JP2020161696A - 複合粒子、コアおよびインダクタ素子 - Google Patents
複合粒子、コアおよびインダクタ素子 Download PDFInfo
- Publication number
- JP2020161696A JP2020161696A JP2019060954A JP2019060954A JP2020161696A JP 2020161696 A JP2020161696 A JP 2020161696A JP 2019060954 A JP2019060954 A JP 2019060954A JP 2019060954 A JP2019060954 A JP 2019060954A JP 2020161696 A JP2020161696 A JP 2020161696A
- Authority
- JP
- Japan
- Prior art keywords
- particles
- binder
- solution
- core
- composite
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000011246 composite particle Substances 0.000 title claims abstract description 110
- 239000002245 particle Substances 0.000 claims abstract description 409
- 239000011230 binding agent Substances 0.000 claims abstract description 123
- 238000004519 manufacturing process Methods 0.000 claims description 28
- 239000006249 magnetic particle Substances 0.000 claims description 24
- 230000002776 aggregation Effects 0.000 claims description 14
- 238000004220 aggregation Methods 0.000 claims description 14
- 239000003112 inhibitor Substances 0.000 claims description 12
- 238000001035 drying Methods 0.000 claims description 5
- 238000000465 moulding Methods 0.000 abstract description 65
- 239000000243 solution Substances 0.000 description 106
- 239000011248 coating agent Substances 0.000 description 29
- 238000000576 coating method Methods 0.000 description 29
- 239000000463 material Substances 0.000 description 29
- 229910045601 alloy Inorganic materials 0.000 description 26
- 239000000956 alloy Substances 0.000 description 26
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 18
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 18
- 230000000052 comparative effect Effects 0.000 description 16
- 229910052751 metal Inorganic materials 0.000 description 12
- 239000002184 metal Substances 0.000 description 12
- 239000008187 granular material Substances 0.000 description 11
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 10
- 238000000034 method Methods 0.000 description 10
- 229920005989 resin Polymers 0.000 description 9
- 239000011347 resin Substances 0.000 description 9
- 239000003822 epoxy resin Substances 0.000 description 7
- 229920000647 polyepoxide Polymers 0.000 description 7
- 229910017082 Fe-Si Inorganic materials 0.000 description 6
- 229910017133 Fe—Si Inorganic materials 0.000 description 6
- 239000004020 conductor Substances 0.000 description 6
- 230000035699 permeability Effects 0.000 description 6
- 239000007787 solid Substances 0.000 description 6
- 229910000859 α-Fe Inorganic materials 0.000 description 6
- 239000002904 solvent Substances 0.000 description 5
- 238000001179 sorption measurement Methods 0.000 description 5
- 238000004804 winding Methods 0.000 description 5
- 230000001186 cumulative effect Effects 0.000 description 4
- 229910052742 iron Inorganic materials 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 description 3
