JP2021141267A - 磁性粉末、磁性粉末成形体、および磁性粉末の製造方法 - Google Patents
磁性粉末、磁性粉末成形体、および磁性粉末の製造方法 Download PDFInfo
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- 239000006247 magnetic powder Substances 0.000 title claims abstract description 111
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 15
- 239000002245 particle Substances 0.000 claims abstract description 45
- 239000000696 magnetic material Substances 0.000 claims abstract description 32
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- 239000000843 powder Substances 0.000 claims description 44
- 238000010438 heat treatment Methods 0.000 claims description 30
- 239000000203 mixture Substances 0.000 claims description 21
- 239000002994 raw material Substances 0.000 claims description 18
- 238000009692 water atomization Methods 0.000 claims description 10
- 238000000227 grinding Methods 0.000 claims description 7
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- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 11
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- 239000004020 conductor Substances 0.000 description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 3
- 238000000635 electron micrograph Methods 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- 239000007769 metal material Substances 0.000 description 3
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- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229910008423 Si—B Inorganic materials 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 238000000113 differential scanning calorimetry Methods 0.000 description 2
- 229910001873 dinitrogen Inorganic materials 0.000 description 2
- 238000010332 dry classification Methods 0.000 description 2
- 238000002296 dynamic light scattering Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000010931 gold Substances 0.000 description 2
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- 229910052742 iron Inorganic materials 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 230000005389 magnetism Effects 0.000 description 2
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- 238000010333 wet classification Methods 0.000 description 2
- 229910001369 Brass Inorganic materials 0.000 description 1
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 239000004734 Polyphenylene sulfide Substances 0.000 description 1
- 239000004115 Sodium Silicate Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 230000002238 attenuated effect Effects 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- NRGIRRZWCDKDMV-UHFFFAOYSA-H cadmium(2+);diphosphate Chemical compound [Cd+2].[Cd+2].[Cd+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O NRGIRRZWCDKDMV-UHFFFAOYSA-H 0.000 description 1
- 239000001506 calcium phosphate Substances 0.000 description 1
- 229910000389 calcium phosphate Inorganic materials 0.000 description 1
- 235000011010 calcium phosphates Nutrition 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
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- 238000005056 compaction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000006837 decompression Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 229910001882 dioxygen Inorganic materials 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 238000009689 gas atomisation Methods 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- CPSYWNLKRDURMG-UHFFFAOYSA-L hydron;manganese(2+);phosphate Chemical compound [Mn+2].OP([O-])([O-])=O CPSYWNLKRDURMG-UHFFFAOYSA-L 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- GVALZJMUIHGIMD-UHFFFAOYSA-H magnesium phosphate Chemical compound [Mg+2].[Mg+2].[Mg+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O GVALZJMUIHGIMD-UHFFFAOYSA-H 0.000 description 1
