JP2021061408A - Soft magnetic metal powder and powder-compact magnetic core - Google Patents
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Abstract
Description
本発明は、軟磁性金属粉末および圧粉磁心に関する。 The present invention relates to soft magnetic metal powders and powder magnetic cores.
民生および車載用等の各種電子機器の電源回路に用いられる電子部品として、トランス、チョークコイル、インダクタ等のコイル型電子部品が知られている。 Coil-type electronic components such as transformers, choke coils, and inductors are known as electronic components used in power supply circuits of various electronic devices for consumer and in-vehicle use.
このようなコイル型電子部品は、所定の磁気特性を発揮する磁性体の周囲あるいは内部に、電気伝導体であるコイル（巻線）が配置されている構成を有している。磁性体としては、所望の特性に応じて、種々の材料を用いることができる。従来、コイル型電子部品においては、磁性体として、高透磁率かつ低電力損失であるフェライト材料が用いられてきた。 Such a coil-type electronic component has a configuration in which a coil (winding wire), which is an electric conductor, is arranged around or inside a magnetic material exhibiting a predetermined magnetic characteristic. As the magnetic material, various materials can be used depending on desired properties. Conventionally, in coil-type electronic components, a ferrite material having a high magnetic permeability and a low power loss has been used as a magnetic material.
近年、コイル型電子部品のさらなる小型化、大電流化に対応するため、フェライト材料よりも、飽和磁束密度が高く、高磁界下においても良好な直流重畳特性を有する軟磁性金属材料が磁性体として用いられている。たとえば、軟磁性金属粒子を含む軟磁性金属粉末を圧縮成形して、磁性体としての磁心（コア）を得ることができる。 In recent years, in order to cope with further miniaturization and large current of coil type electronic components, a soft magnetic metal material having a higher saturation magnetic flux density than a ferrite material and having good DC superimposition characteristics even under a high magnetic field is used as a magnetic material. It is used. For example, a soft magnetic metal powder containing soft magnetic metal particles can be compression-molded to obtain a magnetic core as a magnetic material.
軟磁性金属材料としては、純鉄、Ｆｅ−Ｓｉ系合金等が例示される。これらの材料は、Ｆｅを主成分とした金属であるため、絶縁性または耐食性（特に、酸化に対する耐食性）を高める必要があった。従来、絶縁性または耐食性を確保する方法として、軟磁性金属粒子に対して、有機物または無機物で構成される絶縁被膜を設けることが行われてきた。 Examples of the soft magnetic metal material include pure iron and Fe—Si alloys. Since these materials are metals containing Fe as a main component, it is necessary to improve the insulating property or the corrosion resistance (particularly, the corrosion resistance against oxidation). Conventionally, as a method of ensuring insulation or corrosion resistance, an insulating film composed of an organic substance or an inorganic substance has been provided on soft magnetic metal particles.
しかしながら、軟磁性金属粉末を圧縮成形する場合、それらの被膜は、軟磁性金属粒子の変形、金型との摩擦等により剥離する恐れがあった。その結果、圧縮成形後の圧粉磁心の絶縁性および耐食性の低下が問題となっていた。 However, when the soft magnetic metal powder is compression-molded, those coatings may be peeled off due to deformation of the soft magnetic metal particles, friction with the mold, or the like. As a result, there has been a problem of deterioration of the insulating property and corrosion resistance of the dust core after compression molding.
そこで、たとえば、特許文献１には、軟磁性金属粒子として、Ｆｅに、Ｃｒ、ＭｎおよびＮｉと、Ｓｉ等の元素とを添加した粒子とすることにより、耐食性を向上させることが記載されている。
Therefore, for example,
また、特許文献２には、軟磁性金属粒子として、Ｆｅに、Ｍｎと、Ｎｉ、Ｓｉ等の元素とを添加した粒子とすることにより、絶縁性を確保することが記載されている。
Further,
本発明は、このような実状に鑑みてなされ、その目的は、耐食性の良好な軟磁性金属粉末等を提供することである。 The present invention has been made in view of such an actual situation, and an object of the present invention is to provide a soft magnetic metal powder or the like having good corrosion resistance.
本発明者らは、鉄を主成分とする合金から構成される軟磁性金属材料の耐食性、特に酸化に対する耐食性について検討した結果、湿度が高い環境等の水分が存在するような酸化環境下では、耐食性を向上させる元素として通常用いられるＣｒに依存しなくても、Ｎｉの含有量を特定の範囲に制御することにより軟磁性金属材料が良好な耐食性を示すことを見出し、本発明を完成させるに至った。 As a result of examining the corrosion resistance of a soft magnetic metal material composed of an alloy containing iron as a main component, particularly the corrosion resistance to oxidation, the present inventors have found that in an oxidizing environment where moisture is present, such as in a high humidity environment. In order to complete the present invention, it was found that a soft magnetic metal material exhibits good corrosion resistance by controlling the Ni content within a specific range without depending on Cr which is usually used as an element for improving corrosion resistance. I arrived.
また、Ｎｉに加えて、Ａｌを用いて、その含有量を特定の範囲に制御することにより金属材料が良好な軟磁気特性および耐食性を示すことを見出し、本発明を完成させるに至った。 Further, they have found that a metal material exhibits good soft magnetic properties and corrosion resistance by controlling its content within a specific range by using Al in addition to Ni, and have completed the present invention.
すなわち、本発明の第１の態様は、
［１］Ｆｅ−Ｎｉ系合金から構成される軟磁性金属粒子を複数含む軟磁性金属粉末であって、
前記Ｆｅ−Ｎｉ系合金は、Ｎｉを０．５０質量％以上５．００質量％以下含有し、残部がＦｅおよび不可避的不純物からなる軟磁性金属粉末である。
That is, the first aspect of the present invention is
[1] A soft magnetic metal powder containing a plurality of soft magnetic metal particles composed of an Fe—Ni alloy.
The Fe—Ni alloy is a soft magnetic metal powder containing 0.50% by mass or more and 5.00% by mass or less of Ni, and the balance is Fe and unavoidable impurities.
