KR20140079720A - Fe based soft magnetic powder, composite magnetic powder using the fe based soft magnetic powder, and pressed powder magnetic core using the composite magnetic powder - Google Patents

Abstract

The present invention aims to provide Fe group soft magnetic powder. A density of a hydroxyl group on the surface of the Fe group soft magnetic powder can be adjusted. The Fe group soft magnetic powder can be used for manufacturing a pressed magnetic powder core having a high electrical resistivity. The Fe group soft magnetic powder is characterized in that the density of a hydroxyl group on the surface of the powder is 20-100 at%·g/m^2. The density of a hydroxyl group is represented by {O density × (Metal-OH ratio)}/SA. The Metal-OH ratio means a ratio of hydroxyl group to oxygen on the surface of the powder. O density (at%) and Metal-OH ratio (%) are values measured and analyzed by XPS. SA means a specific surface area (m^2/g) of the surface of the powder.

Description

FIELD OF THE INVENTION [0001] The present invention relates to a Fe-based soft magnetic powder, a Fe-based soft magnetic powder, and a composite magnetic powder using the Fe-based soft magnetic powder. THE COMPOSITE MAGNETIC POWDER}

The present invention relates to an Fe-based amorphous alloy to be applied to, for example, a powder magnetic core such as a transformer or a power choke coil.

BACKGROUND ART [0002] A voltage-boosting circuit such as a hybrid vehicle, a reactor used for power generation, a power-generating facility, and a power distribution magnetic core used for a transformer or a choke coil can be obtained by compacting a compound magnetic powder having a plurality of soft magnetic powders and a binder resin. The following Patent Document discloses a powder (soft magnetic powder) for a powder magnetic core.

In order to reduce the core loss, it is desired that the electric power resistivity is high.

In Patent Document 1, the surface of the soft magnetic powder (soft magnetic metal powder 1) is coated with an alkoxide layer made of an Al-Si-O based composite oxide and the surface of the alkoxide layer is covered with an insulating layer. According to the compacted magnetic core having the soft magnetic powder produced in this way, the effect of high density, high specific resistance and high strength can be obtained.

However, according to Patent Document 1, it is necessary to interpose the alkoxide layer to cover the surface of the soft magnetic powder (soft magnetic metal powder 1) with the insulating layer, and the manufacturing process becomes complicated and the manufacturing cost rises There was a problem of.

Further, according to Patent Document 2, the soft magnetic powder is subjected to steam treatment, and an insulating treatment is performed in which an insulating hydroxyl film is formed on the surface. According to Patent Document 3, there is a description that a hydroxyl group is adsorbed on the surface of the soft magnetic powder.

However, according to Patent Documents 2 and 3, the hydroxyl group density on the powder surface is not adjusted in order to increase the electric resistivity of the powder magnetic core.

Japanese Patent Application Laid-Open No. 2010-251600 Japanese Patent Application Laid-Open No. 2003-133121 Japanese Patent Application Laid-Open No. 2008-305823

It is an object of the present invention to solve the above-mentioned problems, and an object of the present invention is to provide a Fe-based soft magnetic powder capable of adjusting the hydroxyl group density on the surface of the Fe- , A compound magnetic powder using the Fe-based soft magnetic powder and a powder magnetic core using the compound magnetic powder.

The Fe-base soft magnetic powder in the present invention is a Fe-

And the hydroxyl group density on the surface of the powder represented by the following formula (2) is within the range of 20 (at%. G / cm2) to 100 (at%. G / cm2) or less.

The metal-OH ratio in the formula represents the ratio of the hydroxyl group to the O concentration on the powder surface, and the O concentration (at%) and the metal-OH ratio (%) are the analytical results measured by XPS, And the specific surface area of the surface (m 2 / g).

In the present invention, it is preferable that the hydroxyl group density is within a range of 28 (at% · g / cm 2) to 96 (at% · g / cm 2) or less.

Further, in the present invention, it is preferable that the average particle diameter (D50) of the Fe-base soft magnetic powder is 10 m or more and 12.5 m or less.

