JP3532390B2 - Laminated core - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated magnetic core provided with a Fe-based soft magnetic metallic glass alloy used for transformers, choke coils, magnetic sensors and the like.

[0002]

2. Description of the Related Art Conventionally, 50% Ni--Fe permalloy magnetic core, 80% Ni--Fe permalloy magnetic core, and silicon steel have been used as magnetic core materials for transformers, choke coils, magnetic sensors and the like. However, magnetic cores made of these magnetic materials have a large core loss, especially in the high frequency band,
In the frequency band of several tens of kHz or more, there is a problem that the temperature rise of the magnetic core is severe and it is difficult to use.

Therefore, recently, a thin ribbon of a Co-based amorphous alloy having a small core loss and a high squareness ratio in a high frequency band, or a thin ribbon of an Fe-based amorphous alloy having a high saturation magnetic flux density and a maximum magnetic permeability is wound in a toroidal shape. A magnetic core main body or a laminated magnetic core including a magnetic core main body formed by stacking punched pieces in a predetermined shape is used for a transformer, a choke coil, a magnetic sensor, or the like.

[0004]

By the way, for example, when the above-mentioned thin strips having a thickness of 20 μm are wound or laminated, the unevenness of the surface of the thin strips causes a gap of 3 μm between the adjacent strips.
A gap of about m is generated. The volume occupied by the ribbon with respect to the volume of the magnetic core body is called the space factor, and the space factor at this time is calculated to be 20 (μm) / (20 + 3 (μm)) × 100 = 87%, which is the gap occupied by the magnetic core body. However, there is a problem that the magnetic core cannot be downsized because of its large volume.

The present invention has been made to solve the above problems, and an object of the present invention is to provide a laminated magnetic core which has a small core loss and can be miniaturized.

[0006]

In order to achieve the above object, the present invention has the following constitutions. In the laminated magnetic core of the present invention, the temperature interval ΔT _{x of the} supercooled liquid represented by the formula ΔT _x = T _x −T _g (where T _x is the crystallization start temperature and T _g is the glass transition temperature). It is characterized by comprising a magnetic core main body formed by winding a ribbon of a Fe-based soft magnetic metallic glass alloy having the following composition, which has a specific resistance of 35 K or higher and a specific resistance of 1.5 μΩm or higher , and which has a toroidal shape. Al: 1 atomic% to 10 atomic% Ga: 0.5 atomic% to 4 atomic% P: 0 atomic% to 15 atomic% C: 2 atomic% to 7 atomic% B: 2 atomic% to 10 atomic% Si: 1 Atomic% to 15 atomic% Fe: balance The laminated magnetic core of the present invention has the above-described F content.
It is characterized by comprising a magnetic core body formed by laminating thin strips of an e-based soft magnetic metallic glass alloy.

[0007]

Further , in the present invention, the composition of the Fe-based soft magnetic metallic glass alloy may contain Ge in an atomic percentage of 0 to 4%, and more preferably 0.5 to 4%.

In the present invention, the composition of the Fe-based soft magnetic metallic glass alloy contains Nb, Mo, Hf, Ta, W, in atomic%.
At least one kind of Cr may be contained in an amount of 7% or less. Further, in the present invention, the composition of the Fe-based soft magnetic metallic glass alloy may contain at least one of Ni of 10% or less and Co of 30% or less in atomic%.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. The laminated magnetic core according to the present invention is realized, for example, in an annular shape. Such an annular laminated magnetic core is manufactured by manufacturing a Fe-based soft magnetic metallic glass alloy ribbon described later by a liquid quenching method, and then winding the Fe-based soft magnetic metallic glass alloy ribbon into a toroidal shape to form a magnetic core body. A ring is formed by pressing or punching a Fe-based soft magnetic metallic glass alloy ribbon to obtain a ring, and a required number of the rings are laminated to form a magnetic core main body, and the magnetic core main body is coated with, for example, an epoxy resin. Alternatively, the laminated magnetic core is obtained by encapsulating in a resin case for insulation protection.

In order to realize an EI core type laminated magnetic core, an Fe-based soft magnetic metallic glass alloy ribbon is punched into an E type or an I type by press punching to obtain an E type thin piece and an I type thin piece.
After forming a plurality of mold thin pieces, E type thin pieces or I type thin pieces are laminated to form an E type core and an I type core, and these are joined to form a magnetic core body. An EI core type laminated magnetic core can be obtained by covering the required portion of the magnetic core body with an epoxy resin, for example, or encapsulating the magnetic core body in a resin case for insulation protection.

