JPH0974011A - Dust core and manufacture thereof - Google Patents
Dust core and manufacture thereofInfo
- Publication number
- JPH0974011A JPH0974011A JP7230483A JP23048395A JPH0974011A JP H0974011 A JPH0974011 A JP H0974011A JP 7230483 A JP7230483 A JP 7230483A JP 23048395 A JP23048395 A JP 23048395A JP H0974011 A JPH0974011 A JP H0974011A
- Authority
- JP
- Japan
- Prior art keywords
- core
- powder
- alloy powder
- dust core
- annealing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/147—Alloys characterised by their composition
- H01F1/14766—Fe-Si based alloys
- H01F1/14791—Fe-Si-Al based alloys, e.g. Sendust
Landscapes
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Soft Magnetic Materials (AREA)
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は、各種電気、電子機器に
用いられる圧粉コアおよびその製造方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a dust core used in various electric and electronic devices and a method for producing the same.
【０００２】[0002]
【従来の技術】近年、電子、電気機器の小型化が進み、
小型で高効率の圧粉コアが要求されている。小型化する
ひとつの方法は周波数を高く（５０ｋＨｚ以上）するこ
とであるが、この場合コアロスが小さいことが必須条件
となる。センダスト圧粉コアは、低損失であることが知
られているが、これまでのコアロスではチョークコイル
やインダクタの小型化には必ずしも十分とはいえない。2. Description of the Related Art In recent years, miniaturization of electronic and electric devices has advanced,
A compact and highly efficient dust core is required. One method for downsizing is to increase the frequency (50 kHz or more), but in this case, a small core loss is an essential condition. It is known that the sendust dust core has a low loss, but the core loss so far is not always sufficient for downsizing the choke coil and the inductor.
【０００３】センダスト圧粉磁心の損失低減に関して
は、例えば以下に挙げる提案がなされている。The following proposals have been made for reducing the loss of the sendust dust core.
【０００４】特公昭６２−２１０４１号公報では、Ｆｅ
−Ｓｉ−Ａｌ系磁性合金インゴットを７００〜１１００
℃でアニール後、粉砕してプレス成形し、さらに水素雰
囲気中で６００〜８００℃で焼成することにより、モリ
ブデンパーマロイよりも高い透磁率と低い電力損失のＦ
ｅ−Ｓｉ−Ａｌ系磁性合金圧粉磁心が得られるとしてい
る。同公報の実施例では、３２メッシュ以下に整粒して
プレス成形した後、７００℃で焼成することにより、透
磁率が１０ｋＨｚで１４６、電力損失が２５ｋＨｚ、１
０００Ｇで１５８ｋＷ／ｍ3、２０００Ｇで５４８ｋＷ
／ｍ3である圧粉磁心を得ている。しかし、力率改善回
路などに用いられるインダクターでは、コアロスのさら
なる低減が望まれる。また、チョークコイルを小型化す
るにもコアロスの低減が望まれる。In Japanese Patent Publication No. Sho 62-21041, Fe
-Si-Al magnetic alloy ingot 700 to 1100
After annealing at ℃, crushed and press-molded, and then baked at 600 to 800 ℃ in a hydrogen atmosphere to obtain F having higher magnetic permeability and lower power loss than molybdenum permalloy.
It is said that an e-Si-Al magnetic alloy powder magnetic core can be obtained. In the example of the publication, the particles are sized to 32 mesh or less, press-molded, and then fired at 700 ° C., so that the magnetic permeability is 146 at 10 kHz and the power loss is 25 kHz, 1
158 kW / m 3 at 000 G, 548 kW at 2000 G
A powder magnetic core of / m 3 is obtained. However, in inductors used for power factor correction circuits, etc., further reduction of core loss is desired. In addition, reduction in core loss is desired to reduce the size of the choke coil.
【０００５】また、特公平７−５０６４８号公報には、
Ｆｅ−Ｓｉ−Ａｌ系合金圧粉磁心の製造方法が記載され
ている。この方法では、Ｆｅ−Ｓｉ−Ａｌ系合金の溶湯
からガスアトマイズによって球状の粗粉末を製造し、そ
の後に該粗粉末をさらに粉砕して得られた平均粒径が４
０〜１１０μｍ、見かけ密度２．６〜３．８ｇ／ｃｍ3
の粉末を用いる。ガスアトマイズによって得た球状粗粉
末を粉砕するのは、上記した所定の粒度の粉末を廉価に
得るためである。同公報では、透磁率の周波数特性の改
善と成形体の強度向上とを効果としている。同公報記載
の方法は、Ｆｅ−Ｓｉ−Ａｌ系合金粉末の製造方法にガ
スアトマイズ法を用いる点で本発明と類似するが、同公
報ではガスアトマイズ法により製造した粗粉末をさらに
粉砕しているために、粉末にストレスが生じ、ヒステリ
シス損失を小さくすることができない。なお、同公報記
載の発明はコアロス低減を目的としておらず、同公報の
実施例ではコアロスを測定していない。Further, Japanese Patent Publication No. 7-50648 discloses that
A method for manufacturing an Fe-Si-Al alloy powder magnetic core is described. In this method, a spherical coarse powder is produced from a molten Fe—Si—Al alloy by gas atomization, and then the coarse powder is further pulverized to obtain an average particle size of 4
0 to 110 μm, apparent density 2.6 to 3.8 g / cm 3
Powder is used. The spherical coarse powder obtained by gas atomization is pulverized in order to obtain the powder having the above-mentioned predetermined particle size at a low cost. In this publication, it is effective to improve the frequency characteristic of magnetic permeability and the strength of the molded body. The method described in the publication is similar to the present invention in that the gas atomizing method is used for the method for producing the Fe-Si-Al alloy powder, but in the publication, the coarse powder produced by the gas atomizing method is further pulverized. However, stress is generated in the powder, and the hysteresis loss cannot be reduced. The invention described in the publication does not aim to reduce the core loss, and the core loss is not measured in the embodiments of the publication.
【０００６】さらに、特公平３−４６５２１号公報に
は、Ｆｅ、ＳｉおよびＡｌを主成分とする磁性合金の粉
末に、水ガラスと、１〜５ｗｔ％の水分とを添加した
後、成形することを特徴とするＦｅ−Ｓｉ−Ａｌ系磁性
合金圧粉磁心の製造方法が記載されている。同公報で
は、プレス成形性の改善による透磁率の向上と成形体の
強度向上とを効果としている。同公報には、磁性合金の
粉末の製造方法として、溶解して得た合金を粉砕する方
法が記載されている。同公報の実施例では、２５ｋＨ
ｚ、２０００Ｇでコアロスが５００ｋＷ／ｍ3以上とな
っており、コアロスの低減は不十分である。なお、同公
報の実施例では、プレス成形後に７５０℃で焼成してい
るが、本発明者らの実験では、絶縁剤として水ガラスを
用いた場合、７５０℃もの高温では水ガラスが分解して
しまい、合金粒子間の絶縁を保つことが不可能となって
渦電流損失が著増してしまった。Further, in Japanese Examined Patent Publication No. 3-46521, water glass and 1 to 5 wt% of water are added to a powder of a magnetic alloy containing Fe, Si and Al as main components, and then molded. And a method for manufacturing a Fe-Si-Al-based magnetic alloy powder magnetic core. In this publication, improvement in magnetic permeability and improvement in strength of the molded product are made effective by improving press moldability. The publication describes a method of pulverizing an alloy obtained by melting as a method of producing a powder of a magnetic alloy. In the example of the publication, 25 kHz
The core loss is 500 kW / m 3 or more at z and 2000 G, and the reduction of the core loss is insufficient. In addition, in the example of the same publication, it is fired at 750 ° C. after press molding, but in the experiments of the present inventors, when water glass was used as the insulating agent, the water glass decomposed at a high temperature of 750 ° C. As a result, it becomes impossible to maintain the insulation between the alloy particles, and the eddy current loss increases significantly.