上記の軟磁性金属粉末は、水分が存在するような酸化環境下であっても、Ｃｒに依存することなく、酸化に対して良好な耐食性を示すことができる。しかも、Ｎｉは常温で強磁性を示す元素であるため、Ｃｒを含有した場合に悪化する飽和磁化等に関し、所定の磁気特性を発揮することができる。 The above-mentioned soft magnetic metal powder can exhibit good corrosion resistance to oxidation without depending on Cr even in an oxidizing environment in which water is present. Moreover, since Ni is an element that exhibits ferromagnetism at room temperature, it can exhibit predetermined magnetic properties with respect to saturation magnetization and the like that deteriorate when Cr is contained.
［２］Ｎｉを１．００質量％以上４．００質量％以下含有する［１］に記載の軟磁性金属粉末である。 [2] The soft magnetic metal powder according to [1], which contains Ni in an amount of 1.00% by mass or more and 4.00% by mass or less.
Ｆｅ−Ｎｉ系合金におけるＮｉの含有量の割合を上記の範囲とすることにより、上記の効果をより向上させることができる。 By setting the ratio of the Ni content in the Fe—Ni alloy to the above range, the above effect can be further improved.
［３］前記Ｆｅ−Ｎｉ系合金は、さらにＡｌを０．３０質量％以上３．００質量％以下含有する［１］または［２］に記載の軟磁性金属粉末である。 [3] The Fe—Ni alloy is the soft magnetic metal powder according to [1] or [2], which further contains Al in an amount of 0.30% by mass or more and 3.00% by mass or less.
上記の軟磁性金属粉末が、Ａｌを上記の範囲で含有することにより、耐食性をより良好にすることができる。しかも、Ａｌの含有量を上記の範囲とすることにより、飽和磁化等に関し、所定の磁気特性を発揮しつつ、保磁力を低減できる。 When the soft magnetic metal powder contains Al in the above range, the corrosion resistance can be further improved. Moreover, by setting the Al content in the above range, it is possible to reduce the coercive force while exhibiting predetermined magnetic characteristics with respect to saturation magnetization and the like.
本発明の第２の態様は、
［１］から［３］のいずれかに記載の軟磁性金属粉末から構成される圧粉磁心である。
A second aspect of the present invention is
It is a dust core composed of the soft magnetic metal powder according to any one of [1] to [3].
上記の圧粉磁心は、上記の軟磁性金属粉末を用いて構成されるため、酸化に対して良好な耐食性を有していることに加えて、直流重畳特性等に関し、所定の磁気特性が得られる。さらに、Ａｌを含有する軟磁性金属粉末を用いて圧粉磁心を構成した場合には、ヒステリシス損に関する磁気特性も良好にできる。 Since the powder magnetic core is composed of the soft magnetic metal powder, it has good corrosion resistance against oxidation, and in addition, it can obtain predetermined magnetic characteristics with respect to DC superimposition characteristics and the like. Be done. Further, when the dust core is formed by using the soft magnetic metal powder containing Al, the magnetic characteristics related to the hysteresis loss can be improved.
以下、本発明を、具体的な実施形態に基づき、以下の順序で詳細に説明する。
１．軟磁性金属粉末
２．圧粉磁心
３．軟磁性金属粉末の製造方法
４．圧粉磁心の製造方法
５．本実施形態の効果
Hereinafter, the present invention will be described in detail in the following order based on specific embodiments.
1. 1. Soft
（１．軟磁性金属粉末）
本実施形態に係る軟磁性金属粉末は、複数の軟磁性金属粒子の集合体である。本実施形態では、軟磁性金属粒子はＦｅ−Ｎｉ系合金から構成される。Ｆｅ−Ｎｉ系合金としては、第１に、Ｎｉを０．５０質量％以上５．０質量％以下含有し、残部がＦｅおよび不可避的不純物からなるＦｅ−Ｎｉ合金が例示される。
(1. Soft magnetic metal powder)
The soft magnetic metal powder according to the present embodiment is an aggregate of a plurality of soft magnetic metal particles. In this embodiment, the soft magnetic metal particles are composed of a Fe—Ni based alloy. Examples of the Fe—Ni alloy include, first, an Fe—Ni alloy containing 0.50% by mass or more and 5.0% by mass or less of Ni, and the balance being Fe and unavoidable impurities.
このＦｅ−Ｎｉ合金は、パーマロイのようなＮｉ含有量の高いＦｅ−Ｎｉ合金が面心立方格子（ｆｃｃ）構造を有するのに対し体心立方格子（ｂｃｃ）構造を有する。Ｎｉを含有することにより、粒子表面に薄いＮｉを含む酸化被膜が形成され、腐食の進行が妨げられると考えられる。 This Fe-Ni alloy has a body-centered cubic lattice (bcc) structure, whereas a Fe-Ni alloy having a high Ni content such as permalloy has a face-centered cubic lattice (fcc) structure. It is considered that the inclusion of Ni forms an oxide film containing a thin Ni on the surface of the particles, which hinders the progress of corrosion.
したがって、このようなＦｅ−Ｎｉ合金から構成される軟磁性金属粒子を含む軟磁性金属粉末は、水分が存在するような酸化環境下における耐食性を良好にすることができる。しかも、飽和磁化等に関し、所定の磁気特性を発揮することができる。その結果、たとえば、粉末製造時における錆（酸化被膜）の発生、屋外等の多湿環境下における軟磁性金属粉末の酸化を好適に抑制することができる。さらに、当該軟磁性金属粉末を用いて圧粉磁心等の磁性磁心を構成することにより、酸化に対する耐食性が良好であり、かつ所定の磁気特性を有するコイル型電子部品等を得ることができる。 Therefore, the soft magnetic metal powder containing the soft magnetic metal particles composed of such an Fe—Ni alloy can improve the corrosion resistance in an oxidizing environment in which moisture is present. Moreover, it is possible to exhibit predetermined magnetic characteristics with respect to saturation magnetization and the like. As a result, for example, the generation of rust (oxide film) during powder production and the oxidation of soft magnetic metal powder in a humid environment such as outdoors can be suitably suppressed. Further, by forming a magnetic magnetic core such as a dust core using the soft magnetic metal powder, it is possible to obtain a coil-type electronic component or the like having good corrosion resistance against oxidation and having predetermined magnetic characteristics.