FIG. 1 shows an example of a ring-shaped laminated magnetic core. This laminated magnetic core 1 is made of a resin-made hollow circular magnetic core main body housing case 2 and has an Fe-based soft magnetic metallic glass to be described later. A magnetic core body 4 formed by winding a thin ribbon 3 made of an alloy in a toroidal shape is housed. Magnetic core body storage case 2
Is preferably formed using a resin such as a polyacetal resin or a polyethylene terephthalate resin. In addition, at two places on the bottom surface 2a of the magnetic core main body storage case 2,
An adhesive member 5 is applied to stably fix the magnetic core body 4 and the magnetic core body storage case 2. The number of positions where the adhesive member is applied is preferably in the range of 2 to 4 places.
As the adhesive member 5, epoxy resin, silicone rubber or the like is used.

FIG. 2 shows another example of a ring-shaped laminated magnetic core. This laminated magnetic core 11 has an Fe-based soft magnetic material, which will be described later, inside a resin-made hollow circular magnetic core main body lower case 12. A magnetic core main body 13 formed by stacking rings obtained by punching a thin ribbon 3 made of a metallic glass alloy is housed, and a magnetic core main body upper lid 1
4 is fitted into the lower case 12 of the magnetic core body. The magnetic core main body lower case 12 and the magnetic core main body upper cover 14 are preferably formed of a resin such as polyacetal resin or polyethylene terephthalate resin.

Conventionally, as an Fe-based alloy, Fe-P-
C-based, Fe-P-B-based, and Fe-Ni-Si-based compositions are known to cause glass transition.
The temperature width ΔTx of the supercooled liquid region of each of these alloys is extremely small and cannot be practically formed as a metallic glass alloy. On the other hand, the Fe-based soft magnetic metallic glass alloy according to the present invention contains Fe as a main component, and ΔTx =
The temperature width ΔTx of the supercooled liquid region represented by the formula of Tx−Tg (where Tx represents the crystallization start temperature and Tg represents the glass transition temperature) is 20 K or more, and 40 to 60 K depending on the composition.
Since the above remarkable temperature intervals are exhibited, it is possible to perform molding by slow cooling, and it is possible to prepare a relatively thick ribbon-shaped or linear molded body.

To increase the space factor, the laminated magnetic cores 1, 11
It suffices to increase the thickness of the amorphous alloy ribbon used for. Since the conventional amorphous alloy has an extremely small temperature range ΔTx in the supercooled liquid region as described above, it has a soft magnetic property when a thin ribbon is produced by rapidly cooling the molten alloy having a predetermined composition by the liquid quenching method. In order not to reduce the thickness, the thickness of the ribbon needs to be 50 μm or less, and there is a limit to the improvement of the space factor. With the Fe-based soft magnetic metallic glass alloy according to the present invention, it is possible to obtain a ribbon having a plate thickness of about 100 to 200 μm, and a magnetic core body 4 obtained by winding or laminating such a ribbon, 13 has a higher space factor,
Parts can be downsized. Also, since the specific resistance is high,
When a thin strip having the same plate thickness is used, it is possible to reduce the core loss as compared with the conventional amorphous alloy.

In order to obtain an Fe-based soft magnetic metallic glass alloy having a ΔTx of 20 K or more, this Fe-based soft magnetic metallic glass alloy contains a metal element other than Fe and a metalloid element. Among these, the metal other than Fe is composed of at least one of 3B group and 4B group of the periodic table, and specifically, Al, Ga, In, Tl, S.
At least one or more of n and Pb is preferable, and Al, Ga, In or Sn is more preferable. The metalloid element is preferably at least one of P, C, B, Ge and Si. In particular, it is preferable to contain at least one or more of P, C, and B. Further, by adding Si, the temperature interval ΔTx of the supercooled liquid can be improved, and the critical plate thickness that forms an amorphous single-phase structure can be increased. If the Si content is too large, the supercooled liquid region ΔTx disappears, so 15 atomic% or less is preferable.
Further, this Fe-based soft magnetic metallic glass alloy is made of Nb, Mo,
You may contain at least 1 sort (s) or more of Hf, Ta, W, Zr, and Cr. Further, it may contain at least one of Ni and Co.

More specifically, in the present invention, the composition is atomic%, Al: 1-10, Ga: 0.5-.
4, P: 0-15, C: 2-7, B: 2-10, Fe:
A Fe-based soft magnetic metallic glass alloy, which is the balance and may contain inevitable impurities, is obtained. Further, in the present invention,
The composition is atomic%, Al: 1-10, Ga: 0.5-
4, P: 0-15, C: 2-7, B: 2-10, Si:
0 to 15, Fe: The balance, and an Fe-based soft magnetic metallic glass alloy in which unavoidable impurities may be contained is obtained.
In order to obtain a larger supercooled liquid region ΔTx, in the above composition, P and C in atomic%, P: 6 to 15,
When C: 5 to 7, a supercooled liquid region ΔTx of 35K or more can be obtained more preferably. Further, in the above composition, Ge is further contained in an amount of 0 to 4 atomic%, preferably 0.5.
It may be contained in the range of up to 4 atom%. Further, in the above composition, Nb, Mo, Hf, Ta, W, Z
7 at% or more of at least one of r and Cr may be contained, and 0 to 10 at% Ni and 0 to 30 at% are further included.
At least one kind of Co may be contained.