【０００７】本出願者も特願平６−１９２２０７におい
て、ほぼ球状のＦｅ、ＳｉおよびＡｌを含む金属粉末を
用いることで、低損失の圧粉コアが作製できることを開
示した。The present applicant also disclosed in Japanese Patent Application No. 6-192207 that a powder core with low loss can be produced by using a metal powder containing substantially spherical Fe, Si and Al.
【０００８】[0008]
【発明が解決しようとする課題】しかし、前記製造方法
により得られたＦｅ−Ｓｉ−Ａｌ系磁性合金圧粉磁心の
コアロスではチョークコイルやインダクターの小型化に
は充分といえない。そこで、本発明は小型で高周波での
使用が可能であるコアロスの小さい圧粉コアおよびその
製造方法を提供する。However, the core loss of the Fe--Si--Al magnetic alloy powder magnetic core obtained by the above manufacturing method cannot be said to be sufficient for downsizing a choke coil or an inductor. Therefore, the present invention provides a compacted core having a small core loss that can be used at high frequencies and a method for manufacturing the same.
【０００９】[0009]
【課題を解決するための手段】このような目的は下記
（１）〜（５）の構成により達成できる。Such an object can be achieved by the following constitutions (1) to (5).
【００１０】（１）Ｆｅ−Ｓｉ−Ａｌ系合金粉末と絶縁
剤を成形した圧粉コアにおいて、前記合金粉末の粒子内
部の酸素含有量が４００ｐｐｍ以下であって、粒子表面
が酸化されていることを特徴とする圧粉コア。(1) In a dust core formed by molding an Fe-Si-Al alloy powder and an insulating agent, the oxygen content inside the particles of the alloy powder is 400 ppm or less, and the particle surface is oxidized. Powder core characterized by.
【００１１】（２）鉄、シリコンもしくはフェロシリコ
ン、およびアルミニウムもしくはフェロアルミを不活性
雰囲気中で溶融し、不活性雰囲気中で急冷による製造方
法で該合金微粉末を作製し、絶縁剤と混合成形後アニー
ルすることを特徴とする（１）の圧粉コアの製造方法。(2) Iron, silicon or ferro-silicon, and aluminum or ferro-aluminum are melted in an inert atmosphere, and the alloy fine powder is produced by a manufacturing method by rapid cooling in an inert atmosphere, and mixed and molded with an insulating agent. The method for producing a powder core according to (1), characterized in that post-annealing is performed.
【００１２】（３）上記（２）に係る急冷による製造方
法がガスアトマイズ法によることを特徴とする圧粉コア
の製造方法。(3) A method for producing a dust core, characterized in that the production method by rapid cooling according to (2) above is a gas atomizing method.
【００１３】（４）上記（２）に係る急冷による製造方
法が高速急冷法によることを特徴とする圧粉コアの製造
方法。(4) A method for producing a dust core, characterized in that the rapid cooling method according to (2) above is a rapid quenching method.
【００１４】（５）成形したコアを不活性雰囲気中でア
ニール後、さらに酸化雰囲気中でアニールすることを特
徴とする（２）、（３）および（４）の圧粉コアの製造
方法。(5) The method for producing a powder core according to (2), (3) and (4), characterized in that the molded core is annealed in an inert atmosphere and then annealed in an oxidizing atmosphere.
【００１５】（６）不活性雰囲気中でのアニール温度が
５００〜８００℃である（５）の圧粉コアの製造方法。(6) The method for producing a powder core according to (5), wherein the annealing temperature is 500 to 800 ° C. in an inert atmosphere.
【００１６】（７）酸化雰囲気中でのアニール温度が４
００〜７００℃である（５）の圧粉コアの製造方法。(7) The annealing temperature in the oxidizing atmosphere is 4
The method for producing a dust core according to (5), which is from 00 to 700 ° C.
【００１７】本発明の圧粉コアの製造方法は、不活性雰
囲気中で急冷による製造方法で作製されたＦｅ−Ｓｉ−
Ａｌ系合金粉末と絶縁剤とを混合し、混合物を成形す
る。その後、不活性雰囲気でアニールし、さらに酸化雰
囲気でアニールする方法である。各雰囲気でのアニール
温度等を選択することによりコアロスの小さい圧粉コア
の製造が可能となる。The method for producing a dust core according to the present invention is a Fe-Si- produced by a quenching method in an inert atmosphere.
The Al-based alloy powder and the insulating agent are mixed to form a mixture. After that, it is a method of annealing in an inert atmosphere and further annealing in an oxidizing atmosphere. By selecting the annealing temperature and the like in each atmosphere, it becomes possible to manufacture a dust core with a small core loss.
【００１８】高周波領域でコアロスを低減するには、粒
子サイズを小さくすることが効果的であることがフェラ
イトではよく知られている。圧粉コアの場合も、同様に
粒子サイズを小さくすることが低損失化に効果があるこ
とが推定される。そこで我々は、平均粒径の異なるガス
アトマイズ粉および粉砕粉末を用いて圧粉コアを作製
し、粒子サイズを変えた場合にコアロスがどのように変
化するか調査した。結果を図１に示す。これより、圧粉
コアの場合は、コアロスを低減するには、粒子サイズを
小さくするだけでは不十分でＦｅ−Ｓｉ−Ａｌ系合金粉
末の作製方法によりコアロスに大きな違いがあることが
わかった。It is well known that ferrite is effective for reducing the particle size in order to reduce the core loss in the high frequency region. Also in the case of the dust core, it is presumed that similarly reducing the particle size is effective in reducing the loss. Therefore, we made a dust core using gas atomized powder and crushed powder with different average particle diameters, and investigated how the core loss changes when the particle size is changed. The results are shown in FIG. From this, it has been found that in the case of the dust core, it is not sufficient to reduce the particle size to reduce the core loss, and there is a large difference in the core loss depending on the manufacturing method of the Fe-Si-Al alloy powder.