It is also preferable that the O concentration by the infrared absorption method of the Fe-base soft magnetic powder is 0.2 wt% or less.

Also, the Fe-base soft magnetic powder is represented by Fe _{100 -abcxyz- t} Ni _a Sn _b Cr _c P _x C _y B _z Si _t where 0at% < = a < = 10at%, 0at% ? At%? C? 6at%, 6.8at%? X? 10.8at%, 2.0at%? Y? 9.8at%, 0at%? Z? 8.0at%, and 0at%? T? 5.0at%.

The composite magnetic powder according to the present invention is characterized in that a plurality of Fe-based soft magnetic powders described above are bound together by a binder resin. It is preferable that the binder resin has a functional group having polarity. The functional group is preferably a hydroxyl group. In the present invention, it is preferable that the binder resin is an acrylic resin.

Further, the powder magnetic core according to the present invention is characterized by being obtained by compression-molding the composite magnetic powder described above.

According to the present invention, the density of hydroxyl groups on the powder surface is kept high. In other words, the oxidation density on the powder surface can be reduced. By increasing the hydroxyl group density on the powder surface as described above, the polar group on the powder surface is increased, and when the composite magnetic powder is produced with the binder resin, the adhesion with the binder resin can be improved. As a result, the decrease in the amount of the binder resin adhering to the composite magnetic powder can be suppressed, and the adhesion amount can be maintained at an appropriate amount. Thus, a high electrical resistivity can be obtained.

According to the Fe-based soft magnetic powder of the present invention, the hydroxyl group density on the powder surface can be increased and the adhesion with the binder resin can be improved. As a result, it is possible to suppress the decrease in the amount of the binder resin adhering to the composite magnetic powder and to obtain a high electrical resistivity.

1 is a schematic diagram of an Fe-base soft magnetic powder in the present embodiment.
2 is a schematic view showing a cross section of a composite magnetic powder in the present embodiment. However, the binder resin is not shown.
Fig. 3 is a perspective view of a powder magnetic core (core). Fig.
Fig. 4 is a plan view of the coil-enclosed pressure-distribution magnetic core.
5 is a structural schematic diagram of an iron oxide film in the atmosphere.
Fig. 6 shows a chemical reaction formula of adsorbed water on the surface of iron oxide.
7 (a) and 7 (b) are schematic diagrams showing the relationship between the hydroxyl group and the binder resin on the powder surface of the Fe-base soft magnetic powder.
8 is an SEM image of each of the Fe-based soft magnetic powder surfaces of Examples 1, 5, 7 and Comparative Example.
9 is a graph showing the relationship between the waiting time until drying of the Fe-based soft magnetic powder of Examples 1 to 7 and the comparative examples and the electrical resistivity of the powder magnetic core.
10 is a graph showing the relationship between the waiting time until drying of the Fe-based soft magnetic powder of Examples 1 to 7 and the comparative examples and the magnetic permeability of the powder magnetic core.
Fig. 11 is a graph showing the relationship between the waiting time until the Fe-based soft magnetic powder of Examples 1 to 7 and Comparative Example was dried and the O concentration (by the infrared absorption method) of the Fe-based soft magnetic powder.
Fig. 12 is a graph showing the relationship between the waiting time until the Fe-based soft magnetic powder of Examples 1 to 7 and Comparative Example was dried and the specific surface area (SA) of the Fe-based soft magnetic powder.
Fig. 13 (a) is an experimental result in which the O distribution state in the depth direction of the Fe-based soft magnetic powder of Example 1 was measured by AES analysis, and Fig. 13 (b) The experimental results obtained by measuring the O distribution state in the depth direction of the Fe-based soft magnetic powder of Example are shown.
14 (a) is a chemical state analysis result (XPS) of the O atom in Example 1, and Fig. 14 (b) is a chemical state analysis result (XPS) of the O atom in the comparative example.
15 is a graph showing the relationship between the O1 _S peak position of the Fe-based soft magnetic powder and the electric resistivity of the powder magnetic core in Examples 1 to 7 and Comparative Examples.
16 is a graph showing the relationship between the metal-OH ratio of the Fe-base soft magnetic powder in Examples 1 to 7 and Comparative Examples, measured by XPS, and the electrical resistivity of the green compact.
17 shows the analysis results of the FT-IR spectrum (4000 to 600 cm ^-1 ) in Example 1. Fig.
18 shows the analysis results of the FT-IR spectrum (3800 to 3000 cm ^-1 ) in Example 1. Fig.
19 is a graph showing the relationship between the waiting time until the Fe-based soft magnetic powder is dried and the hydroxyl group density on the powder surface in Examples 1 to 7 and Comparative Examples.
20 is a graph showing the relationship between the hydroxyl group density on the powder surface of the Fe-base soft magnetic powder and the electric resistivity of the powder magnetic core in Examples 1 to 7 and Comparative Examples.