The thin strip 3 of the Fe-based soft magnetic metallic glass alloy according to the present invention is formed by melting the mother alloy and then casting, or by a single-roll or twin-roll quenching method, and further by a submerged spinning method or a solution. It is manufactured by the extraction method. According to these manufacturing methods, compared with the conventionally known Fe-based or Co-based amorphous alloys, the thickness of the Fe-based soft magnetic metallic glass alloy having a thickness and shape that are at least twice as large in the quenching method and at least 10 times as large as the casting method. Band 3 can be obtained. The Fe-based soft magnetic metallic glass alloy having the above composition obtained by these methods has soft magnetism at room temperature. This soft magnetic property is further improved by applying a heat treatment in the range of 300 ° C to 500 ° C. Therefore, it is useful for application to magnetic cores. In addition, regarding the manufacturing method, a suitable cooling rate is determined depending on the composition of the alloy, the means for manufacturing, the size and shape of the product, etc., but normally a range of about 1 to 10 ⁴ K / s is a standard. Can be And, in fact, the glass phase (glas
sy phase), Fe ₃ B, Fe ₂ B, Fe as a crystal phase
It can be decided by confirming whether or not a phase such as ₃ P precipitates.

The laminated magnetic cores 1 and 11 of the present invention have ΔT _x = T _x
The temperature interval Δ of the supercooled liquid represented by the formula −T _g (where T _x is the crystallization start temperature and T _g is the glass transition temperature).
F having T _x of 20 K or more, more preferably 35 K or more
Since the ribbon 3 of the e-based soft magnetic metallic glass alloy is provided with the magnetic core body 4 formed by winding in a toroidal shape or the laminated magnetic core body 13, the laminated magnetic core 1 is formed from a thin ribbon having a large plate thickness, 11 can be produced, and the space factor of the laminated magnetic cores 1 and 11 can be increased, so that the size can be reduced. Further, since it has a higher specific resistance than the conventional amorphous alloy, the core loss in the high frequency band is also small. Furthermore, not only the liquid quenching method,
Since the Fe-based soft magnetic metallic glass alloy described above can be obtained also by the casting method, the manufacturing cost of the laminated magnetic cores 1 and 11 can be reduced.

The Fe-based soft magnetic metallic glass alloy of the present invention contains a metal element other than Fe and a metalloid element, and in particular, by containing Si, the temperature interval ΔT of the supercooled liquid is increased. _{Since x} can be increased, the laminated magnetic cores 1 and 11 can be formed from thin ribbons, the space factor of the laminated magnetic cores 1 and 11 can be improved, and the core loss can be reduced.

Further, the laminated magnetic cores 1 and 11 of the present invention each have an atomic% composition of Al: 1 to 10 and Ga: 0.5 to.
4, P: 0-15, C: 2-7, B: 2-10, Fe:
The balance or Al: 1-10, Ga: 0.5-4,
P: 0 to 15, C: 2 to 7, B: 2 to 10, Si: 0
15, Fe: The balance, which has high magnetic permeability, low coercive force, high saturation magnetic flux density, and magnetic core bodies 4 and 13 made of an Fe-based soft magnetic metallic glass alloy excellent in soft magnetic characteristics, Core loss can be reduced.

[0022]

Example ( Reference Example 1 ) Fe, Al and Ga, and Fe-C alloy, Fe-P alloy and B were weighed in predetermined amounts, and these raw materials were placed in a high pressure induction heating apparatus under a reduced pressure Ar atmosphere. It melted and the mother alloy was produced. This master alloy is put in a crucible and melted, and the melt is blown out from a nozzle of the crucible into a rotating roll to rapidly cool the melt, by a single roll method under reduced pressure Ar atmosphere, Fe ₇₃ Al ₅ Ga ₂ P ₁₁ C ₅ B A quenched ribbon of composition ₄ was obtained. At this time, the nozzle diameter of the crucible,
A ribbon sample having a thickness of 35 to 229 μm was obtained by appropriately adjusting the distance (gap) between the nozzle tip and the roll surface, the rotation number of the roll, the injection pressure, and the atmospheric pressure.

