JP2018182140A - 軟磁性粉末、圧粉磁心、磁性素子および電子機器 - Google Patents
軟磁性粉末、圧粉磁心、磁性素子および電子機器 Download PDFInfo
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- JP2018182140A JP2018182140A JP2017081554A JP2017081554A JP2018182140A JP 2018182140 A JP2018182140 A JP 2018182140A JP 2017081554 A JP2017081554 A JP 2017081554A JP 2017081554 A JP2017081554 A JP 2017081554A JP 2018182140 A JP2018182140 A JP 2018182140A
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Abstract
Description
本発明の軟磁性粉末は、Fe100−a−b−c−d−e−fCuaSibBcMdM’eXf(原子%)
[ただし、Mは、Nb、W、Ta、Zr、HfおよびMoからなる群より選択される少なくとも1種の元素であり、M’は、V、Cr、Mn、白金族元素、Sc、Y、Au、Zn、SnおよびReからなる群より選択される少なくとも1種の元素であり、Xは、C、P、Ge、Ga、Sb、In、BeおよびAsからなる群より選択される少なくとも1種の元素であり、a、b、c、d、eおよびfは、0.1≦a≦3、0<b≦30、0<c≦25、5≦b+c≦30、0.1≦d≦30、0≦e≦10および0≦f≦10を満たす数である。]
で表される組成を有し、
粒径1nm以上30nm以下の結晶組織を40体積%以上含有し、
見掛密度を100としたとき、タップ密度が103以上130以下であることを特徴とする。
これにより、結晶組織と非晶質組織とが互いに磁歪を打ち消し合うため、軟磁性粉末の磁歪をより小さくすることができる。その結果、透磁率が特に高い軟磁性粉末が得られる。また、併せて、磁化を制御し易い軟磁性粉末が得られる。
これにより、透磁率の向上が図られた圧粉磁心が得られる。
これにより、高性能化が図られた磁性素子が得られる。
これにより、信頼性の高い電子機器が得られる。
本発明の軟磁性粉末は、軟磁性を示す金属粉末である。かかる軟磁性粉末は、軟磁性を利用したいかなる用途にも適用可能であるが、例えば、結合材を介して粒子同士が結着されるとともに所定の形状に成形されることで、圧粉磁心を製造するのに用いられる。こうして得られた圧粉磁心は、軟磁性粉末の透磁率が高いため、磁気特性が良好なものとなる。
Feは、本発明の軟磁性粉末の基本的な磁気特性や機械的特性に大きな影響を与える。
まず、測定対象の軟磁性粉末0.8gをアルミナ製の円筒に充填する。そして、円筒の上下に真ちゅう製の電極を配置する。
次に、本発明の圧粉磁心および本発明の磁性素子について説明する。
<第1実施形態>
まず、本発明の磁性素子の第1実施形態を適用したチョークコイルについて説明する。
まず、本発明の軟磁性粉末と、結合材と、各種添加剤と、有機溶媒とを混合し、混合物を得る。
この場合の成形方法としては、特に限定されないが、例えば、プレス成形、押出成形、射出成形等の方法が挙げられる。なお、この成形体の形状寸法は、以後の成形体を加熱した際の収縮分を見込んで決定される。また、プレス成形の場合の成形圧力は、1t/cm2(98MPa)以上10t/cm2(981MPa)以下程度とされる。
次に、本発明の磁性素子の第2実施形態を適用したチョークコイルについて説明する。
次いで、前記第1実施形態と同様に、この成形体に熱処理を施す。これにより、結合材を硬化させ、圧粉磁心21およびチョークコイル20(実施形態に係る磁性素子)が得られる。
次に、本発明の軟磁性粉末を製造する方法について説明する。
高速回転水流アトマイズ法では、冷却用筒体の内周面に沿って冷却液を噴出供給し、冷却用筒体の内周面に沿って旋回させることにより、内周面に冷却液層を形成する。一方、軟磁性粉末の原材料を溶融し、得られた溶融金属を自然落下させつつ、これに液体または気体のジェットを吹き付ける。これにより溶融金属を飛散させ、飛散した溶融金属は冷却液層に取り込まれる。その結果、飛散して微粉化した溶融金属が急速冷却されて固化し、軟磁性粉末が得られる。
なお、ガスジェット26は、必要に応じて液体ジェットで代替することもできる。
以上のようにして本実施形態に係る軟磁性粉末を製造することができる。
次いで、本発明の磁性素子を備える電子機器(本発明の電子機器)について、図4〜図6に基づき、詳細に説明する。
1.圧粉磁心の製造
(サンプルNo.1)