- BOTDANWDWHJENH-UHFFFAOYSA-N Tetraethyl orthosilicate Chemical compound CCO[Si](OCC)(OCC)OCC BOTDANWDWHJENH-UHFFFAOYSA-N 0.000 description 3
- JRPBQTZRNDNNOP-UHFFFAOYSA-N barium titanate Chemical compound [Ba+2].[Ba+2].[O-][Ti]([O-])([O-])[O-] JRPBQTZRNDNNOP-UHFFFAOYSA-N 0.000 description 3
- 229910002113 barium titanate Inorganic materials 0.000 description 3
- 125000002915 carbonyl group Chemical group [*:2]C([*:1])=O 0.000 description 3
- 238000013329 compounding Methods 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 238000012856 packing Methods 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 229910017518 Cu Zn Inorganic materials 0.000 description 2
- 229910017752 Cu-Zn Inorganic materials 0.000 description 2
- 229910017943 Cu—Zn Inorganic materials 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 2
- 229910017061 Fe Co Inorganic materials 0.000 description 2
- 229910001030 Iron–nickel alloy Inorganic materials 0.000 description 2
- 229910002796 Si–Al Inorganic materials 0.000 description 2
- 229910008458 Si—Cr Inorganic materials 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 238000009835 boiling Methods 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 238000000280 densification Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000002159 nanocrystal Substances 0.000 description 2
- 239000005011 phenolic resin Substances 0.000 description 2
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 2
- 239000004926 polymethyl methacrylate Substances 0.000 description 2
- 230000001376 precipitating effect Effects 0.000 description 2
- 230000008707 rearrangement Effects 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- 239000007784 solid electrolyte Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 229910052725 zinc Inorganic materials 0.000 description 2
- 239000011701 zinc Substances 0.000 description 2
- 239000004641 Diallyl-phthalate Substances 0.000 description 1
- HBBGRARXTFLTSG-UHFFFAOYSA-N Lithium ion Chemical compound [Li+] HBBGRARXTFLTSG-UHFFFAOYSA-N 0.000 description 1
- 239000004640 Melamine resin Substances 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 239000004962 Polyamide-imide Substances 0.000 description 1
- 239000004695 Polyether sulfone Substances 0.000 description 1
- 239000004734 Polyphenylene sulfide Substances 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 239000008186 active pharmaceutical agent Substances 0.000 description 1
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 1
- 150000001342 alkaline earth metals Chemical class 0.000 description 1
- 229920000180 alkyd Polymers 0.000 description 1
- -1 and the like Polymers 0.000 description 1
- 230000015572 biosynthetic process Effects 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
- 229910000389 calcium phosphate Inorganic materials 0.000 description 1
- 239000001506 calcium phosphate Substances 0.000 description 1