1 is a schematic diagram of an Fe-base soft magnetic powder in the present embodiment.

The Fe-based soft magnetic powder (1) shown in Fig. 1 is, for example, an amorphous soft magnetic powder produced by the water atomization method. The Fe-base soft magnetic powder (1) in the present invention is represented by, for example, a composition formula of Fe _{100 -abcxyz- t} Ni _a Sn _b Cr _c P _x C _y B _z Si _t , where 0at% ? At% 10at%, 0at%? B? 3at%, 0at%? C? 6at%, 6.8at%? X? 10.8at%, 2.0at%? Y? 9.8at%, 0at%? Z? %? T? 5.0at%.

As shown in Fig. 1, the Fe-based soft magnetic powder 1 is, for example, approximately spherical. Further, the Fe-base soft magnetic powder 1 may have an approximately ellipsoid or other shape.

The surface 1a of the Fe-base soft magnetic powder 1 is a fine uneven surface. On the other hand, in the Fe-based soft magnetic powder of the comparative example to be described later, larger particles (precipitates) grow on the surface as compared with the present embodiment, and the irregularities as a whole increase.

The surface 1a of the Fe-based soft magnetic powder 1 shown in FIG. 1 is an oxide film. The oxide film has a metal-O state in which a metal element and an O element are bonded together, a metal- (OH) < / RTI > Here, Metal-OH is a state of chemisorbed water.

Fig. 5 is a structural schematic diagram of an iron oxide surface film in the atmosphere (Hiroaki Mihata, et al., &Quot; Study on development, analysis and evaluation of high purity metal material " Effect of Coating ", Research Report of Fukuoka Industrial Technology Center; 11, P101, (2001)). As shown in FIG. 5, a metal oxide layer exists on the surface of the metal crystal layer (M), and a surface hydroxyl group exists on the surface of the metal oxide layer. There is also a first layer of strongly adsorbed water molecules on it, a multimolecular layer of adsorbed water.

Fig. 6 shows a chemical reaction formula of adsorbed water on the surface of iron oxide (Haruo Watanabe, "Surface Chemistry of Magnetic Powder", Iwate Surface Technology Conference, "Ninth Surface Technology Seminar", p19, (1993)). The state in which water molecules are bonded to the hydroxyl groups of the chemisorbed water by hydrogen bonding (see FIG. 5) is the physical adsorption water.

This embodiment is concerned with appropriately adjusting the density of metal-OH (chemisorptive water) on the powder surface 1a of the surface 1a of the powder.

Here, the density of hydroxyl groups in the powder surface 1a is represented by the following equation (3).

The metal-OH ratio in the equation represents the ratio of the hydroxyl group to the O concentration in the powder surface 1a and the O concentration (at%) and the metal-OH ratio (%) are the analytical results measured by XPS, SA represents the specific surface area (m 2 / g) of the powder surface 1a.