【００１９】具体的には、本発明で用いるＦｅ−Ｓｉ−
Ａｌ系合金粉末は、鉄、シリコンもしくはフェロシリコ
ン、およびアルミニウムもしくはフェロアルミを溶融
し、ガスアトマイズ法または高速急冷法等の急冷による
製造方法で、かつ、不活性雰囲気中で作製される。すな
わち、均一な組成で、極力含有酸素量が少ないことが望
ましい。冷却速度が小さいとＡｌまたはＳｉが冷却過程
で偏析し、組成が不均一になるため保磁力が大きくな
る。従ってヒステリシス損失が大きくなるため好ましく
ない。また、粒子内部の酸素含有量が多いと、磁壁移動
が妨げられ保磁力が大きくなり、従ってヒステリシス損
失が大きくなるため好ましくない。Specifically, Fe-Si- used in the present invention.
The Al-based alloy powder is produced by melting iron, silicon or ferro-silicon, and aluminum or ferro-aluminum, and by a quenching method such as a gas atomizing method or a rapid quenching method and in an inert atmosphere. That is, it is desirable that the composition has a uniform composition and the oxygen content is as small as possible. If the cooling rate is low, Al or Si segregates in the cooling process and the composition becomes non-uniform, so the coercive force increases. Therefore, the hysteresis loss becomes large, which is not preferable. On the other hand, if the oxygen content in the particles is high, the movement of the domain wall is hindered and the coercive force becomes large, and the hysteresis loss becomes large, which is not preferable.
【００２０】本発明では、Ｆｅ−Ｓｉ−Ａｌ系合金粉末
の製造は、上記したようにガスアトマイズ法または高速
急冷法を用いる。ガスアトマイズ法は、ノズルから流下
させた原料合金の溶湯にガス流を噴射して飛沫化すると
ともに冷却し、凝固・粉末化する。なお、後述するよう
に、渦電流を小さく抑えるためには圧粉コアの粒子表面
が酸化されていることが好ましい。しかし、成形前に粒
子が酸化されると、粒子表面にＦｅ−Ｓｉ−Ａｌ系合金
よりも固いＡｌ2Ｏ3が形成されるため、成型時に密度を
上げることができなくなる。このため、冷却のためのガ
スは、粉末の酸化を防ぐために非酸化性のもの、例えば
窒素やアルゴン等を用いる。ガスアトマイズの際の条件
は、例えば溶湯の温度は１４００〜１６００℃とするこ
とが好ましく、ガスの噴射圧力は、２．０〜２．５ＭＰ
ａとすることが好ましい。一方、高速急冷法は、直接、
粉末を得る方法および得られた薄帯を粉砕する方法があ
る。In the present invention, the Fe-Si-Al alloy powder is produced by the gas atomizing method or the rapid quenching method as described above. In the gas atomizing method, a gas flow is injected into a molten metal of a raw material alloy that is made to flow down from a nozzle so as to be sprayed and cooled, and then solidified and powdered. As described later, in order to suppress the eddy current to be small, it is preferable that the particle surface of the dust core is oxidized. However, if the particles are oxidized before forming, Al 2 O 3 that is harder than the Fe-Si-Al alloy is formed on the surface of the particles, so that the density cannot be increased during forming. Therefore, as the cooling gas, a non-oxidizing gas such as nitrogen or argon is used to prevent the powder from being oxidized. The conditions for gas atomization are, for example, preferably a molten metal temperature of 1400 to 1600 ° C., and a gas injection pressure of 2.0 to 2.5 MP.
It is preferably a. On the other hand, the rapid quenching method directly
There are methods of obtaining a powder and crushing the obtained ribbon.
【００２１】いずれの方法により得られたＦｅ−Ｓｉ−
Ａｌ系合金粉末も、比較的偏析が少なく、含有酸素量も
少ない。Fe-Si-obtained by either method
Al-based alloy powder also has relatively little segregation and a small oxygen content.
【００２２】さらに、上記方法にて得られたＦｅ−Ｓｉ
−Ａｌ系合金粉末を成形後、不活性雰囲気でアニール
し、さらに酸化雰囲気でアニールする。不活性雰囲気で
アニールすることにより、成形によるストレスを低減す
る。また後に酸化雰囲気でアニールすることにより、粒
子表面が酸化され渦電流が小さくなる。渦電流を小さく
することで、渦電流損失が小さくなるだけでなくヒステ
リシス損失も小さくなる。これは、１００ｋＨｚ程度の
交流では渦電流により磁壁移動が妨げられるからであ
る。したがって電気抵抗を大きくすることにより、渦電
流が小さくなると磁壁移動が容易となりヒステリシス損
失も小さくなる。ただし、Ｆｅ−Ｓｉ−Ａｌ系合金粉末
内部に酸素含有量が多いと、磁壁移動が妨げられるため
に、酸素含有量の少ないＦｅ−Ｓｉ−Ａｌ系合金粉末を
用いて、粒子表面が酸化され、粒子内部は酸化されない
ようなアニール条件を選択する必要がある。具体的に
は、粒子内部の酸素含有量は４００ｐｐｍが限度であ
る。４００ｐｐｍを超えるころから、上記したように、
磁壁移動が妨げられるためにヒステリシス損失が大きく
なり、結果としてコアロスが大きくなるためである。Further, Fe--Si obtained by the above method
After forming the Al-based alloy powder, it is annealed in an inert atmosphere and further annealed in an oxidizing atmosphere. Annealing in an inert atmosphere reduces stress due to molding. Further, by subsequently annealing in an oxidizing atmosphere, the particle surface is oxidized and the eddy current is reduced. By reducing the eddy current, not only the eddy current loss decreases but also the hysteresis loss decreases. This is because the domain wall movement is hindered by the eddy current in an alternating current of about 100 kHz. Therefore, when the eddy current becomes small by increasing the electric resistance, the domain wall movement becomes easy and the hysteresis loss becomes small. However, when the oxygen content is large inside the Fe-Si-Al alloy powder, the domain wall movement is hindered, so the particle surface is oxidized by using the Fe-Si-Al alloy powder having a low oxygen content, It is necessary to select an annealing condition so that the inside of the grain is not oxidized. Specifically, the oxygen content inside the particles is limited to 400 ppm. From the time of exceeding 400 ppm, as described above,
This is because the domain wall movement is hindered and the hysteresis loss becomes large, resulting in a large core loss.