- 235000011010 calcium phosphates Nutrition 0.000 description 1
- AOWKSNWVBZGMTJ-UHFFFAOYSA-N calcium titanate Chemical compound [Ca+2].[O-][Ti]([O-])=O AOWKSNWVBZGMTJ-UHFFFAOYSA-N 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000000748 compression moulding Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 239000002003 electrode paste Substances 0.000 description 1
- 239000007849 furan resin Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229910000398 iron phosphate Inorganic materials 0.000 description 1
- WBJZTOZJJYAKHQ-UHFFFAOYSA-K iron(3+) phosphate Chemical compound [Fe+3].[O-]P([O-])([O-])=O WBJZTOZJJYAKHQ-UHFFFAOYSA-K 0.000 description 1
- 229910001416 lithium ion Inorganic materials 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- 239000000696 magnetic material Substances 0.000 description 1
- 239000006247 magnetic powder Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000011259 mixed solution Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 229920002312 polyamide-imide Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000009719 polyimide resin Substances 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- VEALVRVVWBQVSL-UHFFFAOYSA-N strontium titanate Chemical compound [Sr+2].[O-][Ti]([O-])=O VEALVRVVWBQVSL-UHFFFAOYSA-N 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
- LRXTYHSAJDENHV-UHFFFAOYSA-H zinc phosphate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O LRXTYHSAJDENHV-UHFFFAOYSA-H 0.000 description 1
- 229910000165 zinc phosphate Inorganic materials 0.000 description 1
Images
Classifications
-
- 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
-
- 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
-
- 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
- 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
-
- 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
- H01F1/147—Alloys characterised by their composition
- H01F1/14708—Fe-Ni based alloys
- H01F1/14733—Fe-Ni based alloys in the form of particles
-
- 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
- H01F1/147—Alloys characterised by their composition
- H01F1/14766—Fe-Si based alloys
-
- 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
- H01F1/34—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 non-metallic substances, e.g. ferrites
- H01F1/36—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 non-metallic substances, e.g. ferrites in the form of particles
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/255—Magnetic cores made from particles
-
- 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
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/32—Composite [nonstructural laminate] of inorganic material having metal-compound-containing layer and having defined magnetic layer
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Manufacturing & Machinery (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Soft Magnetic Materials (AREA)
