JP6745447B2 - 磁性体粒子、圧粉磁心、およびコイル部品 - Google Patents
磁性体粒子、圧粉磁心、およびコイル部品 Download PDFInfo
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- JP6745447B2 JP6745447B2 JP2018561342A JP2018561342A JP6745447B2 JP 6745447 B2 JP6745447 B2 JP 6745447B2 JP 2018561342 A JP2018561342 A JP 2018561342A JP 2018561342 A JP2018561342 A JP 2018561342A JP 6745447 B2 JP6745447 B2 JP 6745447B2
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- magnetic particles
- phosphoric acid
- mixture
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- 239000006249 magnetic particle Substances 0.000 title claims description 92
- 239000000428 dust Substances 0.000 title claims description 30
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims description 118
- 239000011248 coating agent Substances 0.000 claims description 63
- 238000000576 coating method Methods 0.000 claims description 63
- 229910052751 metal Inorganic materials 0.000 claims description 60
- 239000002184 metal Substances 0.000 claims description 60
- 150000004703 alkoxides Chemical class 0.000 claims description 59
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims description 58
- 239000000696 magnetic material Substances 0.000 claims description 56
- 239000000203 mixture Substances 0.000 claims description 53
- 239000006087 Silane Coupling Agent Substances 0.000 claims description 48
- 150000003839 salts Chemical class 0.000 claims description 45
- 239000002245 particle Substances 0.000 claims description 34
- -1 styryl phenyl ether phosphoric acid Chemical compound 0.000 claims description 32
- 239000004094 surface-active agent Substances 0.000 claims description 28
- 229910045601 alloy Inorganic materials 0.000 claims description 15
- 239000000956 alloy Substances 0.000 claims description 15
- 239000007795 chemical reaction product Substances 0.000 claims description 13
- 150000001875 compounds Chemical class 0.000 claims description 10
- 229920005989 resin Polymers 0.000 claims description 10
- 239000011347 resin Substances 0.000 claims description 10
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 claims description 8
- 229910008458 Si—Cr Inorganic materials 0.000 claims description 8
- 238000000748 compression moulding Methods 0.000 claims description 7
- 229910052742 iron Inorganic materials 0.000 claims description 5
- VXUYXOFXAQZZMF-UHFFFAOYSA-N titanium(IV) isopropoxide Chemical compound CC(C)O[Ti](OC(C)C)(OC(C)C)OC(C)C VXUYXOFXAQZZMF-UHFFFAOYSA-N 0.000 claims description 5
- 229920003171 Poly (ethylene oxide) Polymers 0.000 claims description 3
- 239000002253 acid Substances 0.000 claims description 3
- SMZOGRDCAXLAAR-UHFFFAOYSA-N aluminium isopropoxide Chemical compound [Al+3].CC(C)[O-].CC(C)[O-].CC(C)[O-] SMZOGRDCAXLAAR-UHFFFAOYSA-N 0.000 claims description 3
- KQAHMVLQCSALSX-UHFFFAOYSA-N decyl(trimethoxy)silane Chemical compound CCCCCCCCCC[Si](OC)(OC)OC KQAHMVLQCSALSX-UHFFFAOYSA-N 0.000 claims description 3