Ｆｅ−Ｎｉ合金において、Ｎｉの含有量は０．５０質量％以上であり、好ましくは１．００質量％以上である。Ｎｉが少なすぎると、耐食性が悪化する傾向にある。 In the Fe—Ni alloy, the Ni content is 0.50% by mass or more, preferably 1.00% by mass or more. If the amount of Ni is too small, the corrosion resistance tends to deteriorate.
また、Ｆｅ−Ｎｉ合金において、Ｎｉの含有量は５．００質量％以下であり、好ましくは４．００質量％以下である。Ｎｉが多すぎると、耐食性は良好であるものの、保磁力が高くなりすぎ、コイル型電子部品等の磁性体の原料として好ましくない傾向にある。 Further, in the Fe—Ni alloy, the Ni content is 5.00% by mass or less, preferably 4.00% by mass or less. If the amount of Ni is too large, the corrosion resistance is good, but the coercive force becomes too high, which tends to be unfavorable as a raw material for magnetic materials such as coil-type electronic components.
本実施形態に係るＦｅ−Ｎｉ系合金としては、第２に、Ｎｉを０．５０質量％以上５．００質量％以下、Ａｌを０．３０質量％以上３．００質量％以下含有し、残部がＦｅおよび不可避的不純物からなるＦｅ−Ｎｉ−Ａｌ合金が例示される。このＦｅ−Ｎｉ−Ａｌ合金も体心立方格子（ｂｃｃ）構造を有している。また、ＮｉおよびＡｌを含有することにより、粒子表面に薄いＮｉまたはＮｉおよびＡｌを含む酸化被膜が形成され、腐食の進行が妨げられると考えられる。 The Fe—Ni alloy according to the present embodiment secondly contains 0.50% by mass or more and 5.00% by mass or less of Ni, 0.30% by mass or more and 3.00% by mass or less of Al, and the balance. An example is an Fe—Ni—Al alloy consisting of Fe and unavoidable impurities. This Fe-Ni-Al alloy also has a body-centered cubic lattice (bcc) structure. Further, it is considered that the inclusion of Ni and Al forms a thin oxide film containing Ni or Ni and Al on the particle surface, and the progress of corrosion is hindered.
したがって、Ｆｅ−Ｎｉ合金と同様に、このようなＦｅ−Ｎｉ−Ａｌ合金から構成される軟磁性金属粒子を含む軟磁性金属粉末は、水分が存在するような酸化環境下における耐食性を良好にすることができる。しかも、飽和磁化等に関し、所定の磁気特性を発揮することができる。その結果、たとえば、粉末製造時における錆（酸化被膜）の発生、屋外等の多湿環境下における軟磁性金属粉末の酸化を好適に抑制することができる。さらに、当該軟磁性金属粉末を用いて圧粉磁心等の磁性磁心を構成することにより、酸化に対する耐食性が良好であり、かつ所定の磁気特性を有するコイル型電子部品等を得ることができる。特に、Ｆｅ−Ｎｉ−Ａｌ合金から構成される軟磁性金属粒子を含む軟磁性金属粉末は、Ｆｅ−Ｎｉ合金から構成される軟磁性金属粒子を含む軟磁性金属粉末よりも、飽和磁化等の磁気特性は若干劣る傾向にあるが、保磁力が小さい傾向にある。 Therefore, similarly to the Fe—Ni alloy, the soft magnetic metal powder containing the soft magnetic metal particles composed of such a Fe—Ni—Al alloy improves the corrosion resistance in an oxidizing environment in which moisture is present. be able to. Moreover, it is possible to exhibit predetermined magnetic characteristics with respect to saturation magnetization and the like. As a result, for example, the generation of rust (oxide film) during powder production and the oxidation of soft magnetic metal powder in a humid environment such as outdoors can be suitably suppressed. Further, by forming a magnetic magnetic core such as a dust core using the soft magnetic metal powder, it is possible to obtain a coil-type electronic component or the like having good corrosion resistance against oxidation and having predetermined magnetic characteristics. In particular, the soft magnetic metal powder containing the soft magnetic metal particles composed of the Fe—Ni—Al alloy has a higher magnetism such as saturation magnetization than the soft magnetic metal powder containing the soft magnetic metal particles composed of the Fe—Ni alloy. The characteristics tend to be slightly inferior, but the coercive force tends to be small.
Ｆｅ−Ｎｉ−Ａｌ合金において、Ｎｉの含有量は０．５０質量％以上であり、好ましくは１．００質量％以上である。Ｎｉが少なすぎると、耐食性が悪化する傾向にある。 In the Fe—Ni—Al alloy, the Ni content is 0.50% by mass or more, preferably 1.00% by mass or more. If the amount of Ni is too small, the corrosion resistance tends to deteriorate.
また、Ｆｅ−Ｎｉ−Ａｌ合金において、Ｎｉの含有量は５．００質量％以下であり、好ましくは４．００質量％以下である。Ｎｉが多すぎると、耐食性は良好であるものの、保磁力が高くなりすぎ、コイル型電子部品等の磁性体の原料として好ましくない傾向にある。 Further, in the Fe—Ni—Al alloy, the Ni content is 5.00% by mass or less, preferably 4.00% by mass or less. If the amount of Ni is too large, the corrosion resistance is good, but the coercive force becomes too high, which tends to be unfavorable as a raw material for magnetic materials such as coil-type electronic components.
さらに、Ｆｅ−Ｎｉ−Ａｌ合金において、Ａｌの含有量は０．３０質量％以上であり、好ましくは１．００質量％以上である。Ａｌを含むことにより、耐食性をさらに高めつつ、保磁力を低減できる。 Further, in the Fe—Ni—Al alloy, the Al content is 0.30% by mass or more, preferably 1.00% by mass or more. By containing Al, the coercive force can be reduced while further improving the corrosion resistance.