- Coils Or Transformers For Communication (AREA)
Abstract
Description
前記大粒子に付着している2つの前記小粒子の間に、前記バインダ粒子が前記大粒子に付着して存在している前記[1]に記載の複合粒子。
前記第1溶液にバインダ不溶性溶液を添加して第2溶液を準備する工程と、
前記第2溶液を乾燥する工程と、を有し、
前記バインダ可溶性溶液は、前記バインダおよび前記バインダ不溶性溶液に対して可溶性であり、
前記バインダ不溶性溶液は、前記バインダに対して不溶性である複合粒子の製造方法。
図1に示すように、本発明の一実施形態に係るインダクタ素子2は、巻線部4と、コア6と、を有する。巻線部4では、導体5がコイル状に巻回してある。コア6は、粒子およびバインダで構成されている。
図2に示すように、本実施形態に係る複合粒子12は、小粒子18およびバインダ粒子16が大粒子14に付着している構成となっている。ここで、大粒子14の粒径は10μm〜50μmであり、好ましくは10μm〜25μmである。
本実施形態では、大粒子14は磁性粒子である。このような大粒子14を用いてコア6を作製することにより、インダクタ素子2を得ることができる。
本実施形態では、小粒子18は磁性粒子である。このような小粒子18を用いてコア6を作製することにより、コア6の充填密度が上がり、耐電圧がより高いインダクタ素子2を得ることができる。
本実施形態では、大粒子14および小粒子18のそれぞれの表面の少なくとも一部に被覆部を有してもよい。本実施形態の大粒子14および小粒子18は、コア6の製造工程において、水に接触することがあるため、被覆部を有することにより酸化を防止することができる。また、大粒子14同士もしくは小粒子18同士が結合したり、または大粒子14と小粒子18とが直接結合すると磁気的特性(直流重畳特性および耐電圧特性など)に影響を及ぼすことがある。このため、被覆部を形成することにより、粒界を確保することが好ましい。
コア6を構成するバインダとなる樹脂、すなわち、複合粒子2において、バインダ粒子6となる樹脂としては、公知の樹脂を用いることができる。具体的には、エポキシ樹脂、フェノール樹脂、ポリイミド樹脂、ポリアミドイミド樹脂、シリコーン樹脂、メラミン樹脂、ユリア樹脂、フラン樹脂、アルキド樹脂、不飽和ポリエステル樹脂、ジアリルフタレート樹脂などが例示され、好ましくはエポキシ樹脂である。また、バインダ粒子16となる樹脂は、熱硬化性樹脂であってもよいし、熱可塑性樹脂であってもよいが、好ましくは熱硬化性樹脂である。
本実施形態では、上記の複合粒子12を用いてコア6を製造する。このため、まずは、複合粒子2の製造方法を説明し、その次に複合粒子12を用いたコア6の製造方法を説明する。
本実施形態の複合粒子12は、バインダが溶解してある可溶性溶液中に、大粒子14が分散してある第1溶液を準備する工程と、第1溶液にバインダ不溶性溶液を添加して第2溶液を準備する工程と、第2溶液を乾燥する工程と、を有する。
図1に示すように上記の複合粒子12と、導体(ワイヤ)5を所定回数だけ巻回して形成された空心コイルとを、金型内に充填して圧縮成型しコイルが内部に埋設された成型体を得る。圧縮方法は特に限定されず、一方向から圧縮してもよいし、WIP、CIPなどによって等方的に圧縮してもよいが、好ましくは等方的に圧縮する。これにより、大粒子14および小粒子18の再配列と内部組織の高密度化を達成できる。
上記において説明した本実施形態は、粒径が10μm〜50μmの大粒子14と、大粒子14の表面に付着してあり大粒子14よりも小さい粒径のバインダ粒子16とを有する複合粒子12に関する。
静電吸着により、小粒子18が表面に付着した大粒子14を準備した。
実施例2〜4では、成型圧力を表1に記載の通りに変えた以外は実施例1と同様にして直方体状コア6を得て、耐電圧を測定した。結果を表1に示す。
静電吸着により、小粒子18が表面に付着した大粒子14を準備した。大粒子14と小粒子18の材質、平均粒径および被覆部の材質は実施例1と同じ条件とした。
成型圧力を表2に記載の通りに変えた以外は比較例1と同様にして比較例2〜4の直方体状コア6を得て、耐電圧を測定した。結果を表2に示す。
実施例5では、成形圧力を600MPaとして、成形温度を50℃に変えた以外は、実施例1と同様にして直方体状コア6を得て、耐電圧を測定した。結果を表3に示す。また、実施例5では、直方体状コア6の他にトロイダルコアを得て、初透磁率も測定した。結果を表3に示す。トロイダルコアは下記の方法で得た。また、初透磁率は下記の方法で測定した。
実施例6では、成型時の金型の温度を70℃にした以外は、実施例5と同様にして直方体状コアおよびトロイダルコアを得て、耐電圧および初透磁率を測定した。結果を表3に示す。
実施例7では、直方体状コアおよびトロイダルコアの成型時に、成型圧力200MPa、80℃で温間等方圧プレス(WIP:Warm Isostatic Press)にて加圧して、それぞれのコアの成型体を得た以外は、実施例6と同様にして直方体状コアおよびトロイダルコアを得て、耐電圧および初透磁率を測定した。結果を表3に示す。
4… 巻線部
5… 導体
6… コア
12… 複合粒子
14… 大粒子
16… バインダ粒子
18,18a,18b… 小粒子
24… 大金属磁性粒子の被覆部
28a,28b… 小金属磁性粒子の被覆部
38a,38b… 小金属磁性粒子と大金属磁性粒子との接合点
46… バインダ
本実施形態の複合粒子12の製造方法は、バインダが溶解してあるバインダ可溶性溶液中に、大粒子14が分散してある第1溶液を準備する工程と、第1溶液にバインダ不溶性溶液を添加して第2溶液を準備する工程と、第2溶液を乾燥する工程と、を有する。
Claims (12)
- 粒径が10μm〜50μmの大粒子と、前記大粒子の表面に付着してあり前記大粒子よりも小さい粒径のバインダ粒子とを有する複合粒子。
- 前記大粒子の表面に付着してあり前記大粒子の粒径より小さな粒径を持つ2つ以上の小粒子をさらに有し、
前記大粒子に付着している2つの前記小粒子の間に、前記バインダ粒子が前記大粒子に付着して存在している請求項1に記載の複合粒子。 - 前記小粒子が、磁性粒子である請求項2に記載の複合粒子。
- 前記大粒子が、磁性粒子である請求項1〜3のいずれかに記載の複合粒子。
- 前記バインダ粒子は、前記小粒子よりも小さい粒径を有する請求項2〜4のいずれかに記載の複合粒子。
- 前記バインダ粒子は、前記大粒子に析出して付着してある請求項1〜5のいずれかに記載の複合粒子。
