。
軟磁性合金粉末に対し、絶縁材としてエポキシ樹脂(N−695、大日本インキ社製)と硬化剤を合金粉末質量に対して3.0質量%添加し、加圧ニーダにより室温で30分間混練した。次いで、混練物を大気中において自然乾燥させ、潤滑剤としてステアリン酸亜鉛をそれらの全体量に対して0.1質量%添加し、Vミキサーにより10分間混合した。続いて、得られた混合物の成形を行い、外径:11mm、内径:6.5mm、厚さ:2.5mmの圧粉磁芯を作製した。なお、成形圧は600MPaとした。加圧後の成形体を180℃で60分間熱処理することにより、バインダー樹脂を硬化させて、圧粉磁心を得た。
(1)合金粉末中のFe、Ni、Si、Co量の測定
XRF(RIGAKU社製、装置名「ZXS−100E」により測定した。結果を表1に示す。
(2)合金粉末の平均粒子径
平均粒子径はレーザー回折式粒度測定装置・HELOSシステム(JEOL社製)により測定した。結果を表1に示す。
(3)磁心損失測定
得られた圧粉磁芯について、BHアナライザ(SY−8218、岩通製)を用いて、最大磁束密度Bm =10mTの条件で、磁芯損失(Pcv)を測定した。10MHzにおける磁心損失を表1に示す。
(4)磁心透磁率測定
得られた圧粉磁芯について、LCRメーター(4285A、HEWLETT PACKARD製)を用いて、初透磁率(μ)を測定した。8kA/mの直流磁場下、10MHzでの結果を表1に示す。
(5)耐食性試験
得られた圧粉磁芯について、常温常圧下で塩化ナトリウム5質量%水溶液中に浸し、錆の発生時間を評価した。実施例と比較例の耐食性試験結果を表2に示す。
表2はFe、Ni、Co及びSiの合計質量に対して、前記Ni、前記Coの含有量が同程度で、前記Siの含有量が異なる場合の、磁気特性および耐食性を示すものである。これらの結果から明らかなように、前記Siの含有量が1.2質量%以上の場合に高い耐食性が得られる。
従って、表1および表2から明らかなように、Fe、Ni、Co及びSiの合計質量に対して、前記Niを38〜48質量%、前記Coを1.0〜15質量%、前記Siを1.2〜10質量%含み、残部が前記Feで、平均粒子径が1μm超10μm未満あるFe−Ni系粒子を含有する軟磁性合金粉末から成る圧粉磁心において低損失、高透磁率、かつ耐食性に優れる圧粉磁心が得られる。
110 コア
120 コイル
Claims (4)
- Fe、Ni、Co及びSiの合計質量に対して、前記Niを38〜48質量%、前記Coを1.0〜15質量%、前記Siを1.2〜10質量%含み、残部が前記FeであるFe−Ni系粒子を有し、前記Fe−Ni系粒子の平均粒子径が1μm超10μm未満である、Fe−Ni系粒子を含有する軟磁性合金粉末。
- 表面の一部または全部を絶縁材で被覆された前記Fe−Ni系粒子であって、Fe、Ni、Co及びSiの合計質量に対して、前記Niを38〜48質量%、前記Coを1.0〜15質量%、前記Siを1.2〜10質量%含み、残部が前記FeであるFe−Ni系粒子を有し、平均粒子径が1μm超10μm未満である前記Fe−Ni系粒子を含有する、圧粉体。
- 請求項1又は請求項2に記載のFe−Ni系粒子に、樹脂及び潤滑剤を混合し、加圧成形して得られる圧粉体を備える、圧粉磁心。
- 請求項3に記載の圧粉磁心を含む磁性素子。
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JP2012227894A JP5974803B2 (ja) | 2011-12-16 | 2012-10-15 | 軟磁性合金粉末、圧粉体、圧粉磁芯および磁性素子 |
US13/687,072 US9245676B2 (en) | 2011-12-16 | 2012-11-28 | Soft magnetic alloy powder, compact, powder magnetic core, and magnetic element |
CN201210544009.XA CN103165256B (zh) | 2011-12-16 | 2012-12-14 | 软磁性合金粉末、压粉体、压粉磁芯以及磁性元件 |
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JP2018041872A (ja) * | 2016-09-08 | 2018-03-15 | スミダコーポレーション株式会社 | 複合磁性材料、その複合磁性材料を熱硬化して得られる複合磁性成形体、その複合磁性成形体を用いて得られる電子部品、およびそれらの製造方法 |
JP2018206835A (ja) * | 2017-05-31 | 2018-12-27 | Tdk株式会社 | 軟磁性合金粒子および電子部品 |
JP2019192880A (ja) * | 2018-04-27 | 2019-10-31 | 三菱製鋼株式会社 | 軟磁性材料、圧粉磁心、およびインダクタ |
JP7254449B2 (ja) | 2018-04-27 | 2023-04-10 | 三菱製鋼株式会社 | 軟磁性材料、圧粉磁心、およびインダクタ |
JP2020094272A (ja) * | 2018-11-29 | 2020-06-18 | Tdk株式会社 | 軟磁性合金粒子および電子部品 |
JP7358884B2 (ja) | 2018-11-29 | 2023-10-11 | Tdk株式会社 | 軟磁性合金粒子および電子部品 |
WO2023162511A1 (ja) * | 2022-02-24 | 2023-08-31 | 味の素株式会社 | 樹脂組成物 |
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