- WYTZZXDRDKSJID-UHFFFAOYSA-N (3-aminopropyl)triethoxysilane Chemical compound CCO[Si](OCC)(OCC)CCCN WYTZZXDRDKSJID-UHFFFAOYSA-N 0.000 claims description 2
- XDLMVUHYZWKMMD-UHFFFAOYSA-N 3-trimethoxysilylpropyl 2-methylprop-2-enoate Chemical compound CO[Si](OC)(OC)CCCOC(=O)C(C)=C XDLMVUHYZWKMMD-UHFFFAOYSA-N 0.000 claims description 2
- GAYWTJPBIQKDRC-UHFFFAOYSA-N 8-trimethoxysilyloctyl 2-methylprop-2-enoate Chemical compound CO[Si](OC)(OC)CCCCCCCCOC(=O)C(C)=C GAYWTJPBIQKDRC-UHFFFAOYSA-N 0.000 claims description 2
- 229910000838 Al alloy Inorganic materials 0.000 claims description 2
- 229910017082 Fe-Si Inorganic materials 0.000 claims description 2
- 229910017133 Fe—Si Inorganic materials 0.000 claims description 2
- 229910001030 Iron–nickel alloy Inorganic materials 0.000 claims description 2
- 229910002796 Si–Al Inorganic materials 0.000 claims description 2
- BOTDANWDWHJENH-UHFFFAOYSA-N Tetraethyl orthosilicate Chemical compound CCO[Si](OCC)(OCC)OCC BOTDANWDWHJENH-UHFFFAOYSA-N 0.000 claims description 2
- 125000005037 alkyl phenyl group Chemical group 0.000 claims description 2
- BSDOQSMQCZQLDV-UHFFFAOYSA-N butan-1-olate;zirconium(4+) Chemical compound [Zr+4].CCCC[O-].CCCC[O-].CCCC[O-].CCCC[O-] BSDOQSMQCZQLDV-UHFFFAOYSA-N 0.000 claims description 2
- RSKGMYDENCAJEN-UHFFFAOYSA-N hexadecyl(trimethoxy)silane Chemical compound CCCCCCCCCCCCCCCC[Si](OC)(OC)OC RSKGMYDENCAJEN-UHFFFAOYSA-N 0.000 claims description 2
- SLYCYWCVSGPDFR-UHFFFAOYSA-N octadecyltrimethoxysilane Chemical group CCCCCCCCCCCCCCCCCC[Si](OC)(OC)OC SLYCYWCVSGPDFR-UHFFFAOYSA-N 0.000 claims description 2
- NMEPHPOFYLLFTK-UHFFFAOYSA-N trimethoxy(octyl)silane Chemical compound CCCCCCCC[Si](OC)(OC)OC NMEPHPOFYLLFTK-UHFFFAOYSA-N 0.000 claims description 2
- BPSIOYPQMFLKFR-UHFFFAOYSA-N trimethoxy-[3-(oxiran-2-ylmethoxy)propyl]silane Chemical compound CO[Si](OC)(OC)CCCOCC1CO1 BPSIOYPQMFLKFR-UHFFFAOYSA-N 0.000 claims description 2
- QYJYJTDXBIYRHH-UHFFFAOYSA-N trimethoxy-[8-(oxiran-2-ylmethoxy)octyl]silane Chemical compound C(C1CO1)OCCCCCCCC[Si](OC)(OC)OC QYJYJTDXBIYRHH-UHFFFAOYSA-N 0.000 claims description 2
- 150000005215 alkyl ethers Chemical class 0.000 claims 2
- 150000007513 acids Chemical class 0.000 claims 1
- 150000001346 alkyl aryl ethers Chemical class 0.000 claims 1
- 125000002924 primary amino group Chemical group [H]N([H])* 0.000 claims 1
- 230000035699 permeability Effects 0.000 description 23
- 125000004432 carbon atom Chemical group C* 0.000 description 16
- 230000001965 increasing effect Effects 0.000 description 13
- 229910019142 PO4 Inorganic materials 0.000 description 12
- 125000001183 hydrocarbyl group Chemical group 0.000 description 12
- 239000010452 phosphate Substances 0.000 description 12
- 239000000843 powder Substances 0.000 description 12