For the above ribbon sample, 300 to 450
The magnetic properties were measured when heat-treated in the temperature range of ° C.
As the heat treatment conditions, an infrared image furnace was used, and the temperature rising / falling rate was 180 ° C./min in vacuum and the holding temperature was 10 min. FIG. 3 shows the heat treatment temperature dependence of the magnetic properties of each of the ribbon samples. Further, FIG. 4 shows only the data obtained by extracting the necessary number from the data shown in FIG. From these figures, the saturation magnetization (σ _s ) of the thin strip sample in the range of 35 to 180 μm showed almost constant value up to 400 ° C., which was the same as that of the sample without heat treatment. , Showed a tendency to deteriorate. On the other hand, the ribbon sample having a plate thickness of 229 μm showed a peak at 400 ° C. and then tended to deteriorate. It is considered that this is because crystals of Fe ₃ B or the like grew at 400 ° C. or higher. With respect to the coercive force (H _c ) of the ribbon sample without heat treatment, it shows a substantially constant value up to a ribbon sample having a plate thickness of 125 μm which is an amorphous single phase,
There was a tendency for the plate thickness to increase beyond that. In addition, the heat treatment tends to lower the temperature to 400 ° C.
Next, regarding the magnetic permeability μ ′ (1 kHz), the ribbon sample without heat treatment showed a substantially constant value up to 135 μm, which is an amorphous single phase, and showed a tendency to decrease at a plate thickness higher than that. Although the effect of the heat treatment was improved up to 400 ° C, there was a tendency that the heat treatment was significantly deteriorated in the heat treatment at 450 ° C. Further, the effect becomes smaller as the plate thickness increases.

The change in soft magnetic properties due to these heat treatments is considered to be due to the relaxation of the internal stress existing in the ribbon sample without heat treatment. The optimum heat treatment temperature T _a is 35 in this test.
It can be said that it is around 0 ° C. Note that heat treatment at a Curie temperature T _c or lower may cause deterioration of soft magnetic characteristics due to magnetic domain sticking, so the heat treatment temperature is at least 300 ° C.
It seems necessary. Further, since the heat treatment at 450 ° C. tends to deteriorate as compared with the value of the ribbon sample without heat treatment, it is close to the crystallization temperature (about 500 ° C.) of this system, and the formation of crystal nuclei starts (structural short range order). It is thought that the deterioration is caused by the pinning of the domain wall due to the initiation of chemical precipitation) or crystal precipitation. Therefore, the temperature for heat treatment is 30
It was found that the range of 0 to 500 ° C., in other words, the range of 300 ° C. to the crystallization start temperature is preferable, and the range of 300 to 450 ° C. is more preferable.

Further, the saturation magnetization of the ribbon sample of Reference Example 1 (σ
_s ), coercive force (H _c ), magnetic permeability (μ ′), temperature interval (ΔTx) of supercooled liquid, and microstructure are summarized in Table 1. The structure shows the result of structural analysis by XRD (X-ray diffraction method), and amo has an amorphous single phase and amo + cry has an amorphous phase + crystalline phase. About ΔTx, except for the 229 μm thick sample, it is almost constant (ΔTx = 4
7 ° C.).

[0026]

[Table 1]

FIG. 5 shows a comparative sample having a composition of Fe ₇₈ Si ₉ B ₁₃ and a sample without heat treatment and a sample at 12 ° C. at 370 ° C.
Saturation magnetization (σ _s ), coercive force (H _c ), and magnetic permeability (μ) of the sample that was heat-treated for 0 minutes, the ribbon sample of Reference Example 1 and the sample that was not heat-treated and that was heat-treated at 350 ° C. for 10 minutes, respectively. The results of measuring the thickness dependence of each of () are shown. In any of the samples, when the plate thickness was in the range of 30 to 200 μm, the magnetic properties were less deteriorated and excellent properties were obtained.

FIG. 6 shows a comparative sample having a composition of Fe ₇₈ Si ₉ B ₁₃ which was heat-treated at 370 ° C. for 120 minutes,
Regarding a sample having a composition of Fe ₇₃ Al ₅ Ga ₂ P ₁₁ C ₅ B ₄ 3
The bending test is performed on each of the samples heat-treated at 50 ° C. for 10 minutes, and the maximum strain is measured. In the bending test, two rods and a ribbon sample were used, and a ribbon arranged in parallel with the rod was sandwiched between the tip parts of the two rods, and the two rods were gradually brought close to each other to make a ribbon. When the ribbon is bent and cut in this way, the width between the end faces of the rod is L, and the thickness of the ribbon is t, where t / The value of (Lt) is defined as the maximum strain (λf). From the results shown in FIG.
The comparative sample having the composition of Fe ₇₈ Si ₉ B ₁₃ is vulnerable to bending sharply as the plate thickness increases (in other words, becomes brittle), but the sample of the composition system according to the present invention does not bend even if the plate thickness increases. It has the property of being hard to weaken (in other words, hard to be brittle). It was also clarified that when the plate thickness is 60 μm or more, the sample having the composition of the present invention is more resistant to bending than the comparative sample. Therefore, when the alloy ribbon of the composition according to the present invention is wound in a toroidal shape to form a laminated magnetic core, the radius of curvature can be reduced,
The shape of the laminated magnetic core can be made small.

