JP2021093465A - 磁性シート、および、磁性シートを備えるコイルモジュール、並びに非接触給電装置。 - Google Patents
磁性シート、および、磁性シートを備えるコイルモジュール、並びに非接触給電装置。 Download PDFInfo
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- JP2021093465A JP2021093465A JP2019223822A JP2019223822A JP2021093465A JP 2021093465 A JP2021093465 A JP 2021093465A JP 2019223822 A JP2019223822 A JP 2019223822A JP 2019223822 A JP2019223822 A JP 2019223822A JP 2021093465 A JP2021093465 A JP 2021093465A
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/26—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on ferrites
- C04B35/2658—Other ferrites containing manganese or zinc, e.g. Mn-Zn ferrites
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/34—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
- H01F1/342—Oxides
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F7/00—Magnets
- H01F7/02—Permanent magnets [PM]
- H01F7/0205—Magnetic circuits with PM in general
- H01F7/021—Construction of PM
- H01F7/0215—Flexible forms, sheets
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/26—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on ferrites
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/6261—Milling
- C04B35/6262—Milling of calcined, sintered clinker or ceramics
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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Abstract
Description
シート状の焼結体で構成されており、
前記焼結体は、主成分としてMn−Zn系フェライトを含み、
前記焼結体の断面の厚み方向において、酸化物換算したZn含有量の最大値をZMAXとし、酸化物換算したZn含有量の最小値をZMINとすると、
ZMAXに対するZMINの比率(ZMIN/ZMAX×100)が、90%以上である。
第1実施形態では、図1〜3に基づいて、本発明の一実施形態に係る磁性シート2について説明する。本実施形態の磁性シート2は、シート状のフェライト焼結体で構成してある。
本実施形態の磁性シート2は、シート状の焼結体で構成してあり、主成分としてMn−Zn系フェライトを含む。そして、この磁性シート2の断面では、厚み方向におけるZn含有量の最大値(ZMAX)と最小値(ZMIN)の比率(ZMIN/ZMAX×100)が、90%以上である。
第2実施形態では、第1実施形態で説明した磁性シート2の用途の一例として、磁性シート2を有するコイルモジュール10(図4)および非接触給電装置100(図5)について説明する。なお、第2実施形態における第1実施形態と共通の構成に関しては、説明を省略し、同様な符号を使用する。
実験1では、断面におけるZn含有量の比率(ZMIN/ZMAX×100)が90%以上となるように、焼成条件などを調整して、実施例1に係る磁性シートを作製した。実施例1に係る磁性シートは、それぞれ500枚ずつ作製し、実施例1における製品歩留まり、初透磁率μi、磁気損失Pcvを評価した。以下、詳細な実験条件を説明する。
まず、主成分の出発原料と副成分の出発原料とを、所定の配合比で秤量し混合した後、大気雰囲気下において900℃で2時間、仮焼きした。この際、主成分の出発原料は、それぞれ、平均粒径が0.1〜3.0μmの粉末を使用し、最終的な主成分組成が、Fe2O3:53.5mol%、ZnO:10.5mol%、残部MnOとなるように秤量した。また、副成分としては、SiO2、CaCO3、Nb2O5、およびV2O5を添加し、最終的な各副成分の含有量が、主成分100重量部に対して、SiO2:0.01重量部、CaO:0.08重量部、Nb2O5:0.02重量部、V2O5:0.01重量部となるように原料を調合した。
まず、SEM観察時にEPMAによるライン分析を行い、磁性シートの厚み方向におけるZn成分のばらつき度合いを評価した。具体的に、図1に示すように、磁性シートの断面において、厚み方向と略平行な測定線4(線長は磁性シートの厚みT0と同程度)を引き、その測定線4上で点幅1μmの間隔で成分分析を行い、連続データを得た。この際、加速電圧は15kV、照射電流は50nAとした。また、測定用の試料は、磁性シートをX−Y平面の略中央位置で切断したうえで、樹脂埋めし、その断面を鏡面研磨することで得た。実験1におけるライン分析した結果を、図2に示す。また、ライン分析により得られた連続データを解析し、最小値ZMIN、最大値ZMAX、平均値ZA、標準偏差σ、ZMIN/ZMAX、およびZA/ZTを算出した。その結果を表2に示す。
