JP2020161560A - Composite magnetic material and metal composite core composed of the same - Google Patents
Composite magnetic material and metal composite core composed of the same Download PDFInfo
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- 239000000696 magnetic material Substances 0.000 title claims abstract description 39
- 239000002131 composite material Substances 0.000 title claims abstract description 38
- 239000002905 metal composite material Substances 0.000 title claims abstract description 9
- 229920005989 resin Polymers 0.000 claims abstract description 61
- 239000011347 resin Substances 0.000 claims abstract description 61
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims abstract description 38
- 239000004810 polytetrafluoroethylene Substances 0.000 claims abstract description 38
- 239000006247 magnetic powder Substances 0.000 claims abstract description 34
- 238000002156 mixing Methods 0.000 claims abstract description 14
- -1 polytetrafluoroethylene Polymers 0.000 claims abstract description 5
- 239000000843 powder Substances 0.000 claims description 72
- 239000011248 coating agent Substances 0.000 claims description 36
- 238000000576 coating method Methods 0.000 claims description 36
- 239000002245 particle Substances 0.000 claims description 9
- 230000035699 permeability Effects 0.000 description 40
- 230000000052 comparative effect Effects 0.000 description 35
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 17
- 238000000465 moulding Methods 0.000 description 10
- NIPNSKYNPDTRPC-UHFFFAOYSA-N N-[2-oxo-2-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)ethyl]-2-[[3-(trifluoromethoxy)phenyl]methylamino]pyrimidine-5-carboxamide Chemical compound O=C(CNC(=O)C=1C=NC(=NC=1)NCC1=CC(=CC=C1)OC(F)(F)F)N1CC2=C(CC1)NN=N2 NIPNSKYNPDTRPC-UHFFFAOYSA-N 0.000 description 8
- 229910052742 iron Inorganic materials 0.000 description 8
- 238000000034 method Methods 0.000 description 7
- 230000007423 decrease Effects 0.000 description 5
- 229910045601 alloy Inorganic materials 0.000 description 4
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- 238000005259 measurement Methods 0.000 description 4
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- 229920001187 thermosetting polymer Polymers 0.000 description 3
- 238000004804 winding Methods 0.000 description 3
- LLQHSBBZNDXTIV-UHFFFAOYSA-N 6-[5-[[4-[2-(2,3-dihydro-1H-inden-2-ylamino)pyrimidin-5-yl]piperazin-1-yl]methyl]-4,5-dihydro-1,2-oxazol-3-yl]-3H-1,3-benzoxazol-2-one Chemical compound C1C(CC2=CC=CC=C12)NC1=NC=C(C=N1)N1CCN(CC1)CC1CC(=NO1)C1=CC2=C(NC(O2)=O)C=C1 LLQHSBBZNDXTIV-UHFFFAOYSA-N 0.000 description 2
- 229910017082 Fe-Si Inorganic materials 0.000 description 2
- 229910017133 Fe—Si Inorganic materials 0.000 description 2
- 239000002033 PVDF binder Substances 0.000 description 2
- 229910000676 Si alloy Inorganic materials 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
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- 229920000647 polyepoxide Polymers 0.000 description 2
- 229920002981 polyvinylidene fluoride Polymers 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004641 Diallyl-phthalate Substances 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 229910002796 Si–Al Inorganic materials 0.000 description 1
- 229910000808 amorphous metal alloy Inorganic materials 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- QUDWYFHPNIMBFC-UHFFFAOYSA-N bis(prop-2-enyl) benzene-1,2-dicarboxylate Chemical compound C=CCOC(=O)C1=CC=CC=C1C(=O)OCC=C QUDWYFHPNIMBFC-UHFFFAOYSA-N 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- UHESRSKEBRADOO-UHFFFAOYSA-N ethyl carbamate;prop-2-enoic acid Chemical compound OC(=O)C=C.CCOC(N)=O UHESRSKEBRADOO-UHFFFAOYSA-N 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
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- 239000004814 polyurethane Substances 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- KCTAWXVAICEBSD-UHFFFAOYSA-N prop-2-enoyloxy prop-2-eneperoxoate Chemical compound C=CC(=O)OOOC(=O)C=C KCTAWXVAICEBSD-UHFFFAOYSA-N 0.000 description 1
- 229910000702 sendust Inorganic materials 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
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Abstract
Description
本発明は、磁性粉末と樹脂から成る複合磁性材料及びこの複合磁性材料によって構成されたメタルコンポジットコアに関する。 The present invention relates to a composite magnetic material composed of a magnetic powder and a resin, and a metal composite core composed of the composite magnetic material.
ＯＡ機器、太陽光発電システム、自動車など様々な用途にリアクトルが用いられている。様々な用途に対応するため、リアクトルに用いられるコアの形状の多様化が要求されている。この要求に応えるため、リアクトルは、メタルコンポジットコア（以下、ＭＣコアとも称する）と呼ばれるコアが用いられる。 Reactors are used in various applications such as office automation equipment, photovoltaic power generation systems, and automobiles. In order to support various applications, diversification of the shape of the core used for the reactor is required. In order to meet this demand, a core called a metal composite core (hereinafter, also referred to as MC core) is used as the reactor.
このＭＣコアは、磁性粉末と樹脂とを混合させた複合磁性材料を所定の形状に成型し、固化させて成るコアである。複合磁性材料は粘土状である。そのため、複合磁性材料を容器に流し込みやすいので、容器の形状に合わせて成型しやすく、コアを所望の形状に成型できる。 This MC core is a core formed by molding a composite magnetic material, which is a mixture of magnetic powder and resin, into a predetermined shape and solidifying it. The composite magnetic material is clay-like. Therefore, since the composite magnetic material can be easily poured into the container, it can be easily molded according to the shape of the container, and the core can be molded into a desired shape.