For the XPS analysis, a measurement sample in the powder classifying below 3㎛ (D ₅₀ = 2~3㎛). The X-ray source was Al. The measurement area was set to 800 mu m phi. In addition, measurements were taken after removal of the contamination. For removal of contaminants, sputtering was carried out at a sputtering rate of 4.1 nm / min (in terms of SiO ₂ ) for 0.8 min. The metal-OH ratio (%) can be obtained by analyzing the state of the O1 _S peak position in XPS (waveform separation).

The specific surface area SA was measured by the BET one-point method.

In the present embodiment, the hydroxyl group density according to the formula (3) is set to be not less than 20 (at% · g / cm 2) and not more than 100 (at% · g / cm 2). Preferably, the hydroxyl group density is at least 28 (at% · g / cm 2) and not more than 96 (at% · g / cm 2).

In the present embodiment, it is preferable that the Fe-based soft magnetic powder (1) has an average particle diameter (D50) of 10 탆 or more and 12.5 탆 or less. The average particle diameter (D50) is based on the volume distribution.

In this embodiment, it is preferable that the O concentration in the Fe-based soft magnetic powder 1 by the infrared absorption method is 0.2 wt% or less. In the comparative example described later, irregularities considered to be precipitates are recognized on the surface of the powder, which is considered to be attributed to the promotion of oxidation on the surface of the powder. On the other hand, in this embodiment, the O concentration is lower than that of the comparative example, and no precipitate as large as the comparative example is found on the powder surface 1a.

2 is a schematic view showing a cross section of a composite magnetic powder in the present embodiment. However, the binder resin is not shown.

The composite magnetic powder (granulated powder) 10 of this embodiment shown in Fig. 2 is formed by binding a plurality of soft magnetic powders 1 with a binder resin (not shown). However, in FIG. 2, only one soft magnetic powder 1 is denoted by reference numeral 1. In the soft magnetic powder having a particle diameter (D50 (average particle diameter) of 50% of the volume cumulative value in terms of the bulk particle volume distribution of several micrometers to several tens of micrometers), the average particle diameter (D50) ≪ / RTI > of the composite magnetic powder of the present invention.

The binder resin is an acrylic resin, a silicone resin, an epoxy resin, a phenol resin, a urea resin, a melamine resin, or the like. Here, it is preferable that the binder resin has a functional group having polarity. The functional group is preferably a hydroxyl group, and the binder resin is preferably an acrylic resin.

The binder resin is added in an amount of about 0.5 to 5.0 mass% with respect to the total mass of the composite magnetic powder (10) (soft magnetic powder (1), binder resin and lubricant).

Fig. 2 shows a cross section passing through the center O of the composite magnetic powder 10. Here, "center" can be defined as a geometric center point. If the compound magnetic powder 10 is substantially spherical or substantially ellipsoidal, the point where the respective middle points in the X, Y and Z directions intersect is the center. The " center " can also be defined as a " center of gravity ".

Fig. 2 shows an X-Z cross section passing the center O of the composite magnetic powder 10 on the X-Y plane.

The composite magnetic powder 10 shown in Fig. 2 is substantially spherical, approximately spheroid, or the like. Or the composite magnetic powder 10 may have a shape other than a sphere or an ellipsoid. However, it is preferable that the composite magnetic powder 10 has a substantially circular or substantially elliptical cross-sectional shape as shown in Fig. At this time, the aspect ratio of the composite magnetic powder 10 is preferably 1 to 1.5. The aspect ratio is expressed by the ratio (d / e) of the major axis (d) and the minor axis (e) passing through the center O shown in Fig.

The composite magnetic powder 10 in this embodiment is manufactured by the spray drying method. The spray drying method is a method in which a mixed slurry of the soft magnetic powder 11 and the binder resin is sprayed in an arbitrary direction and dried. A spray dryer may be used for the spray drying method.

In the present embodiment, the average particle diameter of the composite magnetic powder 10 can be formed within a range of 80 to 110 mu m.

In the present embodiment, a plurality of compound magnetic powders 10 shown in Fig. 2 are compression molded to obtain a powder compacted core 11 shown in Fig. 3 and a coil-enclosed powdered magnetic core 2 shown in Fig. 4 4 < / RTI > coil).