また、Ｆｅ−Ｎｉ−Ａｌ合金において、Ａｌの含有量は３．００質量％以下であり、好ましくは２．５０質量％以下である。Ａｌが多すぎると、耐食性をさらに高めつつ、保磁力の低減効果は大きくなるものの、飽和磁化等の磁気特性が悪化する傾向にあるため、コイル型電子部品等の磁性体の原料として好ましくない傾向にある。 Further, in the Fe—Ni—Al alloy, the Al content is 3.00% by mass or less, preferably 2.50% by mass or less. If the amount of Al is too large, the effect of reducing the coercive force is increased while further improving the corrosion resistance, but the magnetic properties such as saturation magnetization tend to deteriorate, which is not preferable as a raw material for a magnetic material such as a coil type electronic component. It is in.
上記のＦｅ−Ｎｉ系合金（Ｆｅ−Ｎｉ合金およびＦｅ−Ｎｉ−Ａｌ合金）は、通常、不可避的不純物を含んでいる。この不可避的不純物は、目的物（本実施形態では、軟磁性金属粉末）の原料、あるいは、製造過程等において混入し、目的物に残存する微量成分であり、目的物の所定の特性に影響を与えない程度で含有されている。 The above Fe—Ni based alloys (Fe—Ni alloys and Fe—Ni—Al alloys) usually contain unavoidable impurities. This unavoidable impurity is a raw material of the target product (soft magnetic metal powder in this embodiment), or a trace component that is mixed in during the manufacturing process and remains in the target product, and affects the predetermined characteristics of the target product. It is contained to the extent that it is not given.
したがって、不可避的不純物は、目的物の純度の観点からは除去した方がよいが、除去に要するコスト等と、所望の特性とのバランスを考慮して、目的物に所定量残存することが許容される成分である。 Therefore, it is better to remove the unavoidable impurities from the viewpoint of the purity of the target product, but it is permissible to remain in the target product in a predetermined amount in consideration of the balance between the cost required for removal and the desired characteristics. It is an ingredient to be used.
本実施形態では、不可避的不純物としては、Ｃ、Ｐ、Ｓ、Ｎ、Ｏ等が例示される。 In this embodiment, examples of unavoidable impurities include C, P, S, N, O and the like.
また、本実施形態に係るＦｅ−Ｎｉ系合金に関して、Ａｌ以外の添加元素として、たとえば、ＳｉあるいはＭｎ等が考えられるが、これらの元素は飽和磁化等に関して所定の磁気特性が悪化する傾向にあるため、好ましくない。 Further, with respect to the Fe—Ni alloy according to the present embodiment, for example, Si or Mn or the like can be considered as an additive element other than Al, but these elements tend to deteriorate predetermined magnetic properties with respect to saturation magnetization and the like. Therefore, it is not preferable.
本実施形態に係る軟磁性金属粉末の平均粒子径（Ｄ５０）は、用途に応じて選択すればよい。本実施形態では、平均粒子径（Ｄ５０）は、１〜１００μｍの範囲内であることが好ましい。軟磁性金属粉末の平均粒子径を上記の範囲内とすることにより、十分な成形性あるいは所定の磁気特性を維持することが容易となる。平均粒子径の測定方法としては、特に制限されないが、レーザー回折散乱法を用いることが好ましい。なお、軟磁性金属粉末を構成する軟磁性金属粒子の形状は特に制限されない。 The average particle size (D50) of the soft magnetic metal powder according to the present embodiment may be selected according to the intended use. In this embodiment, the average particle size (D50) is preferably in the range of 1 to 100 μm. By setting the average particle size of the soft magnetic metal powder within the above range, it becomes easy to maintain sufficient moldability or predetermined magnetic properties. The method for measuring the average particle size is not particularly limited, but it is preferable to use the laser diffraction / scattering method. The shape of the soft magnetic metal particles constituting the soft magnetic metal powder is not particularly limited.
（２．圧粉磁心）
本実施形態に係る圧粉磁心は、上述した軟磁性金属粉末から構成され、所定の形状を有するように形成されていれば特に制限されない。本実施形態では、当該圧粉磁心は、当該軟磁性金属粉末と結合剤とを含み、当該軟磁性金属粉末を構成する軟磁性金属粒子同士が結合剤を介して結合することにより所定の形状に固定されている。また、当該圧粉磁心は、上述した軟磁性金属粉末と他の磁性粉末との混合粉末から構成され、所定の形状に形成されていてもよい。
(2. Powder magnetic core)
The dust core according to the present embodiment is not particularly limited as long as it is composed of the above-mentioned soft magnetic metal powder and is formed so as to have a predetermined shape. In the present embodiment, the dust core contains the soft magnetic metal powder and a binder, and the soft magnetic metal particles constituting the soft magnetic metal powder are bonded to each other via a binder to form a predetermined shape. It is fixed. Further, the dust core may be composed of a mixed powder of the above-mentioned soft magnetic metal powder and another magnetic powder, and may be formed in a predetermined shape.
このような圧粉磁心は、上述した軟磁性金属粉末から構成されているので、酸化に対する耐食性が良好であることに加えて、直流重畳特性等に関し、所定の磁気特性を発揮することができる。 Since such a dust core is composed of the above-mentioned soft magnetic metal powder, in addition to having good corrosion resistance against oxidation, it is possible to exhibit predetermined magnetic characteristics with respect to DC superimposition characteristics and the like.