リアクトルは、使用する用途に合わせた透磁率や鉄損などの磁気特性が要求される。そして、鉄損はヒステリシス損失と渦電流損失の和で表される。一般的に、コアの密度を増加させることで、透磁率の向上やヒステリシス損失の低減を図ることができる。近年では、リアクトルの使用用途の多様化に伴い、透磁率の向上及びヒステリシス損失の低減がより高い水準で望まれている。 The reactor is required to have magnetic properties such as magnetic permeability and iron loss according to the intended use. The iron loss is represented by the sum of the hysteresis loss and the eddy current loss. Generally, by increasing the density of the core, it is possible to improve the magnetic permeability and reduce the hysteresis loss. In recent years, with the diversification of applications of the reactor, improvement of magnetic permeability and reduction of hysteresis loss are desired at a higher level.
本発明の目的は、密度を向上させ、透磁率の向上及びヒステリシス損失の低減を図ることができる複合磁性材料及びこれによって構成されたメタルコンポジットコアを提供することにある。 An object of the present invention is to provide a composite magnetic material capable of improving the density, improving the magnetic permeability and reducing the hysteresis loss, and a metal composite core composed of the composite magnetic material.
上記目的を達成するため、本発明の複合磁性材料は、磁性粉末と樹脂とを混合してなる複合磁性材料であって、前記磁性粉末は、ポリテトラフルオロエチレンを含み構成される絶縁被膜で覆われていること、を特徴とする。 In order to achieve the above object, the composite magnetic material of the present invention is a composite magnetic material obtained by mixing a magnetic powder and a resin, and the magnetic powder is covered with an insulating coating containing polytetrafluoroethylene. It is characterized by being magnetized.
本発明によれば、密度を向上させ、磁気特性の優れた複合磁性材料及びこれによって構成されたメタルコンポジットコアを得ることができる。 According to the present invention, it is possible to obtain a composite magnetic material having excellent magnetic properties and a metal composite core composed of the composite magnetic material with improved density.
（実施形態）
まず、本実施形態の構成について説明する。本実施形態のメタルコンポジットコア（以下、ＭＣコアとも称する）は、複合磁性材料を所定の容器に充填し、加圧することで所定の形状のコアとなる。このＭＣコアは、リアクトルの磁性体として使用される。
(Embodiment)
First, the configuration of this embodiment will be described. The metal composite core of the present embodiment (hereinafter, also referred to as MC core) becomes a core having a predetermined shape by filling a predetermined container with a composite magnetic material and pressurizing it. This MC core is used as a magnetic material for the reactor.
複合磁性材料は、磁性粉末と樹脂とを含み構成される。磁性粉末としては、軟磁性粉末が使用でき、特に、Ｆｅ粉末、Ｆｅ−Ｓｉ合金粉末、Ｆｅ−Ａｌ合金粉末、Ｆｅ−Ｓｉ−Ａｌ合金粉末（センダスト）、非晶質合金粉末、ナノクリスタル、又はこれら２種以上の粉末の混合粉などが使用できる。Ｆｅ−Ｓｉ合金粉末としては、例えば、Ｆｅ−６．５％Ｓｉ合金粉末、Ｆｅ−３．５％Ｓｉ合金粉末を使用できる。 The composite magnetic material is composed of a magnetic powder and a resin. As the magnetic powder, soft magnetic powder can be used, and in particular, Fe powder, Fe-Si alloy powder, Fe-Al alloy powder, Fe-Si-Al alloy powder (Sendust), amorphous alloy powder, nanocrystals, or A mixed powder of these two or more kinds of powder can be used. As the Fe-Si alloy powder, for example, Fe-6.5% Si alloy powder and Fe-3.5% Si alloy powder can be used.
磁性粉末は、平均粒子径の異なる磁性粉末を使用する。つまり、磁性粉末は、第１の粉末と、第１の粉末より平均粒子径が小さい第２の粉末から成る。本明細書において平均粒子径とは、特に断りがない限り、Ｄ５０、すなわちメジアン径を指すものとする。また、第１の粉末と第２の粉末の種類は、同じものでもよいし、異なるものでもよい。なお、本実施形態では、磁性粉末は平均粒子径の異なる第１の粉末及び第２の粉末の２種類の粉末で構成させているが、磁性粉末は、第１の粉末のみ１種類で構成させてもよい。 As the magnetic powder, magnetic powders having different average particle diameters are used. That is, the magnetic powder is composed of a first powder and a second powder having an average particle size smaller than that of the first powder. In the present specification, the average particle size refers to D50, that is, the median diameter, unless otherwise specified. Further, the types of the first powder and the second powder may be the same or different. In the present embodiment, the magnetic powder is composed of two types of powder, a first powder and a second powder having different average particle diameters, but the magnetic powder is composed of only one type of the first powder. You may.
第１の粉末の平均粒子径は１００μｍ〜２００μｍ、第２の粉末は、３μｍ〜１０μｍが好ましい。この範囲とすることで、第１の粉末同士の隙間に平均粒子径の小さい第２の粉末が入り込み、密度及び透磁率の向上と低鉄損化を図ることができるからである。 The average particle size of the first powder is preferably 100 μm to 200 μm, and the average particle size of the second powder is preferably 3 μm to 10 μm. This is because, within this range, the second powder having a small average particle diameter enters the gap between the first powders, and the density and magnetic permeability can be improved and the iron loss can be reduced.
