JPWO2018180659A1 - 複合磁性体の製造方法、磁性粉体、複合磁性体およびコイル部品 - Google Patents
複合磁性体の製造方法、磁性粉体、複合磁性体およびコイル部品 Download PDFInfo
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- JPWO2018180659A1 JPWO2018180659A1 JP2019509325A JP2019509325A JPWO2018180659A1 JP WO2018180659 A1 JPWO2018180659 A1 JP WO2018180659A1 JP 2019509325 A JP2019509325 A JP 2019509325A JP 2019509325 A JP2019509325 A JP 2019509325A JP WO2018180659 A1 JPWO2018180659 A1 JP WO2018180659A1
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 29
- 239000006247 magnetic powder Substances 0.000 title claims description 28
- 238000010438 heat treatment Methods 0.000 claims abstract description 189
- 239000000696 magnetic material Substances 0.000 claims abstract description 186
- 239000002184 metal Substances 0.000 claims abstract description 161
- 229910052751 metal Inorganic materials 0.000 claims abstract description 161
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 88
- 239000001301 oxygen Substances 0.000 claims abstract description 88
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 88
- 239000012298 atmosphere Substances 0.000 claims abstract description 26
- 229910017082 Fe-Si Inorganic materials 0.000 claims abstract description 18
- 229910017133 Fe—Si Inorganic materials 0.000 claims abstract description 18
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Abstract
Description
[1−1.複合磁性体の構成]
本実施の形態に係る複合磁性材料は、鉄(Fe)およびシリコン(Si)を主成分とする合金であるFe−Si系の金属磁性材料である。この金属磁性材料を所定の形状に加圧成形することにより、複合磁性体である複合磁性体2が形成されている。また、複合磁性体2に導体3が巻き回され、コイル部品1が形成されている。
以下、本実施の形態にかかる複合磁性体2の製造方法について説明する。図3は、本実施の形態に係る複合磁性体2の製造工程を示すフローチャートである。
以下、一次熱処理工程における第1の酸素分圧と第1の温度、および、二次熱処理工程における第2の酸素分圧と第2の温度について説明する。以下の実施例では、酸素分圧と熱処理温度を変更して、上述の製造方法により複数種類の複合磁性体2の成形を行った結果を示す。また、形成した各複合磁性体2について、酸素分圧と熱処理温度、および、磁気特性の評価を行った。酸素分圧と熱処理温度の値の組み合わせを、以下の実施例に示す。また、各複合磁性体2について、磁気特性として初透磁率および損失[kW/m3]を、以下の実施例に示す。
実施例1では、金属磁性材料20を加圧成形した成形体の熱処理として、一次熱処理および二次熱処理を行うことの効果を評価した。図4は、本実施例および比較例に係る複合磁性材料の熱処理条件および磁気特性を示す図である。本実施例では、複合磁性体2として図4に示す試料No.1の作成を行った。作成した試料は、外形14mm、内径10mm、高さ2mm程度のトロイダルコアである。なお、図4において、試料No.2〜4は、比較例である。
実施例2では、金属磁性材料20を加圧成形した成形体の熱処理について、二次熱処理の条件を一定とし、一次熱処理の条件を変更したときの効果を評価した。図5は、本実施例および比較例に係る複合磁性材料の熱処理条件および磁気特性を示す図である。本実施例では、複合磁性体2として図5に示す試料No.5〜21の作成を行った。作成した試料は、外形14mm、内径10mm、高さ2mm程度のトロイダルコアである。なお、図5において、試料No.6〜8、10〜12、14〜16は本実施例に係る複合磁性体2であり、試料No.5、9、13、17〜21は比較例に係る複合磁性体2である。