- 請求項1〜6のいずれかに記載の複合粒子が観察される断面または表面を持つコア。
- 請求項7に記載のコアを有するインダクタ素子。
- バインダが溶解してあるバインダ可溶性溶液中に、粒径が10μm〜50μmの大粒子が分散してある第1溶液を準備する工程と、
前記第1溶液にバインダ不溶性溶液を添加して第2溶液を準備する工程と、
前記第2溶液を乾燥する工程と、を有し、
前記バインダ可溶性溶液は、前記バインダおよび前記バインダ不溶性溶液に対して可溶性であり、
前記バインダ不溶性溶液は、前記バインダに対して不溶性である複合粒子の製造方法。 - 前記第2溶液を準備する際に、前記第1溶液に凝集抑制剤を添加する請求項9に記載の複合粒子の製造方法。
- 前記第1溶液中の前記大粒子には、前記大粒子よりも粒径が小さい小粒子が付着してある請求項9または10に記載の複合粒子の製造方法。
- 請求項9〜11のいずれかに記載の複合粒子の製造方法により得られる複合粒子。
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2019060954A JP7392275B2 (ja) | 2019-03-27 | 2019-03-27 | 複合粒子、コアおよびインダクタ素子 |
US16/827,950 US11651880B2 (en) | 2019-03-27 | 2020-03-24 | Composite particle, core, and inductor element |
CN202010221790.1A CN111755198B (zh) | 2019-03-27 | 2020-03-26 | 复合颗粒、磁芯和电感器元件 |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2019060954A JP7392275B2 (ja) | 2019-03-27 | 2019-03-27 | 複合粒子、コアおよびインダクタ素子 |
Publications (2)
Publication Number | Publication Date |
---|---|
JP2020161696A true JP2020161696A (ja) | 2020-10-01 |
JP7392275B2 JP7392275B2 (ja) | 2023-12-06 |
Family
ID=72607349
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
JP2019060954A Active JP7392275B2 (ja) | 2019-03-27 | 2019-03-27 | 複合粒子、コアおよびインダクタ素子 |
Country Status (3)
Country | Link |
---|---|
US (1) | US11651880B2 (ja) |
JP (1) | JP7392275B2 (ja) |
CN (1) | CN111755198B (ja) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2022057927A (ja) * | 2020-09-30 | 2022-04-11 | 株式会社村田製作所 | 磁性粉、磁性成形体およびインダクタ |
Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2005243769A (ja) * | 2004-02-25 | 2005-09-08 | Sumitomo Electric Ind Ltd | 圧粉磁心の製造方法および圧粉磁心 |
JP2013149613A (ja) * | 2011-12-22 | 2013-08-01 | Sekisui Chem Co Ltd | 導電性粒子、導電材料及び接続構造体 |
JP2013251099A (ja) * | 2012-05-31 | 2013-12-12 | Hitachi Chemical Co Ltd | 導電粒子及びその製造方法 |
US20140097377A1 (en) * | 2012-10-05 | 2014-04-10 | Nec Tokin Corporation | Magnetic powder, forming method thereof and magnetic sheet |
JP2016180154A (ja) * | 2015-03-24 | 2016-10-13 | Ntn株式会社 | 磁心用粉末および圧粉磁心、並びに磁心用粉末の製造方法 |
US20180261385A1 (en) * | 2017-03-09 | 2018-09-13 | Tdk Corporation | Dust core |
JP2018152557A (ja) * | 2017-03-09 | 2018-09-27 | Tdk株式会社 | 圧粉磁心 |
US20190333666A1 (en) * | 2018-04-27 | 2019-10-31 | Seiko Epson Corporation | Insulator-Coated Soft Magnetic Powder, Powder Magnetic Core, Magnetic Element, Electronic Device, And Vehicle |
JP2021072336A (ja) * | 2019-10-30 | 2021-05-06 | セイコーエプソン株式会社 | 絶縁体被覆磁性合金粉末粒子、圧粉磁心、およびコイル部品 |
Family Cites Families (19)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6136265A (en) | 1999-08-09 | 2000-10-24 | Delphi Technologies Inc. | Powder metallurgy method and articles formed thereby |
JP2012238841A (ja) | 2011-04-27 | 2012-12-06 | Taiyo Yuden Co Ltd | 磁性材料及びコイル部品 |
CN102623123B (zh) * | 2012-04-05 | 2015-04-22 | 天通控股股份有限公司 | 一种μ125铁硅铝磁粉芯的制造方法 |
JP6159512B2 (ja) * | 2012-07-04 | 2017-07-05 | 太陽誘電株式会社 | インダクタ |