【００２３】不活性雰囲気でのアニール条件は、Ｆｅ−
Ｓｉ−Ａｌ系合金粉末の粒径および粒度分布ならびに成
形条件に応じて適宜決定すればよいが、シリコーン樹脂
と有機チタンを添加した場合の処理温度は、好ましくは
５００〜８００℃、より好ましくは６００〜７６０℃で
ある。処理温度が５００℃に満たない場合、アニールの
効果が現れずヒステリシス損失の低減をはかれない。一
方、８００℃を超える場合は、Ｆｅ−Ｓｉ−Ａｌ系合金
粉末が焼結しやすくなり、強磁性粒子間の絶縁性が劣化
して渦電流損失が大きくなりやすい。処理時間、すなわ
ち上記温度範囲内を通過する時間または上記温度範囲内
で一定の温度に保持する時間は、好ましくは１０〜６０
分間である。処理時間が上記範囲に満たない場合、アニ
ールの効果が現れずヒステリシス損失の低減をはかれな
い。一方、処理時間が上記範囲を超える場合はＦｅ−Ｓ
ｉ−Ａｌ系合金粉末が焼結しやすくなり好ましくない。The annealing conditions in the inert atmosphere are Fe-
The treatment temperature when the silicone resin and the organic titanium are added is preferably 500 to 800 ° C., more preferably 600, although it may be appropriately determined depending on the particle size and particle size distribution of the Si—Al alloy powder and the molding conditions. ~ 760 ° C. If the processing temperature is less than 500 ° C., the effect of annealing does not appear and the hysteresis loss cannot be reduced. On the other hand, when the temperature exceeds 800 ° C., the Fe—Si—Al alloy powder is likely to be sintered, the insulating property between the ferromagnetic particles is deteriorated, and the eddy current loss is likely to be large. The treatment time, that is, the time of passing through the above temperature range or the time of maintaining a constant temperature within the above temperature range is preferably 10 to 60.
It's a minute. When the treatment time is less than the above range, the effect of annealing does not appear and the hysteresis loss cannot be reduced. On the other hand, when the processing time exceeds the above range, Fe-S
This is not preferable because the i-Al alloy powder is easily sintered.
【００２４】また、酸化雰囲気でのアニール条件もま
た、不活性雰囲気でのアニール条件と同様に、Ｆｅ−Ｓ
ｉ−Ａｌ系合金粉末の粒径および粒度分布ならびに成形
条件に応じて適宜決定すればよいが、シリコーン樹脂と
有機チタンを添加した場合の処理温度は４００〜７００
℃が好ましい。処理温度が上記範囲に満たない場合、Ｆ
ｅ−Ｓｉ−Ａｌ系合金粉末表面の酸化が十分でなく、コ
アロスの低減がはかれない。一方、処理温度が上記範囲
を超える場合、Ｆｅ−Ｓｉ−Ａｌ系合金粉末の酸化が進
みすぎ透磁率が小さくなり好ましくない。このとき特に
Ａｌが酸化物を形成している。The annealing conditions in the oxidizing atmosphere are also Fe--S, as in the inert atmosphere.
It may be appropriately determined depending on the particle size and particle size distribution of the i-Al alloy powder and the molding conditions, but the processing temperature when the silicone resin and the organic titanium are added is 400 to 700.
C is preferred. If the processing temperature is below the above range, F
The oxidation of the surface of the e-Si-Al alloy powder is not sufficient, and the core loss cannot be reduced. On the other hand, when the treatment temperature exceeds the above range, the Fe—Si—Al alloy powder is excessively oxidized and the magnetic permeability becomes small, which is not preferable. At this time, especially Al forms an oxide.
【００２５】ここで、シリコーン樹脂と有機チタンを添
加し、アニール処理を行った場合、アニールの雰囲気に
よらずコア中には、シリコーン樹脂がより高分子化して
存在している。これは、ＦＴ−ＩＲ（フーリエ変換赤外
分光）透過方法等の分析方法により確認することができ
る。Here, when the silicone resin and the organic titanium are added and the annealing treatment is performed, the silicone resin is present in a higher polymer in the core regardless of the annealing atmosphere. This can be confirmed by an analysis method such as an FT-IR (Fourier transform infrared spectroscopy) transmission method.
【００２６】本発明の圧粉コアは、上記Ｆｅ−Ｓｉ−Ａ
ｌ系合金粉末と絶縁剤を成形したものである。絶縁剤は
特に限定されないが、上記温度でのアニール処理に耐え
ること、また、コアの機械的強度向上効果が高いことか
らシリコーン樹脂を用いることが好ましい。The dust core of the present invention is the above Fe-Si-A.
It is formed by molding an l-based alloy powder and an insulating agent. The insulating agent is not particularly limited, but it is preferable to use a silicone resin because it can withstand the annealing treatment at the above temperature and has a high effect of improving the mechanical strength of the core.
【００２７】シリコーン樹脂は、オルガノシロキサン結
合を有するオルガノポリシロキサンであり、狭義には、
３次元網目構造を有するオルガノポリシロキサンであ
る。本発明で用いるシリコーン樹脂は特に限定されない
が、狭義のシリコーン樹脂は必ず用いる。これは他の樹
脂では耐熱性に難があり、アニールを高温でできないた
めである。ただし、シリコーンオイルやシリコーンゴム
等の広義のシリコーン樹脂を併用してもよい。使用する
全シリコーン樹脂中における狭義のシリコーン樹脂の割
合は、好ましくは５０ｗｔ％以上、より好ましくは狭義
のシリコーン樹脂のみを用いる。シリコーン樹脂は、通
常、ジメチルポリシロキサンを主成分とするが、メチル
基の一部が他のアルキル基またはアリール基で置換され
てもよい。The silicone resin is an organopolysiloxane having an organosiloxane bond, and in a narrow sense,
It is an organopolysiloxane having a three-dimensional network structure. The silicone resin used in the present invention is not particularly limited, but a silicone resin in a narrow sense is always used. This is because other resins have poor heat resistance and cannot be annealed at high temperatures. However, a silicone resin in a broad sense such as silicone oil or silicone rubber may be used together. The proportion of the narrowly defined silicone resin in all the silicone resins used is preferably 50 wt% or more, and more preferably only the narrowly defined silicone resin is used. The silicone resin usually contains dimethylpolysiloxane as a main component, but a part of the methyl group may be substituted with another alkyl group or aryl group.
【００２８】シリコーン樹脂とＦｅ−Ｓｉ−Ａｌ系合金
粉末とを混合するときには、固体状または液状のシリコ
ーン樹脂を溶液化して混合してもよく、液状のシリコー
ン樹脂を直接混合してもよいが、溶液化して用いる場合
には成形前に溶液を乾燥する必要があるため、好ましく
は溶液化せずに液状のシリコーン樹脂を直接混合する。
液状のシリコーン樹脂の粘度は、２５℃において好まし
くは１０〜１００００ＣＰ、より好ましくは１０００〜
９０００ＣＰである。上記範囲外すなわち粘度が１０Ｃ
Ｐより低すぎても１００００ＣＰより高すぎても、強磁
性金属粒子表面に均一な皮膜を形成することが難しくな
る。When the silicone resin and the Fe-Si-Al alloy powder are mixed, the solid or liquid silicone resin may be dissolved and mixed, or the liquid silicone resin may be directly mixed. When the solution is used, it is necessary to dry the solution before molding. Therefore, it is preferable to directly mix the liquid silicone resin without solution.
The viscosity of the liquid silicone resin at 25 ° C. is preferably 10 to 10000 CP, more preferably 1000 to
9000 CP. Outside the above range, that is, viscosity is 10C
If it is lower than P or higher than 10,000 CP, it becomes difficult to form a uniform film on the surface of the ferromagnetic metal particles.
