JP2018152559A - 圧粉磁心 - Google Patents
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
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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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/16—Metallic particles coated with a non-metal
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
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- H—ELECTRICITY
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- 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
- H01F1/33—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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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/08—Cores, Yokes, or armatures made from powder
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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
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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
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
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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
- H01F1/14—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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Abstract
Description
金属磁性材料および樹脂を含み、
前記金属磁性材料の表面に接し、前記金属磁性材料を被覆している絶縁膜が存在し、
前記絶縁膜は第1膜および第2膜を有し、前記金属磁性材料の表面に接している膜を前記第1膜、前記第1膜の表面に接している膜を前記第2膜とする場合において、
前記第1膜の密度が前記第2膜の密度よりも高いことを特徴とする。
0.075<D1/D2<10.0を満たすことが好ましい。
金属磁性材料として、重量比でSi/Fe=4.5/95.5であり、FeとSiとの合計量が99重量%であるFe−Si系合金粒子をガスアトマイズ法で作製した。なお、当該Fe−Si系合金粒子の粒子径の中央値(D50)は30μmであった。
得られた圧粉磁心を切断し、研磨を行うことによって、圧粉磁心の断面を露出させた。露出させた断面を集束イオンビーム(FIB:Forcused Ion Beam)によって掘削加工し、面積1μm×1μm、厚み100nmの薄片を切り出した。得られた薄片をTEMにより観察し、500nm×500nmの視野で画像解析を行った。図3は表2の実施例30について実際に画像解析(TEM観察)を行った結果である。
TEM−EDS分析により第1膜および第2膜についてSi検出強度を測定した。第1膜のSi検出強度は、第1膜の中からランダムに10か所測定した。10か所のSi検出強度の平均値をI1とした。第2膜についても第1膜と同様にランダムに10か所、Si検出強度を測定した。10か所のSi検出強度の平均値をI2とした。その後、I1/I2を算出した。
第1膜および第2膜の膜厚をTEM観察によって計測した。金属磁性材料の表面に測定点を設定した。そして、当該測定点から第1膜および第2膜の方向に垂線を引き、当該垂線のうち第1膜にある部分の長さを当該測定点における第1膜の厚みとした。同様にして、第2膜にある部分の長さを当該測定点における第2膜の厚みとした。測定点を10点設定して各測定点について第1膜の厚みおよび第2膜の厚みを測定した。そして、第1膜の厚みの平均をD1、第2膜の厚みの平均をD2とした。その後、D1/D2を算出した。
各実施例で得られたトロイダル形状の圧粉磁心について、巻き数を50ターンとして初透磁率をLCRメータ(HP社製LCR428A)により測定した。印加する直流磁界を0〜20000A/mで変化させて初透磁率の変化を観察した。直流磁界を印加していない状態での初透磁率をμiとした場合において、初透磁率がμi*0.8になるときの直流磁界の値(Hμi*0.8)を評価した。Hμi*0.8≧4500A/ mの場合に直流重畳特性が良好であるとした。Hμi*0.8≧10000A/ mの場合に直流重畳特性がさらに良好であるとし、Hμi*0.8≧12000A/mの場合に直流重畳特性が特に良好であるとした。
本実験例では、アルコキシシラン溶液の湿式噴霧後の熱処理条件を変化させることでI1/I2を変化させて各実施例および比較例を作成した。結果を表4および表5に示す。表4では第1膜の湿式塗布時間を0.3時間、第2膜の湿式塗布時間を6.1時間に固定した。表5では第1膜の湿式塗布時間を4.3時間、第2膜の湿式塗布時間を5.2時間に固定した。
本実験例では、アルコキシシラン溶液を前記金属磁性材料へ湿式噴霧せず、絶縁膜を形成しなかった点以外は実験例1と同様に実施した。その結果、絶縁膜が存在しない場合には成型が困難であり、圧粉磁心を作製することができなかった。
11・・・金属磁性材料
11a・・・金属磁性材料11の表面
12・・・樹脂
13・・・絶縁膜
13a・・・第1膜
13b・・・第2膜
Claims (7)
- 金属磁性材料および樹脂を含み、
前記金属磁性材料の表面に接し、前記金属磁性材料を被覆している絶縁膜が存在し、
前記絶縁膜は第1膜および第2膜を有し、前記金属磁性材料の表面に接している膜を前記第1膜、前記第1膜の表面に接している膜を前記第2膜とする場合において、
前記第1膜の密度が前記第2膜の密度よりも高いことを特徴とする圧粉磁心。 - 前記第1膜および前記第2膜がいずれもSi−O系の酸化物からなる請求項1に記載の圧粉磁心。
- 前記第1膜と前記第2膜とがTEM観察にて互いに異なるコントラストを有する請求項2に記載の圧粉磁心。
- 前記第1膜および前記第2膜についてTEM−EDS分析を行う場合において、第1膜のSi検出強度をI1、第2膜のSi検出強度をI2とした場合に、1.25<I1/I2<10.0を満たす請求項2または3に記載の圧粉磁心。
- 前記第1膜の厚みをD1、前記第2膜の厚みをD2とする場合において、