JP6550731B2 (ja) * | 2014-11-28 | 2019-07-31 | Tdk株式会社 | コイル部品 |
JP6403093B2 (ja) * | 2015-02-04 | 2018-10-10 | 住友電気工業株式会社 | 複合材料、磁気部品用の磁性コア、リアクトル、コンバータ、及び電力変換装置 |
JP6583627B2 (ja) * | 2015-11-30 | 2019-10-02 | Tdk株式会社 | コイル部品 |
US10071421B2 (en) * | 2016-01-22 | 2018-09-11 | Kabushiki Kaisha Toshiba | Flaky magnetic metal particles, pressed powder material, rotating electric machine, motor, and generator |
JP6479074B2 (ja) * | 2016-08-30 | 2019-03-06 | サムソン エレクトロ−メカニックス カンパニーリミテッド. | 磁性体組成物、インダクタおよび磁性体本体 |
JP6926419B2 (ja) * | 2016-09-02 | 2021-08-25 | Tdk株式会社 | 圧粉磁心 |
JP7059593B2 (ja) | 2017-01-12 | 2022-04-26 | Tdk株式会社 | 軟磁性材料、コア及びインダクタ |
JP2018152449A (ja) * | 2017-03-13 | 2018-09-27 | 株式会社東芝 | 複数の扁平磁性金属粒子、圧粉材料及び回転電機 |
JP7246143B2 (ja) * | 2018-06-21 | 2023-03-27 | 太陽誘電株式会社 | 金属磁性粒子を含む磁性基体及び当該磁性基体を含む電子部品 |
US11440093B2 (en) * | 2019-08-21 | 2022-09-13 | Tdk Corporation | Composite particle and dust core |
US11699542B2 (en) * | 2019-08-21 | 2023-07-11 | Tdk Corporation | Dust core |
JP2021093468A (ja) * | 2019-12-11 | 2021-06-17 | Tdk株式会社 | コイル部品 |
CN113451013A (zh) * | 2020-03-25 | 2021-09-28 | Tdk株式会社 | 磁芯、磁性部件和电子设备 |
JP7459639B2 (ja) * | 2020-04-28 | 2024-04-02 | Tdk株式会社 | 複合粒子、コアおよび電子部品 |
JP2021174935A (ja) * | 2020-04-28 | 2021-11-01 | Tdk株式会社 | 成形体、コアおよび電子部品 |
-
2019
- 2019-03-27 JP JP2019060954A patent/JP7392275B2/ja active Active
-
2020
- 2020-03-24 US US16/827,950 patent/US11651880B2/en active Active
- 2020-03-26 CN CN202010221790.1A patent/CN111755198B/zh active Active
Patent Citations (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2005243769A (ja) * | 2004-02-25 | 2005-09-08 | Sumitomo Electric Ind Ltd | 圧粉磁心の製造方法および圧粉磁心 |
JP2013149613A (ja) * | 2011-12-22 | 2013-08-01 | Sekisui Chem Co Ltd | 導電性粒子、導電材料及び接続構造体 |
JP2013251099A (ja) * | 2012-05-31 | 2013-12-12 | Hitachi Chemical Co Ltd | 導電粒子及びその製造方法 |
US20140097377A1 (en) * | 2012-10-05 | 2014-04-10 | Nec Tokin Corporation | Magnetic powder, forming method thereof and magnetic sheet |
JP2014075511A (ja) * | 2012-10-05 | 2014-04-24 | Nec Tokin Corp | 磁性扁平粉及びその製造方法並びに磁性シート |
JP2016180154A (ja) * | 2015-03-24 | 2016-10-13 | Ntn株式会社 | 磁心用粉末および圧粉磁心、並びに磁心用粉末の製造方法 |
US20180043431A1 (en) * | 2015-03-24 | 2018-02-15 | Ntn Corporation | Magnetic core powder, dust core, and method for producing magnetic core powder |
US20180261385A1 (en) * | 2017-03-09 | 2018-09-13 | Tdk Corporation | Dust core |
JP2018152557A (ja) * | 2017-03-09 | 2018-09-27 | Tdk株式会社 | 圧粉磁心 |
US20190333666A1 (en) * | 2018-04-27 | 2019-10-31 | Seiko Epson Corporation | Insulator-Coated Soft Magnetic Powder, Powder Magnetic Core, Magnetic Element, Electronic Device, And Vehicle |
JP2019192868A (ja) * | 2018-04-27 | 2019-10-31 | セイコーエプソン株式会社 | 絶縁物被覆軟磁性粉末、圧粉磁心、磁性素子、電子機器および移動体 |
JP2021072336A (ja) * | 2019-10-30 | 2021-05-06 | セイコーエプソン株式会社 | 絶縁体被覆磁性合金粉末粒子、圧粉磁心、およびコイル部品 |
US20210129218A1 (en) * | 2019-10-30 | 2021-05-06 | Seiko Epson Corporation | Insulator-coated magnetic alloy powder particle, powder magnetic core, and coil part |