【００２９】シリコーン樹脂の混合量は、Ｆｅ−Ｓｉ−
Ａｌ系合金粉末に対し好ましくは０．５〜５ｗｔ％、よ
り好ましくは１〜３ｗｔ％である。シリコーン樹脂の混
合量が０．５ｗｔ％に満たない場合、強磁性金属粒子間
の絶縁性が不十分となり、また、コアの機械強度も不十
分となる。一方、シリコーン樹脂の混合量が５ｗｔ％を
超える場合、コア中の非磁性領域の比率が高くなって透
磁率が低くなる。また、上記範囲外すなわちシリコーン
樹脂が少なすぎても多すぎても、コアの密度が低くなる
傾向がある。The mixing amount of the silicone resin is Fe-Si-
It is preferably 0.5 to 5 wt%, and more preferably 1 to 3 wt% with respect to the Al-based alloy powder. If the mixing amount of the silicone resin is less than 0.5 wt%, the insulating property between the ferromagnetic metal particles becomes insufficient, and the mechanical strength of the core also becomes insufficient. On the other hand, when the mixing amount of the silicone resin exceeds 5 wt%, the ratio of the non-magnetic region in the core becomes high and the magnetic permeability becomes low. Further, if the content is out of the above range, that is, the amount of silicone resin is too small or too large, the density of the core tends to be low.
【００３０】絶縁剤としてシリコーン樹脂を用いる場
合、架橋剤として有機チタンを混合する。有機チタンを
添加することにより、コアの機械的強度がさらに向上す
る。When a silicone resin is used as the insulating agent, organic titanium is mixed as the crosslinking agent. By adding the organic titanium, the mechanical strength of the core is further improved.
【００３１】本発明で用いる有機チタンとは、チタンの
アルコキシドおよびキレートから選択される少なくとも
１種であり、シリコーン樹脂の架橋剤として使用できる
ものである。The organic titanium used in the present invention is at least one selected from titanium alkoxides and chelates, and can be used as a crosslinking agent for silicone resins.
【００３２】アルコキシドは、モノマーであってもオリ
ゴマーないしポリマーであってもよく、これらを併用し
てもよい。アルコキシドとしては、例えば、アルキル基
の炭素数が１〜８のテトラアルコキシチタン、具体的に
は、テトラ−ｉ−プロポキシチタン、テトラ−ｎ−ブト
キシチタン、テトラキス（２−エチルヘソキシキ）チタ
ンが好ましく、これらのうち、テトラ−ｎ−ブトキシチ
タンが最も好ましい。特に、下記化１で表されるテトラ
−ｎ−ブトキシチタンのオリゴマーないしポリマーが好
ましい。The alkoxide may be a monomer, an oligomer or a polymer, and these may be used in combination. As the alkoxide, for example, tetraalkoxytitanium having an alkyl group having 1 to 8 carbon atoms, specifically, tetra-i-propoxytitanium, tetra-n-butoxytitanium, and tetrakis (2-ethylhesoxyki) titanium are preferable. Of these, tetra-n-butoxy titanium is the most preferable. Particularly, an oligomer or polymer of tetra-n-butoxytitanium represented by the following chemical formula 1 is preferable.
【００３３】[0033]
【化１】 Embedded image
【００３４】上記化１において、ｎは好ましくは１０以
下の整数であり、より好ましくはｎ＝２、４、７、１０
であり、より好ましくはｎ＝４である。ｎが１０を超え
る場合、架橋反応の速度が低くなる傾向がある。In the above chemical formula 1, n is preferably an integer of 10 or less, more preferably n = 2, 4, 7, 10
And more preferably n = 4. When n exceeds 10, the crosslinking reaction rate tends to be low.
【００３５】キレートとしては、ジ−ｎ−プロポキシ・
ビス（アセチルアセトナト）チタン、ジ−ｎ−ブトキシ
・ビス（トリエタノールアミナト）チタンが好ましい。As the chelate, di-n-propoxy.
Bis (acetylacetonato) titanium and di-n-butoxy bis (triethanolaminato) titanium are preferred.
【００３６】これら有機チタンのうち、上記した各種ア
ルコキシドを用いることが好ましい。上記アルコキシド
は、常温で液体であるために混合する際に液状のシリコ
ーン樹脂と共に直接混合でき、また、加水分解速度が適
当であり、入手も容易である。Of these organic titanium, it is preferable to use the above-mentioned various alkoxides. Since the alkoxide is a liquid at room temperature, it can be directly mixed with a liquid silicone resin at the time of mixing, the hydrolysis rate is appropriate, and the alkoxide is easily available.
【００３７】有機チタンの混合量は、シリコーン樹脂の
混合量に対し、好ましくは１０〜７０ｗｔ％、より好ま
しくは２５〜５０ｗｔ％である。有機チタンの混合量が
１０ｗｔ％より少ないと、コアの機械的強度をさらに向
上させる効果が不十分となる。一方、混合量が７０ｗｔ
％より多くても機械的強度は顕著には向上せず、コアの
透磁率が低くなる。The mixing amount of the organic titanium is preferably 10 to 70 wt%, more preferably 25 to 50 wt% with respect to the mixing amount of the silicone resin. If the mixing amount of the organic titanium is less than 10 wt%, the effect of further improving the mechanical strength of the core becomes insufficient. On the other hand, the mixing amount is 70 wt
%, The mechanical strength is not significantly improved, and the magnetic permeability of the core becomes low.
【００３８】なお、シリコーン樹脂以外にも、従来の圧
粉コアに用いられている水ガラス等が使用可能である
が、水ガラスは３００℃程度を超える温度では分解して
絶縁性を保てなくなるため、高温のアニール処理が不可
能であり、磁気特性向上が難しい。Besides the silicone resin, water glass or the like used in the conventional dust core can be used, but the water glass decomposes at a temperature exceeding about 300 ° C. and cannot maintain its insulating property. Therefore, high-temperature annealing cannot be performed, and it is difficult to improve magnetic characteristics.