FIG. 7 shows the results of measuring the plate thickness dependence of the specific resistance of a comparative sample having a composition of Fe ₇₈ Si ₉ B ₁₃ and a sample having a composition of Fe ₇₃ Al ₅ Ga ₂ P ₁₁ C ₅ B _4. Indicates.
In the sample of the composition system of the present invention, the specific resistance is higher than that of the sample of the comparative example.
The value was 5 μΩcm or more. Therefore, it was revealed that the sample of the composition system of the present invention has a small eddy current loss at high frequencies and can provide a laminated magnetic core with a small high frequency loss.

Reference Example 2 Next, Fe _{70 + X} Al ₅ Ga ₂ (P ₅₅ C
In _{25 B 20) 23-X} having the composition, by changing the Fe concentration was prepared ribbon sample were each examined the structure and characteristics of each ribbon samples. For the preparation of ribbon samples, refer to the above
The same procedure as in Example 1 was carried out, and the plate thickness of the sample was 30 μm.

FIG. 8 shows the magnetism of each ribbon sample (without heat treatment).
The results of measuring the characteristics are shown. Also in this figure
Is a conventional Fe-Si-B based amorpha as a comparative sample.
Material (plate thickness 25 μm, 370 ° C. for 120 minutes in vacuum)
(After heat treatment), saturation magnetization (σ _s) And coercive force (H_c) And magnetic permeability
The values of the rate μ'are shown by broken lines. Clear from this figure
Saturation magnetization (σ_s), Increase in Fe concentration
It can be seen that it will improve with. And amorphous
In the Fe concentration range having a single-phase structure, the Fe concentration is
At 75 atomic%, a Fe-Si-B system comparative sample (σ
_s= 183 emu / g)_s= 150 emu
A value of / g was obtained. Also the coercive force H_cFor
Fe concentration with morphus single-phase structure = up to 75 atomic%
Sample shows almost constant value, and Fe concentration higher than that shows almost constant value.
It has increased significantly. Permeability (μ '(1kHz))
As for the Fe content, it tends to decrease as the Fe concentration increases.
However, when the Fe concentration is in the range of 70 to 76 atomic%,
Excellent soft magnetic characteristics with a magnetic susceptibility of 5000 or more were obtained. this
The results show that the Fe-based soft magnetic metallic glass alloy of the present invention
The saturation magnetization (σ_s)
Can be improved, Fe₇₅Al_FiveGa₂P_{9 .9}C_4.5B
_3.6In the following composition, the conventional Fe-Si-B system
Σ that is almost the same as that of fass material_sFe-based soft magnetic metal with
Glass alloy can be obtained by single roll liquid quenching method
I understood.

Example 1 Next, an example will be given of an Fe-based soft magnetic metallic glass alloy obtained by adding Si to the composition of Reference Example 1 above, and the effect thereof will be clarified. Atomic composition ratio is Fe ₇₂ Al ₅ Ga ₂ P
_{A 10} C ₆ B ₄ Si ingot was prepared, which was placed in a crucible to be melted, and the molten metal was blown out from a nozzle of the crucible onto a rotating roll to rapidly cool the ingot.
A quenched ribbon was obtained under a reduced pressure Ar atmosphere. The manufacturing conditions
Nozzle diameter 0.4-0.5 mm, distance between nozzle tip and roll surface (gap) 0.3 mm, roll rotation speed 20
0 ~ 2500r.pm, injection pressure 0.35 ~ 0.40kgf /
cm ² , atmosphere pressure-10 cmHg, roll surface condition # 100
When it was manufactured by setting it to 0, a ribbon having a thickness of 20 to 250 μm was obtained.

With respect to each of the ribbon samples having a thickness of 20 to 250 μm obtained above, the magnetic characteristics were measured without heat treatment and with heat treatment. FIG. 9 shows the plate thickness dependence of the magnetic properties of each ribbon sample. The heat treatment condition is that the infrared image furnace is used and the Si of Reference Example 1 is used in vacuum.
The conditions were the optimum conditions for the sample without addition of 180 ° C./minute of temperature rising / falling temperature, 350 ° C. holding temperature, and 30 minutes holding time. As is clear from this figure, the saturation magnetization (σ _s ) shows a value of about 145 emu / g which is almost constant regardless of the plate thickness without heat treatment. The saturation magnetization (σ _s ) after heat treatment is not much different from that without heat treatment up to a plate thickness of 160 μm that maintains an amorphous single phase structure, but it deteriorates compared with that without heat treatment at a plate thickness above that. Showed a trend. It is considered that this is because the crystals of Fe ₃ B, Fe ₃ C, etc. grew by the heat treatment.

The coercive force (H _c ) of the sample without heat treatment tended to increase as the plate thickness increased. Further, the coercive force (H _c ) of the sample after the heat treatment is lower than that of the sample without the heat treatment, and the coercive force (H _c ) is less than 0.
The value was 625 to 0.125 Oe. The holding force by the heat treatment in this manner (H _c) is lowered, the reference example
Like in No. 1 , it is considered that the internal stress existing in the sample without heat treatment was relaxed by the heat treatment.