Also Published As
Publication number | Publication date |
---|---|
CN111755198A (zh) | 2020-10-09 |
CN111755198B (zh) | 2023-09-26 |
US20200312502A1 (en) | 2020-10-01 |
JP7392275B2 (ja) | 2023-12-06 |
US11651880B2 (en) | 2023-05-16 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
JP5358562B2 (ja) | 複合磁性材料の製造方法および複合磁性材料 | |
CN104488042B (zh) | 复合磁芯和磁性元件 | |
WO2015147064A1 (ja) | 磁性コア部品および磁性素子、ならびに磁性コア部品の製造方法 | |
JPWO2010073590A1 (ja) | 複合軟磁性材料とその製造方法 | |
WO2018179812A1 (ja) | 圧粉磁心 | |
JP7128439B2 (ja) | 圧粉磁芯およびインダクタ素子 | |
TWI540602B (zh) | 電子零件 | |
JP2017135342A (ja) | アモルファス磁性コアおよび磁性素子、ならびに磁性コアの製造方法 | |
CN111065613A (zh) | 陶瓷复合材料 | |
CN111724964B (zh) | 磁性体芯及线圈部件 | |
TW201712699A (zh) | 壓粉磁芯、該壓粉磁芯之製造方法、具備該壓粉磁芯之電氣.電子零件及安裝有該電氣.電子零件之電氣.電子機器 | |
JP7392275B2 (ja) | 複合粒子、コアおよびインダクタ素子 | |
KR20170141605A (ko) | 연자성 금속 분말, 연자성 금속 소성체 및 코일형 전자 부품 | |
JP7459639B2 (ja) | 複合粒子、コアおよび電子部品 | |
US20210391112A1 (en) | Element body, core, and electronic component | |
CN109961917B (zh) | 压粉磁芯及电感元件 | |
JP7128438B2 (ja) | 圧粉磁芯およびインダクタ素子 | |
JP2020174127A (ja) | インダクタ素子 | |
JP6790584B2 (ja) | 軟磁性金属粉末および圧粉磁心 | |
JP2015185776A (ja) | 磁性コア部品および磁性素子、ならびに磁性コア部品の製造方法 | |
JP4527225B2 (ja) | 圧粉磁心の製造方法 | |
CN107430919B (zh) | 金属磁性材料和电子部件 | |
JP2002179460A (ja) | フェライト材料及びこれを用いたフェライトコア | |
JP2019029675A (ja) | アモルファス磁性コアおよび磁性素子 | |
JP2017135341A (ja) | アモルファス磁性コアおよび磁性素子、ならびに磁性コアの製造方法 |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
A521 | Request for written amendment filed |
Free format text: JAPANESE INTERMEDIATE CODE: A523 Effective date: 20200303 |
|
A621 | Written request for application examination |
Free format text: JAPANESE INTERMEDIATE CODE: A621 Effective date: 20220114 |
|
A977 | Report on retrieval |
Free format text: JAPANESE INTERMEDIATE CODE: A971007 Effective date: 20221128 |
|
A131 | Notification of reasons for refusal |
Free format text: JAPANESE INTERMEDIATE CODE: A131 Effective date: 20221206 |
|
A521 | Request for written amendment filed |
Free format text: JAPANESE INTERMEDIATE CODE: A523 Effective date: 20230203 |
|
A131 | Notification of reasons for refusal |
Free format text: JAPANESE INTERMEDIATE CODE: A131 Effective date: 20230523 |
|
A521 | Request for written amendment filed |
Free format text: JAPANESE INTERMEDIATE CODE: A523 Effective date: 20230721 |
|
TRDD | Decision of grant or rejection written | ||
A01 | Written decision to grant a patent or to grant a registration (utility model) |
Free format text: JAPANESE INTERMEDIATE CODE: A01 Effective date: 20231024 |
|
A61 | First payment of annual fees (during grant procedure) |
Free format text: JAPANESE INTERMEDIATE CODE: A61 Effective date: 20231106 |
|
R150 | Certificate of patent or registration of utility model |
Ref document number: 7392275 Country of ref document: JP Free format text: JAPANESE INTERMEDIATE CODE: R150 |