【００３９】Ｆｅ−Ｓｉ−Ａｌ系合金粉末とシリコーン
樹脂と有機チタンとを混合した後、混合物に乾燥処理を
施すことが好ましい。乾燥処理では、好ましくは５０〜
３００℃、より好ましくは５０〜１５０℃の温度範囲に
保持する。処理温度が５０℃に満たない場合、シリコー
ン樹脂の接着性が弱くならないためＦｅ−Ｓｉ−Ａｌ系
合金粉末が凝集しやすくなって成形性が低下し、処理温
度が１５０℃を超える場合、シリコーン樹脂の接着性が
弱くなりすぎてコアの機械的強度向上効果が不十分とな
る。処理時間、すなわち、上記温度範囲内を通過する時
間あるいは上記処理温度内の一定の時間に保持する時間
は、好ましくは０．５〜２時間とする。上記処理時間の
範囲に満たない場合、シリコーン樹脂の接着性が弱くな
らず、上記処理時間の範囲を超える場合、シリコーン樹
脂の接着性が弱くなりすぎる。処理条件は比較的低温で
行うので、非酸化雰囲気中で行う必要はなく、空気中で
行ってよい。After the Fe-Si-Al alloy powder, the silicone resin and the organic titanium are mixed, it is preferable to dry the mixture. In the drying process, preferably 50 to
The temperature is maintained at 300 ° C, more preferably 50 to 150 ° C. When the treatment temperature is lower than 50 ° C, the adhesiveness of the silicone resin does not become weak, so that the Fe-Si-Al alloy powder easily aggregates and the moldability deteriorates. When the treatment temperature exceeds 150 ° C, the silicone resin The adhesiveness of is too weak, and the effect of improving the mechanical strength of the core becomes insufficient. The processing time, that is, the time of passing through the above temperature range or the time of maintaining the above processing temperature for a certain period of time is preferably 0.5 to 2 hours. If it is less than the above treatment time range, the adhesiveness of the silicone resin does not become weak, and if it exceeds the above treatment time range, the adhesiveness of the silicone resin becomes too weak. Since the treatment is performed at a relatively low temperature, it is not necessary to perform it in a non-oxidizing atmosphere, and it may be performed in air.
【００４０】乾燥処理後、成形前に、前記混合物に潤滑
剤を添加することが好ましい。潤滑剤は、成形時の粒子
間潤滑性を高めたり、金型からの離型性を向上させたり
するために用いられる。潤滑剤には、圧粉コアに通常用
いられている各種のものを選択でき、例えば、ステアリ
ン酸アミド等の高級脂肪酸、その塩、あるいはワックス
など、常温で固体の有機潤滑剤や、二酸化モリブデン等
の無機潤滑剤などから適宜選択すればよい。潤滑剤の割
合量は種類によっても異なるが、常温で固体の有機潤滑
剤ではＦｅ−Ｓｉ−Ａｌ系合金粉末に対し好ましくは
０．１〜１ｗｔ％とし、無機潤滑剤ではＦｅ−Ｓｉ−Ａ
ｌ系合金粉末に対し好ましくは０．１〜０．５ｗｔ％と
する。上記割合量の範囲に満たない場合は、添加による
効果が不十分となり、上記割合量の範囲を超える場合
は、コアの透磁率が低くなり、また、コアの強度も低く
なる。A lubricant is preferably added to the mixture after the drying treatment and before the molding. The lubricant is used to enhance interparticle lubricity during molding and to improve releasability from the mold. As the lubricant, various kinds of substances usually used for powder cores can be selected. For example, higher fatty acids such as stearamide and salts thereof, waxes, organic lubricants that are solid at room temperature, molybdenum dioxide, etc. It may be appropriately selected from the above inorganic lubricants. The proportion of the lubricant varies depending on the type, but for an organic lubricant that is solid at room temperature, it is preferably 0.1 to 1 wt% with respect to the Fe-Si-Al alloy powder, and for an inorganic lubricant, Fe-Si-A.
It is preferably 0.1 to 0.5 wt% with respect to the l-based alloy powder. If the amount is less than the above range, the effect of addition becomes insufficient, and if the amount exceeds the above range, the magnetic permeability of the core becomes low and the strength of the core also becomes low.
【００４１】なお、潤滑剤は、通常、乾燥処理後に混合
するが、乾燥処理の際の加熱に耐えられる潤滑剤を用い
る場合には、潤滑剤を乾燥処理前に添加してもよい。The lubricant is usually mixed after the drying treatment, but if a lubricant that can withstand the heating during the drying treatment is used, the lubricant may be added before the drying treatment.
【００４２】成形工程では、所望のコア形状に成形す
る。本発明が適用されるコア形状は特に限定されず、い
わゆるトロイダル型、ＥＥ型、ＥＩ型、ＥＲ型、ＥＰＣ
型、ドラム型、ポット型、カップ型等の各種形状のコア
の製造に本発明は適用される。In the molding step, a desired core shape is formed. The shape of the core to which the present invention is applied is not particularly limited, and so-called toroidal type, EE type, EI type, ER type, EPC
The present invention is applied to the production of cores of various shapes such as molds, drum shapes, pot shapes, cup shapes and the like.
【００４３】成形条件は特に限定されず、目的とするコ
ア形状やコア寸法、コア密度などに応じて適宜決定すれ
ばよいが、通常、最大圧力は６〜２０ｔ／ｃｍ2程度、
最大圧力に保持する時間は０．１秒間〜１分間程度とす
る。The molding conditions are not particularly limited and may be appropriately determined according to the desired core shape, core size, core density, etc., but normally the maximum pressure is about 6 to 20 t / cm 2 .
The time for maintaining the maximum pressure is about 0.1 second to 1 minute.
【００４４】[0044]
【実施例】以下、本発明の具体的実施例を示す。EXAMPLES Specific examples of the present invention will be described below.
【００４５】（実施例１）合金の製造方法を変え、表１
に示す５種類のＦｅ−Ｓｉ−Ａｌ合金粉末を得た。な
お、これら合金粉末の具体的な製造方法を以下に示す。(Example 1) Table 1
Five kinds of Fe-Si-Al alloy powders shown in were obtained. In addition, the concrete manufacturing method of these alloy powders is shown below.
【００４６】ガスアトマイズ粉末はガスアトマイズ法に
よりＦｅが８４．３ｗｔ％、Ｓｉが９．８ｗｔ％、Ａｌ
が５．９ｗｔ％となるように製造した。The gas atomized powder was prepared by the gas atomizing method so that Fe was 84.3 wt%, Si was 9.8 wt% and Al was Al.
Was manufactured to be 5.9 wt%.
【００４７】高速急冷粉末は単ロール型高速急冷法を用
いて、上記組成と同様になるようにＦｅ−Ｓｉ−Ａｌ合
金の薄帯を作製し、ボールミルで粉砕し、Ｆｅ−Ｓｉ−
Ａｌ合金粉末を作製した。The rapid-quenching powder was produced by using a single-roll type rapid-quenching method to prepare a thin strip of Fe-Si-Al alloy so as to have the same composition as described above, and crushed by a ball mill to obtain Fe-Si-
An Al alloy powder was produced.
【００４８】粉砕粉末は溶解鋳造により製造したインゴ
ットを、ジョークラッシャー、ブラウンミルおよびベッ
セルミルにより粉砕し、Ｆｅ−Ｓｉ−Ａｌ合金粉末を作
製した。粉砕後、水素雰囲気中で８００℃にて１時間熱
処理を施した。なお粉末の組成は上記ガスアトマイズ法
による粉末と同様とした。As the crushed powder, the ingot produced by melting and casting was crushed by a jaw crusher, a brown mill and a vessel mill to prepare a Fe-Si-Al alloy powder. After crushing, heat treatment was performed at 800 ° C. for 1 hour in a hydrogen atmosphere. The composition of the powder was the same as that of the powder obtained by the gas atomizing method.