Next, the magnetic permeability (μ '(1 kHz)) of the sample without heat treatment tended to decrease as the plate thickness increased. Further, the magnetic permeability (μ ′) was improved by the heat treatment, and a value almost equal to that of the Fe-based soft magnetic metallic glass alloy of the composition containing no Si in Reference Example 1 was obtained. Similar to Reference Example 1 , the effect of heat treatment tended to decrease as the plate thickness increased in this example.

Samples of various plate thicknesses obtained in this example
Saturation magnetization (without heat treatment) (σ _s) And coercive force
(H_c) And supercooled liquid temperature interval (△ Tx) and permeability
(Μ ′) and the tissue structure are summarized in Table 2.

[0037]

[Table 2]

FIG. 10 shows a comparative sample having a composition of Fe ₇₈ Si ₉ B ₁₃ which was heat-treated at 370 ° C. for 120 minutes and a sample having a composition of Fe ₇₂ Al ₅ Ga ₂ P ₁₀ C ₆ B ₄ Si _{1 at} 350 ° C. The results of measuring the plate thickness dependences of the saturation magnetization (σ _s ), the coercive force (H _c ), and the magnetic permeability (μ ′) are shown for each of the samples that have been heat-treated for 30 minutes. From this result, Fe ₇₂ Al ₅ Ga ₂ P ₁₀ C ₆ B ₄ Si ₁
The Fe-based metallic glass alloy sample of the present invention having the composition
Compared with a conventional comparative sample having a composition of Fe ₇₈ Si ₉ B ₁₃ ,
It was confirmed that when the plate thickness is in the range of 20 to 250 μm, the magnetic properties are less deteriorated and excellent properties are obtained. Particularly regarding soft magnetic properties, in the sample according to the present invention,
It has been found that the value of the magnetic permeability is superior to that of the conventional material, and that it is possible to obtain the excellent soft magnetic property of the magnetic permeability of 5000 or more in the plate thickness range of 20 to 250 μm.

( Example 2 ) Fe, Al and Ga, and Fe-C alloy, Fe-P alloy and B, and optionally Si as raw materials were weighed in predetermined amounts, and these raw materials were placed under a reduced pressure Ar atmosphere. Was melted with a high frequency induction heating device to prepare a mother alloy. This mother alloy is put into a crucible and melted, and the melt is blown from a nozzle of the crucible to a rotating roll to rapidly cool the melt, by a single roll method under reduced pressure Ar atmosphere, Fe ₇₃ Al ₅ Ga.
₂ P ₁₁ C ₅ B ₄ , Fe ₇₃ Al ₅ Ga ₂ P ₁₀ C ₅ B
₄ Si ₁ , Fe ₇₂ Al ₅ Ga ₂ P ₁₀ C6B ₄ S
i ₁ , Fe ₇₀ Al _3.57 Ga _1.43 P _13.8 C
_6.25 B ₅ , Fe ₇₇ Al _2.14 Ga _0.86 P
_8.4 C ₅ B ₄ Si _2.6 , Fe ₅₈ Co ₇ Ni ₇ Zr
A quenched ribbon having a composition of ₁₀ B ₁₈ , Fe ₅₆ Co ₇ Ni ₇ Zr ₁₀ B ₂₀ was obtained. At this time, the nozzle diameter of the crucible, the distance (gap) between the nozzle tip and the roll surface,
By appropriately adjusting the number of rotations of the roll, the injection pressure, and the atmospheric pressure, a ribbon having a thickness of 25 to 229 μm was obtained.

Next, each of the thin strips obtained as described above was punched in a ring shape to stack a required number of layers, and silicon rubber was impregnated between the layers for insulation and fixing of each layer, and then, as shown in FIG. 8mm outer diameter, 4mm inner diameter, 5 thickness
An annular laminated magnetic core of mm was prepared.