The Fe-based soft magnetic powder (1), the compound magnetic powder (10) and the method for producing the magnetic flux dividing magnetic core in this embodiment will be described.

The Fe-base soft magnetic powder (1) is prepared, for example, by the water atomization method. Subsequently, the Fe-base soft magnetic powder (1) is put into a drier. The waiting time until the charging is set to 10 hours or less, preferably about 5 hours or less. More preferably, the waiting time is set to about 2 hours, more preferably about 1 hour or less.

After the Fe base soft magnetic powder (1) is put into a drier, the holding temperature in the drier is set to about 80 캜 to 120 캜. Also, the holding time in the dryer is set to about 3 hours. Also, the atmosphere in the dryer is reduced under reduced pressure.

The Fe-based soft magnetic powder (1), the binder resin, the lubricant and the coupling agent which have undergone the above-described steps are stirred and mixed in a solvent to obtain a clay-like slurry. Here, water is used as a solvent. As the lubricant, zinc stearate, aluminum stearate and the like can be used. As the coupling agent, a silane coupling agent or the like can be used.

Then, a granular composite magnetic powder (granular component) 10 made of the soft magnetic powder 11 and the binder resin is produced by a spray drying method.

Subsequently, the composite magnetic powder 10 is filled in a mold and compression-molded in the form of a powder magnetic core. The pressing pressure at this time is different between the pressure-dividing magnetic core 11 of Fig. 3 and the coil-enclosed pressure dividing core 2 of Fig. 3 is about 6 to 20 t / cm 2 in the power distribution magnetic core 11 and about 6 to 7 t / cm 2 in the coil-enclosed power distribution magnetic core 2 in FIG.

Then, the powder magnetic core is subjected to heat treatment. The heat treatment temperature is lower than the crystallization temperature of the Fe-based soft magnetic powder (1). This heat treatment is not intended to sinter the Fe-based soft magnetic powder (1) in order to obtain good magnetic properties. Further, it is considered that the lubricant and the coupling agent are mostly vaporized and disappear by this heat treatment, and are integrated with the binder resin. The binder resin is partially vaporized and disappears.

Even when the compound magnetic powder 10 of the present embodiment is compression molded to form a powder magnetic core, it can be inferred that the powder magnetic powder 10 of the present embodiment is molded using the cross-sectional shape of the powder magnetic core .

The Fe-based soft magnetic powder 1 in the present embodiment is a Fe-based soft magnetic powder having a hydroxyl group density represented by the above-mentioned formula (3) in a range of not less than 20 (at% · g / It is inside. As described above, in the present embodiment, the density of hydroxyl groups on the powder surface 1a is kept high. In other words, the oxidation density at the powder surface 1a can be reduced. By increasing the hydroxyl group density at the powder surface 1a, the polar group at the powder surface 1a is increased.

As shown in Fig. 7, the hydroxyl group (chemisorbed water) of the powder surface 1a of the Fe-based soft magnetic powder 1 is bonded to the hydroxyl group of, for example, an acrylic resin (binder resin). 7 (a), the higher the hydroxyl group density is, the lower the hydroxyl group density shown in Fig. 7 (b) is, the lower the Fe group magnetic powder 1 is, And the adhesion of the binder resin can be improved. This makes it possible to suppress the decrease in the amount of the binder resin adhering to the composite magnetic powder (10). Thus, a high electrical resistivity can be obtained.

According to this embodiment, as shown in, for example, Patent Document 1, when an insulating layer (binder resin) is attached to the surface of the Fe-base soft magnetic powder, an Fe-base soft magnetic powder It is possible to suppress the decrease in the amount of the binder resin adhered by adjusting the hydroxyl group density by directly applying a hydroxyl group to the powder surface 1a of the powder 1 and obtaining a high electrical resistivity effectively.

