JP6867966B2 - 軟磁性合金粉末、圧粉磁心および磁性部品 - Google Patents
軟磁性合金粉末、圧粉磁心および磁性部品 Download PDFInfo
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- JP6867966B2 JP6867966B2 JP2018043652A JP2018043652A JP6867966B2 JP 6867966 B2 JP6867966 B2 JP 6867966B2 JP 2018043652 A JP2018043652 A JP 2018043652A JP 2018043652 A JP2018043652 A JP 2018043652A JP 6867966 B2 JP6867966 B2 JP 6867966B2
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Description
[1]組成式(Fe(1−(α+β))X1αX2β)(1−(a+b+c+d+e+f+g))MaBbPcSidCeSfTigで表される軟磁性合金からなる軟磁性合金粒子を複数含む軟磁性合金粉末であって、
X1は、CoおよびNiからなる群から選択される1種以上であり、
X2は、Al,Mn,Ag,Zn,Sn,As,Sb,Cu,Cr,Bi,N,Oおよび希土類元素からなる群より選択される1種以上であり、
Mは、Nb,Hf,Zr,Ta,Mo,WおよびVからなる群から選択される1種以上であり、
a、b、c、d、e、f、g、αおよびβが、
0.020≦a≦0.14、
0.020<b≦0.20、
0<c≦0.15、
0≦d≦0.060、
0≦e≦0.040、
0≦f≦0.010、
0≦g≦0.0010、
α≧0、
β≧0、
0≦α+β≦0.50である関係を満足し、fとgのうち、少なくとも1つ以上が0より大きく、
軟磁性合金は、初期微結晶が非晶質中に存在するナノヘテロ構造を有し、
軟磁性合金粒子の表面は被覆部により覆われており、
被覆部は、P、Si、BiおよびZnからなる群から選ばれる1つ以上の元素の化合物を含むことを特徴とする軟磁性合金粉末である。
X1は、CoおよびNiからなる群から選択される1種以上であり、
X2は、Al,Mn,Ag,Zn,Sn,As,Sb,Cu,Cr,Bi,N,Oおよび希土類元素からなる群より選択される1種以上であり、
Mは、Nb,Hf,Zr,Ta,Mo,WおよびVからなる群から選択される1種以上であり、
a、b、c、d、e、f、g、αおよびβが、
0.020≦a≦0.14、
0.020<b≦0.20、
0<c≦0.15、
0≦d≦0.060、
0≦e≦0.040、
0≦f≦0.010、
0≦g≦0.0010、
α≧0、
β≧0、
0≦α+β≦0.50である関係を満足し、fとgのうち、少なくとも1つ以上が0より大きく、
軟磁性合金は、Fe基ナノ結晶を有し、
軟磁性合金粒子の表面は被覆部により覆われており、
被覆部は、P、Si、BiおよびZnからなる群から選ばれる1つ以上の元素の化合物を含むことを特徴とする軟磁性合金粉末である。
1.軟磁性合金粉末
1.1.軟磁性合金
1.1.1.第1の観点
1.1.2.第2の観点
1.2.被覆部
2.圧粉磁心
3.磁性部品
4.圧粉磁心の製造方法
4.1.軟磁性合金粉末の製造方法
4.2.圧粉磁心の製造方法
本実施形態に係る軟磁性合金粉末は、図1に示すように、軟磁性合金粒子2の表面に被覆部10が形成された被覆粒子1を複数含む。軟磁性合金粉末に含まれる粒子の個数割合を100%とした場合、被覆粒子の個数割合が90%以上であることが好ましく、95%以上であることが好ましい。なお、軟磁性合金粒子2の形状は特に制限されないが、通常、球形である。
軟磁性合金粒子は、所定の構造および組成を有する軟磁性合金からなる。本実施形態では、当該軟磁性合金を、第1の観点に係る軟磁性合金と、第2の観点に係る軟磁性合金と、に分けて説明する。第1の観点に係る軟磁性合金と、第2の観点に係る軟磁性合金と、の違いは、軟磁性合金の構造の違いであり、組成は共通する。
