JP2023093520A - フェライト焼結体およびコイル部品 - Google Patents
フェライト焼結体およびコイル部品 Download PDFInfo
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- JP2023093520A JP2023093520A JP2023060649A JP2023060649A JP2023093520A JP 2023093520 A JP2023093520 A JP 2023093520A JP 2023060649 A JP2023060649 A JP 2023060649A JP 2023060649 A JP2023060649 A JP 2023060649A JP 2023093520 A JP2023093520 A JP 2023093520A
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- 229910000859 α-Fe Inorganic materials 0.000 title claims abstract description 55
- 239000011148 porous material Substances 0.000 claims abstract description 35
- 238000005204 segregation Methods 0.000 claims abstract description 22
- 229910052802 copper Inorganic materials 0.000 claims abstract description 15
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 13
- 229910052742 iron Inorganic materials 0.000 claims abstract description 12
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 12
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 12
- GEYXPJBPASPPLI-UHFFFAOYSA-N manganese(III) oxide Inorganic materials O=[Mn]O[Mn]=O GEYXPJBPASPPLI-UHFFFAOYSA-N 0.000 claims abstract description 10
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims abstract description 8
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims abstract description 6
- 229910052698 phosphorus Inorganic materials 0.000 claims description 9
- 229910052804 chromium Inorganic materials 0.000 claims description 8
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 7
- 229910052717 sulfur Inorganic materials 0.000 claims description 7
- XLOMVQKBTHCTTD-UHFFFAOYSA-N zinc oxide Inorganic materials [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 abstract description 38
- QPLDLSVMHZLSFG-UHFFFAOYSA-N CuO Inorganic materials [Cu]=O QPLDLSVMHZLSFG-UHFFFAOYSA-N 0.000 abstract description 24
- 230000035699 permeability Effects 0.000 abstract description 16
- GNRSAWUEBMWBQH-UHFFFAOYSA-N nickel(II) oxide Inorganic materials [Ni]=O GNRSAWUEBMWBQH-UHFFFAOYSA-N 0.000 abstract description 5
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 abstract 1
- 229910052593 corundum Inorganic materials 0.000 abstract 1
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 21
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- 239000000843 powder Substances 0.000 description 19
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- 235000013339 cereals Nutrition 0.000 description 13
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 11
- 238000004458 analytical method Methods 0.000 description 8
- 239000011572 manganese Substances 0.000 description 8
- 239000011701 zinc Substances 0.000 description 8
- 238000000034 method Methods 0.000 description 7
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- 239000000696 magnetic material Substances 0.000 description 6
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- 239000000203 mixture Substances 0.000 description 5
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 4
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- 229910052782 aluminium Inorganic materials 0.000 description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 4
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- 239000002994 raw material Substances 0.000 description 4
- 238000001878 scanning electron micrograph Methods 0.000 description 4
- 229910052726 zirconium Inorganic materials 0.000 description 4
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- 229910000431 copper oxide Inorganic materials 0.000 description 2