また、第１の粉末と第２の粉末の重量比率は、第１の粉末：第２の粉末＝８０：２０〜６０：４０とすることが好ましい。この範囲とすることで密度及び透磁率が向上するとともに、鉄損を小さくすることができる。 The weight ratio of the first powder to the second powder is preferably 1st powder: 2nd powder = 80:20 to 60:40. Within this range, the density and magnetic permeability can be improved, and the iron loss can be reduced.
第１の粉末の周囲は、絶縁被膜により覆われている。絶縁被膜は、絶縁性を有する樹脂から成る。この樹脂の種類は、ポリテトラフルオロエチレン（以下、ＰＴＦＥと称する）を含む。なお、本明細書において、絶縁被膜となる絶縁性を有する樹脂を絶縁被膜樹脂と呼ぶ場合がある。 The circumference of the first powder is covered with an insulating film. The insulating coating is made of an insulating resin. This type of resin includes polytetrafluoroethylene (hereinafter referred to as PTFE). In addition, in this specification, a resin having an insulating property which becomes an insulating film may be referred to as an insulating film resin.
ＰＴＦＥの添加量は、磁性粉末に対して、０．１ｗｔ％以上１．０ｗｔ％以下の範囲が好ましい。ＰＴＦＥの添加量が０．１ｗｔ％未満、又は、ＰＴＦＥの添加量が１．０ｗｔ％を超えると、ＭＣコアの密度増加の効果が低い。 The amount of PTFE added is preferably in the range of 0.1 wt% or more and 1.0 wt% or less with respect to the magnetic powder. When the amount of PTFE added is less than 0.1 wt%, or the amount of PTFE added exceeds 1.0 wt%, the effect of increasing the density of the MC core is low.
複合磁性材料を構成する樹脂は、磁性粉末と混合され、磁性粉末を保持する。樹脂としては、熱硬化性樹脂、紫外線硬化樹脂、又は熱可塑性樹脂を使用することができる。熱硬化性樹脂としては、フェノール樹脂、エポキシ樹脂、不飽和ポリエステル樹脂、ポリウレタン、ジアリルフタレート樹脂、シリコーン樹脂などが使用できる。紫外線硬化性樹脂としては、ウレタンアクリレート系、エポキシアクリレート系、アクリレート系、エポキシ系の樹脂を使用できる。熱可塑性樹脂としては、ポリイミドやフッ素樹脂などの耐熱性に優れた樹脂を使用することが好ましい。 The resin constituting the composite magnetic material is mixed with the magnetic powder and holds the magnetic powder. As the resin, a thermosetting resin, an ultraviolet curable resin, or a thermoplastic resin can be used. As the thermosetting resin, phenol resin, epoxy resin, unsaturated polyester resin, polyurethane, diallyl phthalate resin, silicone resin and the like can be used. As the ultraviolet curable resin, urethane acrylate-based, epoxy acrylate-based, acrylate-based, and epoxy-based resins can be used. As the thermoplastic resin, it is preferable to use a resin having excellent heat resistance such as polyimide or fluororesin.
また、樹脂は、磁性粉末に対して３〜１０ｗｔ％含有されていることが好ましい。樹脂の含有量が３ｗｔ％より少ないと、磁性粉末の接合力が不足し、ＭＣコアの機械的強度が低下する。また、樹脂の含有量が１０ｗｔ％より多いと、磁性粉末を隙間なく保持することができなくなるなど、ＭＣコアの密度が低下し、透磁率が低下する。 Further, the resin is preferably contained in an amount of 3 to 10 wt% with respect to the magnetic powder. If the content of the resin is less than 3 wt%, the bonding force of the magnetic powder is insufficient, and the mechanical strength of the MC core is lowered. On the other hand, if the resin content is more than 10 wt%, the magnetic powder cannot be held without gaps, the density of the MC core decreases, and the magnetic permeability decreases.
次に、この複合磁性材料を用いたＭＣコアの製造方法について説明する。本実施形態におけるＭＣコアの製造方法は、（１）被覆工程、（２）混合工程、（３）成型工程、（４）硬化工程を有する。 Next, a method for manufacturing an MC core using this composite magnetic material will be described. The method for producing an MC core in the present embodiment includes (1) coating step, (2) mixing step, (3) molding step, and (4) curing step.
（１）被覆工程
被覆工程は、第１の粉末をＰＴＦＥから成る絶縁被膜で覆う工程である。被覆工程では、第１の粉末とＰＴＦＥを混合し、乾燥させることで、第１の粉末の周囲にＰＴＦＥを被覆させる。第１の粉末とＰＴＦＥの混合は、所定の混合器を用いて自動又は手動で行うことができる。混合する時間は、適宜設定することができる。混合する時間は、例えば２分間である。また、乾燥温度や乾燥時間は、ＰＴＦＥで第１の粉末を被覆できるのであれば、適宜な温度及び時間を設定できるが、例えば、１８０度で１２０分間乾燥する。
(1) Coating Step The coating step is a step of covering the first powder with an insulating coating made of PTFE. In the coating step, the first powder and PTFE are mixed and dried to coat the periphery of the first powder with PTFE. The mixing of the first powder and PTFE can be performed automatically or manually using a predetermined mixer. The mixing time can be set as appropriate. The mixing time is, for example, 2 minutes. The drying temperature and drying time can be set as appropriate as long as the first powder can be coated with PTFE. For example, the powder is dried at 180 degrees for 120 minutes.