（３．軟磁性金属粉末の製造方法）
続いて、上記の軟磁性金属粉末を製造する方法について説明する。本実施形態では、軟磁性金属粉末は、公知の軟磁性金属粉末の製造方法と同様の方法を用いて得ることができる。具体的には、ガスアトマイズ法、水アトマイズ法、回転ディスク法等を用いて製造することができる。これらの中では、所望の磁気特性を有する軟磁性金属粉末が得られやすいという観点から、ガスアトマイズ法を用いることが好ましい。
(3. Manufacturing method of soft magnetic metal powder)
Subsequently, a method for producing the above-mentioned soft magnetic metal powder will be described. In the present embodiment, the soft magnetic metal powder can be obtained by using the same method as the known method for producing the soft magnetic metal powder. Specifically, it can be produced by using a gas atomizing method, a water atomizing method, a rotating disc method, or the like. Among these, it is preferable to use the gas atomizing method from the viewpoint that a soft magnetic metal powder having desired magnetic properties can be easily obtained.
本実施形態に係る軟磁性金属粉末は、上述したように、水分が存在するような酸化環境下においても良好な耐食性を有しているので、水アトマイズ法による粉末製造時においても錆の発生を効果的に抑制することができる。 As described above, the soft magnetic metal powder according to the present embodiment has good corrosion resistance even in an oxidizing environment where water is present, so that rust is generated even during powder production by the water atomization method. It can be effectively suppressed.
水アトマイズ法またはガスアトマイズ法では、溶融した原料（溶湯）をルツボ底部に設けられたノズルを通じて線状の連続的な流体として供給し、供給された溶湯に高圧の水またはガスを吹き付けて、溶湯を液滴化するとともに、急冷して微細な粉末を得る。 In the water atomization method or the gas atomization method, the molten raw material (molten metal) is supplied as a linear continuous fluid through a nozzle provided at the bottom of the crucible, and high-pressure water or gas is sprayed on the supplied molten metal to spray the molten metal. Along with making droplets, it is rapidly cooled to obtain a fine powder.
本実施形態では、Ｆｅの原料、Ｎｉの原料およびＡｌの原料を溶融し、この溶融物を、水アトマイズ法またはガスアトマイズ法により微粉化することにより、本実施形態に係る軟磁性金属粉末を製造することができる。 In the present embodiment, the soft magnetic metal powder according to the present embodiment is produced by melting the raw material of Fe, the raw material of Ni, and the raw material of Al, and pulverizing the melt by a water atomizing method or a gas atomizing method. be able to.
（４．圧粉磁心の製造方法）
本実施形態では、このようにして得られた軟磁性金属粉末を用いて、圧粉磁心を製造する。磁心の製造方法としては、特に制限されず、公知の方法を採用することができる。まず、軟磁性金属粉末と、結合剤としての公知のバインダとを混合し、混合物を得る。また、必要に応じて、得られた混合物を造粒粉としてもよい。そして、混合物または造粒粉を金型に充填して圧縮成形し、作製すべき磁性体（磁心）の形状を有する成形体を得る。得られた成形体に対して、熱処理を行うことにより、軟磁性金属粒子が固定された所定形状の圧粉磁心が得られる。得られた圧粉磁心に、巻線を所定回数だけ巻回することにより、インダクタ等のコイル型電子部品が得られる。
(4. Manufacturing method of dust core)
In the present embodiment, the powder magnetic core is produced using the soft magnetic metal powder thus obtained. The method for producing the magnetic core is not particularly limited, and a known method can be adopted. First, the soft magnetic metal powder and a known binder as a binder are mixed to obtain a mixture. Further, if necessary, the obtained mixture may be used as a granulated powder. Then, the mixture or granulated powder is filled in a mold and compression molded to obtain a molded product having the shape of a magnetic material (magnetic core) to be produced. By heat-treating the obtained molded product, a dust core having a predetermined shape in which soft magnetic metal particles are fixed can be obtained. A coil-type electronic component such as an inductor can be obtained by winding a winding around the obtained dust core a predetermined number of times.
また、上記の混合物または造粒粉と、巻線を所定回数だけ巻回して形成された空心コイルとを、金型に充填して圧縮成形しコイルが内部に埋設された成形体を得てもよい。得られた成形体に対して、熱処理を行うことにより、コイルが埋設された所定形状の圧粉磁心が得られる。このような圧粉磁心は、その内部にコイルが埋設されているので、インダクタ等のコイル型電子部品として機能する。 Further, even if the above mixture or granulated powder and an air-core coil formed by winding a winding a predetermined number of times are filled in a mold and compression-molded to obtain a molded body in which the coil is embedded inside. Good. By heat-treating the obtained molded product, a dust core having a predetermined shape in which a coil is embedded can be obtained. Since a coil is embedded in such a dust core, it functions as a coil-type electronic component such as an inductor.
（５．本実施形態の効果）
上記の（１）から（４）において説明した本実施形態では、軟磁性金属粉末に含まれる軟磁性金属粒子を、Ｆｅ−Ｎｉ合金粒子またはＦｅ−Ｎｉ−Ａｌ合金粒子で構成し、ＮｉおよびＡｌの含有量範囲を特定の範囲としている。
(5. Effect of this embodiment)
In the present embodiment described in (1) to (4) above, the soft magnetic metal particles contained in the soft magnetic metal powder are composed of Fe—Ni alloy particles or Fe—Ni—Al alloy particles, and Ni and Al are formed. The content range of is set to a specific range.
このようにすることにより、本実施形態に係る軟磁性金属粉末は、耐食性を向上させる元素として通常用いられるＣｒに依存することなく、酸化に対する耐食性を向上させることができる。したがって、水アトマイズ法による粉末製造時における粉末の酸化（錆の発生）を抑制できる。また、水分が存在するような多湿環境下であっても、粉末の酸化（錆の発生）を抑制できる。しかも、飽和磁化等の磁気特性を悪化させるＣｒではなく、常温で強磁性を示すＮｉを含有しているので、飽和磁化等の磁気特性をも良好にすることができる。 By doing so, the soft magnetic metal powder according to the present embodiment can improve the corrosion resistance to oxidation without depending on Cr which is usually used as an element for improving the corrosion resistance. Therefore, it is possible to suppress the oxidation (generation of rust) of the powder during the production of the powder by the water atomization method. Further, even in a humid environment where water is present, oxidation of powder (generation of rust) can be suppressed. Moreover, since it contains Ni, which exhibits ferromagnetism at room temperature, instead of Cr, which deteriorates magnetic properties such as saturation magnetization, magnetic properties such as saturation magnetization can also be improved.