【００４９】水アトマイズ粉末は水アトマイズ法によ
り、組成が上記ガスアトマイズ法による粉末と同様とな
るようにＦｅ−Ｓｉ−Ａｌ合金粉末を作製した。The Fe-Si-Al alloy powder was produced by the water atomizing method so that the composition was the same as that of the powder by the gas atomizing method.
【００５０】ガスアトマイズ＋粉砕粉末は上記ガスアト
マイズ法により作製した粉末をベッセルミルを用いて粉
砕した。粉砕粉を水素雰囲気中で８００℃にて１時間加
熱処理を施した。The gas atomized + pulverized powder was obtained by pulverizing the powder produced by the above gas atomizing method using a vessel mill. The pulverized powder was heat-treated in a hydrogen atmosphere at 800 ° C. for 1 hour.
【００５１】[0051]
【表１】 [Table 1]
【００５２】上記これらの粉末にシリコーン樹脂と有機
チタンとを自動乳鉢により混合し、１００℃で１時間乾
燥した。シリコーン樹脂には、無溶剤型シリコーン樹脂
（トーレ・シリコーン社製ＳＲ２４１４：２５℃におけ
る粘度２０００〜８０００ＣＰ）を用い、有機チタン酸
には、前記した化１の化合物でｎ＝４のもの（日曹社製
ＴＢＴポリマーＢ−４）を用いた。Ｆｅ−Ｓｉ−Ａｌ合
金粉末に対するシリコーン樹脂の混合量は１．８ｗｔ％
とし、シリコーン樹脂に対する有機チタンの添加量は３
３ｗｔ％とした。Silicone resin and organic titanium were mixed with these powders in an automatic mortar and dried at 100 ° C. for 1 hour. Solvent-free silicone resin (SR2414 manufactured by Toray Silicone Co., Ltd .: Viscosity 2000-8000 CP at 25 ° C.) is used as the silicone resin, and organic titanic acid is the compound of the above chemical formula 1 with n = 4 (Nisso TBT polymer B-4) manufactured by the same company was used. The amount of the silicone resin mixed with the Fe-Si-Al alloy powder is 1.8 wt%
And the amount of organotitanium added to the silicone resin is 3
It was set to 3 wt%.
【００５３】乾燥後、潤滑剤を混合した。潤滑剤には、
Ｆｅ−Ｓｉ−Ａｌ合金粉末に対し０．４ｗｔ％のステア
リン酸アミドを用いた。次に、乾燥物を加圧成形し、ト
ロイダル状（外形１７．５ｍｍ、内径１０．２ｍｍ、高
さ６ｍｍ）の圧粉体を得た。成形圧力は、１２ｔ／ｃｍ
2とし、加圧時間は１０秒間とした。After drying, the lubricant was mixed. For lubricant,
0.4 wt% stearic acid amide was used with respect to the Fe-Si-Al alloy powder. Next, the dried product was pressure-molded to obtain a toroidal green powder (outer shape 17.5 mm, inner diameter 10.2 mm, height 6 mm). Molding pressure is 12t / cm
2 and the pressing time was 10 seconds.
【００５４】得られたトロイダルコアを窒素雰囲気、７
００℃、３０分間アニールし１００ｋＨｚにおける初透
磁率（μｉ）を求め、また、１００ｋＨｚ、１００ｍＴ
におけるヒステリシス損失（Ｐｈ）、渦電流損失（Ｐ
ｅ）、コアロス（Ｐｔ）を求めた。その結果を表２に示
す。The resulting toroidal core was placed in a nitrogen atmosphere,
Annealing is performed at 00 ° C. for 30 minutes to obtain the initial magnetic permeability (μi) at 100 kHz. Also, 100 kHz, 100 mT
Hysteresis loss (Ph) and eddy current loss (Ph)
e) and core loss (Pt) were determined. The results are shown in Table 2.
【００５５】[0055]
【表２】 [Table 2]
【００５６】表２より冷却速度の比較的大きいガスアト
マイズ、高速急冷法により作製した強磁性金属粉末を使
用したトロイダルコアはコアロスが小さいことがわか
る。またガスアトマイズにより作製した強磁性金属粉末
をさらに粉砕したものを使用したトロイダルコアは粉砕
によるストレスがあり、粉末のアニールをしても粉砕の
歪みが完全にリリースしないため、保磁力が大きく、従
ってヒステリシス損失も大きい。It can be seen from Table 2 that the core loss of the toroidal core using the ferromagnetic metal powder produced by the gas atomization and the rapid quenching method, which has a relatively high cooling rate, is small. In addition, the toroidal core made by further crushing the ferromagnetic metal powder produced by gas atomization has stress due to crushing, and even if the powder is annealed, the distortion of crushing does not completely release, so the coercive force is large and therefore the hysteresis Loss is also large.
【００５７】（実施例２）さらにコアロスを低減するた
めにアニール条件を検討した。その結果を表３に示す。Example 2 The annealing conditions were examined to further reduce the core loss. Table 3 shows the results.
【００５８】ここで試料となるトロイダルコアは平均粒
径１１μｍのガスアトマイズ粉を用いて実施例１と同様
な方法により作製した。また、各コアの測定も実施例１
と同様である。The toroidal core used as a sample was prepared by the same method as in Example 1 using gas atomized powder having an average particle size of 11 μm. In addition, the measurement of each core was also performed in Example 1.
Is the same as
【００５９】[0059]
【表３】 [Table 3]
【００６０】表３より、２回目のアニールを酸化雰囲気
で行うことにより、コアロスを低減できることがわか
る。２回目のアニールは、４００〜７００℃が好まし
い。アニール温度が４００℃より低い場合、コアロスの
低減が不十分であり、アニール温度が７００℃より高い
と透磁率が小さくなる。２回目のアニールを不活性雰囲
気中で行うと、コアロスの低減は認められず好ましくな
い。また、アニールを酸化雰囲気のみで行うと、コアロ
スは小さくなるものの、初透磁率が小さくなりすぎてし
まい好ましくない。Table 3 shows that core loss can be reduced by performing the second annealing in an oxidizing atmosphere. The temperature of the second annealing is preferably 400 to 700 ° C. When the annealing temperature is lower than 400 ° C, the core loss is insufficiently reduced, and when the annealing temperature is higher than 700 ° C, the magnetic permeability becomes small. When the second annealing is performed in an inert atmosphere, reduction of core loss is not recognized, which is not preferable. Further, if the annealing is performed only in an oxidizing atmosphere, the core loss is reduced, but the initial magnetic permeability becomes too small, which is not preferable.
【００６１】不活性雰囲気でアニール後、酸化雰囲気で
アニールを行うことにより、コアロスを低減できるの
は、強磁性金属粒子表面が酸化し電気抵抗が大きくなる
ことにより、渦電流が小さくなるためである。１００ｋ
Ｈｚ程度の交流では、圧粉コアのヒステリシス損失も渦
電流が小さくなることで小さくなる。これは、渦電流に
よる磁界が磁壁移動を妨げられる作用を抑えられるため
である。The core loss can be reduced by performing the annealing in the oxidizing atmosphere after the annealing in the inert atmosphere, because the surface of the ferromagnetic metal particles is oxidized and the electric resistance is increased, so that the eddy current is reduced. . 100k
With an alternating current of about Hz, the hysteresis loss of the dust core also becomes smaller as the eddy current becomes smaller. This is because the magnetic field due to the eddy current can suppress the effect of hindering the domain wall movement.