（２）混合工程
混合工程は、磁性粉末と樹脂を混合する工程である。混合工程では、まず、被覆工程を経た第１の粉末と、第２の粉末を混合することで、磁性粉末を得る。そして、この磁性粉末に、磁性粉末に対して３〜１０ｗｔ％の樹脂を添加し、磁性粉末と樹脂を混合する。この混合工程を経ることで、磁性粉末と樹脂との混合物である複合磁性材料を得ることができる。
(2) Mixing step The mixing step is a step of mixing the magnetic powder and the resin. In the mixing step, first, the first powder that has undergone the coating step and the second powder are mixed to obtain a magnetic powder. Then, 3 to 10 wt% of the resin is added to the magnetic powder, and the magnetic powder and the resin are mixed. By going through this mixing step, a composite magnetic material which is a mixture of magnetic powder and resin can be obtained.
（３）成型工程
成型工程は、複合磁性材料を製造するコアの形状に合わせて成型する工程である。成型工程では、まず、製造するコアの形状に合わせた容器に複合磁性材料を充填する。その後、容器に充填された複合磁性材料を、押圧部材で加圧する。この押圧部材で加圧することで、容器の形状に複合磁性材料を押し広げるとともに、複合磁性材料に含まれていた空隙を減少させることでコアの密度が大きくなる。
(3) Molding process The molding process is a process of molding according to the shape of the core for producing the composite magnetic material. In the molding process, first, the composite magnetic material is filled in a container that matches the shape of the core to be manufactured. Then, the composite magnetic material filled in the container is pressed by the pressing member. By pressurizing with this pressing member, the composite magnetic material is spread in the shape of the container, and the voids contained in the composite magnetic material are reduced to increase the density of the core.
複合磁性材料を加圧する圧力は、数ｔｏｎ〜数十ｔｏｎで磁性粉末を押し固めて成形する圧粉磁心とは異なり、数ｋｇ〜数十ｋｇと低い圧力をかければ足りる。そのため、圧粉磁心は磁性粉末が変形するが、ＭＣコアは、加圧しても磁性粉末は変形しない。なお、ＭＣコアの成型においては、圧粉磁心の成型のように加圧することは、必須要件ではないため、複合磁性材料を押圧部材で加圧しなくてもよい。 The pressure for pressurizing the composite magnetic material is several tons to several tens of tons, which is different from the powder magnetic core formed by compacting the magnetic powder, and it is sufficient to apply a low pressure of several kg to several tens of kg. Therefore, the magnetic powder is deformed in the dust core, but the magnetic powder is not deformed in the MC core even when pressurized. In molding the MC core, it is not necessary to pressurize the composite magnetic material with the pressing member because it is not an essential requirement to pressurize as in the molding of the dust core.
（４）硬化工程
硬化工程は、複合磁性材料に含まれる樹脂を硬化させる工程である。樹脂の硬化は、樹脂の種類によって適宜の方法で硬化すればよい。例えば、樹脂が熱硬化性樹脂の場合には、熱を加えることで樹脂を硬化させる。
(4) Curing Step The curing step is a step of curing the resin contained in the composite magnetic material. The resin may be cured by an appropriate method depending on the type of resin. For example, when the resin is a thermosetting resin, the resin is cured by applying heat.
このように、所望の形状の容器に複合磁性材料を充填し、複合磁性材料に含まれる樹脂を硬化させることで、所望の形状となったＭＣコアが作製される。つまり、ＭＣコアにおいては、混合工程において添加した樹脂は硬化するだけなので、当該樹脂の成分は、分解されない。一方、圧粉磁心では、絶縁被膜として添加した樹脂は、焼鈍工程を経るため熱分解され、残った無機成分などが粉末間のバインダとして機能する。また、圧粉磁心は、数ｔｏｎ〜数十ｔｏｎで加圧成形することで、所望の形状にしており、樹脂を硬化させることでコアの形状を形成させるＭＣコアとは異なる。 In this way, a container having a desired shape is filled with the composite magnetic material, and the resin contained in the composite magnetic material is cured to produce an MC core having a desired shape. That is, in the MC core, since the resin added in the mixing step is only cured, the components of the resin are not decomposed. On the other hand, in the dust core, the resin added as the insulating film is thermally decomposed because it undergoes an annealing step, and the remaining inorganic components and the like function as a binder between the powders. Further, the dust core is formed into a desired shape by pressure molding at several tons to several tens of tons, which is different from the MC core in which the shape of the core is formed by curing the resin.
（実施例）
本発明の実施例を表１及び図１−図４を参照しつつ説明する。
(Example)
Examples of the present invention will be described with reference to Table 1 and FIGS. 1 to 4.
実施例１−３は、第１の粉末としては、平均粒子径が１５０μｍのＦｅ−６．５Ｓｉ合金粉末を使用した。実施例１−３は、絶縁被膜としてＰＴＦＥを使用し、第１の粉末の周囲を被覆する。実施例１−３は、このＰＴＦＥを第１の粉末に対してそれぞれ１．０ｗｔ％、０．５ｗｔ％、０．１ｗｔ％添加した。 In Examples 1-3, Fe-6.5Si alloy powder having an average particle diameter of 150 μm was used as the first powder. In Examples 1-3, PTFE is used as an insulating coating to coat the periphery of the first powder. In Examples 1-3, 1.0 wt%, 0.5 wt%, and 0.1 wt% of this PTFE was added to the first powder, respectively.