また、Ｎｉに加えて、Ａｌを特定の範囲内で含有することにより、耐食性をさらに向上でき、しかも飽和磁化等の低下を抑制して所定の磁気特性を維持しつつ、保磁力を低減することができる。 Further, by containing Al in a specific range in addition to Ni, the corrosion resistance can be further improved, and the coercive force can be reduced while suppressing the decrease in saturation magnetization and the like to maintain a predetermined magnetic characteristic. Can be done.
また、本実施形態に係る圧粉磁心は、本実施形態に係る軟磁性金属粉末で構成することにより、酸化に対する耐食性が良好になる。したがって、水分が存在するような多湿環境下であっても、磁心表面における錆の発生を抑制でき、磁心が有する磁気特性が損なわれず、直流重畳特性等に関し、所定の磁気特性を発揮することができる。また、Ｆｅ−Ｎｉ−Ａｌ合金粒子を含む軟磁性金属粉末から構成される圧粉磁心については、保磁力が低減されているので、ヒステリシス損を低減することができる。 Further, the dust core according to the present embodiment is made of the soft magnetic metal powder according to the present embodiment, so that the corrosion resistance to oxidation is improved. Therefore, even in a humid environment where moisture is present, the generation of rust on the surface of the magnetic core can be suppressed, the magnetic characteristics of the magnetic core are not impaired, and the predetermined magnetic characteristics can be exhibited with respect to the DC superimposition characteristics and the like. it can. Further, since the coercive force of the dust core composed of the soft magnetic metal powder containing Fe—Ni—Al alloy particles is reduced, the hysteresis loss can be reduced.
以上、本発明の実施形態について説明してきたが、本発明は上記の実施形態に何ら限定されるものではなく、本発明の範囲内において種々の態様で改変しても良い。 Although the embodiments of the present invention have been described above, the present invention is not limited to the above embodiments, and may be modified in various ways within the scope of the present invention.
以下、実施例を用いて、発明をより詳細に説明するが、本発明はこれらの実施例に限定されるものではない。 Hereinafter, the invention will be described in more detail with reference to Examples, but the present invention is not limited to these Examples.
（実験例１）
まず、原料として、Ｆｅ単体およびＮｉ単体のインゴット、チャンク（塊）、またはショット（粒子）を準備した。次に、それらを混合して、ガスアトマイズ装置内に配置されたルツボに収容した。続いて、不活性雰囲気下において、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１６００℃以上まで加熱し、ルツボ中のインゴット、チャンクまたはショットを溶融、混合して溶湯を得た。
(Experimental Example 1)
First, as raw materials, ingots, chunks (lumps), or shots (particles) of Fe alone and Ni alone were prepared. They were then mixed and housed in a crucible placed in a gas atomizer. Subsequently, in an inert atmosphere, the crucible was heated to 1600 ° C. or higher by high-frequency induction using a work coil provided outside the crucible, and the ingot, chunk or shot in the crucible was melted and mixed to obtain a molten metal. ..
次いで、ルツボに設けられたノズルから、線状の連続的な流体を形成するように供給された溶湯に、１〜１０ＭＰａのガス流を衝突させ、液滴化すると同時に急冷することにより、Ｆｅ−Ｎｉ合金粒子からなる軟磁性金属粉末を製造した。 Next, a gas stream of 1 to 10 MPa is made to collide with the molten metal supplied so as to form a linear continuous fluid from a nozzle provided in the crucible, and the mixture is formed into droplets and rapidly cooled to form Fe-. A soft magnetic metal powder composed of Ni alloy particles was produced.
得られた軟磁性金属粉末を篩い分けして、粒度を調整し、平均粒子径を２５μｍである軟磁性金属粉末を得た。 The obtained soft magnetic metal powder was sieved to adjust the particle size to obtain a soft magnetic metal powder having an average particle size of 25 μm.
得られた軟磁性金属粉末をペレット化して蛍光Ｘ線分析法により組成分析した結果、表１に示す組成を有していた。 As a result of pelletizing the obtained soft magnetic metal powder and analyzing the composition by a fluorescent X-ray analysis method, it had the composition shown in Table 1.
続いて、得られた軟磁性金属粉末の磁気特性および耐食性を評価した。磁気特性は、飽和磁化および保磁力を測定した。まず、飽和磁化は、玉川製作所製ＶＳＭ（振動試料型磁力計）を用いて測定した。本実施例では、飽和磁化は大きいほど好ましい。結果を表１に示す。 Subsequently, the magnetic properties and corrosion resistance of the obtained soft magnetic metal powder were evaluated. For magnetic properties, saturation magnetization and coercive force were measured. First, the saturation magnetization was measured using a VSM (vibrating sample magnetometer) manufactured by Tamagawa Seisakusho. In this example, the larger the saturation magnetization, the more preferable. The results are shown in Table 1.
保磁力は、φ６ｍｍ×５ｍｍのプラスチックケースに２０ｍｇの粉末を入れ、パラフィンを融解、凝固させて固定したものを、東北特殊鋼製保磁力計（K-HC1000型）を用いて測定した。測定磁界は１５０ｋＡ／ｍとした。保磁力は、粉末粒子径にも影響されるため、絶対値による評価は必要ないが、本実施例では、保磁力は純鉄（比較例１ａ）が示す保磁力に近いほど好ましく、１２００Ａ／ｍ程度であれば許容範囲内である。結果を表１に示す。 The coercive force was measured by putting 20 mg of powder in a plastic case of φ6 mm × 5 mm, melting paraffin, solidifying and fixing it, and using a Tohoku Steel coercive force magnetometer (K-HC1000 type). The measurement magnetic field was 150 kA / m. Since the coercive force is also affected by the powder particle size, it is not necessary to evaluate it by an absolute value, but in this example, the coercive force is preferably closer to the coercive force shown by pure iron (Comparative Example 1a) at 1200 A / m. If it is a degree, it is within the permissible range. The results are shown in Table 1.
