JP4308864B2 - 軟磁性合金粉末、圧粉体及びインダクタンス素子 - Google Patents
軟磁性合金粉末、圧粉体及びインダクタンス素子 Download PDFInfo
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- 239000000843 powder Substances 0.000 title claims description 111
- 229910001004 magnetic alloy Inorganic materials 0.000 title claims description 84
- 239000000428 dust Substances 0.000 claims description 42
- 239000002245 particle Substances 0.000 claims description 35
- 229910001030 Iron–nickel alloy Inorganic materials 0.000 claims description 31
- 229910052742 iron Inorganic materials 0.000 claims description 31
- 229910052759 nickel Inorganic materials 0.000 claims description 31
- 239000011810 insulating material Substances 0.000 claims description 25
- 229910052710 silicon Inorganic materials 0.000 claims description 23
- 229910000531 Co alloy Inorganic materials 0.000 claims 1
- 229910000640 Fe alloy Inorganic materials 0.000 claims 1
- 229910000990 Ni alloy Inorganic materials 0.000 claims 1
- 230000005389 magnetism Effects 0.000 claims 1
- 239000011162 core material Substances 0.000 description 114
- 230000005415 magnetization Effects 0.000 description 33
- 230000000052 comparative effect Effects 0.000 description 19
- 230000035699 permeability Effects 0.000 description 18
- 238000000034 method Methods 0.000 description 13
- 239000000203 mixture Substances 0.000 description 13
- 239000000314 lubricant Substances 0.000 description 11
- 238000000465 moulding Methods 0.000 description 11
- 229910052751 metal Inorganic materials 0.000 description 9
- 239000002184 metal Substances 0.000 description 9
- 229910000889 permalloy Inorganic materials 0.000 description 9
- 239000000463 material Substances 0.000 description 8
- 229910045601 alloy Inorganic materials 0.000 description 7
- 239000000956 alloy Substances 0.000 description 7
- 239000013078 crystal Substances 0.000 description 7
- 239000003431 cross linking reagent Substances 0.000 description 6
- 230000007423 decrease Effects 0.000 description 6
- 239000000696 magnetic material Substances 0.000 description 6
- 238000005259 measurement Methods 0.000 description 6
- 230000004907 flux Effects 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- 239000004020 conductor Substances 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 4
- 239000006247 magnetic powder Substances 0.000 description 4
- 230000002265 prevention Effects 0.000 description 4
- CEGOLXSVJUTHNZ-UHFFFAOYSA-K aluminium tristearate Chemical compound [Al+3].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CEGOLXSVJUTHNZ-UHFFFAOYSA-K 0.000 description 3
- 229940063655 aluminum stearate Drugs 0.000 description 3
- 230000003247 decreasing effect Effects 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- 229920002050 silicone resin Polymers 0.000 description 3
