JP6902695B2 - 圧粉磁心及び混合軟磁性粉末 - Google Patents
圧粉磁心及び混合軟磁性粉末 Download PDFInfo
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- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/06—Metallic powder characterised by the shape of the particles
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Description
表面平滑性が4.0以上20.0以下かつ偏平度が3.0以上15.0以下である第二の楕円体状の軟磁性粒子と、
を混合した混合軟磁性粉末が含まれていることを特徴とする。
表面平滑性が4.0以上20.0以下かつ偏平度が3.0以上15.0以下である楕円体状の第二の軟磁性粒子と、
を混合した混合軟磁性粉末が含まれている。
表面平滑性が4.0以上20.0以下かつ偏平度が3.0以上15.0以下である楕円体状の第二の軟磁性粒子と、
が混合されている。
図1は、実施の形態1に係る圧粉磁心を構成する楕円体状の第一の軟磁性粒子1および楕円体状の第二の軟磁性粒子2の混合軟磁性粉末の電子顕微鏡写真である。
実施の形態1に係る圧粉磁心は、楕円体状の第一の軟磁性粒子1と、楕円体状の第二の軟磁性粒子2と、を混合した混合軟磁性粉末を含んでいる。第一の軟磁性粒子1は、表面平滑性が1.1以上2.0以下である。第二の軟磁性粒子2は、表面平滑性が4.0以上20.0以下かつ偏平度が3.0以上15.0以下である。
なお、第一の軟磁性粒子1および第二の軟磁性粒子2の材料としては、透磁率が高い金属材料であれば特に制限されるものではなく、例えば、鉄、コバルト、ニッケルなどの単金属、あるいはパーマロイ、センダストなどそれらを基とする合金などの透磁率が高い金属材料を用いることができる。本発明は粒子の形状の違いに着目して効果を得るものである。そのため、第一の軟磁性粒子と第二の軟磁性粒子とは必ずしも別種の材料を用いる必要はなく、第一の軟磁性粒子と第二の軟磁性粒子とを同一材料とすれば、より安価に圧粉磁心を得ることもできる。
この圧粉磁心によれば、上記所定の特性を有する第一の軟磁性粒子と第二の軟磁性粒子とを混合した混合軟磁性粉末を含むので、高い透磁率と高い耐電圧性能を両立できる。
楕円体状の第一の軟磁性粒子1としては、表面平滑性が1.1以上2.0以下で平滑な表面を有する粒子を用いる。図1に示されるように、第一の軟磁性粒子1の輪郭形状は鋭利なエッジ部を有さない丸められた楕円体状の粒子としていることにより、圧粉磁心の製造時における加圧成形にて大きな荷重を負荷しても粒子同士の絶縁を確保することができる。
次に、楕円体状の第二の軟磁性粒子2としては、表面平滑性が4.0以上20.0以下かつ偏平度が3.0以上15.0以下で表面が粗く偏平な粒子を用いる。
第二の軟磁性粒子の表面平滑性を4.0以上20.0以下かつ偏平度を3.0以上15.0以下とすることができれば、その製造方法を特に限定するものではない。例えば、粗大な軟磁性体をジェットミル、ジョークラッシャー、ハンマークラッシャー、ボールミル、ビーズミル、ピンミル、スタンプミル、遊星ボールミル、高速ミキサ、摩砕機およびサイクロンミル等のような粉砕装置を用いて粉砕することによって得ることができる。ごく短時間の粉砕処理では、輪郭形状が直線的な粒子が多く得られるが、粉砕時間や条件を適切に調整することで粒子の輪郭形状が丸められた楕円体状の粒子を得ることができる。第二の軟磁性粒子も第一の軟磁性粒子と同様に、粒子の輪郭形状が丸められた楕円体状の粒子とすることにより、圧粉磁心の製造時における加圧成形にて大きな荷重を負荷しても粒子同士の絶縁を確保することができる。
以下に圧粉磁心の製造方法の一例を説明する。
(1)まず、上記第一の軟磁性粒子と第二の軟磁性粒子とを混合した混合軟磁性粉末を用意する。
(2)次に、混合軟磁性粉末と、熱硬化性樹脂、例えば、未硬化シリコーン樹脂とトルエンを混合した後、乾燥を行う。ここで、混合軟磁性粉末に対するシリコーン樹脂とトルエンの混合比は、混合物の粘度を、例えば100Pasとなるように調整してもよい。
(3)乾燥後、固まった粉末をボールミルを用いて再粉砕した後、コア金型を使用して、例えば、4t/cm2の成形圧で成形する。
以上によって、混合軟磁性粉末を含む圧粉磁心を得ることができる。
乾燥後、固まった粉末をボールミルを用いて再粉砕した後、コア金型を使用して4t/cm2の成形圧で成形して、環形圧粉磁心を製造した。
これに対して、比較例1では耐電圧が著しく低くなり、また、比較例2および比較例3においては粒子の充填密度が上がらずに透磁率が低くなり、いずれにおいても満足できる性能は得られなかった。
2 楕円体状の第二の軟磁性粒子
Claims (4)
- 表面平滑性が1.1以上2.0以下である楕円体状の第一の軟磁性粒子と、
表面平滑性が4.0以上20.0以下かつ偏平度が3.0以上15.0以下である楕円体状の第二の軟磁性粒子と、
を混合した混合軟磁性粉末が含まれている、圧粉磁心。 - 前記第一の軟磁性粒子の平均粒子径D1と前記第二の軟磁性粒子の平均粒子径D2との比率D1/D2が0.5以上2.0以下である、請求項1に記載の圧粉磁心。
- 前記第一の軟磁性粒子と前記第二の軟磁性粒子とが同一の材料からなる、請求項1又は2に記載の圧粉磁心。
- 表面平滑性が1.1以上2.0以下である楕円体状の第一の軟磁性粒子と、
表面平滑性が4.0以上20.0以下かつ偏平度が3.0以上15.0以下である楕円体状の第二の軟磁性粒子と、
が混合されている混合軟磁性粉末。
Priority Applications (3)
