JP6519754B2 - 磁心、コイル部品および磁心の製造方法 - Google Patents
磁心、コイル部品および磁心の製造方法 Download PDFInfo
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Description
本発明の第1の態様について具体的に説明する。後述するように、第1の態様における磁心は、M1、Si及びRを含むFe基軟磁性合金粒により形成された合金相を含み、その合金相が粒界相で繋がれた組織を有する。
本発明の第1の態様の実施例について具体的に説明する。まず、Fe−Al−Cr合金インゴットと所定量のZrやTi(いずれも純度が99.8%以上)をルツボに装入し、Ar雰囲気中で高周波溶解した後、水アトマイズ法により合金粉末を作製した。次に、作製した合金粉末を440メッシュ(目開き32μm)の篩に通して、粗大粒を取り除いた。なお、溶解方法としては、Fe,Al,Crの素原料を使用して溶解してもよい。また、アトマイズ方法としては、水アトマイズ法に限らず、ガスアトマイズ法などでも可能である。このようにして得られた粉末の組成分析結果および平均粒径(メジアン径d50)を表2に示す。AlとZrはICP発光分析法により、Crは容量法により、SiとTiは吸光光度法により、それぞれ得られた分析値である。Rの他の元素もICP発光分析法によって測定される。平均粒径は、レーザー回折散乱式粒度分布測定装置(堀場製作所製LA−920)による測定値である。これらのFe基軟磁性合金粒を用いて下記(1)〜(3)の工程により磁心を製造し、それぞれ参考例1、比較例1及び実施例1〜5とした。
撹拌擂潰機を用いて、Fe基軟磁性合金粒100重量部に対して、バインダとしてPVA(株式会社クラレ製ポバールPVA−205;固形分10%)を2.5重量部添加して混合した。得られた混合物を120℃で10時間乾燥した後、篩に通して混合粉の顆粒を得て、その平均粒径(d50)を60〜80μmの範囲内とした。また、顆粒100重量部に対して、ステアリン酸亜鉛を0.4重量部添加し、容器回転揺動型粉体混合機により混合して、加圧成形に供する混合粉の顆粒を得た。
得られた顆粒を成形金型内に給粉し、油圧プレス機を使用して室温で加圧成形した。成形圧力は0.74GPaとした。得られた成形体は、内径φ7.8mm、外径φ13.5mm、厚み4.3mmのトロイダル形の環状体とした。
得られた成形体を電気炉により大気中で焼鈍し、代表寸法を内径φ7.7mm、外径φ13.4mm、厚み4.3mmとする磁心を得た。熱処理では、室温から焼鈍温度である750℃まで2℃/分で昇温し、その焼鈍温度で1時間保持した後、炉冷した。また、造粒時に添加したバインダなどの有機物が分解されるように、450℃で1時間保持する脱脂工程を熱処理の途中に含めた。
(A)成形体密度dg、焼鈍後密度ds
環状体の成形体と磁心に対し、それらの寸法と質量から体積重量法により密度(kg/m3)を算出し、それぞれを成形体密度dg、焼鈍後密度dsとした。
算出した焼鈍後密度dsを軟磁性合金の真密度で除して磁心の占積率(相対密度)[%]を算出した。なお、上記の真密度は、あらかじめ鋳造して得られた軟磁性合金のインゴットに対する体積重量法により求めた。
環状体の磁心を被測定物として、一次側巻線と二次側巻線とをそれぞれ15ターン巻回し、岩通計測株式会社製B−HアナライザーSY−8232を用いて、最大磁束密度30mT、周波数50kHz〜1000kHzの条件で、室温における磁心損失Pcv(kW/m3)を測定した。
環状体の磁心を被測定物として、導線を30ターン巻回し、LCRメータ(アジレント・テクノロジー株式会社製4284A)を用いて、周波数100kHzで室温にてインダクタンスLを測定し、次式により初透磁率μiを求めた。
初透磁率μi=(le×L)/(μ0×Ae×N2)
[le:磁路長(m)、L:試料のインダクタンス(H)、μ0:真空の透磁率=4π×10−7(H/m)、Ae:磁心の断面積(m2)、N:コイルの巻数]
環状体の磁心を被測定物として、導線を30ターン巻回し、10kA/mの直流磁界を印加した状態にて、LCRメータ(アジレント・テクノロジー株式会社製4284A)を用いて、周波数100kHzで室温にてインダクタンスLを測定し、前述した初透磁率μiと同様にして増分透磁率μΔを求めた。
JISZ2507に基づき、引張・圧縮試験機(株式会社島津製作所製オートグラフAG−1)の定盤間に被測定物である環状体の磁心を配置し、その磁心に径方向から荷重を与えて破壊時の最大加重P(N)を測定し、次式から圧環強度σr(MPa)を求めた。
圧環強度σr(MPa)=P(D−d)/(Id2)
[D:磁心の外径(mm)、d:磁心の厚み〔内外径差の1/2〕(mm)、I:磁心の高さ(mm)]
被測定物である磁心の対向する二平面に導電性接着剤を塗り、その接着剤が乾燥し固化してから電極の間に磁心をセットし、電気抵抗測定装置(株式会社エーディーシー製8340A)により50Vの直流電圧を印加して抵抗値R(Ω)を測定し、次式により比抵抗ρ(Ω・m)を算出した。
比抵抗ρ(Ω・m)=抵抗値R×(A/t)
[A:磁心の平面の面積〔電極面積〕(m2)、t:磁心の厚み〔電極間距離〕(m)]
