JPH11241101A - Production of magnetic alloy powder for core material - Google Patents
Production of magnetic alloy powder for core materialInfo
- Publication number
- JPH11241101A JPH11241101A JP10045848A JP4584898A JPH11241101A JP H11241101 A JPH11241101 A JP H11241101A JP 10045848 A JP10045848 A JP 10045848A JP 4584898 A JP4584898 A JP 4584898A JP H11241101 A JPH11241101 A JP H11241101A
- Authority
- JP
- Japan
- Prior art keywords
- powder
- alloy
- alloy powder
- permalloy
- powders
- 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- Withdrawn
Links
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- Manufacture Of Metal Powder And Suspensions Thereof (AREA)
- Powder Metallurgy (AREA)
Abstract
Description
【0001】[0001]
【発明の属する技術分野】本発明は、スイッチング電源
用トランスコア、平滑チョーク等のコア材に用いられる
磁性合金粉末に関し、特に高い飽和磁束密度と優れた高
周波特性を両立させることができるコア材用磁性合金粉
末の製造方法に関するものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a magnetic alloy powder used for a core material such as a transformer core for a switching power supply and a smoothing choke, and more particularly to a core material capable of achieving both high saturation magnetic flux density and excellent high frequency characteristics. The present invention relates to a method for producing a magnetic alloy powder.
【0002】[0002]
【従来の技術】近年、スイッチング電源用トランスコア
や平滑チョークなどの電子部品は、小型化、高性能化さ
れる傾向にあり、それに伴ってそれらのコア材に結合材
と共に使用される磁性材料粉末についても高性能化の要
求が高まっている。従来、コア材用に一般的に使用され
ている粉末として、Fe−Si系合金やFe−Si−A
l系合金(センダスト)、酸化物磁性材料であるソフト
フェライトなどが知られている。2. Description of the Related Art In recent years, electronic components such as a transformer core for a switching power supply and a smoothing choke have tended to be miniaturized and improved in performance. Demands for higher performance have also increased. Conventionally, powders generally used for core materials include Fe-Si alloys and Fe-Si-A
An l-based alloy (Sendust), a soft ferrite as an oxide magnetic material, and the like are known.
【0003】これらの磁性材料粉末の中で、Fe−Si
系合金やFe−Ni系パーマロイ合金をはじめとする金
属磁性材料は酸化物磁性材料に比べて飽和磁束密度が高
く、小型化の要求に応えられる材料として期待されてい
るが、コアに成形した場合は、粉末同士の接触部分の電
気電導率が高いため高周波特性が悪くなる欠点があっ
た。これは高周波領域で用いた場合、過電流損失が増加
することに起因する。[0003] Among these magnetic material powders, Fe-Si
Metal alloys such as iron-based alloys and Fe-Ni-based permalloy alloys have higher saturation magnetic flux density than oxide magnetic materials, and are expected to meet the demand for miniaturization. However, there is a disadvantage that the high-frequency characteristics are deteriorated due to the high electrical conductivity of the contact portion between the powders. This is due to an increase in overcurrent loss when used in a high frequency region.
【0004】また、Fe−Si−Al系合金は金属磁性
材料の中でも極めて大きい透磁率を有し、コアへの適用
が期待されるが、前述した金属磁性材料共通の欠点に加
えて粉末の硬度が高く、プレス成形によっても殆ど変形
しないため、充填密度を高くして部品としての磁束密度
を大きくすることが極めて困難であると言う課題があっ
た。[0004] Further, Fe-Si-Al-based alloys have extremely high magnetic permeability among metal magnetic materials and are expected to be applied to cores. Therefore, there is a problem that it is extremely difficult to increase the packing density and increase the magnetic flux density as a part because the deformation is hardly caused by press molding.
【0005】一方、酸化物系磁性材料は粉末同士の接触
部分の電気電導率が低く、金属系磁性材料に比べて高周
波特性は良好であるが、飽和磁束密度が低いために近年
の小型化、高性能化に対応できなくなっている。この欠
点は酸化物系磁性材料固有の性質によるものであり、根
本的な改善は不可能な範疇のものである。On the other hand, an oxide-based magnetic material has a low electric conductivity at a contact portion between powders and has good high-frequency characteristics as compared with a metal-based magnetic material. It cannot support high performance. This disadvantage is due to the inherent properties of the oxide-based magnetic material, and is in a category where fundamental improvement is impossible.