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JP2017098093A JP6902695B2 (ja) | 2017-05-17 | 2017-05-17 | 圧粉磁心及び混合軟磁性粉末 |
CN201810436571.8A CN108962530A (zh) | 2017-05-17 | 2018-05-09 | 压粉磁芯以及混合软磁性粉末 |
US15/977,369 US20180336983A1 (en) | 2017-05-17 | 2018-05-11 | Mixed soft magnetic powder and dust core including the mixed soft magnetic powder |
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JP2017098093A JP6902695B2 (ja) | 2017-05-17 | 2017-05-17 | 圧粉磁心及び混合軟磁性粉末 |
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JP2018195691A JP2018195691A (ja) | 2018-12-06 |
JP6902695B2 true JP6902695B2 (ja) | 2021-07-14 |
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JP2021034609A (ja) * | 2019-08-27 | 2021-03-01 | パナソニック株式会社 | 圧粉磁心およびその製造方法 |
CN111145986A (zh) * | 2018-11-01 | 2020-05-12 | 松下电器产业株式会社 | 压粉磁芯及其制造方法 |
WO2020179535A1 (ja) * | 2019-03-07 | 2020-09-10 | 株式会社村田製作所 | 磁性体粉末とその製造方法、及び磁心コアとその製造方法、並びにコイル部品 |
JP2021052075A (ja) * | 2019-09-25 | 2021-04-01 | 太陽誘電株式会社 | コイル部品 |
US20220051841A1 (en) * | 2020-08-14 | 2022-02-17 | Cyntec Co., Ltd. | Method to form multiple electrical components and a single electrical component made by the method |
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JPS6283401A (ja) * | 1985-10-07 | 1987-04-16 | Riken Corp | 電磁クラツチおよびブレ−キ用磁性粉末とその製造方法 |
US5135586A (en) * | 1989-12-12 | 1992-08-04 | Hitachi Metals, Ltd. | Fe-Ni alloy fine powder of flat shape |
JP2000282104A (ja) * | 1999-03-30 | 2000-10-10 | Kubota Corp | 軟質磁性金属粉末および粉末集合体並びに圧縮成形体 |
JP2002249802A (ja) * | 2001-02-26 | 2002-09-06 | Alps Electric Co Ltd | 非晶質軟磁性合金圧密体及びそれを用いた圧粉磁心 |
JP3771224B2 (ja) * | 2002-09-11 | 2006-04-26 | アルプス電気株式会社 | 非晶質軟磁性合金粉末及びそれを用いた圧粉コア及び電波吸収体 |
JP2005209753A (ja) * | 2004-01-21 | 2005-08-04 | Sanyo Special Steel Co Ltd | 軟磁性偏平粉末 |
JP2009117484A (ja) * | 2007-11-02 | 2009-05-28 | Tamura Seisakusho Co Ltd | 圧粉磁心の製造方法及び圧粉磁心 |
JP4909312B2 (ja) * | 2008-04-04 | 2012-04-04 | 株式会社神戸製鋼所 | 圧粉磁心用軟磁性材および圧粉磁心 |
JP6088284B2 (ja) * | 2012-10-03 | 2017-03-01 | 株式会社神戸製鋼所 | 軟磁性混合粉末 |
JP6189633B2 (ja) * | 2013-05-16 | 2017-08-30 | 山陽特殊製鋼株式会社 | シート表面の平滑性に優れ高透磁率を有する磁性シート用軟磁性扁平粉末およびこれを用いた磁性シート並びに軟磁性扁平粉末の製造方法 |
CN104766684A (zh) * | 2014-01-07 | 2015-07-08 | 昆山玛冀电子有限公司 | 软磁合金粉末组成物 |
US10071421B2 (en) * | 2016-01-22 | 2018-09-11 | Kabushiki Kaisha Toshiba | Flaky magnetic metal particles, pressed powder material, rotating electric machine, motor, and generator |
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US20180336983A1 (en) | 2018-11-22 |
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