耐食性は以下のようにして評価した。まず、得られた軟磁性金属粉末を５％食塩水溶液に浸漬して、３５℃で２４時間維持する試験を行った。試験後の軟磁性金属粉末をイオン交換水で洗浄し、乾燥させた後、試験前後の重量から錆(酸化)による重量変化を算出し、耐食性の評価を行った。結果を表１に示す。なお、表１において、重量変化率が０．３００％以上の場合を「×」と表記し、耐食性が低いと判定した。重量変化率が０．２５０％以上０．３００％未満の場合を「△」と表記し、耐食性を有すると判定した。重量変化率が０．１５０％以上０．２５０％未満の場合を「○」と表記し、耐食性が優れていると判定した。重量変化率が０．１５０％未満の場合を「◎」と表記し、耐食性が非常に優れていると判定した。 Corrosion resistance was evaluated as follows. First, a test was conducted in which the obtained soft magnetic metal powder was immersed in a 5% aqueous salt solution and maintained at 35 ° C. for 24 hours. After the soft magnetic metal powder after the test was washed with ion-exchanged water and dried, the weight change due to rust (oxidation) was calculated from the weight before and after the test, and the corrosion resistance was evaluated. The results are shown in Table 1. In Table 1, the case where the weight change rate was 0.300% or more was indicated by “x”, and it was determined that the corrosion resistance was low. When the weight change rate was 0.250% or more and less than 0.300%, it was indicated as "Δ" and was judged to have corrosion resistance. When the weight change rate was 0.150% or more and less than 0.250%, it was described as “◯”, and it was judged that the corrosion resistance was excellent. When the weight change rate was less than 0.150%, it was described as "⊚", and it was judged that the corrosion resistance was very excellent.
続いて、圧粉磁心の評価を行った。熱硬化樹脂であるエポキシ樹脂および硬化剤であるイミド樹脂の総量が、得られた軟磁性金属粉末１００質量％に対して４質量％となるようにして、さらにアセトンに加えて溶液化し、その溶液と軟磁性金属粉末とを混合した。混合後、アセトンを揮発させて得られた顆粒を、３５５μｍのメッシュで整粒した。これを外径１７．５ｍｍ、内径１１．０ｍｍのトロイダル形状の金型に充填し、成形圧５８８ＭＰａで加圧し圧粉磁心の成形体を得た。成形体重量は５ｇとした。作製した圧粉磁心の成形体を１８０℃で３時間、大気中での熱硬化処理を行った。 Subsequently, the powder magnetic core was evaluated. The total amount of the epoxy resin as the thermosetting resin and the imide resin as the curing agent is adjusted to 4% by mass with respect to 100% by mass of the obtained soft magnetic metal powder, and the solution is further added to acetone to form a solution. And soft magnetic metal powder were mixed. After mixing, the granules obtained by volatilizing acetone were sized with a mesh of 355 μm. This was filled in a toroidal mold having an outer diameter of 17.5 mm and an inner diameter of 11.0 mm, and pressed at a molding pressure of 588 MPa to obtain a compact magnetic core molded body. The weight of the molded product was 5 g. The prepared compact magnetic core molded body was heat-cured in the air at 180 ° C. for 3 hours.
熱硬化処理後の圧粉磁心に巻線を巻きつけ（一次巻線：５０ｔｓ、二次巻線：１０ｔｓ）、直流磁化測定装置(METRON SK110)を用いて、磁界８ｋＡ／ｍにおける磁束密度を測定した。本実施例では、磁束密度が大きいほど好ましい。結果を表２に示す。また、直流重畳特性は、ＬＣＲメータ（アジレント・テクノロジー社製４２８４Ａ）と直流バイアス電源（アジレント・テクノロジー社製４２８４１Ａ）とを用いて測定を行った。結果を表２に示す。表２において、直流重畳特性における初透磁率はμ0とし、μ0が８０%まで低下する磁場をＨ（μ0×０．８）と記載した。 A winding is wound around the dust core after the heat curing treatment (primary winding: 50 ts, secondary winding: 10 ts), and the magnetic flux density at a magnetic field of 8 kA / m is measured using a DC magnetization measuring device (METRON SK110). did. In this embodiment, the larger the magnetic flux density, the more preferable. The results are shown in Table 2. The DC superimposition characteristic was measured using an LCR meter (4284A manufactured by Agilent Technologies) and a DC bias power supply (42841A manufactured by Agilent Technologies). The results are shown in Table 2. In Table 2, initial permeability at DC superposition characteristics and mu 0, a magnetic field mu 0 is reduced to 80% was expressed as H (μ 0 × 0.8).
また、保磁力は、軟磁性金属粉末の場合と同様にして、保磁力計(東北特殊鋼社製、K-HC1000型)にて測定した。結果を表２に示す。 The coercive force was measured with a coercive force meter (manufactured by Tohoku Steel Co., Ltd., K-HC1000 type) in the same manner as in the case of soft magnetic metal powder. The results are shown in Table 2.
耐食性は以下のようにして評価した。まず、作製した圧粉磁心の成形体に対し、５％食塩水溶液を噴霧して、３５℃で２４時間保持する試験を行った。試験後の圧粉磁心をイオン交換水で洗浄し、乾燥させた後、発錆状況を光学顕微鏡（５０倍）で観察し、任意の視野内において、錆と考えられる部分に印をつけ、錆が占める面積率を市販の画像解析ソフト (Mountech社製のMac View)を用いて計算した。結果を表２に示す。なお、表２において、錆が占める面積率が１０．０％以上の場合を「×」と表記し、耐食性が低いと判定した。面積率が８．０％以上１０．０％未満の場合を「△」と表記し、耐食性を有すると判定した。面積率が５．０％以上８．０％未満の場合を「○」と表記し、耐食性が優れていると判定した。面積率が５．０％未満の場合を「◎」と表記し、耐食性が非常に優れていると判定した。 Corrosion resistance was evaluated as follows. First, a test was conducted in which a 5% aqueous salt solution was sprayed onto the prepared compact magnetic core molded product and kept at 35 ° C. for 24 hours. After washing the dust core after the test with ion-exchanged water and drying it, observe the rusting condition with an optical microscope (50 times), mark the part considered to be rust in any field of view, and rust. The area ratio occupied by was calculated using a commercially available image analysis software (Mac View manufactured by Mountech). The results are shown in Table 2. In Table 2, when the area ratio occupied by rust was 10.0% or more, it was indicated as “x”, and it was determined that the corrosion resistance was low. When the area ratio was 8.0% or more and less than 10.0%, it was indicated as "Δ" and was judged to have corrosion resistance. When the area ratio was 5.0% or more and less than 8.0%, it was described as “◯”, and it was judged that the corrosion resistance was excellent. When the area ratio was less than 5.0%, it was described as "◎", and it was judged that the corrosion resistance was very excellent.