【0006】従って、部品の小型化、高性能化に対応す
るにはFe−Si−Al系合金等のように飽和磁束密度
の高く、かつ極めて透磁率が高い金属磁性材料を主に用
いた上で、粉末の充填密度を向上させて、さらに磁束密
度を大きくし、さらに粉末接触部分の電気電導率を下げ
て高周波特性を改善することが望まれている。これに対
し、上記目的を達成させることを目的として、金属粉末
の表面を熱処理によって酸化させる、金属粉末の表面に
酸化物系磁性材料を複合させるなどの工夫によって電気
電導率を下げる提案が、例えば特開平6−204021
号公報に開示されている。Accordingly, in order to cope with miniaturization and high performance of parts, a metal magnetic material having a high saturation magnetic flux density and an extremely high magnetic permeability, such as an Fe-Si-Al alloy, is mainly used. Therefore, it is desired to improve the high-frequency characteristics by increasing the packing density of the powder, further increasing the magnetic flux density, and further decreasing the electric conductivity of the contact portion of the powder. On the other hand, for the purpose of achieving the above object, a proposal to lower the electric conductivity by oxidizing the surface of the metal powder by heat treatment, or combining an oxide-based magnetic material with the surface of the metal powder, for example, JP-A-6-202021
No. 6,086,045.
【0007】[0007]
【発明が解決しようとする課題】しかしながら、金属粉
末の表面を熱処理だけによって酸化させる方法による
と、熱処理温度の選択の仕方や時間によっては極表面に
電気電導率を下げる酸化皮膜を生じるだけでなく、その
内部にまで酸化物層が生成し、高い磁束密度を生じさせ
る金属相比率が減少するために、部品にした際の特性が
低下する危険がある。これは熱処理前の金属粉末表面の
一部が空気中の酸素などと反応し、部分的に酸化物や窒
化物を生じているために粉末の電気電導率を有効に下げ
る表面酸化の熱処理条件が一定でなく、熱処理温度を高
めにして処理時間も長めに設定する必要があることに起
因する。However, according to the method of oxidizing the surface of the metal powder only by heat treatment, depending on the method of selecting the heat treatment temperature and the time, not only an oxide film which lowers the electric conductivity on the surface of the metal powder, but also an oxide film is formed. Since the oxide layer is formed inside the metal layer and the ratio of the metal phase that causes a high magnetic flux density is reduced, there is a risk that the characteristics of the component may deteriorate. This is because heat treatment conditions for surface oxidation, which reduce the electrical conductivity of the powder effectively, because a part of the surface of the metal powder before heat treatment reacts with oxygen in the air and partially generates oxides and nitrides. This is because the heat treatment temperature is not constant and the treatment time needs to be set longer.
【0008】また、粉末表面に酸化物系磁性材料を複合
させる方法によると、酸化物系磁性材料の複合比率が高
まるに従い高周波特性は改善されるが、金属粉末単体を
用いた場合に比べて部品としての磁束密度は低下するよ
うになるために、有効な解決手段とは言えない。本発明
の目的は、従来技術が抱える上述の問題点を解決し、ス
イッチング電源用トランスコアや平滑チョークの小型
化、高性能化に対応することを目的として、飽和磁束密
度と高周波特性の両方に優れた特性を示す磁性材料を提
供することにある。According to the method of compounding an oxide-based magnetic material on the surface of a powder, high-frequency characteristics are improved as the composite ratio of the oxide-based magnetic material is increased. This is not an effective solution because the magnetic flux density as a result decreases. An object of the present invention is to solve both the above-mentioned problems of the conventional technology and to reduce the size and performance of a transformer core for a switching power supply and a smoothing choke, and to improve both the saturation magnetic flux density and the high-frequency characteristics. An object of the present invention is to provide a magnetic material exhibiting excellent characteristics.