第1の観点に係る軟磁性合金は、初期微結晶が非晶質中に存在するナノへテロ構造を有している。このような構造は、軟磁性合金の原料が溶解した溶湯を急冷することにより得られる非晶質合金中に、多数の微結晶が析出し分散している構造である。したがって、初期微結晶の平均粒径は非常に小さい。本実施形態では、初期微結晶の平均粒径は0.3nm以上10nm以下であることが好ましい。
第2の観点に係る軟磁性合金は、その構造が異なる以外は、第1の観点に係る軟磁性合金の構成と同一であり、重複する説明は省略する。すなわち、第1の観点に係る軟磁性合金の組成に関する説明は、第2の観点に係る軟磁性合金にも適用される。
被覆部10は、図1に示すように、軟磁性金属粒子2の表面を覆うように形成されている。また、本実施形態では、表面が物質により被覆されているとは、当該物質が表面に接触して接触した部分を覆うように固定されている形態をいう。また、軟磁性合金粒子を被覆する被覆部は、粒子の表面の少なくとも一部を覆っていればよいが、表面の全部を覆っていることが好ましい。さらに、被覆部は粒子の表面を連続的に覆っていてもよいし、断続的に覆っていてもよい。
本実施形態に係る圧粉磁心は、上述した軟磁性合金粉末から構成され、所定の形状を有するように形成されていれば特に制限されない。本実施形態では、軟磁性合金粉末と結合剤としての樹脂とを含み、当該軟磁性合金粉末を構成する軟磁性合金粒子同士が樹脂を介して結合することにより所定の形状に固定されている。また、当該圧粉磁心は、上述した軟磁性合金粉末と他の磁性粉末との混合粉末から構成され、所定の形状に形成されていてもよい。
本実施形態に係る磁性部品は、上記の圧粉磁心を備えるものであれば特に制限されない。たとえば、所定形状の圧粉磁心内部に、ワイヤが巻回された空芯コイルが埋設された磁性部品であってもよいし、所定形状の圧粉磁心の表面にワイヤが所定の巻き数だけ巻回されてなる磁性部品であってもよい。本実施形態に係る磁性部品は、耐電圧性が良好であるため、電源回路に用いられるパワーインダクタに好適である。
続いて、上記の磁性部品が備える圧粉磁心を製造する方法について説明する。まず、圧粉磁心を構成する軟磁性合金粉末を製造する方法について説明する。
本実施形態に係る軟磁性合金粉末は、公知の軟磁性合金粉末の製造方法と同様の方法を用いて得ることができる。具体的には、ガスアトマイズ法、水アトマイズ法、回転ディスク法等を用いて製造することができる。また、単ロール法等により得られる薄帯を機械的に粉砕して製造してもよい。これらの中では、所望の磁気特性を有する軟磁性合金粉末が得られやすいという観点から、ガスアトマイズ法を用いることが好ましい。
圧粉磁心は、上記の軟磁性合金粉末を用いて製造する。具体的な製造方法としては、特に制限されず、公知の方法を採用することができる。まず、被覆部を形成した軟磁性合金粒子を含む軟磁性合金粉末と、結合剤としての公知の樹脂とを混合し、混合物を得る。また、必要に応じて、得られた混合物を造粒粉としてもよい。そして、混合物または造粒粉を金型内に充填して圧縮成形し、作製すべき圧粉磁心の形状を有する成形体を得る。上記の軟磁性合金粒子の球形度が高いので、当該軟磁性合金粒子を含む粉末を圧縮成形することにより、当該軟磁性合金粒子が金型内で密に充填され、密度の高い圧粉磁心を得ることができる。
まず、軟磁性合金の原料金属を準備した。準備した原料金属を、表1に示す組成となるように秤量し、アトマイズ装置内に配置されたルツボに収容した。続いて、チャンバー内を真空引きした後、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加熱し、ルツボ中の原料金属を溶融、混合して1250℃の溶湯(溶融金属)を得た。
実験例1、4および8の試料において、組成式中の「M」を表2に示す元素とした以外は、実験例4、8および10と同様にして軟磁性合金粉末を作製し、実験例1、4および8と同様の評価を行った。また、得られた粉末を用いて、実験例1、4および8と同様にして圧粉磁心を作製し、実験例1、4および8と同様の評価を行った。結果を表2に示す。