実施例1に係る磁性シートの量産性を評価するために、製品歩留まりを算出した。実施例1では、磁性シートを500枚作製したが、その500枚の磁性シートについて、それぞれ外観検査を実施し、変形不良、クラック不良、融着不良などの各種不良の発生有無を評価した。そして、外観検査の結果を基に、作製枚数に対する良品数の割合、すなわち製品歩留まりを算出した。製品歩留まりは、97%以上である場合を合格とし、量産性が良好であると判断する。算出した製品歩留まりを表2に示す。
磁気特性を評価するための前段階として、まず、各実施例1〜3の磁性シートを、レーザ加工により、外形20mm、内径10mmのトロイダル形状にカットした。そして、この評価用サンプルに、線径0.35mmの導線を10ターン分巻き付け、初透磁率μi(無次元量)と磁気損失Pcv(単位:kW/m3)とを測定した。
比較例1では、実施例1とは異なり表1に示す従来条件1で焼成を行い、比較例1に係る磁性シートを作製した。具体的に、比較例1では、焼成時の保持温度を1300〜1350℃とし、保持時間を3〜5時間とした。また、焼成雰囲気中の酸素分圧の制御は、温度保持過程と降温過程でのみ行い、その際の最大酸素濃度を0.03vol%〜3.0vol%とした。また、セッタとしては、気孔率が30〜32%で、表面粗さRaが2.1〜2.6μmで、純度が95%程度のアルミナ基板を使用した。比較例1の上記以外の実験条件は、実施例1と共通として、実施例1と同様の評価を実施した。
比較例2では、ダミー部材を使用して焼成を行い(従来条件2)、比較例2に係る磁性シートを作製した。具体的に、比較例2では、グリーンシートの周囲にダミー部材として酸化亜鉛のブロックを設置して、焼成を行った。比較例2における上記以外の焼成条件(保持温度、保持時間、酸素濃度、セッタの特性等)は、比較例1と共通とした。
図2において、実線ex1が実施例1のライン分析結果であり、点線ce1が比較例1のライン分析結果、一点鎖線ce2が比較例2のライン分析結果である。比較例1では、表面側およびセッタ側の双方において、Zn含有量が狙い値(10.5mol%)よりも大きく減少している。また、比較例2については、表面側ではダミー部材によりZn含有量の減少がある程度抑制されているものの、セッタ側でZn含有量が大きく減少している。このように、比較例1および2では、厚み方向におけるZn成分のばらつきが大きく、ZMIN/ZMAXが90%未満となった。
(実施例11〜16)
実験2では、磁性シートの平均厚みT0を変えて、実施例11〜16に係る磁性シートを作製した。特に実施例11〜12では、実験1と同様にしてドクターブレード法でグリーンシートを成形しており、その際にフェライトペーストの塗布量を変えることで、得られる磁性シートの厚みを調整した。一方、実施例13〜16では、押出成形法でグリーンシートを成形し、その際に使用する金型の径(押出径)を変えることで、得られる磁性シートの厚みを調整した。各実施例11〜16における平均厚みT0を、表3に示す。なお、実験2における上記以外の実験条件は、実験1と共通しており、実験1と同様の評価を実施した。
比較例11〜15では、成形条件を変更することで、平均厚みT0を変えた磁性シートを作製した。比較例11〜15における平均厚みT0を、表3に示す。なお、比較例11〜15の上記以外の実験条件は、実験1の比較例1と共通している。
実験2における実施例11〜16および比較例11〜15の評価結果を表3に示す。
実験3では、主成分の組成比を変えて、実施例21〜23に係る磁性シートを作製した。各実施例21〜23における主成分の構成を表4に示す。なお、実験3における上記以外の実験条件は、実験1と共通しており、実験1と同様の評価を実施した。
実験3における実施例21〜23の評価結果を表4に示す。
2a … 表面
2b … 裏面
3 … グリーンシート
4 … 測定線
6 … セッタ
6a … セッタ表面
10 … コイルモジュール
12 … コイル
13 … リード端子
100 … 非接触給電装置
10a … 送電側コイルモジュール
10b … 受電側コイルモジュール
20a … 送電側内部回路
20b … 受電側内部回路
22 … 電源
24 … 二次電池
Claims (5)
- シート状の焼結体で構成される磁性シートであって、
前記焼結体は、主成分としてMn−Zn系フェライトを含み、
前記焼結体の断面の厚み方向において、酸化物換算したZn含有量の最大値をZMAXとし、酸化物換算したZn含有量の最小値をZMinとすると、
ZMAXに対するZMINの比率(ZMIN/ZMAX×100)が、90%以上である磁性シート。 - 前記焼結体の平均厚みが、2500μm以下である請求項1に記載の磁性シート。
- 前記焼結体の断面の厚み方向において、酸化物換算したZn含有量の標準偏差が、0.3mol%以下である請求項1または2に記載の磁性シート。
- 請求項1〜3のいずれかに記載の磁性シートを備えるコイルモジュール。
- 請求項4に記載のコイルモジュールを備える非接触給電装置。
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JPH053114A (ja) * | 1991-06-21 | 1993-01-08 | Kawasaki Steel Corp | 亜鉛を含有するソフトフエライトの製造方法およびそれに用いる焼成用敷板 |
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