【0009】[0009]
【課題を解決するための手段】上述の目的を実現すべく
検討した結果、発明者らはFe−Si系合金またはFe
−Si−Al系合金粉末とFe−Ni系パーマロイ合金
粉末を攪拌機能の付いたミキサー中で酸性溶液によって
表面処理を施した後、酸素を含む雰囲気中で熱処理し、
さらに該処理を施したFe−Si系合金またはFe−S
i−Al系合金粉末とFe−Ni系パーマロイ合金粉末
を混合することによって、Fe−Si系合金やFe−S
i−Al系磁性材料が持つ高い飽和磁束密度を最大限に
利用でき、さらにプレス圧縮で変形しにくいこれらの合
金粉末の隙間に柔らかいパーマロイ合金粉末が充填され
ていることによって、さらに高い磁束密度を稼ぐことが
できることを見出すと同時に、それらの粉末表面に均質
に生成した酸化物層によって優れた高周波特性を実現で
きることにある。As a result of studying to achieve the above object, the present inventors have found that an Fe--Si alloy or Fe
-Si-Al-based alloy powder and Fe-Ni-based permalloy alloy powder are subjected to surface treatment with an acidic solution in a mixer with a stirring function, and then heat-treated in an atmosphere containing oxygen.
Further, the Fe-Si alloy or Fe-S
By mixing i-Al-based alloy powder and Fe-Ni-based permalloy powder, Fe-Si-based alloy and Fe-S
The high saturation magnetic flux density possessed by the i-Al-based magnetic material can be used to the maximum, and the soft permalloy alloy powder is filled in the gaps between these alloy powders that are not easily deformed by press compression, thereby further increasing the magnetic flux density. At the same time as finding out that it can be profitable, excellent high-frequency characteristics can be realized by an oxide layer uniformly formed on the surface of the powder.
【0010】[0010]
【発明の実施の形態】本発明の特徴は、Fe−Si系ま
たはFe−Si−Al系合金粉末、Fe−Ni系合金粉
末とパーマロイ合金粉末の表面を攪拌機能の付いたミキ
サーで酸処理することによって、空気中の酸素や窒素と
反応した合金粉末表面の反応層を除去し、極めてクリー
ンで均一な状態の金属面を生成する。酸処理後のクリー
ンな金属面は極めて活性な状態にあり、表面処理を施さ
ない粉末に比べて低い温度、短い熱処理時間で均質で極
めて薄い酸化皮膜を形成する。このようなプロセスを施
すことによって、合金相比率を下げることなく表面だけ
に電気電導率の低い酸化層を作り出すことが可能にな
る。DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention is characterized in that the surfaces of Fe-Si-based or Fe-Si-Al-based alloy powder, Fe-Ni-based alloy powder and permalloy alloy powder are acid-treated by a mixer having a stirring function. As a result, a reaction layer on the surface of the alloy powder that has reacted with oxygen or nitrogen in the air is removed, and an extremely clean and uniform metal surface is generated. The clean metal surface after the acid treatment is in an extremely active state, and forms a uniform and extremely thin oxide film at a lower temperature and a shorter heat treatment time than a powder without surface treatment. By performing such a process, it becomes possible to create an oxide layer having low electric conductivity only on the surface without reducing the alloy phase ratio.
【0011】さらに、これらの処理を施したFe−Si
系粉末またはFe−Si−Al系粉末とFe−Ni系パ
ーマロイ粉末を混合することによって、Fe−Si系粉
末またはFe−Si−Al系粉末の優れた磁気特性を活
かした状態で、軟らかいためにプレス圧縮で容易に変形
して、Fe−Si系粉末またはFe−Si−Al系粉末
の間隔にFe−Ni系パーマロイ粉末の粉末充填さるこ
とによって、さらに磁束密度を向上させることが可能に
なる。これらの粉末は極めて均質で薄い表面酸化皮膜で
覆われているため、粉末間の電気電導度は低く抑えら
れ、その結果優れた高周波特性を得ることが可能にな
る。Further, Fe-Si treated with these treatments
By mixing the Fe-Si-based powder or the Fe-Si-Al-based powder with the Fe-Si-based powder, the softness is improved by mixing the Fe-Si-based powder or the Fe-Si-Al-based powder. By being easily deformed by press compression and filling the space between the Fe-Si-based powder or the Fe-Si-Al-based powder with the Fe-Ni-based permalloy powder, the magnetic flux density can be further improved. Since these powders are covered with a very uniform and thin surface oxide film, the electric conductivity between the powders is kept low, and as a result, excellent high-frequency characteristics can be obtained.