[Example]

The Fe-based soft magnetic powders of Examples 1 to 7 and Comparative Examples shown in the following Table 1 were produced by the water atomization method. In addition, the compositions of the respective samples were all of Fe _{74.43 at%} Cr _{1.96 at%} P _{9.04 at%} C _{2.16 at%} B _{7.54 at%} Si _{4.87 at%} .

As shown in Table 1, in Example 1, the Fe-based soft magnetic powder was prepared by the water atomization method, and then the waiting time until the Fe-based soft magnetic powder was put into the dryer was 1.8 hours. In Example 2, the waiting time is 0.93 hours, the waiting time is 1.5 hours in Example 3, the waiting time is 0.83 hours in Example 4, the waiting time is 1.1 hours in Example 5, The standby time was set to 1.8 hours, the standby time was set to 4.6 hours in Example 7, and the standby time was set to 24 hours in the comparative example.

After drying, the powder characteristics of each Fe-based soft magnetic powder were measured. The average particle size (D50) of each Fe-based soft magnetic powder was measured by laser diffraction turbulence method.

The O concentration of each Fe-based soft magnetic powder was measured by infrared absorption method. The specific surface area of each Fe-based soft magnetic powder was measured by the BET one-point method. The experimental results of the above powder characteristics are shown in Table 1.

8 is an SEM photograph of the powder surface of each Fe-based soft magnetic powder in Examples 1, 5, and 7 and Comparative Example after drying. SEM observation was carried out with an acceleration voltage of 0.7 kV and a magnification of 200 k. In Fig. 8, the electric resistivity in the powder magnetic core is also shown.

As shown in Fig. 8, in the comparative example, it was found that the precipitate was greatly grown on the surface of the powder, and the unevenness of the powder surface was increased. On the other hand, in Examples 1, 5 and 7, it was found that the growth of precipitates was suppressed as compared with Comparative Examples. Particularly, Examples 1 and 5, in which the waiting time until drying is small, are extremely fine uneven surfaces in the state of the powder surface as compared with Example 7. In Examples 1 and 5, And it was found to be more suppressed.

Next, the Fe-based soft magnetic powder, the acrylic resin (binder resin), the zinc stearate (lubricant), and the silane coupling agent, which had undergone the drying step, were mixed in a solvent (water) to obtain a slurry. The amount of the acrylic resin to be blended was 2.0 wt% with respect to the solid component of the Fe-base soft magnetic powder, acrylic resin and lubricant, 0.3 wt% with respect to the solid component of zinc stearate, and 0.5 wt% with respect to the soft magnetic powder.

Then, the slurry was put in a spray drier to prepare a composite magnetic powder (granulated powder) 10. The number of revolutions of the rotor in the spray dryer apparatus was adjusted within a range of 4000 to 6000 rpm. The temperature of the hot air introduced into the apparatus was controlled in the range of 130 to 170 DEG C and the temperature of the lower portion of the chamber was controlled to be in the range of 80 to 90 DEG C. The pressure inside the chamber was ₂ mmH2O (about 0.02 kPa). The inside of the chamber was set to an air (air) atmosphere.

The composite magnetic powder thus obtained was passed through a sieve of 212 mu m in order to remove coarse powder and the average particle diameter of the composite magnetic powder after passing through the sieve was within a range of 80 mu m to 110 mu m.

Next, each compound magnetic powder of each of the examples and the comparative examples was separately charged into a metal mold and pressure-molded at a surface pressure of 588 MPa (6 t / cm 2) to prepare respective pressure magnetic cores having an outer diameter of 12 mm, an inner diameter of 6 mm and a thickness of 3 mm. Each of the obtained green compacts was subjected to heat treatment at 372 占 폚 for 17 minutes in a nitrogen atmosphere. Thereafter, the substrate was impregnated with a silicon solution (13.5 wt%), dried at 70 DEG C for 30 minutes, and then heated at 285 DEG C for 1 minute to carry out a coating treatment.

The electrical resistivity of each of the thus-obtained green compacts was measured using a super-megaohmmeter (SM-8213, manufactured by DKK-TOA) under a voltage of 100V.