- 125000000217 alkyl group Chemical group 0.000 description 10
- 125000004429 atom Chemical group 0.000 description 10
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 10
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 9
- 238000006243 chemical reaction Methods 0.000 description 8
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 7
- 125000003118 aryl group Chemical group 0.000 description 7
- 125000000547 substituted alkyl group Chemical group 0.000 description 6
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical class N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 5
- 239000011734 sodium Substances 0.000 description 5
- 239000002904 solvent Substances 0.000 description 5
- 150000001768 cations Chemical class 0.000 description 4
- LYCAIKOWRPUZTN-UHFFFAOYSA-N ethylene glycol Natural products OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 4
- 238000011049 filling Methods 0.000 description 4
- 230000004907 flux Effects 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical group OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- LRHPLDYGYMQRHN-UHFFFAOYSA-N N-Butanol Chemical compound CCCCO LRHPLDYGYMQRHN-UHFFFAOYSA-N 0.000 description 3
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 3
- 125000003277 amino group Chemical group 0.000 description 3
- BTANRVKWQNVYAZ-UHFFFAOYSA-N butan-2-ol Chemical compound CCC(C)O BTANRVKWQNVYAZ-UHFFFAOYSA-N 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 3
- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 description 3
- BDERNNFJNOPAEC-UHFFFAOYSA-N propan-1-ol Chemical compound CCCO BDERNNFJNOPAEC-UHFFFAOYSA-N 0.000 description 3
- 229910052708 sodium Inorganic materials 0.000 description 3
- 238000003756 stirring Methods 0.000 description 3
- 125000001424 substituent group Chemical group 0.000 description 3
- WFRBDWRZVBPBDO-UHFFFAOYSA-N 2-methyl-2-pentanol Chemical compound CCCC(C)(C)O WFRBDWRZVBPBDO-UHFFFAOYSA-N 0.000 description 2
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 2
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 2
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 2
- AMQJEAYHLZJPGS-UHFFFAOYSA-N N-Pentanol Chemical compound CCCCCO AMQJEAYHLZJPGS-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 230000008878 coupling Effects 0.000 description 2
- 238000010168 coupling process Methods 0.000 description 2
- 238000005859 coupling reaction Methods 0.000 description 2
- 230000001186 cumulative effect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 2
- 238000011156 evaluation Methods 0.000 description 2
- ZXEKIIBDNHEJCQ-UHFFFAOYSA-N isobutanol Chemical compound CC(C)CO ZXEKIIBDNHEJCQ-UHFFFAOYSA-N 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 125000000956 methoxy group Chemical group [H]C([H])([H])O* 0.000 description 2