実験例1の試料において、組成式中の「X1」および「X2」元素および含有量を表3に示す元素および含有量とした以外は、実験例1と同様にして軟磁性合金粉末を作製し、実験例1と同様の評価を行った。また、得られた粉末を用いて、実験例1と同様にして圧粉磁心を作製し、実験例1と同様の評価を行った。結果を表3に示す。
実験例1の試料において、コーティング材の組成を表4に示す組成とし、コーティング材を用いて形成される被覆部の厚みを表4に示す値とした以外は、実験例1と同様にして軟磁性合金粉末を作製し、実験例1と同様の評価を行った。また、得られた粉末を用いて、実験例1と同様にして圧粉磁心を作製し、実験例1と同様の評価を行った。結果を表4に示す。なお、実験例151の試料に対しては、被覆部を形成しなかった。
実験例1の試料において、アトマイズ時の溶湯の温度およびアトマイズにより得られた粉末の熱処理条件を表5に示す条件とした以外は、実験例1と同様にして軟磁性合金粉末を作製し、実験例1と同様の評価を行った。また、得られた粉末を用いて、実験例1と同様にして圧粉磁心を作製し、実験例1と同様の評価を行った。結果を表5に示す。
10…被覆部
2…軟磁性合金粒子
Claims (6)
- 組成式(Fe(1−(α+β))X1αX2β)(1−(a+b+c+d+e+f+g))MaBbPcSidCeSfTigで表される軟磁性合金からなる軟磁性合金粒子を複数含む軟磁性合金粉末であって、
X1は、CoおよびNiからなる群から選択される1種以上であり、
X2は、Al,Zn,Sn,Cr,Bi,LaおよびYからなる群より選択される1種以上であり、
Mは、Nb,Hf,Zr,Ta,Mo,WおよびVからなる群から選択される1種以上であり、
a、b、c、d、e、f、g、αおよびβが、
0.020≦a≦0.14、
0.020<b≦0.20、
0.001≦c≦0.15、
0.001≦d≦0.060、
0≦e≦0.040、
0≦f≦0.010、
0≦g≦0.0010、
α≧0、
β≧0、
0≦α+β≦0.50である関係を満足し、fとgのうち、少なくとも1つ以上が0より大きく、
前記軟磁性合金は、初期微結晶が非晶質中に存在するナノヘテロ構造を有し、
前記軟磁性合金粒子の表面は被覆部により覆われており、
前記被覆部は、Pの化合物を含むことを特徴とする軟磁性合金粉末。 - 前記初期微結晶の平均粒径が、0.3nm以上10nm以下であることを特徴とする請求項1に記載の軟磁性合金粉末。
- 組成式(Fe(1−(α+β))X1αX2β)(1−(a+b+c+d+e+f+g))MaBbPcSidCeSfTigで表される軟磁性合金からなる軟磁性合金粒子を複数含む軟磁性合金粉末であって、
X1は、CoおよびNiからなる群から選択される1種以上であり、
X2は、Al,Zn,Sn,Cr,Bi,LaおよびYからなる群より選択される1種以上であり、
Mは、Nb,Hf,Zr,Ta,Mo,WおよびVからなる群から選択される1種以上であり、
a、b、c、d、e、f、g、αおよびβが、
0.020≦a≦0.14、
0.020<b≦0.20、
0.001≦c≦0.15、
0.001≦d≦0.060、
0≦e≦0.040、
0≦f≦0.010、
0≦g≦0.0010、
α≧0、
β≧0、
0≦α+β≦0.50である関係を満足し、fとgのうち、少なくとも1つ以上が0より大きく、
前記軟磁性合金は、Fe基ナノ結晶を有し、
前記軟磁性合金粒子の表面は被覆部により覆われており、
前記被覆部は、Pの化合物を含むことを特徴とする軟磁性合金粉末。 - 前記Fe基ナノ結晶の平均粒径が、5nm以上30nm以下であることを特徴とする請求項3に記載の軟磁性合金粉末。
- 請求項1から4のいずれかに記載の軟磁性合金粉末から構成される圧粉磁心。
- 請求項5に記載の圧粉磁心を備える磁性部品。
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