- 239000004137 magnesium phosphate Substances 0.000 description 1
- 229910000157 magnesium phosphate Inorganic materials 0.000 description 1
- 229960002261 magnesium phosphate Drugs 0.000 description 1
- 235000010994 magnesium phosphates Nutrition 0.000 description 1
- 230000005415 magnetization Effects 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052755 nonmetal Inorganic materials 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 229920000069 polyphenylene sulfide Polymers 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 150000004760 silicates Chemical class 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 229910052911 sodium silicate Inorganic materials 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000007921 spray Substances 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
- 238000004804 winding Methods 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
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Abstract
Description
FeaCubNbcSidBe
但し、a、b、c、d、およびeは原子百分率を示し、71.0at%≦a≦76.0at%、0.5at%≦b≦1.5at%、2.0at%≦c≦4.0at%、11.0at%≦d≦16.0at%、8.0at%≦e≦13.0at%を満たす。
FeaCubNbcSidBe
但し、a、b、c、d、およびeは原子百分率を示し、71.0at%≦a≦76.0at%、0.5at%≦b≦1.5at%、2.0at%≦c≦4.0at%、11.0at%≦d≦16.0at%、8.0at%≦e≦13.0at%を満たす。
1.1.磁性粉末
実施形態に係る磁性粉末の構成について説明する。本実施形態の磁性粉末は、下記組成式(1)で表される軟磁性材料を含む。
FeaCubNbcSidBe ・・・(1)
但し、a、b、c、d、およびeは原子百分率を示し、71.0at%≦a≦76.0at%、0.5at%≦b≦1.5at%、2.0at%≦c≦4.0at%、11.0at%≦d≦16.0at%、8.0at%≦e≦13.0at%を満たす。
本実施形態に係る磁性粉末の製造方法について、図1を参照して説明する。
比抵抗[MΩ・cm]=電気抵抗[MΩ]×円筒内部の横断面積[cm2]/加圧時の電極間距離[cm] ・・・(2)
本実施形態の磁性粉末は、インダクターやトロイダルコイルなどのコイル部品に備わる圧粉磁心の他、アンテナ、磁気シートなどにも好適に用いられる。そのため、磁性粉末はこれらの用途に合わせて所望の形状に成形される。以下、本実施形態の磁性粉末を含む磁性粉末成形体として圧粉磁心を例示する。
以下、実施例および比較例を示して、本発明の効果をより具体的に説明する。なお、本発明は以下の実施例によって何ら限定されるものではない。
まず、以下に述べる手順で実施例1から実施例3、および比較例1から比較例6の磁性粉末を製造した。
実施例1について、熱処理工程における熱処理を施す前の粉末、および熱処理を施した後の磁性粉末について、内部の結晶状態を観察した。具体的には、試料の一粒子について、粒子内部の断面薄片サンプルを作製し、透過型電子顕微鏡にて観察した。その電子顕微鏡写真を、図4および図5に示した。
実施例2および比較例3から比較例6の磁性粉末について、磁気特性の一つである保磁力を測定した。具体的には、磁化測定装置として玉川製作所社のVSMシステム TM−VSM1230−MHHLを用いて保磁力を測定した。その各測定値を表1に記載した。表1から、実施例2の磁性粉末は、比較例3、4、6の磁性粉末に対して、保磁力が向上することが示された。
実施例2および比較例4の磁性粉末から作製した磁性粉末成形体について、磁気特性の一つである透磁率を測定した。具体的には、各磁性粉末からチョークコイルに用いるリング状の磁心、所謂トロイダルコアを作製し、該トロイダルコアにおける透磁率を測定した。
実施例2、3および比較例1、2の磁性粉末から作製した磁性粉末成形体について、高周波特性を調査した。具体的には、まず実施例2と同様にして夫々トロイダルコアを作製した。その後、線径0.5mmの樹脂被覆された銅線を、1次側および2次側共に巻き数36で巻き回してトロイダルコイルとした。
Claims (7)
- 下記組成式で表される軟磁性材料を含み、
平均粒子径が2μm以上10μm以下であり、
少なくとも表層がナノ結晶化していることを特徴とする磁性粉末。
FeaCubNbcSidBe
但し、a、b、c、d、およびeは原子百分率を示し、71.0at%≦a≦76.0at%、0.5at%≦b≦1.5at%、2.0at%≦c≦4.0at%、11.0at%≦d≦16.0at%、8.0at%≦e≦13.0at%を満たす。 - 前記軟磁性材料は、Fe73.5Cu1.0Nb3.0Si13.5B9.0である、請求項1に記載の磁性粉末。
- 請求項1または請求項2に記載の磁性粉末を含むことを特徴とする磁性粉末成形体。
- 下記組成式で表される軟磁性材料を含む溶融金属を、水アトマイズ法によって原料粉末とする粉末化工程と、
前記原料粉末を、平均粒子径が2μm以上10μm以下に分級して粉末とする分級工程と、
前記粉末を加熱して、前記粉末の少なくとも表層をナノ結晶化して磁性粉末とする熱処理工程と、を備えることを特徴とする磁性粉末の製造方法。
FeaCubNbcSidBe
但し、a、b、c、d、およびeは原子百分率を示し、71.0at%≦a≦76.0at%、0.5at%≦b≦1.5at%、2.0at%≦c≦4.0at%、11.0at%≦d≦16.0at%、8.0at%≦e≦13.0at%を満たす。 - 前記分級工程では風力分級を用いる、請求項4に記載の磁性粉末の製造方法。
- 前記熱処理工程では、前記軟磁性材料の相転移温度以上の加熱温度で前記粉末を加熱する、請求項4または請求項5に記載の磁性粉末の製造方法。
- 前記加熱温度が550℃以上600℃以下である、請求項6に記載の磁性粉末の製造方法。
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