[1]まず、原材料を高周波誘導炉で溶融するとともに、高速回転水流アトマイズ法により粉末化して軟磁性粉末を得た。この際、坩堝から流下させる溶融金属の流下量を0.5kg/分、坩堝の流下口の内径を1mm、ガスジェットの流速を900m/sとした。次いで、風力分級機により分級を行った。得られた軟磁性粉末の合金組成を表1に示す。なお、合金組成の特定には、SPECTRO社製固体発光分光分析装置(スパーク発光分析装置)、モデル:SPECTROLAB、タイプ:LAVMB08Aを用いた。
・成形方法 :プレス成形
・成形体の形状:リング状
・成形体の寸法:外径28mm、内径14mm、厚さ5mm
・成形圧力 :1t/cm2(98MPa)
軟磁性粉末として表1に示すものをそれぞれ用いるようにした以外は、サンプルNo.1と同様にして圧粉磁心を得た。なお、各サンプルの平均粒径D50は、3μm以上30μm以下の範囲内に収まっていた。
軟磁性粉末として、表2に示すものをそれぞれ用いるようにした以外は、サンプルNo.1と同様にして圧粉磁心を得た。なお、各サンプルの平均粒径D50は、3μm以上30μm以下の範囲内に収まっていた。
2.1 軟磁性粉末の粉末特性の測定
各実施例および各比較例で得られた軟磁性粉末について、見掛密度ADおよびタップ密度TDを測定した。
測定結果および算出結果を表3、4に示す。
2.2.1 軟磁性粉末の保磁力の測定
各実施例および各比較例で得られた軟磁性粉末について、それぞれの保磁力を以下の測定条件に基づいて測定した。
・測定装置 :磁化測定装置(株式会社玉川製作所製VSMシステム、TM−VSM1230−MHHL)
そして、測定した保磁力を、以下の評価基準にしたがって評価した。
◎ :保磁力が0.5未満
○ :保磁力が0.5以上1.0未満
△○:保磁力が1.0以上1.33未満
△△:保磁力が1.33以上1.67未満
△×:保磁力が1.67以上2.0未満
× :保磁力が2.0以上
評価結果を表3、4に示す。
各実施例および各比較例で得られた軟磁性粉末について、それぞれの透磁率を以下の測定条件に基づいて測定した。
・測定装置 :インピーダンスアナライザー(HEWLETT PACKARD 4194A)
・測定周波数 :100kHz
・巻線の巻き数:7回
・巻線の線径 :0.5mm
測定結果を表3、4に示す。
各実施例および各比較例で得られた軟磁性粉末について、長軸を含む平面で粒子を切断した。そして、切断面を透過型電子顕微鏡で観察し、結晶組織および非晶質組織を特定した。
測定結果を表3、4に示す。
各実施例および各比較例で得られた軟磁性粉末について、X線回折により取得された回折ピークの幅に基づき、結晶組織の平均粒径を求めた。
測定結果を表3、4に示す。
各実施例および各比較例で得られた軟磁性粉末について、長軸を含む平面で粒子を切断した。そして、切断面の中心部について、マイクロビッカース硬さ試験機によりビッカース硬度を測定した。
測定結果を表3、4に示す。
各実施例および各比較例で得られた軟磁性粉末について、圧粉体としたときの体積抵抗率をデジタルマルチメーターを用いて測定した。
測定結果を表3、4に示す。
各実施例および各比較例で得られた圧粉磁心について、絶縁破壊電圧を測定した。
測定結果を表3、4に示す。
一方、各比較例で得られた軟磁性粉末では、透磁率が相対的に低いことが認められた。
Claims (7)
- Fe100−a−b−c−d−e−fCuaSibBcMdM’eXf(原子%)
[ただし、Mは、Nb、W、Ta、Zr、HfおよびMoからなる群より選択される少なくとも1種の元素であり、M’は、V、Cr、Mn、白金族元素、Sc、Y、Au、Zn、SnおよびReからなる群より選択される少なくとも1種の元素であり、Xは、C、P、Ge、Ga、Sb、In、BeおよびAsからなる群より選択される少なくとも1種の元素であり、a、b、c、d、eおよびfは、0.1≦a≦3、0<b≦30、0<c≦25、5≦b+c≦30、0.1≦d≦30、0≦e≦10および0≦f≦10を満たす数である。]
で表される組成を有し、
粒径1nm以上30nm以下の結晶組織を40体積%以上含有し、
見掛密度を100としたとき、タップ密度が103以上130以下であることを特徴とする軟磁性粉末。 - 前記組成は、Fe100−a−b−c−d−e−f−g−hCuaSibBcMdM’eXfAlgTih(原子%)で表され、gおよびhは、0.002≦g≦0.032および0≦h≦0.038を満たす数である請求項1に記載の軟磁性粉末。
- 圧粉された状態における圧粉体の体積抵抗率が1kΩ・cm以上500kΩ・cm以下である請求項1または2に記載の軟磁性粉末。
- 非晶質組織をさらに含有する請求項1ないし3のいずれか1項に記載の軟磁性粉末。
- 請求項1ないし4のいずれか1項に記載の軟磁性粉末を含むことを特徴とする圧粉磁心。
- 請求項5に記載の圧粉磁心を備えることを特徴とする磁性素子。
- 請求項6に記載の磁性素子を備えることを特徴とする電子機器。
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