Fe ₇₃ Al ₅ Ga ₂ P ₁₁ C ₅ B _{4 having} a thickness of 50 μm and Fe _{72 having a} thickness of 100 μm obtained as described above.
Al ₅ Ga ₂ P ₁₀ C ₆ B ₄ Si ₁ and Fe with a thickness of 200 μm
_{70 Al 5 Ga 2 P 9.65 C} 5.75 B 4.6 Si 3 becomes occupied by these laminated cores with a laminated magnetic core prepared from the melt spun ribbons of composition
Table 3 shows the result of measuring the product ratio. In addition, Fe ₇₇ Al
Fig. 11 shows the relationship between the strip thickness and the space factor for laminated magnetic cores of the above-mentioned size and shape obtained from quenched ribbons of various thicknesses with a composition of _2.14 Ga _0.86 P _8.4 C ₅ B ₄ Si _2.6 . Shown in. The space factor was measured by observing the cross section of the laminated magnetic core with a microscope. As shown in FIG. 11, the space factor increases with an increase in the plate thickness, and when it exceeds 100 μm, the space factor becomes 97.
It is almost constant at over%. Since the laminated magnetic core made of the Fe-based metallic glass alloy according to the present invention does not deteriorate the soft magnetic characteristics as described above even when the strip thickness exceeds 100 μm, the laminated core has a small core loss. The magnetic core is obtained. On the other hand, the conventionally known amorphous alloy of Fe ₇₈ Si ₉ B ₁₃ can obtain only a plate thickness of about 20 μm,
The space factor is as low as 87%. Since the conventional amorphous alloy has a small temperature range ΔTx in the supercooled liquid region, in the case of rapidly cooling the molten alloy having a predetermined composition by the liquid quenching method to produce a ribbon, it is necessary to prevent the soft magnetic characteristics from deteriorating. It is necessary to set the thickness of the ribbon to 50 μm or less, and if the thickness exceeds this thickness, the soft magnetic characteristics deteriorate, so that it is not possible to increase the space factor and improve the soft magnetic characteristics at the same time. It was not possible to obtain a small laminated magnetic core.

[0042]

[Table 3]

[0043]

Further, Fe ₇₃ Al ₅ Ga ₂ P _{11 having} various thicknesses is used.
The core loss of the laminated magnetic core prepared from the alloy ribbon of the composition C ₅ B ₄ , Fe ₇₇ Al _2.14 Ga _0.86 P _8.4 C ₅ B ₄ Si _2.6, and the alloy of the composition Fe ₇₈ Si ₉ B ₁₃ (comparative example) The dependence of (W), magnetic permeability (μ _e (real value)), coercive force (H _c ) and saturation magnetic flux density (B _s ) on the thin strip thickness was investigated. Results are shown in FIG . Further, FIG. 13 shows the results of investigation of the thickness dependence of the core loss (W) when a laminated magnetic core made of silicon steel (Si 6.5%) ribbons is added as a comparative example. In FIG. 12 , the saturation magnetic flux density (B _s ) is Fe ₇₇
The laminated magnetic core having the composition of Al _2.14 Ga _0.86 P _8.4 C ₅ B ₄ Si _2.6 exhibits almost the same saturation magnetic flux density as the laminated magnetic core of the comparative example having the composition of Fe ₇₈ Si ₉ B ₁₃ . Fe ₇₃ Al ₅ Ga ₂
The low saturation magnetic flux density of the laminated magnetic core having the composition P ₁₁ C ₅ B ₄ is presumed to be due to the slightly low concentration of Fe. Regarding the coercive force, the laminated magnetic core of the example does not show the dependency of the plate thickness, but the laminated magnetic core of the composition of Fe ₇₈ Si ₉ B _{13 of} the comparative example shows that the coercive force increases as the plate thickness of the ribbon increases. It can be seen that the soft magnetic properties are increased and the soft magnetic properties are deteriorated. Further, regarding the magnetic permeability (real value), in the laminated magnetic core of the embodiment, the magnetic permeability (μ _e (real value)) is slightly decreased due to an increase in the plate thickness of the ribbon. On the other hand, in the laminated magnetic core having the composition of Fe ₇₈ Si ₉ B _{13 of} the comparative example, the magnetic permeability (real value) is greatly deteriorated with the increase of the strip thickness. Furthermore, regarding core loss, FIG. 12 and FIG.
3 , it can be seen that the core loss of the laminated magnetic core having the composition of Fe ₇₈ Si ₉ B ₁₃ of the comparative example sharply increases when the plate thickness of the ribbon exceeds 100 μm. The laminated magnetic core made of silicon steel, which is another comparative example, shows a substantially constant value without showing the dependence of the core loss on the thin strip thickness, but has a larger core loss than the laminated magnetic core of the example.

As described above, the Fe-based metallic glass alloy according to the present invention has a temperature interval in the supercooled region which is larger than that of the conventional amorphous alloy (Fe ₇₈ Si ₉ B ₁₃ ) and has a large plate thickness. Since it is obtained, the space factor of the laminated magnetic core can be increased, and the core loss of the laminated magnetic core can be reduced.

The present invention is not limited to the above examples, and it is needless to say that the composition, the manufacturing method, the heat treatment conditions, the shape and the like can be variously modified.