- JYVLIDXNZAXMDK-UHFFFAOYSA-N pentan-2-ol Chemical compound CCCC(C)O JYVLIDXNZAXMDK-UHFFFAOYSA-N 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- ZIBGPFATKBEMQZ-UHFFFAOYSA-N triethylene glycol Chemical compound OCCOCCOCCO ZIBGPFATKBEMQZ-UHFFFAOYSA-N 0.000 description 2
- GZMAAYIALGURDQ-UHFFFAOYSA-N 2-(2-hexoxyethoxy)ethanol Chemical compound CCCCCCOCCOCCO GZMAAYIALGURDQ-UHFFFAOYSA-N 0.000 description 1
- SBASXUCJHJRPEV-UHFFFAOYSA-N 2-(2-methoxyethoxy)ethanol Chemical compound COCCOCCO SBASXUCJHJRPEV-UHFFFAOYSA-N 0.000 description 1
- XNWFRZJHXBZDAG-UHFFFAOYSA-N 2-METHOXYETHANOL Chemical compound COCCO XNWFRZJHXBZDAG-UHFFFAOYSA-N 0.000 description 1
- POAOYUHQDCAZBD-UHFFFAOYSA-N 2-butoxyethanol Chemical compound CCCCOCCO POAOYUHQDCAZBD-UHFFFAOYSA-N 0.000 description 1
- ZNQVEEAIQZEUHB-UHFFFAOYSA-N 2-ethoxyethanol Chemical compound CCOCCO ZNQVEEAIQZEUHB-UHFFFAOYSA-N 0.000 description 1
- 229940093475 2-ethoxyethanol Drugs 0.000 description 1
- QCAHUFWKIQLBNB-UHFFFAOYSA-N 3-(3-methoxypropoxy)propan-1-ol Chemical compound COCCCOCCCO QCAHUFWKIQLBNB-UHFFFAOYSA-N 0.000 description 1
- LCGLNKUTAGEVQW-UHFFFAOYSA-N Dimethyl ether Chemical compound COC LCGLNKUTAGEVQW-UHFFFAOYSA-N 0.000 description 1
- 229910017061 Fe Co Inorganic materials 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- CPZRAGFXLPDWOZ-UHFFFAOYSA-N N'-(8-trimethoxysilyloctyl)ethane-1,2-diamine Chemical compound CO[Si](CCCCCCCCNCCN)(OC)OC CPZRAGFXLPDWOZ-UHFFFAOYSA-N 0.000 description 1
- 229920000388 Polyphosphate Polymers 0.000 description 1
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 description 1
- XXPIVMBNLKIMFE-UHFFFAOYSA-N [NH4+].[NH4+].[NH4+].[NH4+].[NH4+].[NH4+].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O Chemical compound [NH4+].[NH4+].[NH4+].[NH4+].[NH4+].[NH4+].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O XXPIVMBNLKIMFE-UHFFFAOYSA-N 0.000 description 1
- DVSHRJHVSAEVGT-UHFFFAOYSA-N [SiH4].C(CCCCCCCCCCCCCCC)[Si](OC)(OC)OC Chemical compound [SiH4].C(CCCCCCCCCCCCCCC)[Si](OC)(OC)OC DVSHRJHVSAEVGT-UHFFFAOYSA-N 0.000 description 1
- DWCBWHINVBESJA-UHFFFAOYSA-N [SiH4].CO[Si](OC)(OC)CCCOCC1CO1 Chemical compound [SiH4].CO[Si](OC)(OC)CCCOCC1CO1 DWCBWHINVBESJA-UHFFFAOYSA-N 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 229910001413 alkali metal ion Inorganic materials 0.000 description 1
- 229910001420 alkaline earth metal ion Inorganic materials 0.000 description 1
- 125000004103 aminoalkyl group Chemical group 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 125000000129 anionic group Chemical group 0.000 description 1
- 239000003945 anionic surfactant Substances 0.000 description 1
- 229910052788 barium Inorganic materials 0.000 description 1
- 150000007514 bases Chemical class 0.000 description 1
- 229910052790 beryllium Inorganic materials 0.000 description 1
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical class OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 1