一方、比較例１は、第１の粉末を絶縁被膜によって覆わず、第１の粉末そのものである。比較例２−４は、絶縁被膜樹脂として実施例１−３及び後述する比較例５−６とは異なるフッ素樹脂を使用した。比較例２−４は、この絶縁被膜樹脂を第１の粉末に対してそれぞれ１．０ｗｔ％、０．５ｗｔ％、０．１ｗｔ％添加した。また、比較例５及び６は、絶縁被膜樹脂としてポリフッ化ビニリデン（ＰＶＤＦ）を使用した。比較例５−６は、この絶縁被膜樹脂を第１の粉末に対してそれぞれ０．２５ｗｔ％、０．１ｗｔ％添加した。 On the other hand, Comparative Example 1 is the first powder itself without covering the first powder with the insulating film. In Comparative Example 2-4, a fluororesin different from that of Example 1-3 and Comparative Example 5-6 described later was used as the insulating coating resin. In Comparative Example 2-4, 1.0 wt%, 0.5 wt%, and 0.1 wt% of this insulating coating resin were added to the first powder, respectively. Further, in Comparative Examples 5 and 6, polyvinylidene fluoride (PVDF) was used as the insulating coating resin. In Comparative Example 5-6, 0.25 wt% and 0.1 wt% of this insulating coating resin were added to the first powder, respectively.
そして、実施例１−３及び比較例１−６の第１の粉末のかさ密度を測定した。かさ密度は、絶縁被膜樹脂で覆った第１の粉末を１００ｃｃのシリンダーに摺り切りまで充填させた状態で測定した。その際、測定器として、タップデンサーＫＹＴ−５０００（セイシン企業製）を用いた。その測定結果を表１及び図１に示す。なお、測定結果の考察は後述する。
次に、実施例１−３及び比較例１−６の第１の粉末から混合工程、成型工程、硬化工程を経て、ＭＣコアを作製した。作製したＭＣコアは、外径３５ｍｍ、内径２０ｍｍ、高さ１０ｍｍのトロイダル形状とした。なお、本実施例では、第２の粉末は使用せず、複合磁性材料を作製した。 Next, an MC core was produced from the first powders of Examples 1-3 and Comparative Examples 1-6 through a mixing step, a molding step, and a curing step. The produced MC core had a toroidal shape with an outer diameter of 35 mm, an inner diameter of 20 mm, and a height of 10 mm. In this example, a composite magnetic material was produced without using the second powder.
絶縁被膜樹脂で被覆した磁性粉末に、磁性粉末に対して６ｗｔ％のエポキシ樹脂を添加し、２分間ヘラを用いて手動で混合し、複合磁性材料を形成した。この複合磁性材料を容器に充填し、加圧は行わなかった。そして、容器ごと複合磁性材料を大気中にて８５℃で２時間乾燥させ、その後１２０℃で１時間乾燥させ、さらに１５０℃で４時間乾燥することで樹脂を硬化した。このようにして、ＭＣコアを作製した。そして、作製したＭＣコアに、巻線を巻回し、リアクトルを作製した。 To the magnetic powder coated with the insulating coating resin, 6 wt% epoxy resin was added to the magnetic powder and manually mixed with a spatula for 2 minutes to form a composite magnetic material. The container was filled with this composite magnetic material and was not pressurized. Then, the composite magnetic material together with the container was dried in the air at 85 ° C. for 2 hours, then dried at 120 ° C. for 1 hour, and further dried at 150 ° C. for 4 hours to cure the resin. In this way, the MC core was produced. Then, a winding was wound around the produced MC core to produce a reactor.
以上のように作製した実施例１−３及び比較例１−６のリアクトルの透磁率、ヒステリシス損失Ｐｈ、ＭＣコアの密度を下記の条件の下で測定した。 The magnetic permeability, hysteresis loss Ph, and MC core density of the reactors of Examples 1-3 and Comparative Examples 1-6 prepared as described above were measured under the following conditions.
ＭＣコアの密度は、見かけ密度である。即ち、実施例１−３及び比較例１−６のＭＣコアの外径、内径、及び高さを測り、これらの値から各ＭＣコアの体積（ｃｍ３）を、π×（外径２−内径２）×高さに基づき算出した。そして、各ＭＣコアの質量を測定し、測定した質量を算出した体積で除してＭＣコアの密度を算出した。 The density of the MC core is the apparent density. That is, the outer diameter, inner diameter, and height of the MC cores of Examples 1-3 and Comparative Examples 1-6 are measured, and the volume (cm 3 ) of each MC core is calculated from these values by π × (outer diameter 2 −. Calculated based on inner diameter 2 ) x height. Then, the mass of each MC core was measured, and the measured mass was divided by the calculated volume to calculate the density of the MC core.
透磁率及び鉄損の測定条件は、周波数１００ｋＨｚ、最大磁束密度Ｂｍ＝３０ｍＴとした。透磁率は、鉄損Ｐｃｖ測定時に最大磁束密度Ｂｍを設定したときの振幅透磁率とした。ヒステリシス損失Ｐｈについては、ＭＣコアにφ１．２ｍｍの銅線で１次巻線４０ターン、２次巻線３ターンの巻線を巻回し、磁気計測機器であるＢＨアナライザ（岩通計測株式会社：ＳＹ−８２１９）を用いて算出した。この算出は、鉄損の周波数曲線を次の（１）〜（３）式で最小２乗法により、ヒステリシス損失係数、渦電流損失係数を算出することで行った。 The measurement conditions for magnetic permeability and iron loss were a frequency of 100 kHz and a maximum magnetic flux density of Bm = 30 mT. The magnetic permeability was taken as the amplitude magnetic permeability when the maximum magnetic flux density Bm was set at the time of iron loss Pcv measurement. Regarding the hysteresis loss Ph, a copper wire of φ1.2 mm is wound around the MC core with 40 turns of the primary winding and 3 turns of the secondary winding, and a BH analyzer (Iwadori Measurement Co., Ltd .:) is a magnetic measuring device. It was calculated using SY-8219). This calculation was performed by calculating the hysteresis loss coefficient and the eddy current loss coefficient by the least squares method using the following equations (1) to (3) for the frequency curve of iron loss.