0.075<D1/D2<10.0を満たす請求項1〜4のいずれかに記載の圧粉磁心。 - 前記金属磁性材料が、Feを主成分として含む請求項1〜5のいずれかに記載の圧粉磁心。
- 前記金属磁性材料が、FeおよびSiを主成分として含む請求項1〜5のいずれかに記載の圧粉磁心。
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US15/915,901 US11043320B2 (en) | 2017-03-09 | 2018-03-08 | Dust core |
CN201810198223.1A CN108573799B (zh) | 2017-03-09 | 2018-03-09 | 压粉磁芯 |
KR1020180028212A KR102026347B1 (ko) | 2017-03-09 | 2018-03-09 | 압분자심 |
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JP2017045489 | 2017-03-09 | ||
JP2017045489 | 2017-03-09 |
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JP2018152559A true JP2018152559A (ja) | 2018-09-27 |
JP7069849B2 JP7069849B2 (ja) | 2022-05-18 |
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JP2021111737A (ja) * | 2020-01-15 | 2021-08-02 | セイコーエプソン株式会社 | 圧粉磁心の製造方法および圧粉磁心 |
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CN111433264B (zh) | 2018-08-31 | 2022-10-28 | 株式会社Lg化学 | 交联聚烯烃隔膜及其制造方法 |
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JP2006202956A (ja) * | 2005-01-20 | 2006-08-03 | Sumitomo Electric Ind Ltd | 軟磁性材料および圧粉磁心 |
JP2007088156A (ja) * | 2005-09-21 | 2007-04-05 | Sumitomo Electric Ind Ltd | 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 |
JP2008041961A (ja) * | 2006-08-07 | 2008-02-21 | Toshiba Corp | 絶縁性磁性金属粒子および絶縁性磁性材料の製造方法 |
JP2009164470A (ja) * | 2008-01-09 | 2009-07-23 | Toyota Motor Corp | 磁性粉及び圧粉磁心 |
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US300A (en) * | 1837-07-29 | Machine foe spinning woolen roving | ||
US3957918A (en) | 1974-12-31 | 1976-05-18 | Ford Motor Company | Radiation polymerizable coating composition containing an unsaturated phosphoric ester |
JPS624681A (ja) | 1985-06-29 | 1987-01-10 | Kazuhiko Kami | モノコツクボデ−自動車二次製作の工法 |
JP3624681B2 (ja) | 1997-04-18 | 2005-03-02 | 松下電器産業株式会社 | 複合磁性材料およびその製造方法 |
JP2002324714A (ja) * | 2001-02-21 | 2002-11-08 | Tdk Corp | コイル封入圧粉磁芯およびその製造方法 |
JP4740417B2 (ja) | 2007-11-16 | 2011-08-03 | 株式会社神戸製鋼所 | 圧粉磁心用鉄粉及びその製造方法 |
JP5190331B2 (ja) | 2008-11-14 | 2013-04-24 | 東光株式会社 | 電子部品及びその製造方法 |
JP5140042B2 (ja) * | 2009-07-10 | 2013-02-06 | 株式会社豊田中央研究所 | 圧粉磁心およびその製造方法 |
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- 2018-03-08 US US15/915,901 patent/US11043320B2/en active Active
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Publication number | Priority date | Publication date | Assignee | Title |
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JP2006202956A (ja) * | 2005-01-20 | 2006-08-03 | Sumitomo Electric Ind Ltd | 軟磁性材料および圧粉磁心 |
JP2007088156A (ja) * | 2005-09-21 | 2007-04-05 | Sumitomo Electric Ind Ltd | 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 |
JP2008041961A (ja) * | 2006-08-07 | 2008-02-21 | Toshiba Corp | 絶縁性磁性金属粒子および絶縁性磁性材料の製造方法 |
JP2009164470A (ja) * | 2008-01-09 | 2009-07-23 | Toyota Motor Corp | 磁性粉及び圧粉磁心 |
Cited By (2)
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JP2021111737A (ja) * | 2020-01-15 | 2021-08-02 | セイコーエプソン株式会社 | 圧粉磁心の製造方法および圧粉磁心 |
JP7413786B2 (ja) | 2020-01-15 | 2024-01-16 | セイコーエプソン株式会社 | 圧粉磁心の製造方法および圧粉磁心 |
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JP7069849B2 (ja) | 2022-05-18 |
KR102026347B1 (ko) | 2019-09-27 |
US20180294084A1 (en) | 2018-10-11 |
US11043320B2 (en) | 2021-06-22 |
KR20180103770A (ko) | 2018-09-19 |
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