- 229910001417 caesium ion Inorganic materials 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 125000002091 cationic group Chemical group 0.000 description 1
- 239000003093 cationic surfactant Substances 0.000 description 1
- 239000007809 chemical reaction catalyst Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000007822 coupling agent Substances 0.000 description 1
- 229940028356 diethylene glycol monobutyl ether Drugs 0.000 description 1
- XXJWXESWEXIICW-UHFFFAOYSA-N diethylene glycol monoethyl ether Chemical compound CCOCCOCCO XXJWXESWEXIICW-UHFFFAOYSA-N 0.000 description 1
- 229940075557 diethylene glycol monoethyl ether Drugs 0.000 description 1
- USIUVYZYUHIAEV-UHFFFAOYSA-N diphenyl ether Chemical group C=1C=CC=CC=1OC1=CC=CC=C1 USIUVYZYUHIAEV-UHFFFAOYSA-N 0.000 description 1
- DDXLVDQZPFLQMZ-UHFFFAOYSA-M dodecyl(trimethyl)azanium;chloride Chemical compound [Cl-].CCCCCCCCCCCC[N+](C)(C)C DDXLVDQZPFLQMZ-UHFFFAOYSA-M 0.000 description 1
- KQPPJWHBSYEOKV-UHFFFAOYSA-M dodecyl-ethyl-dimethylazanium;ethyl sulfate Chemical compound CCOS([O-])(=O)=O.CCCCCCCCCCCC[N+](C)(C)CC KQPPJWHBSYEOKV-UHFFFAOYSA-M 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 125000003700 epoxy group Chemical group 0.000 description 1
- 150000002170 ethers Chemical class 0.000 description 1
- 125000001301 ethoxy group Chemical group [H]C([H])([H])C([H])([H])O* 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 150000002334 glycols Chemical class 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 125000004435 hydrogen atom Chemical group [H]* 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 229910000398 iron phosphate Inorganic materials 0.000 description 1
- WBJZTOZJJYAKHQ-UHFFFAOYSA-K iron(3+) phosphate Chemical compound [Fe+3].[O-]P([O-])([O-])=O WBJZTOZJJYAKHQ-UHFFFAOYSA-K 0.000 description 1
- 229940035429 isobutyl alcohol Drugs 0.000 description 1
- 125000000959 isobutyl group Chemical group [H]C([H])([H])C([H])(C([H])([H])[H])C([H])([H])* 0.000 description 1
- 125000001449 isopropyl group Chemical group [H]C([H])([H])C([H])(*)C([H])([H])[H] 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 229910001463 metal phosphate Inorganic materials 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000011812 mixed powder Substances 0.000 description 1
- 125000004108 n-butyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 125000004123 n-propyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 239000002736 nonionic surfactant Substances 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- JCGNDDUYTRNOFT-UHFFFAOYSA-N oxolane-2,4-dione Chemical compound O=C1COC(=O)C1 JCGNDDUYTRNOFT-UHFFFAOYSA-N 0.000 description 1
- 125000006353 oxyethylene group Chemical group 0.000 description 1
- 125000002467 phosphate group Chemical group [H]OP(=O)(O[H])O[*] 0.000 description 1
- 230000026731 phosphorylation Effects 0.000 description 1