本発明の第2の態様について具体的に説明する。第2の態様は、以下で説明する事柄の他は第1の態様と略同様であるので、共通点を省略して主に相違点について説明する。また、第1の態様において説明した構成に相当する構成には、同一の符号を付し、重複した説明を省略する。後述するように、第2の態様における磁心は、M2、Si及びRを含むFe基軟磁性合金粒により形成された合金相を含み、その合金相が粒界相で繋がれた組織を有する。
本発明の第2の態様の実施例について具体的に説明する。表8には、Fe基軟磁性合金粒を水アトマイズ法により作製した後、440メッシュ(目開き32μm)の篩を通して粗い粒子を取り除いた合金粒について、それらの組成分析と平均粒径(メジアン径d50)の測定結果を示している。本実施例では、選択元素M2としてCrを、選択元素RとしてZrを選択している。組成の分析や粒径の測定に用いた手法や装置は、第1の態様において説明した通りである。これらのFe基軟磁性合金粒を用いて、(1)混合、(2)加圧成形及び(3)熱処理の工程により磁心を製造し、それぞれ実施例12、比較例2とした。この(1)〜(3)の工程は、加圧成形時の成形圧力を0.93GPaとしたこと以外は、第1の態様と同じである。
20 合金相
30 粒界相
30a 酸化物領域の第1領域(中央部)
30b 酸化物領域の第2領域
30c 酸化物領域の第3領域(縁部)
Claims (12)
- M1(ただし、M1は、Al及びCrの両方の元素)、Si及びR(ただし、Rは、Y、Zr、Nb、La、Hf及びTaからなる群より選ばれる少なくとも1種の元素)を含むFe基軟磁性合金粒により形成された合金相を含み、前記合金相が粒界相で繋がれた組織を有し、
前記粒界相に、Fe、M1、Si及びRを含み、且つ、質量比で前記合金相よりも多くのAlを含む酸化物領域を備え、
前記酸化物領域が、その前記酸化物領域内の他の領域よりもRの比率が高い領域を備える磁心。 - 前記磁心は、Fe、M1及びRの和を100質量%として、Alを3質量%以上且つ10質量%以下、Crを3質量%以上且つ10質量%以下、Rを0.01質量%以上且つ1質量%以下で含み、残部がFe及び不可避不純物である請求項1に記載の磁心。
- M2(ただし、M2は、Al又はCrのいずれかの元素)、Si及びR(ただし、Rは、Y、Zr、Nb、La、Hf及びTaからなる群より選ばれる少なくとも1種の元素)を含むFe基軟磁性合金粒により形成された合金相を含み、前記合金相が粒界相で繋がれた組織を有し、
前記粒界相に、Fe、M2、Si及びRを含み、且つ、質量比で前記合金相よりも多くのM2を含む酸化物領域を備え、
前記酸化物領域が、その前記酸化物領域内の他の領域よりもRの比率が高い領域を備える磁心。 - 前記磁心は、Fe、M2、Si及びRの和を100質量%として、M2を1.5質量%以上且つ8質量%以下、Siを1質量%超え且つ7質量%以下、Rを0.01質量%以上且つ3質量%以下で含み、残部がFe及び不可避不純物である請求項3に記載の磁心。
- RがZr又はHfである請求項1〜4のいずれか1項に記載の磁心。
- Rを0.3質量%以上で含む請求項2または4に記載の磁心。
- Rを0.6質量%以下で含む請求項2,4または6に記載の磁心。
- 前記粒界相が、Fe、M1、Si及びRの和に対するAlの比率がFe、Cr、Si及びRの各々の比率よりも高い第1領域と、Fe、M1、Si及びRの和に対するFeの比率がM1、Si及びRの各々の比率よりも高い第2領域とを有している請求項1または2に記載の磁心。
- 比抵抗が1×105Ω・m以上で、圧環強度が120MPa以上である請求項1または2に記載の磁心。
- 請求項1〜9のいずれか1項に記載の磁心と、その磁心に施されたコイルとを有するコイル部品。
- M1(ただし、M1は、Al及びCrの両方の元素)、Si及びR(ただし、Rは、Y、Zr、Nb、La、Hf及びTaからなる群より選ばれる少なくとも1種の元素)を含むFe基軟磁性合金粒とバインダとを混合して混合粉を得る工程と、
前記混合粉を加圧成形して成形体を得る工程と、
酸素を含む雰囲気中で前記成形体を熱処理して、前記Fe基軟磁性合金粒により形成された合金相を含む組織を有する磁心を得る工程とを備え、
前記熱処理によって、前記合金相を繋ぐ粒界相を形成するとともに、前記粒界相に、Fe、M1、Si及びRを含み、且つ、質量比で前記合金相よりも多くのAlを含む酸化物領域を生成し、
前記酸化物領域が、その前記酸化物領域内の他の領域よりもRの比率が高い領域を備える磁心の製造方法。 - M2(ただし、M2は、Cr又はAlのいずれかの元素)、Si及びR(ただし、Rは、Y、La、Zr、Hf、Nb、及びTaからなる群より選ばれる少なくとも1種の元素)を含むFe基軟磁性合金粒とバインダとを混合して混合粉を得る工程と、
前記混合粉を成形して成形体を得る工程と、
酸素を含む雰囲気中で前記成形体を熱処理して、前記Fe基軟磁性合金粒により形成された合金相を含む組織を有する磁心を得る工程とを備え、
前記熱処理によって、前記合金相を繋ぐ粒界相を形成するとともに、前記粒界相に、Fe、M2、Si及びRを含み、且つ、質量比で前記合金相よりも多くのM2を含む酸化物領域を生成し、
前記酸化物領域が、その前記酸化物領域内の他の領域よりもRの比率が高い領域を備える磁心の製造方法。
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