【0012】[0012]
【実施例】センダスト合金成分(Fe−9.6%Si−
5.4%Al)の粉末とパーマロイ合金成分(Fe−7
0%Ni−2%Mo)の粉末をArガスアトマイズで作
製し、得られた粉末をそれぞれ−105μに分級した。
分級後の各粉末について、処理槽下部に回転翼を有する
ミキサー(三井鉱山(株)製:ヘンシェルミキサー)に
粉末と酸性溶液(pH:1.0の塩酸水溶液)を重量比
1対1で投入し、回転翼の周速10m/secで攪拌さ
せながら表面処理を行った。pH変化が飽和した時点
(pH:6.5付近)で処理を終了し、純水で濾過洗浄
した後、常温真空中で乾燥させた。これらの表面処理粉
末について大気中で500℃×1時間保持して表面に酸
化皮膜処理を施した後、両者の粉末を重量比1対1で混
合してリング試料作製用の供試材粉末とした。Example: Sendust alloy component (Fe-9.6% Si-
5.4% Al) powder and permalloy alloy component (Fe-7)
(0% Ni-2% Mo) powder was produced by Ar gas atomization, and the obtained powders were each classified into -105μ.
With respect to each of the classified powders, the powder and an acidic solution (aqueous hydrochloric acid solution having a pH of 1.0) are put into a mixer (Henschel mixer manufactured by Mitsui Mining Co., Ltd.) at a weight ratio of 1: 1 to a mixer having a rotor blade at the lower part of the processing tank. Then, the surface treatment was performed while stirring at a peripheral speed of the rotor of 10 m / sec. When the pH change was saturated (pH: around 6.5), the treatment was terminated, and the mixture was filtered and washed with pure water, and then dried at room temperature under vacuum. These surface-treated powders were kept in the air at 500 ° C. for 1 hour to perform an oxide film treatment on their surfaces, and then the two powders were mixed at a weight ratio of 1: 1 to obtain a test material powder for producing a ring sample. did.
【0013】得られた供試材混合粉末をその粉末重量に
対して1.5wt%のシリコン系バインダーと0.5w
t%の架橋剤を加えて乳鉢で混合し、10t/cm2 の
圧力でプレス成形後、700℃で熱処理を行ない、交流
特性測定用のリング試料を得た。また、同時に比較用と
して、一連の表面処理及び酸化皮膜処理を施さないアト
マイズままの粉末を混合したものと表面処理を行わずに
酸化皮膜処理だけを施した粉末同士を混合したものにつ
いても同様の手順でリング試料を作製し、その特性を比
較した。特性の指標として、100kHzにおける交流
初透磁率を測定した。測定結果を表1に纏めて示す。表
1に示すように、表面処理及び酸化皮膜処理を施さない
アトマイズままの粉末を混合したものと表面処理を行わ
ずに酸化皮膜処理だけを施した粉末同士を混合したもも
の比較例に比べて、本発明は極めて優れた交流初透磁率
を示していることが判る。[0013] A 1.5 wt% silicon-based binder and 0.5 w
A t% crosslinking agent was added, mixed in a mortar, press-molded at a pressure of 10 t / cm 2 , and heat-treated at 700 ° C. to obtain a ring sample for measuring AC characteristics. At the same time, for comparison, the same applies to a mixture of as-atomized powder not subjected to a series of surface treatment and oxide film treatment and a mixture of powders subjected to only oxide film treatment without surface treatment. Ring samples were prepared according to the procedure, and their characteristics were compared. As an index of the characteristics, the AC initial permeability at 100 kHz was measured. The measurement results are summarized in Table 1. As shown in Table 1, as compared with the comparative example, the mixture of the powder as-atomized without the surface treatment and the oxide film treatment and the mixture of the powders with only the oxide film treatment without the surface treatment were compared. It can be seen that the present invention shows extremely excellent AC initial permeability.