[0047]

As described above in detail, in the laminated magnetic core of the present invention, ΔT _x = T _x −T _g (where T _x is the crystallization start temperature and T _g is the glass transition temperature). A magnetic core body formed by winding a thin ribbon of a Fe-based soft magnetic metallic glass alloy having a temperature interval ΔT _x of the supercooled liquid represented by the formula of 20 K or more in a toroidal shape or a laminated magnetic core body. Since it is possible to form the laminated magnetic core from the thin ribbon having a large plate thickness and the space factor of the laminated magnetic core can be increased, the laminated magnetic core can be downsized.
Further, since the specific resistance is large, the core loss in the high frequency band can be reduced. Furthermore, since the Fe-based soft magnetic metallic glass alloy described above can be obtained by the casting method as well as the liquid quenching method, the manufacturing cost of the laminated magnetic core can be reduced.

The Fe-based soft magnetic metallic glass alloy of the present invention contains a metal element other than Fe and a metalloid element, and in particular, by containing Si, the temperature interval ΔT of the supercooled liquid is increased. _{Since x} can be increased, the laminated magnetic core can be formed from a thin ribbon having a large plate thickness, the space factor of the laminated magnetic core can be improved, and the core loss can be reduced.

The laminated magnetic core of the present invention has a composition of atomic% of Al: 1 to 10, Ga: 0.5 to 4, and P: 0.
-15, C: 2-7, B: 2-10, Fe: balance, or Al: 1-10, Ga: 0.5-4, P: 0-1
5, C: 2 to 7, B: 2 to 10, Si: 1 to 15, F
e: Remainder, high magnetic permeability, low coercive force, high saturation magnetic flux density, and a magnetic core body made of an Fe-based metallic glass alloy having excellent soft magnetic characteristics, so core loss can be reduced. .

[Brief description of drawings]

FIG. 1 is an exploded view showing a laminated magnetic core according to an embodiment of the present invention.

FIG. 2 is an exploded view showing a laminated magnetic core that is an embodiment of the present invention.

FIG. 3 is a diagram showing plate thickness dependence of saturation magnetization, coercive force, and magnetic permeability.

FIG. 4 is a diagram showing an excerpt of part of the plate thickness dependence data shown in FIG. 3.

FIG. 5 is a diagram showing plate thickness dependence of saturation magnetization, coercive force, and magnetic permeability of samples having different compositions.

FIG. 6 is a diagram showing a relationship between maximum strain and plate thickness of samples having different compositions.

FIG. 7 is a diagram showing plate thickness dependence of specific resistance of a conventional Fe-based amorphous alloy and a metallic glass alloy having a composition according to the present invention.

FIG. 8 is a diagram showing the Fe concentration dependence of saturation magnetization, coercive force, and magnetic permeability.

FIG. 9 is a diagram showing plate thickness dependence of saturation magnetization, coercive force, and magnetic permeability in a sample to which Si is added without heat treatment and after heat treatment.

FIG. 10 is a diagram showing plate thickness dependence of saturation magnetization, coercive force, and magnetic permeability of a conventional Fe-based amorphous alloy and a Si-added metallic glass alloy according to the present invention.

FIG. 11 is a diagram showing the relationship between the plate thickness and the space factor of the metallic glass alloy according to the present invention.

FIG. 12 is made from a ribbon of metallic glass alloy according to the present invention .
The saturation magnetic flux density, coercive force, permeability and
It is a figure which shows the relationship between Aros and the board thickness of a thin strip.

FIG. 13: Made from ribbon of metallic glass alloy according to the invention
The relationship between the core loss of the manufactured laminated magnetic core and the thickness of the ribbon is shown.
It is a figure.

[Explanation of symbols]

1 laminated magnetic core 2 Magnetic core storage case 3 ribbon 4 Magnetic core body 5 Adhesive members

─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Akihiro Makino 1-7 Yukiya Otsuka-cho, Ota-ku, Tokyo Alps Electric Co., Ltd. (72) Akihisa Inoue 35 Kawachi, Aoba-ku, Sendai-shi, Miyagi Kawauchi Kawauchi Housing 11-806 (56) Reference JP-A-8-333660 (JP, A) JP-A-62-76607 (JP, A) (58) Fields investigated (Int.Cl. ⁷ , DB name) H01F 1 / 12-1/38 H01F 27/24-27/26

Claims (2)

(57) [Claims] 1. The temperature interval ΔT _x of the supercooled liquid represented by the formula ΔT _x = T _x −T _g (where T _x is the crystallization start temperature and T _g is the glass transition temperature) is 20 K or more. , and the and the specific resistance of 1.5μΩm above, the following composition
Laminated magnetic core ribbons comprising Fe-based soft magnetic glassy alloy, characterized in that it comprises a magnetic core main body formed by winding in a toroidal shape. Al: 1 atomic% to 10 atomic% Ga: 0.5 atomic% to 4 atomic% P: 0 atomic% to 15 atomic% C: 2 atomic% to 7 atomic% B: 2 atomic% to 10 atomic% Si: 1 Atomic% to 15 atomic% Fe: balance 2. A laminated magnetic core comprising a magnetic core main body formed by laminating thin ribbons of the Fe-based soft magnetic metallic glass alloy according to claim 1.