Ｐｃｖ ＝Ｋｈ×ｆ＋Ｋｅ×ｆ２・・（１）
Ｐｈ ＝Ｋｈ×ｆ・・（２）
Ｐｅ ＝Ｋｅ×ｆ２・・（３）
Ｐｃｖ：鉄損
Ｋｈ ：ヒステリシス損失係数
Ｋｅ ：渦電流損失係数
ｆ ：周波数
Ｐｈ ：ヒステリシス損失
Ｐｅ ：渦電流損失
Pcv = Kh x f + Ke x f 2 ... (1)
Ph = Kh x f ... (2)
Pe = Ke × f 2 ... (3)
Pcv: Iron loss Kh: Hysteresis loss coefficient Ke: Eddy current loss coefficient f: Frequency Ph: Hysteresis loss Pe: Eddy current loss
表１は、実施例１−３及び比較例１−６の密度及びヒステリシス損失Ｐｈを示す表である。表２における透磁率は、振幅透磁率であり、ＬＣＲメータ（アジレント・テクノロジー株式会社製：４２８４Ａ）を使用して、１００ｋＨｚ、１．０Ｖにおける各磁界の強さのインダクタンスから算出した。表２の「μ０」は、直流を重畳させていない状態、即ち、磁界の強さが０Ｈ（Ａ／ｍ）の時の初透磁率を示す。表２の「μ１２０００」は、磁界の強さが１２ｋＨ（Ａ／ｍ）の時の透磁率を示す。また、図１は、絶縁被膜樹脂の添加量とかさ密度の関係を示したグラフである。図２は、絶縁被膜樹脂の添加量と密度の関係を示したグラフである。図３は、絶縁被膜樹脂の添加量と初透磁率μ０の関係を示したグラフである。図４は、絶縁被膜樹脂の添加量と透磁率μ１２０００の関係を示したグラフである。図５は、絶縁被膜樹脂の添加量とヒステリシス損失の関係を示したグラフである。 Table 1 is a table showing the density and hysteresis loss Ph of Examples 1-3 and Comparative Example 1-6. The magnetic permeability in Table 2 is the amplitude magnetic permeability, which was calculated from the inductance of the strength of each magnetic field at 100 kHz and 1.0 V using an LCR meter (manufactured by Agilent Technologies, Inc .: 4284 A). “Μ0” in Table 2 indicates the initial magnetic permeability in a state where direct current is not superimposed, that is, when the strength of the magnetic field is 0H (A / m). “Μ12000” in Table 2 indicates the magnetic permeability when the magnetic field strength is 12 kHz (A / m). Further, FIG. 1 is a graph showing the relationship between the amount of the insulating coating resin added and the bulk density. FIG. 2 is a graph showing the relationship between the amount of the insulating coating resin added and the density. FIG. 3 is a graph showing the relationship between the amount of the insulating coating resin added and the initial magnetic permeability μ0. FIG. 4 is a graph showing the relationship between the amount of the insulating coating resin added and the magnetic permeability μ12000. FIG. 5 is a graph showing the relationship between the amount of the insulating coating resin added and the hysteresis loss.
（密度の比較）
表２及び図２に示すように、第１の粉末をＰＴＦＥで被覆した実施例１−３の密度は、絶縁被膜で覆わず第１の粉末そのものであった比較例１の密度より大幅に増加している。具体的には、実施例１−３の密度は、全て５．０（ｇ／ｃｍ３）より大きくなっているのに対し、比較例１−６の密度は、全て５．０（ｇ／ｃｍ３）より小さくなっている。このことから、第１の粉末をＰＴＦＥで被覆する方がＭＣコアの密度が向上することが分かる。
(Density comparison)
As shown in Table 2 and FIG. 2, the density of Example 1-3 in which the first powder was coated with PTFE was significantly higher than the density of Comparative Example 1 in which the first powder itself was not covered with the insulating coating. are doing. Specifically, the densities of Examples 1-3 are all higher than 5.0 (g / cm 3 ), whereas the densities of Comparative Examples 1-6 are all 5.0 (g / cm 3 ). It is smaller than 3 ). From this, it can be seen that the density of the MC core is improved by coating the first powder with PTFE.
また、実施例１−３は、実施例１−３と絶縁被膜樹脂を変えた比較例２−４及び比較例５−６と比較しても、密度が増加していることが分かる。これは、絶縁被膜樹脂の添加量が同一の０．１ｗｔ％である実施例３、比較例４及び比較例６を比べても、実施例３は５．２４（ｇ／ｃｍ３）であるのに対し、比較例４は４．６６（ｇ／ｃｍ３）、比較例６は４．４７（ｇ／ｃｍ３）であることからも示されている。よって、ＰＴＦＥを０．１ｗｔ％以上添加することで、コアの密度が向上する。 Further, it can be seen that the densities of Examples 1-3 are also increased as compared with Example 1-3 and Comparative Examples 2-4 and 5-6 in which the insulating coating resin is changed. This is 5.24 (g / cm 3 ) in Example 3 even when comparing Example 3, Comparative Example 4 and Comparative Example 6 in which the addition amount of the insulating coating resin is the same 0.1 wt%. On the other hand, it is also shown that Comparative Example 4 is 4.66 (g / cm 3 ) and Comparative Example 6 is 4.47 (g / cm 3 ). Therefore, the density of the core is improved by adding 0.1 wt% or more of PTFE.