- 229910052800 carbon group element Inorganic materials 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000000748 compression moulding Methods 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- HQKMJHAJHXVSDF-UHFFFAOYSA-L magnesium stearate Chemical compound [Mg+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O HQKMJHAJHXVSDF-UHFFFAOYSA-L 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 229910052723 transition metal Inorganic materials 0.000 description 2
- 150000003624 transition metals Chemical class 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 238000009692 water atomization Methods 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 238000002441 X-ray diffraction Methods 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- AGXUVMPSUKZYDT-UHFFFAOYSA-L barium(2+);octadecanoate Chemical compound [Ba+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O AGXUVMPSUKZYDT-UHFFFAOYSA-L 0.000 description 1
- 230000003796 beauty Effects 0.000 description 1
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 1
- 235000013539 calcium stearate Nutrition 0.000 description 1
- 239000008116 calcium stearate Substances 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 230000002542 deteriorative effect Effects 0.000 description 1
- 239000011363 dried mixture Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000010408 film Substances 0.000 description 1
- 238000009689 gas atomisation Methods 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 235000019359 magnesium stearate Nutrition 0.000 description 1
- 229920000620 organic polymer Polymers 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 239000002952 polymeric resin Substances 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
- 239000010703 silicon 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
- FRKHZXHEZFADLA-UHFFFAOYSA-L strontium;octadecanoate Chemical compound [Sr+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O FRKHZXHEZFADLA-UHFFFAOYSA-L 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- PIILXFBHQILWPS-UHFFFAOYSA-N tributyltin Chemical compound CCCC[Sn](CCCC)CCCC PIILXFBHQILWPS-UHFFFAOYSA-N 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 1
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- C22C33/00—Making ferrous alloys
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
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Description
〜55質量%、かつNiを45〜55質量%含み、Fe、Ni、Co及びSiの合計質量
に対して、Coを1〜6質量%、かつSiを1.2〜4.5質量%含んだFe−Ni系
粒子を含有する軟磁性合金粉末を提供する。
まず、Fe−Ni合金、Fe単体、Ni単体、Co単体及びSi単体のインゴット、チャンク(塊)、又はショット(粒子)を準備した。次にそれらを、表1、2に示す組成となるよう混合して、水アトマイズ装置内に配置されたルツボに収容した。次いで、不活性雰囲気中、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1500℃以上まで加熱し、ルツボ中のインゴット、チャンク又はショットを溶融、混合して融液を得た。
得られた軟磁性合金粉末に対し、絶縁材としてシリコーン樹脂(東レダウコーニングシリコーン(株)製:SR2414LV)を、その硬化触媒としてトリブチル錫を、全体量に対してそれぞれ2.4質量%、0.4質量%添加し、これらを加圧ニーダにより室温で30分間混合した。次いで、混合物を空気中において110℃で30分間乾燥した。乾燥後の磁性粉末に、潤滑剤としてステアリン酸アルミニウム(堺化学製:SA−1000)をそれらの全体量に対して0.4質量%添加し、Vミキサーにより15分間混合した。
(粒内抵抗測定)