【００６２】（実施例３）実施例２よりアニールの雰囲
気等によりコアロスを低減できることがわかった。そこ
で実施例１で作製したコアをさらに酸化雰囲気（空気
中）、４００℃、３０分間アニールした。これらのコア
を実施例１と同様に初透磁率、コアロスを測定し、Ｆｅ
−Ｓｉ−Ａｌ合金粉末の製造方法の違いによる影響を見
た。結果を表４に示す。(Example 3) From Example 2, it was found that the core loss can be reduced by the annealing atmosphere and the like. Therefore, the core manufactured in Example 1 was further annealed at 400 ° C. for 30 minutes in an oxidizing atmosphere (in air). These cores were measured for initial permeability and core loss in the same manner as in Example 1, and Fe
The effect of the difference in the manufacturing method of the -Si-Al alloy powder was observed. The results are shown in Table 4.
【００６３】[0063]
【表４】 [Table 4]
【００６４】ガスアトマイズまたは高速急冷で作製した
Ｆｅ−Ｓｉ−Ａｌ合金粉末を用いた場合は、表２と比較
して２回目のアニールでコアロスが低減する。２回目の
アニールで金属粒子表面が酸化し、電気抵抗が高くなる
ことにより渦電流の影響が少なくなりコアロスが小さく
なる。When the Fe-Si-Al alloy powder produced by gas atomization or rapid quenching is used, the core loss is reduced by the second annealing as compared with Table 2. By the second annealing, the surface of the metal particles is oxidized and the electric resistance is increased, so that the influence of the eddy current is reduced and the core loss is reduced.
【００６５】一方、粉砕または水アトマイズで作成した
Ｆｅ−Ｓｉ−Ａｌ合金粉末を用いた場合は、コアロスが
大きく２回目のアニールでコアロスがほとんど低減しな
い。粉砕粉末を使用した場合は、金属粉末の酸素量が多
すぎるため磁壁移動が妨げられ、保磁力が大きくなり、
ヒステリシス損失が大きくなっている。On the other hand, when the Fe-Si-Al alloy powder prepared by pulverization or water atomization is used, the core loss is large and the core loss is hardly reduced by the second annealing. When pulverized powder is used, the amount of oxygen in the metal powder is too large, which hinders domain wall movement and increases coercive force.
The hysteresis loss is large.
【００６６】合金を構成している各元素の偏析の度合い
は、例えば、ＥＰＭＡなどにより分析できる。また、合
金粉末の酸素量はガス分析により知ることができる。The degree of segregation of each element constituting the alloy can be analyzed by, for example, EPMA. The oxygen content of the alloy powder can be known by gas analysis.
【００６７】[0067]
【発明の効果】ガスアトマイズ法または高速急冷法等に
より製造されたＦｅ−Ｓｉ−Ａｌ合金粉末は粉砕粉末等
に比べ、成形後の不活性雰囲気でのアニールによりスト
レスが開放されやすい。さらに不活性雰囲気で作製され
るため含有酸素量が少ないために、酸化物による磁壁移
動の妨げが少なく、保磁力が小さくなり、従ってヒステ
リシス損失が小さくなる。また２回目の酸化雰囲気での
アニールにより、コアロスの低減がはかれる。よって本
発明に係る製造方法により作製された圧粉コアは小型
化、高周波での使用が可能となる。The Fe-Si-Al alloy powder produced by the gas atomizing method or the rapid quenching method is easier to release the stress by annealing in the inert atmosphere after molding than the pulverized powder. Further, since it is produced in an inert atmosphere, the amount of oxygen contained is small, so that there is little obstruction of domain wall movement due to oxides, the coercive force is small, and therefore hysteresis loss is small. Also, the core loss can be reduced by the second annealing in the oxidizing atmosphere. Therefore, the dust core manufactured by the manufacturing method according to the present invention can be downsized and used at high frequency.
【図１】強磁性金属粒子の粒径とコアロスの関係を示す
図である。FIG. 1 is a diagram showing the relationship between the particle size of ferromagnetic metal particles and core loss.
Claims (7)
形した圧粉コアにおいて、前記合金粉末の粒子内部の酸
素含有量が４００ｐｐｍ以下であって、粒子表面が酸化
されていることを特徴とする圧粉コア。1. In a dust core formed by molding a Fe—Si—Al alloy powder and an insulating agent, the oxygen content inside the particles of the alloy powder is 400 ppm or less, and the surface of the particles is oxidized. Characterized dust core.
よびアルミニウムもしくはフェロアルミを不活性雰囲気
中で溶融し、不活性雰囲気中で急冷による製造方法で該
合金微粉末を作製し、絶縁剤と混合成形後アニールする
ことを特徴とする請求項１の圧粉コアの製造方法。2. Iron, silicon or ferro-silicon, and aluminum or ferro-aluminum are melted in an inert atmosphere, and the alloy fine powder is manufactured by a manufacturing method by quenching in an inert atmosphere, and after mixing and molding with an insulating agent. Annealing is performed, The manufacturing method of the dust core of Claim 1 characterized by the above-mentioned.
アトマイズ法によることを特徴とする圧粉コアの製造方
法。3. A method for producing a dust core, wherein the method for producing by quenching according to claim 2 is a gas atomizing method.
急冷法によることを特徴とする圧粉コアの製造方法。4. A method of manufacturing a dust core, wherein the method of manufacturing by rapid cooling according to claim 2 is a rapid cooling method.
後、さらに酸化雰囲気中でアニールすることを特徴とす
る請求項２、請求項３および請求項４の圧粉コアの製造
方法。5. The method for manufacturing a dust core according to claim 2, wherein the molded core is annealed in an inert atmosphere and then annealed in an oxidizing atmosphere.
〜８００℃である請求項５の圧粉コアの製造方法。6. An annealing temperature of 500 in an inert atmosphere.
The method for producing a dust core according to claim 5, wherein the temperature is from about 800 ° C.
７００℃である請求項５の圧粉コアの製造方法。7. An annealing temperature in an oxidizing atmosphere of 400 to.
The method for producing a dust core according to claim 5, wherein the temperature is 700 ° C.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP7230483A JPH0974011A (en) | 1995-09-07 | 1995-09-07 | Dust core and manufacture thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP7230483A JPH0974011A (en) | 1995-09-07 | 1995-09-07 | Dust core and manufacture thereof |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH0974011A true JPH0974011A (en) | 1997-03-18 |
Family
ID=16908501
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP7230483A Withdrawn JPH0974011A (en) | 1995-09-07 | 1995-09-07 | Dust core and manufacture thereof |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH0974011A (en) |
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