このように、第１の粉末をＰＴＦＥで被覆した実施例の密度が向上した要因は、ＰＴＦＥの摩擦係数が小さいため、第１の粉末の流動性が向上することに起因するものと考える。即ち、第１の粉末をＰＴＦＥで被覆することで、第１の粉末の流動性が向上し、第１の粉末をより密接に配置でき、コアの見かけ密度が増加する。このことは、表１及び図１を参照すると、ＰＴＦＥで被覆した実施例１−３の第１の粉末のかさ密度が、比較例１−６の第１の粉末のかさ密度よりも大きいことからも示されている。 It is considered that the reason why the density of the example in which the first powder is coated with PTFE is improved is that the fluidity of the first powder is improved because the friction coefficient of PTFE is small. That is, by coating the first powder with PTFE, the fluidity of the first powder is improved, the first powder can be arranged more closely, and the apparent density of the core is increased. This is because, referring to Table 1 and FIG. 1, the bulk density of the first powder of Example 1-3 coated with PTFE is higher than the bulk density of the first powder of Comparative Example 1-6. Is also shown.
また、第２の粉末が第１の粉末と接触しても、第１の粉末の周囲は摩擦係数の小さいＰＴＦＥで覆われているため、第２の粉末の流動性も抑制されにくい。そのため、第１の粉末間に形成される隙間により多くの第２の粉末が入り込み、コアの密度が増加する。 Further, even if the second powder comes into contact with the first powder, the fluidity of the second powder is not easily suppressed because the periphery of the first powder is covered with PTFE having a small friction coefficient. Therefore, more second powder enters the gap formed between the first powders, and the density of the core increases.
（透磁率の比較）
表２及び図３、４に示すように、ＰＴＦＥで被覆した実施例の初透磁率（μ０）及び透磁率（μ１２０００）は、比較例１−６と比較して向上している。具体的には、比較例１と実施例１−３の初透磁率を比べると、実施例１−３の初透磁率が高い。また、比較例１と実施例１−３の透磁率を比べると、実施例１−３の透磁率が高い。このように、第１の粉末をＰＴＦＥで被覆した方が、初透磁率及び透磁率が向上していることが示されている。
(Comparison of magnetic permeability)
As shown in Table 2 and FIGS. 3 and 4, the initial magnetic permeability (μ0) and the magnetic permeability (μ12000) of the examples coated with PTFE are improved as compared with Comparative Examples 1-6. Specifically, when the initial magnetic permeability of Comparative Example 1 and Example 1-3 is compared, the initial magnetic permeability of Example 1-3 is high. Further, comparing the magnetic permeability of Comparative Example 1 and Example 1-3, the magnetic permeability of Example 1-3 is high. As described above, it is shown that the initial magnetic permeability and the magnetic permeability are improved when the first powder is coated with PTFE.
一方、比較例１と比較例２−６の初透磁率を比べると、比較例１の初透磁率の方が高い。また、比較例１の透磁率と比較例２−６の透磁率を比較すると、比較例１の透磁率の方が高い。つまり、ＰＴＦＥ以外の種類で被覆すると、絶縁被覆樹脂で被覆していない場合と比べて、初透磁率及び透磁率が低下することが示されている。 On the other hand, when the initial magnetic permeability of Comparative Example 1 and Comparative Example 2-6 is compared, the initial magnetic permeability of Comparative Example 1 is higher. Further, when the magnetic permeability of Comparative Example 1 and the magnetic permeability of Comparative Example 2-6 are compared, the magnetic permeability of Comparative Example 1 is higher. That is, it is shown that when coated with a type other than PTFE, the initial magnetic permeability and the magnetic permeability are lowered as compared with the case where the coating is not coated with the insulating coating resin.
このことから、ＰＴＦＥで第１の粉末を被覆すると、初透磁率及び透磁率が向上することが示されている。これは、ＰＴＦＥで被覆したことでコアの密度が増加したためであると考える。つまり、コアの密度が増加したことで、磁束密度も増加し、その結果、透磁率が向上すると考える。 From this, it is shown that coating the first powder with PTFE improves the initial magnetic permeability and the magnetic permeability. It is considered that this is because the density of the core is increased by coating with PTFE. That is, it is considered that the magnetic flux density increases as the core density increases, and as a result, the magnetic permeability improves.