実施例10、13、15及び16、比較例6及び7の圧粉磁芯における軟磁性合金粉末の粒内抵抗を、原子間力顕微鏡を用いてファン・デル・パウ(van der Pauw)法により測定した。結果を表3及び図2に示す。図2において横軸はSiの含有量を示す。
得られた実施例1〜3、5、6、8、10〜12、14及び17、比較例1、2、4及び5の圧粉磁芯について、25mTの印加磁界で磁芯損失(Pcv)を測定した。結果を図3に示す。図3の(a)は高周波領域(1MHz)、(b)は低周波領域(0.3MHz)での磁芯損失をそれぞれ示し、横軸はSiの含有量を示す。また、(v)、(w)、(x)、(y)、(z)は、Co含有量が順に、0、3、4、6、8質量%の場合の磁芯損失である。Siを1.2質量%以上添加することにより、圧粉磁芯の磁芯損失が低下し、特に高周波領域において、顕著に低下することが確認できた。また、Coの含有量を1質量%以上に高めることで、磁芯損失の維持又は更なる低下が認められることも明らかになった。
実施例1〜3、5、6、8、10〜12、14及び17、比較例1、2、4及び5の圧粉磁芯について、0.3MHzでの透磁率(μi/μ0)、並びに、6000A/mのバイアス磁場を印加した際の直流重畳特性(μdc)を測定した。結果を図4に示す。図4の(a)は透磁率、(b)は直流重畳特性をそれぞれ示し、横軸はSiの含有量を示す。また、(v)、(w)、(x)、(y)、(z)は、Co含有量が順に、0、3、4、6、8質量%の場合の透磁率、直流重畳特性を示す。Siを1.2質量%以上添加することにより、透磁率を45まで高めることが確認された。また、Coを1質量%以上含有することにより、直流重畳特性を向上できることも確認された。
実施例1〜3、5、10、12及び14、比較例1、2、4及び5の圧粉磁芯について、公知のマイクロビッカース硬度計を用いてビッカース硬度(Hv)を測定した。結果を図5に示す。図5中、(v)、(w)、(y)は、Co含有量が順に、0、3、6質量%の場合のビッカース硬度を示し、横軸はSiの含有量を示す。軟磁性合金粉末以外の材料はどの圧粉磁芯についても同様の組成であることから、このビッカース硬度の数値は軟磁性合金粉末の硬度に依存しているものと推測される。したがって、図5に示す結果から、Siを添加しているにも関わらず、圧粉磁芯及び軟磁性合金粉末の硬度が低く抑えられていることが確認できた。
実施例1〜4、6、9〜12、14、参考例17、並びに比較例1〜3、5、9、22及び23、の軟磁性合金粉末について、公知の振動試料型磁力計(VSM)を用いて、室温における飽和磁化(Is)を測定した。結果を表3、4及び図7に示す。図7は、飽和磁化の等高線を示しており、横軸はSiの含有量、縦軸はCoの含有量を示し、Co及びSiの含有量に対応する飽和磁化の数値をプロットしている。これらの結果から、Siを添加することにより飽和磁化が低減し、特にSiの含有量が2質量%を超えるとその傾向が顕著になるものの、更にCoを1質量%以上添加することにより飽和磁化が高くなり、飽和磁化の低減を十分抑制できることが確認できた。特に、Siの含有量が低いところでCoを1質量%以上添加することによる飽和磁化の低減抑制効果が大きくなった。
実施例1、3、7、9〜12、並びに比較例1〜3、8、22及び23の軟磁性合金粉末について、公知の振動試料型磁力計(VSM)を用いて熱磁気特性の測定を行い、飽和磁化(Is)の温度特性を測定すると共に、キュリー温度(Tc)を求めた。昇温速度は200℃/hとした。キュリー温度(Tc)の結果を表3、4及び図6に示す。図6は、キュリー温度の等高線を示しており、横軸はSiの含有量、縦軸はCoの含有量を示し、Co及びSiの含有量に対応するキュリー温度の数値をプロットしている。これらの結果から、Siを添加することによりキュリー温度が低下する傾向を示すものの、更にCoを1質量%以上添加することによりキュリー温度が上昇し、キュリー温度の低下を十分抑制できることが確認できた。また、本発明の範囲内では、従来のCo及びSiを含有していないパーマロイBと同等又はより良好なキュリー温度が得られることが分かった。
Claims (5)
- Fe及びNiの合計質量に対して、前記Feを45〜55質量%、かつ前記Niを45〜55質量%含み、
前記Fe、前記Ni、Co及びSiの合計質量に対して、前記Coを1〜6質量%、かつ前記Siを1.2〜4.5質量%含んだFe−Ni系粒子を含有する軟磁性合金粉末。 - 前記Fe−Ni系粒子の平均粒径が10μm超100μm未満である、請求項1記載の軟磁性合金粉末。
- 表面の一部又は全部を絶縁材で被覆されたFe−Ni系粒子であって、Fe及びNiの合計質量に対して、前記Feを45〜55質量%、かつ前記Niを45〜55質量%含み、前記Fe、前記Ni、Co及びSiの合計質量に対して、前記Coを1〜6質量%、かつ前記Siを1.2〜4.5質量%含んだ前記Fe−Ni系粒子、を含有する圧粉体。
- 圧粉体からなる圧粉磁芯を備え、
前記圧粉体が、
表面の一部又は全部を絶縁材で被覆されたFe−Ni系粒子であって、Fe及びNiの合計質量に対して、前記Feを45〜55質量%、かつ前記Niを45〜55質量%含み、前記Fe、前記Ni、Co及びSiの合計質量に対して、前記Coを1〜6質量%、かつ前記Siを1.2〜4.5質量%含んだ前記Fe−Ni系粒子、
を含有するものであるインダクタンス素子。 - 圧粉体からなる圧粉磁芯と、前記圧粉磁芯内に埋設されたコイルと、を備え、
前記圧粉体が、
表面の一部又は全部を絶縁材で被覆されたFe−Ni系粒子であって、Fe及びNiの合計質量に対して、前記Feを45〜55質量%、かつ前記Niを45〜55質量%含み、前記Fe、前記Ni、Co及びSiの合計質量に対して、前記Coを1〜6質量%、かつ前記Siを1.2〜4.5質量%含んだ前記Fe−Ni系粒子、
を含有するものであるインダクタンス素子。
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US11/976,029 US7744702B2 (en) | 2006-10-31 | 2007-10-19 | Soft magnetic alloy powder, compact, and inductance element |
TW096139951A TW200845056A (en) | 2006-10-31 | 2007-10-24 | Soft magnetic alloy powder, compact, and inductance element |
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