- 238000006366 phosphorylation reaction Methods 0.000 description 1
- QVLTXCYWHPZMCA-UHFFFAOYSA-N po4-po4 Chemical compound OP(O)(O)=O.OP(O)(O)=O QVLTXCYWHPZMCA-UHFFFAOYSA-N 0.000 description 1
- 239000001818 polyoxyethylene sorbitan monostearate Substances 0.000 description 1
- 235000010989 polyoxyethylene sorbitan monostearate Nutrition 0.000 description 1
- 239000001205 polyphosphate Substances 0.000 description 1
- 235000011176 polyphosphates Nutrition 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 229910052701 rubidium Inorganic materials 0.000 description 1
- 125000002914 sec-butyl group Chemical group [H]C([H])([H])C([H])([H])C([H])(*)C([H])([H])[H] 0.000 description 1
- 229910000077 silane Inorganic materials 0.000 description 1
- AKLJIUURIIIOLU-UHFFFAOYSA-N silane 3-trimethoxysilylpropyl 2-methylprop-2-enoate Chemical compound [SiH4].CO[Si](OC)(OC)CCCOC(=O)C(C)=C AKLJIUURIIIOLU-UHFFFAOYSA-N 0.000 description 1
- UNOCCDTUMZJROZ-UHFFFAOYSA-N silane trimethoxy(octadecyl)silane Chemical compound [SiH4].CCCCCCCCCCCCCCCCCC[Si](OC)(OC)OC UNOCCDTUMZJROZ-UHFFFAOYSA-N 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 229940080264 sodium dodecylbenzenesulfonate Drugs 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 229910052712 strontium Inorganic materials 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 125000000472 sulfonyl group Chemical group *S(*)(=O)=O 0.000 description 1
- 125000000999 tert-butyl group Chemical group [H]C([H])([H])C(*)(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/102—Metallic powder coated with organic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
- B22F5/106—Tube or ring forms
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
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Description
絶縁被膜が、金属アルコキシドおよび有機リン酸またはその塩を含む混合物のゾル−ゲル反応生成物により構成されている、磁性体粒子が提供される。
ここで、「絶縁被膜がゾル−ゲル反応生成物により構成されている」とは、絶縁被膜がゾルーゲル反応生成物を含んでいることを意味する。
絶縁被膜が、金属アルコキシドおよび界面活性剤を含む混合物から形成されている、磁性体粒子が提供される。この磁性体粒子は、樹脂と混合されてコイル部品の素体を形成する。
本実施形態では、磁性体粒子は、磁性材料のコアと、コアを覆う絶縁被膜とを備え、絶縁被膜は、金属アルコキシドと界面活性剤の混合物から形成される。磁性材料及び金属アルコキシドについては、第1の実施形態と同じであるので説明を省略する。
下記のように、金属アルコキシドおよび有機リン酸またはその塩の混合物から形成された第1の絶縁被膜を有する磁性体粒子、およびかかる磁性体粒子の圧粉磁心を製造した。
アルコキシド1:テトラエトキシシラン
アルコキシド2:チタンテトライソポロポキシド
アルコキシド3:ジルコニウムn−ブトキシド
アルコキシド4:アルミニウムイソプロポキシド
リン酸塩1:ポリオキシアルキレンスチリルフェニルエーテルリン酸ナトリウム
リン酸塩2:ポリオキシアルキレンアルキルエーテルリン酸ナトリウム
リン酸塩3:ポリオキシアルキレンアルキルアリールエーテルリン酸モノエタノールアミン塩
リン酸塩4:アルキルエーテルリン酸ナトリウム
リン酸塩5:不飽和ポリオキシエチレンアルキルフェニルエーテルリン酸アンモニウム
リン酸6:ポリオキシアルキレンスチリルフェニルエーテルリン酸
リン酸7:ポリオキシアルキレンアルキルエーテルリン酸
リン酸8:ポリオキシアルキレンアルキルアリールエーテルリン酸
・比透磁率
作製したトロイダルコイルについてアジレント・テクノロジー株式会社製のRFインピーダンスアナライザー(E4991A)を用いて、1MHz、1Vrmsでの比透磁率を測定した(n=3の平均値を表1に示す)。
角板試料について株式会社アドバンテスト社製の高抵抗測定器(R8340A ULTRA HIGH RESISTANCE METER)を用い、900Vの直流電圧を印加し、5秒後の抵抗を測定し、試料寸法から比抵抗を算出した(n=3の平均値を表1に示す)。
*を付した試料22および23は、比較例である。
**は、試料番号23では、無機リン酸を用いている。
(試料番号22)