（ヒステリシス損失の比較）
表２及び図５に示すように、ＰＴＦＥを０．１ｗｔ％添加した実施例３のヒステリシス損失は１３７．６である。一方、絶縁被覆樹脂で被覆していない比較例１のヒステリシス損失は、２０５．３である。また、ＰＴＦＥとは異なる種類の樹脂を０．１ｗｔ％添加した比較例４及び６のヒステリシス損失は、それぞれ２００．５、１５８．３である。つまり、絶縁被膜樹脂で被覆していない比較例１のヒステリシス損失を基準にすると、実施例３のヒステリシス損失は比較例１の約６７％に低減している、一方、比較例４及び６のヒステリシス損失は、比較例１の約９８％、約７７％であり、実施例３の方がヒステリシス損失の低減率が高い。よって、ＰＴＦＥで第１の粉末を被覆した方がヒステリシス損失をより低減できる。
(Comparison of hysteresis loss)
As shown in Table 2 and FIG. 5, the hysteresis loss of Example 3 to which 0.1 wt% of PTFE was added is 137.6. On the other hand, the hysteresis loss of Comparative Example 1 not coated with the insulating coating resin is 205.3. The hysteresis loss of Comparative Examples 4 and 6 to which 0.1 wt% of a resin different from PTFE was added was 200.5 and 158.3, respectively. That is, based on the hysteresis loss of Comparative Example 1 not coated with the insulating coating resin, the hysteresis loss of Example 3 is reduced to about 67% of that of Comparative Example 1, while the hysteresis of Comparative Examples 4 and 6 is reduced. The loss is about 98% and about 77% of Comparative Example 1, and the reduction rate of the hysteresis loss is higher in Example 3. Therefore, the hysteresis loss can be further reduced by coating the first powder with PTFE.
このように、実施例３のヒステリシス損失は、比較例１、４及び６のヒステリシス損失よりも低下している。この要因も、実施例のコアの密度を増加させることができたためである。そして、この結果は、１００ｋＨｚという高周波において用いた場合にも、同様にヒステリシス損失を抑制できることを示している。なお、ここでいう高周波とは、１００ｋＨｚのみを指すものではなく、２０ｋＨｚを超えていれば高周波に含まれる。 As described above, the hysteresis loss of Example 3 is lower than that of Comparative Examples 1, 4 and 6. This factor is also due to the fact that the core density of the examples could be increased. And this result shows that the hysteresis loss can be similarly suppressed even when it is used at a high frequency of 100 kHz. The high frequency referred to here does not mean only 100 kHz, but is included in the high frequency if it exceeds 20 kHz.
（ＰＴＦＥの添加量）
以上のように、少なくともＰＴＦＥを０．１ｗｔ％以上添加することで、コアの密度が増加し、透磁率の向上及びヒステリシス損失の抑制を図ることができる。一方、図２を参照すると、実施例の密度の増加は、ＰＴＦＥを０．５ｗｔ％添加した時点（実施例２）が最大値となり、０．５ｗｔ％以上添加すると、コアの密度は低下する傾向にある。本実施例では、ＰＴＦＥの添加量は１．０ｗｔ％までとしたが、仮にこれ以上添加した場合、さらにコアの密度が低下することが容易に推察できる。密度が低下すると、それに伴って透磁率が低下し、又、ヒステリシス損失が増加する。よって、ＰＴＦＥの添加量の上限は、１．０ｗｔ％とすることが好ましい。したがって、ＰＴＦＥの添加量は、０．１ｗｔ％以上１．０ｗｔ以下であることが好ましい。
(Amount of PTFE added)
As described above, by adding at least 0.1 wt% or more of PTFE, the density of the core can be increased, the magnetic permeability can be improved, and the hysteresis loss can be suppressed. On the other hand, referring to FIG. 2, the increase in the density of the examples reaches the maximum value when 0.5 wt% of PTFE is added (Example 2), and when 0.5 wt% or more is added, the density of the core tends to decrease. It is in. In this example, the amount of PTFE added was up to 1.0 wt%, but if more than this is added, it can be easily inferred that the density of the core is further reduced. As the density decreases, the magnetic permeability decreases accordingly, and the hysteresis loss increases. Therefore, the upper limit of the amount of PTFE added is preferably 1.0 wt%. Therefore, the amount of PTFE added is preferably 0.1 wt% or more and 1.0 wt or less.
（他の実施形態）
本明細書においては、本発明に係る実施形態を説明したが、この実施形態は例として提示したものであって、発明の範囲を限定することを意図していない。上記のような実施形態は、その他の様々な形態で実施されることが可能であり、発明の範囲を逸脱しない範囲で、種々の省略や置き換え、変更を行うことができる。実施形態やその変形は、発明の範囲や要旨に含まれると同様に、特許請求の範囲に記載された発明とその均等の範囲に含まれるものである。
(Other embodiments)
Although the embodiment according to the present invention has been described in the present specification, this embodiment is presented as an example and is not intended to limit the scope of the invention. The above-described embodiment can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. The embodiments and modifications thereof are included in the scope and the gist of the invention as well as the invention described in the claims and the equivalent scope thereof.
Claims (5)
前記磁性粉末は、ポリテトラフルオロエチレンを含み構成される絶縁被膜で覆われていること、
を特徴とする複合磁性材料。 A composite magnetic material made by mixing magnetic powder and resin.
The magnetic powder is covered with an insulating coating containing polytetrafluoroethylene.
A composite magnetic material characterized by.
第１の粉末と、
前記第１の粉末より平均粒子径が小さい第２の粉末と、
を有し、
前記第１の粉末は、前記絶縁被膜で覆われていること、
を特徴とする請求項１に記載の複合磁性材料。 The magnetic powder is
The first powder and
A second powder having an average particle size smaller than that of the first powder,
Have,
The first powder is covered with the insulating coating.
The composite magnetic material according to claim 1.
を特徴とする請求項１又は２に記載の複合磁性材料。 The amount of the polytetrafluoroethylene added is 0.1 wt% or more and 1.0 wt% or less with respect to the magnetic powder.
The composite magnetic material according to claim 1 or 2.
を特徴とする請求項４に記載のメタルコンポジットコア。
The resin is cured.
The metal composite core according to claim 4.
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