【0014】[0014]
【表1】 [Table 1]
【0015】[0015]
【発明の効果】以上述べたように、本発明により、従来
法では両立できなかった磁束密度と高周波特性が、高い
飽和磁束密度と優れた高周波特性を両立させることが可
能となり、コア材への適用用途が広まり、工業上極めて
有利なものとなる。As described above, according to the present invention, the magnetic flux density and the high-frequency characteristics which cannot be achieved by the conventional method can be made compatible with the high saturation magnetic flux density and the excellent high-frequency characteristics. The application is widespread, which is extremely advantageous industrially.
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.6 識別記号 FI C22C 38/08 C22C 38/08 ──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. 6 Identification code FI C22C 38/08 C22C 38/08
Claims (1)
Si系合金またはFe−Si−Al系合金粉末とFe−
Ni系パーマロイ合金粉末について、該粉末を攪拌機能
の付いたミキサー中で酸性溶液によって表面処理を施し
た後、酸素を含む雰囲気中で熱処理し、さらに該処理を
施したFe−Si系合金またはFe−Si−Al系合金
粉末とFe−Ni系パーマロイ合金粉末を混合すること
を特徴とするコア材用磁性合金粉末の製造方法。1. An Fe— produced by gas atomization.
Si-based alloy or Fe-Si-Al-based alloy powder and Fe-
Ni-based permalloy powder is subjected to surface treatment with an acidic solution in a mixer equipped with a stirring function, and then heat-treated in an atmosphere containing oxygen, and further subjected to the Fe-Si-based alloy or Fe-treated alloy. A method for producing a magnetic alloy powder for a core material, comprising mixing an Si-Al alloy powder and an Fe-Ni permalloy alloy powder.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP10045848A JPH11241101A (en) | 1998-02-26 | 1998-02-26 | Production of magnetic alloy powder for core material |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP10045848A JPH11241101A (en) | 1998-02-26 | 1998-02-26 | Production of magnetic alloy powder for core material |
Publications (1)
Publication Number | Publication Date |
---|---|
JPH11241101A true JPH11241101A (en) | 1999-09-07 |
Family
ID=12730641
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
JP10045848A Withdrawn JPH11241101A (en) | 1998-02-26 | 1998-02-26 | Production of magnetic alloy powder for core material |
Country Status (1)
Country | Link |
---|---|
JP (1) | JPH11241101A (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102945720A (en) * | 2012-10-15 | 2013-02-27 | 广州市德珑电子器件有限公司 | Preparation method of sendust core with high direct current bias characteristic |
CN103495725A (en) * | 2013-09-27 | 2014-01-08 | 青岛联瑞精密机械有限公司 | Shape treating method for iron silicon aluminum soft magnetic powdery particles |
CN105014065A (en) * | 2015-08-12 | 2015-11-04 | 湖州南浔闻天磁性材料有限公司 | Fe-Si-Al soft magnetic powder |
-
1998
- 1998-02-26 JP JP10045848A patent/JPH11241101A/en not_active Withdrawn
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102945720A (en) * | 2012-10-15 | 2013-02-27 | 广州市德珑电子器件有限公司 | Preparation method of sendust core with high direct current bias characteristic |
CN102945720B (en) * | 2012-10-15 | 2016-08-03 | 广州市德珑电子器件有限公司 | A kind of preparation method of high direct current biasing characteristic Fe-Si-Al magnetic core |
CN103495725A (en) * | 2013-09-27 | 2014-01-08 | 青岛联瑞精密机械有限公司 | Shape treating method for iron silicon aluminum soft magnetic powdery particles |
CN105014065A (en) * | 2015-08-12 | 2015-11-04 | 湖州南浔闻天磁性材料有限公司 | Fe-Si-Al soft magnetic powder |
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