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- 229940105990 diglycerin Drugs 0.000 description 2
- GPLRAVKSCUXZTP-UHFFFAOYSA-N diglycerol Chemical compound OCC(O)COCC(O)CO GPLRAVKSCUXZTP-UHFFFAOYSA-N 0.000 description 2
- 230000000977 initiatory effect Effects 0.000 description 2
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- 239000002245 particle Substances 0.000 description 2
- XNGIFLGASWRNHJ-UHFFFAOYSA-N phthalic acid Chemical compound OC(=O)C1=CC=CC=C1C(O)=O XNGIFLGASWRNHJ-UHFFFAOYSA-N 0.000 description 2
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- 238000004876 x-ray fluorescence Methods 0.000 description 2
- LSNNMFCWUKXFEE-UHFFFAOYSA-M Bisulfite Chemical compound OS([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-M 0.000 description 1
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- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
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Abstract
Description
しかしながら、本発明は、以下の構成に限定されるものではなく、本発明の要旨を変更しない範囲において適宜変更して適用することができる。なお、以下において記載する本発明の個々の望ましい構成を2つ以上組み合わせたものもまた本発明である。
本発明のフェライト焼結体は、Fe、Mn、Zn、CuおよびNiを含有する。
Fe2O3+Mn2O3:48.47mol%以上、49.93mol%以下、
Mn2O3:0.07mol%以上、0.37mol%以下、
ZnO:28.95mol%以上、33.50mol%以下、
CuO:2.98mol%以上、6.05mol%以下、である。
ZrをZrO2に換算して102ppm以上、4010ppm以下、
AlをAl2O3に換算して10ppm以上、220ppm以下、含有する。
(1)焼成後に表1に示す割合となるように各成分の原料を秤量し、それらをすべてボールミルを用いて水中で湿式混合し、水を飛ばした後、仮焼して仮焼粉を得た。本実施例では、空気中、800℃、2時間の仮焼を実施した。
焼成後に得られたトロイダル形状の焼結体に対して、Cu線を用いて20Tの巻き線を施した。インピーダンスアナライザー(型式4294A、KEYSIGHT TECHNOLOGIES製)を用いて、25℃、100kHzの比透磁率μ、および、100kHzの比透磁率の温度特性を測定する。また、JIS C 2560-2に従い、キュリー点を算出した。
焼成後に得られた板状の焼結体に対して、JIS R 1601:2008に従い、3点曲げ強度を測定した。
各試料に対して、焼結体の中心近傍断面を研磨し、研磨断面の任意の2箇所でXRF分析により測定を行い、その平均値からFe、Mn、Zn、CuおよびNiの含有量を求めた。Zr、Al、PおよびCrの含有量は、焼結体のICP分析により測定した。Sの含有量は、JIS G 1215-4:2010に準じた燃焼-赤外線吸収法を用いた焼結体の分析により測定した。各成分の含有量を表1に示す。S以外の含有量については、酸化物に換算した値を表1に示している。
各試料に対して、焼結体の中心近傍断面を研磨し、SEMを用いて倍率3000倍で撮影した画像を二値化処理して解析し、ポアと認識した部分の面積割合を求めた。これを任意の5視野を撮影し、平均値からポア率を算出した。各試料のポア率を表1に示す。
ポア率を求めるときと同じ研磨面について、SEM/WDX分析により、20μm×20μmの視野を加速電圧20kVで各元素の分布を確認し、10atom%以上Cuが存在している部分の面積割合を求めた。これを任意の5視野を撮影し、平均値からCu偏析率を算出した。各試料のCu偏析率を表1に示す。
各試料に対して、焼結体の中心近傍断面を研磨し、SEMを用いて倍率1000倍で撮影した画像を取得し、100×100μmのエリアを画像処理により、各ポアの円相当径の分布を測定した。これを任意の5視野を測定することにより、円相当径で5μm以上のポアの有無を判別するとともに、円相当径で2μm以下のポアが全ポア中に占める個数割合を算出した。結果を表1に示す。
各試料について、以下の方法により異常粒成長の抑制を判別した。焼結体の外観を5視野確認し、最も大きいグレインの直径が30μm以上90μm以下の場合は○(良)、30μm未満の場合は◎(優)とした。結果を表1に示す。
本発明のコイル部品は、本発明のフェライト焼結体を磁性体コアとして備える。本発明のコイル部品においては、磁性体コアに巻線が巻回される。
図5に示すコイル部品1は、ドラム型の磁性体コア12と、巻線20および21と、外部電極22、23、24および25と、を備える。磁性体コア12は、本発明のフェライト焼結体から構成される。
12 磁性体コア
14 巻芯部
16、18 鍔部
20、21 巻線
22、23、24、25 外部電極
Claims (5)
- Fe、Mn、Zn、CuおよびNiを含有するフェライト焼結体であって、
Fe、Mn、Zn、CuおよびNiをそれぞれFe2O3、Mn2O3、ZnO、CuOおよびNiOに換算し、
Fe2O3、Mn2O3、ZnO、CuOおよびNiOの合計含有量を100mol%としたときの含有量が、
Fe2O3+Mn2O3:48.47mol%以上、49.93mol%以下、
Mn2O3:0.07mol%以上、0.37mol%以下、
ZnO:28.95mol%以上、33.50mol%以下、
CuO:2.98mol%以上、6.05mol%以下、であり、
さらに、Fe2O3、Mn2O3、ZnO、CuOおよびNiOの合計含有量100重量部に対して、
ZrをZrO2に換算して102ppm以上、4010ppm以下、
AlをAl2O3に換算して10ppm以上、220ppm以下、含有し、
前記フェライト焼結体の断面においては、ポアの面積率が2.0%以下であり、かつ、Cuを含む偏析の面積率が2.0%以下である、フェライト焼結体。 - さらに、P、CrおよびSを含有する、請求項1に記載のフェライト焼結体。
- さらに、Fe2O3、Mn2O3、ZnO、CuOおよびNiOの合計含有量100重量部に対して、
PをP2O5に換算して5ppm以上、50ppm以下、
CrをCr2O3に換算して10ppm以上、305ppm以下、
Sを5ppm以上、108ppm以下、含有し、
前記フェライト焼結体の断面において、ポアの面積率が1.0%以下である、請求項1に記載のフェライト焼結体。 - 前記フェライト焼結体の断面においては、円相当径で5μm以上のポアがなく、かつ、円相当径で2μm以下のポアが全ポア中に占める個数割合が90%以上である、請求項3に記載のフェライト焼結体。
- 請求項1~4のいずれか1項に記載のフェライト焼結体を磁性体コアとして備える、コイル部品。
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