16重量%アンモニア水10.0gを溶解した70gのエタノールの代わりに、ゾル−ゲル反応触媒であるアンモニアを含まない70gのエタノールを準備し、磁性材料の添加後120分間撹拌する代わりに、1分間浸漬した以外は、上記実施例の試料番号11と同様にして、表面に絶縁被膜が形成された磁性体粒子を得た。
また、有機リン酸及びその塩の代わりに無機リン酸を用いた以外は実施例1と同様にして磁性体粒子を得た。
下記のように、金属アルコキシド、シランカップリング剤および有機リン酸またはその塩の混合物から形成された絶縁被膜を有する磁性体粒子、およびかかる磁性体粒子の圧粉磁心を製造した。
シランカップリング剤1:オクタデシルトリメトキシシラン
シランカップリング剤2:ヘキサデシルトリメトキシシラン
シランカップリング剤3:3−グリシジルオキシプロピルトリメトキシシラン
シランカップリング剤4:8−メタクリロイルオキシ−オクチルトリメトキシシラン
シランカップリング剤5:8−(2−アミノエチルアミノ)オクチルトリメトキシシラン
シランカップリング剤6:8−グリシジルオキシ−オクチルトリメトキシシラン
シランカップリング剤7:アミノプロピルトリエトキシシラン
シランカップリング剤8:3−(メタクリロイルオキシ)プロピルトリメトキシシラン
シランカップリング剤9:デシルトリメトキシシラン
試料番号50〜56は、有機リン酸またはその塩の代わりにその他の界面活性剤を用いた以外は、第1の実施形態の実施例1と同様の方法で磁性体粒子を作成し、実施例1と同様の方法で比抵抗と比透磁率の評価を行った。金属アルコキシドと界面活性剤の量、及び評価結果を表3に示す。表3は、さらに、実施例3は、実施例1の試料番号3〜5、15〜18、23を含む。試料番号23は、比較例である。
実施例3の金属アルコキシドの一部をシランカップリング剤に置換し、表4に示す比率となるように混合してコーティング剤としたこと以外は、実施例3の試料番号50〜56と同様にして、磁性体粒子および圧粉磁心を製造した。
2 コア
3 第1の絶縁被膜
4 第2の絶縁被膜
10 コイル部品
11 圧粉磁心
12 コイル
20 コイル部品
21 素体
22 コイル
Claims (20)
- 磁性材料のコアと、前記磁性材料のコアを被覆する絶縁被膜とを有してなる磁性体粒子であって、
前記絶縁被膜が、金属アルコキシドおよび有機リン酸またはその塩を含む混合物のゾル−ゲル反応生成物により構成されている、磁性体粒子。 - 前記磁性材料100重量部に対し、前記混合物中の前記金属アルコキシドの含有量が、0.06重量部以上15.0重量部以下である、請求項1に記載の磁性体粒子。
- 前記磁性材料100重量部に対し、前記混合物中の前記有機リン酸またはその塩の含有量が、0.3重量部以上10.0重量部以下である、請求項1または2に記載の磁性体粒子。
- 前記混合物における有機リン酸またはその塩に対する金属アルコキシドの重量比が、0.06以上40.0以下である、請求項1〜3のいずれかに記載の磁性体粒子。
- 前記混合物における有機リン酸またはその塩に対する金属アルコキシドの重量比が、0.06以上15.0以下である、請求項1〜4のいずれかに記載の磁性体粒子。
- 前記混合物が、さらにシランカップリング剤を含む、請求項1〜5のいずれか1項に記載の磁性体粒子。
- 前記混合物におけるシランカップリング剤の含有量が、金属アルコキシドとシランカップリング剤の合計に対して、5重量%以上40重量%以下である、請求項6に記載の磁性体粒子。
- 前記金属アルコキシドが、テトラエトキシシラン、チタンテトライソプロポキシド、ジルコニウムn−ブトキシド、およびアルミニウムイソプロポキシドから選択される1種またはそれ以上の化合物である、請求項1〜7のいずれか1項に記載の磁性体粒子。
- 前記有機リン酸またはその塩が、ポリオキシアルキレンスチリルフェニルエーテルリン酸、ポリオキシアルキレンアルキルエーテルリン酸、ポリオキシアルキレンアルキルアリールエーテルリン酸、アルキルエーテルリン酸、および不飽和ポリオキシエチレンアルキルフェニルエーテルリン酸ならびにこれらの塩から選択される1種またはそれ以上の化合物である、請求項1〜8のいずれか1項に記載の磁性体粒子。
- 前記シランカップリング剤が、オクタデシルトリメトキシシラン、ヘキサデシルトリメトキシシラン、アミノプロピルトリエトキシシラン、3−グリシジルオキシプロピルトリメトキシシラン、8−メタクリロイルオキシ−オクチルトリメトキシシラン、8−(2−アミノエチルアミノ)オクチルトリメトキシシラン、8−グリシジルオキシ−オクチルトリメトキシシラン、3−(メタクリロイルオキシ)プロピルトリメトキシシラン、およびデシルトリメトキシシランから選択される1種またはそれ以上の化合物である、請求項6〜9のいずれか1項に記載の磁性体粒子。
- 前記磁性材料が、Fe、Fe−Si合金、Fe−Si−Cr合金、Fe−Al合金、Fe−Si−Al合金、またはFe−Ni合金である、請求項1〜10のいずれか1項に記載の磁性体粒子。
- コアの表面と前記絶縁被膜との間に別の絶縁被膜を有する、請求項1〜11のいずれか1項に記載の磁性体粒子。
- 請求項1〜12のいずれか1項に記載の磁性体粒子を圧縮成形した、圧粉磁心。
- 請求項13の圧粉磁心と、当該圧粉磁心の周囲に巻回されたコイルとを有して成るコイル部品。
- 請求項1〜12のいずれか1項に記載の磁性体粒子と樹脂とを含む素体と、素体に埋め込まれたコイルとを備えるコイル部品。
- 磁性材料のコアと、前記磁性材料のコアを被覆する絶縁被膜とを有してなる磁性体粒子であって、
前記絶縁被膜が、金属アルコキシドおよび界面活性剤を含む混合物から形成されている、磁性体粒子。 - 前記磁性材料100重量部に対し、前記混合物中の前記金属アルコキシドの含有量が、0.06重量部以上15.0重量部以下である、請求項16に記載の磁性体粒子。
- 前記磁性材料100重量部に対し、前記混合物中の前記界面活性剤の量が、0.3重量部以上10.0重量部以下である、請求項16または17に記載の磁性体粒子。
- 前記混合物における界面活性剤に対する金属アルコキシドの重量比が、0.06以上40以下である、請求項16〜18のいずれか1項に記載の磁性体粒子。
- 前記混合物が、さらにシランカップリング剤を含み、
前記混合物におけるシランカップリング剤の含有量が、金属アルコキシドとシランカップリング剤の合計に対して、5重量%以上40重量%以下である、請求項16〜19のいずれか1項に記載の磁性体粒子。
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