表１より、Ｆｅ−Ｎｉ合金におけるＮｉの含有量が上述した範囲内である場合には、良好な耐食性が得られていることが確認できた。また、磁気特性も良好であることが確認できた。 From Table 1, it was confirmed that good corrosion resistance was obtained when the Ni content in the Fe—Ni alloy was within the above range. It was also confirmed that the magnetic characteristics were also good.
一方、Ｎｉの含有量が少なすぎる場合には、耐食性が悪化する傾向にあることが確認できた。また、Ｎｉの含有量が多すぎる場合には、耐食性の向上効果が飽和する傾向にあるのに対し、保磁力が大きくなるので好ましくないことが確認できた。 On the other hand, it was confirmed that when the Ni content is too small, the corrosion resistance tends to deteriorate. Further, it was confirmed that when the Ni content is too large, the effect of improving the corrosion resistance tends to be saturated, whereas the coercive force becomes large, which is not preferable.
上記の傾向は、Ｎｉの含有量と軟磁性金属粉末の耐食性との関係を示すグラフである図１からも明らかである。すなわち、図１は、Ｎｉの含有量が増えるにつれ、耐食性が良好になることを示している。 The above tendency is also clear from FIG. 1, which is a graph showing the relationship between the Ni content and the corrosion resistance of the soft magnetic metal powder. That is, FIG. 1 shows that the corrosion resistance becomes better as the Ni content increases.
また、表２より、圧粉磁心についても、表１の粉体と同様に、良好な耐食性および磁気特性が得られていることが確認できた。上記の傾向は、図１と同様に、Ｎｉの含有量と、圧粉磁心の耐食性と、の関係を示すグラフである図２からも明らかである。 Further, from Table 2, it was confirmed that the powder magnetic core also had good corrosion resistance and magnetic properties as in the case of the powder in Table 1. Similar to FIG. 1, the above tendency is clear from FIG. 2, which is a graph showing the relationship between the Ni content and the corrosion resistance of the dust core.
（実験例２）
原料として、Ｆｅ単体およびＮｉ単体に加えて、Ａｌ単体を用いて、Ｆｅ−Ｎｉ−Ａｌ合金とした以外は、実験例１と同じ方法により粉末試料を作製し、実験例１と同じ方法により組成および粉体特性を評価した。結果を表３に示す。
(Experimental Example 2)
A powder sample was prepared by the same method as in Experimental Example 1 except that Al alone was used as a raw material in addition to Fe alone and Ni alone to form an Fe—Ni—Al alloy, and the composition was formed by the same method as in Experimental Example 1. And the powder properties were evaluated. The results are shown in Table 3.
また、上記で作製したＦｅ−Ｎｉ−Ａｌ合金の軟磁性金属粉末を用いて、実験例１と同じ方法により圧粉磁心の試料を作製し、実験例１と同じ方法により磁心特性を評価した。結果を表４に示す。 Further, using the soft magnetic metal powder of the Fe—Ni—Al alloy prepared above, a powder magnetic core sample was prepared by the same method as in Experimental Example 1, and the magnetic core characteristics were evaluated by the same method as in Experimental Example 1. The results are shown in Table 4.
表３より、Ｆｅ−Ｎｉ−Ａｌ合金の場合についても、実験例１と同様に、Ｎｉの含有量およびＡｌの含有量が上述した範囲内である場合には、良好な耐食性が得られていることが確認できた。図１も、Ａｌの含有量が２．８質量％の場合に、Ｎｉの含有量が増えるにつれ、耐食性が良好になることを示している。また、磁気特性も良好であることが確認できた。 From Table 3, also in the case of the Fe—Ni—Al alloy, good corrosion resistance is obtained when the Ni content and the Al content are within the above-mentioned ranges, as in Experimental Example 1. I was able to confirm that. FIG. 1 also shows that when the Al content is 2.8% by mass, the corrosion resistance becomes better as the Ni content increases. It was also confirmed that the magnetic characteristics were also good.
また、表４より、圧粉磁心についても、表３の粉体と同様に、良好な耐食性および磁気特性が得られていることが確認できた。図２も、Ａｌの含有量が２．８質量％の場合に、Ｎｉの含有量が増えるにつれ、耐食性が良好になることを示している。 Further, from Table 4, it was confirmed that the powder magnetic core also had good corrosion resistance and magnetic properties as in the case of the powder in Table 3. FIG. 2 also shows that when the Al content is 2.8% by mass, the corrosion resistance becomes better as the Ni content increases.
Claims (4)
前記Ｆｅ−Ｎｉ系合金は、Ｎｉを０．５０質量％以上５．００質量％以下、Ａｌを０．３０質量％以上３．００質量％以下含有し、残部がＦｅおよび不可避的不純物からなる軟磁性金属粉末。 A soft magnetic metal powder for coil-type electronic components containing a plurality of soft magnetic metal particles composed of Fe—Ni alloys.
The Fe-Ni alloy contains 0.50% by mass or more and 5.00% by mass or less of Ni, 0.30% by mass or more and 3.00% by mass or less of Al, and the balance is soft composed of Fe and unavoidable impurities. Magnetic metal powder.
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