実施例3では、金属磁性材料20を加圧成形した成形体の熱処理について、一次熱処理の条件を一定とし、二次熱処理の条件を変更したときの効果を評価した。図6は、本実施例および比較例に係る複合磁性材料の熱処理条件および磁気特性を示す図である。本実施例では、複合磁性体2として図6に示す試料No.22〜41の作成を行った。作成した試料は、外形14mm、内径10mm、高さ2mm程度のトロイダルコアである。なお、図6において、試料No.23〜25、27〜32、34〜36は本実施例に係る複合磁性体2であり、試料No.22、26、33、37〜41は比較例に係る複合磁性体2である。
以下、上述した複合磁性体2の磁気特性、並びに、一次熱処理工程および二次熱処理工程の意義について説明する。
・・・(式3)
以上、本実施の形態にかかる複合磁性体の製造方法は、Fe−Si系の金属磁性材料を所定の形状に加圧成形する加圧成形工程と、前記金属磁性材料を第1の酸素分圧の雰囲気中で熱処理して、前記金属磁性材料の表面にSi酸化物被膜を形成する一次熱処理工程と、前記一次熱処理工程後の前記金属磁性材料を、前記第1の酸素分圧よりも高い第2の酸素分圧の雰囲気中で熱処理して、前記Si酸化物被膜の表面の少なくとも一部にFe酸化物層を形成する二次熱処理工程とを含む。
次に、実施の形態2について説明する。実施の形態1では、金属磁性材料20が加圧成形された複合磁性体2を例に挙げて説明したが、本実施の形態では、金属磁性材料20により構成される磁性粉体20aについて説明する。
図8は、本実施の形態に係る磁性粉体20aの構成を示す断面図である。図8に示すように、磁性粉体20aは、実施の形態1に示した複合磁性体2と同様、Fe−Si系の金属磁性材料20により構成されている。金属磁性材料20の表面には、Si酸化物被膜22が形成されている。また、Si酸化物被膜22の表面の少なくとも一部には、Fe酸化物層24が形成されている。
以下、本実施の形態にかかる磁性粉体20aの製造方法、および、当該磁性粉体20aを用いた複合磁性体の製造方法について説明する。図9は、本実施の形態に係る磁性粉体20aの製造工程を示すフローチャートである。
なお、図1に示したように、上述した実施の形態では、コイル部品1をトロイダルコイルとし、複合磁性体2を円筒状の形状を有する構成としたが、コイル部品1および複合磁性体2はこの構成に限られず、変更してもよい。例えば、複合磁性体は2つの分割磁心で構成され、2つの分割磁心の内部にコイル部が保持された構成であってもよい。
以上、本開示の実施の形態および変形例に係る複合磁性体および磁性粉体について説明したが、本開示は、この実施の形態に限定されるものではない。
2 複合磁性体
3、130 導体
20 金属磁性材料
20a 磁性粉体
22 Si酸化物被膜
24 Fe酸化物層
26 結着剤
120 分割磁心(複合磁性体)
120a 基台
120b 芯部
120c 壁部
140 コイル支持体
140a 基部
140b 円筒部
Claims (7)
- Fe−Si系の金属磁性材料を所定の形状に加圧成形する加圧成形工程と、
前記金属磁性材料を第1の酸素分圧の雰囲気中で熱処理して、前記金属磁性材料の表面にSi酸化物被膜を形成する一次熱処理工程と、
前記一次熱処理工程後の前記金属磁性材料を、前記第1の酸素分圧よりも高い第2の酸素分圧の雰囲気中で熱処理して、前記Si酸化物被膜の表面の少なくとも一部にFe酸化物層を形成する二次熱処理工程とを含む、
複合磁性体の製造方法。 - 前記一次熱処理工程において、前記金属磁性材料を第1の温度で熱処理し、
前記二次熱処理工程において、前記金属磁性材料を前記第1の温度よりも高い第2の温度で熱処理する、
請求項1に記載の複合磁性体の製造方法。 - 前記一次熱処理工程の前に、前記加圧成形工程と、前記加圧成形後の前記金属磁性材料を脱脂する脱脂工程とを行い、
前記一次熱処理工程に連続して前記二次熱処理工程を行う、
請求項1または2に記載の複合磁性体の製造方法。 - 前記一次熱処理工程に連続して前記二次熱処理工程を行った後、前記加圧成形工程を行い、
前記加圧成形工程を行った後、前記第2の温度と同程度の第3の温度により、前記金属磁性材料の歪みを緩和する歪み緩和工程をさらに含む、
請求項2に記載の複合磁性体の製造方法。 - Fe−Si系の金属磁性材料と、
前記金属磁性材料の表面を覆うSi酸化物被膜と、
前記Si酸化物被膜の表面の少なくとも一部に形成されたFe酸化物層とを備える、
磁性粉体。 - 複数の請求項5に記載の磁性粉体が所定の形状に加圧成形された、
複合磁性体。 - 請求項6に記載の複合磁性体と、
前記複合磁性体の周囲に巻き回された導体とを備える、
コイル部品。
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