Further, a copper wire was wound around each of the obtained magnetic flux concentrators, and the magnetic permeability at a frequency of 100 kHz was measured using an impedance analyzer (HP 4192A). Table 1 shows the electrical resistance and permeability of each compact magnetic core.

9 is a graph showing the relationship between the waiting time until drying of the Fe-based soft magnetic powder of Examples 1 to 7 and the comparative examples and the electrical resistivity of the powder magnetic core.

As shown in Fig. 9 and Table 1, in Examples 1 to 7, in which the waiting time until drying was short, the electric resistivity was higher than that in the comparative example in which the waiting time until drying was long.

10 is a graph showing the relationship between the waiting time until drying of the Fe-based soft magnetic powder of Examples 1 to 7 and the comparative examples and the magnetic permeability of the powder magnetic core. As for the magnetic permeability, there was no significant difference between the examples and the comparative examples.

11 is a graph showing the relationship between the waiting time until drying of the Fe-based soft magnetic powder of Examples 1 to 7 and the comparative example and the O concentration of the Fe-based soft magnetic powder (by the infrared absorption method).

As shown in Fig. 11 and Table 1, in Examples 1 to 7, the O concentration was lower than that of Comparative Example.

Fig. 12 is a graph showing the relationship between the waiting time until the Fe-based soft magnetic powder of Examples 1 to 7 and Comparative Example was dried and the specific surface area (SA) of the Fe-based soft magnetic powder.

As shown in Fig. 12 and Table 1, in Examples 1 to 7, the specific surface area (SA) was smaller than that of the comparative example.

As described above, it was found that the O concentration and the specific surface area of the comparative example having a low electrical resistivity were larger than those of the examples. Also, as shown in the SEM photograph of FIG. 8, in the comparative example, a large precipitate was observed on the surface of the powder. From the above, it is considered that the oxidation of the comparative example on the powder surface is accelerated as compared with the examples.

Thus, in order to investigate the oxidation state in each of the examples and the comparative examples, the O distribution state in the depth direction from the powder surface was determined by AES analysis (Auger electron spectroscopy).

As an analysis condition, an Fe-based soft magnetic powder having an average particle diameter of about 2 占 퐉 was selected, and an acceleration voltage was set to 5 keV. The spot size was set to 1 占 퐉 and the depth direction from the surface of the powder toward the center Were analyzed. As the sputtering conditions, the energy was 2000 eV, the Ar gas pressure was 8.5 × 10 ^-2 Pa, and the sputtering rate was 6.5 nm / min (in terms of SiO ₂ ).

The AES analysis was performed on Example 1 and Comparative Example. The experimental results are shown in Fig. Fig. 13 (a) shows the experimental results of Example 1, and Fig. 13 (b) shows the experimental results of the comparative example.

As shown in Fig. 13, the state of O distribution in the depth direction is not much changed in the embodiment and the comparative example. However, the peak value of the O concentration was higher in the comparative example than in the example. Contamination (contamination with an inorganic component or an organic component) was recognized on the outermost surface of the powder by the AES analysis in all of the examples and the comparative examples. Therefore, in the subsequent XPS analysis, in order to remove contaminants, To remove a depth of about 3.3 nm from the surface.

O concentration and chemical state of the powder surface in each of Examples and Comparative Examples were examined by XPS (X-ray photoelectron spectroscopy) analysis.

As the XPS analysis condition, the powder classified into 3 탆 or less was used, the X-ray source was made to be Al, the measurement area was set to 800 탆, and after quantification removal (sputter 0.8 min) Analysis. The sputtering rate was 4.1 nm / min (SiO ₂ Conversion).

The O concentration (after removal of the contamination) (at%), the O1 _S peak position, the metal-OH ratio, and the metal-oxide ratio in Examples 1 to 7 and Comparative Examples were determined by XPS analysis.

Fig. 14 shows the result of analysis of the chemical state of O atoms on the powder surface. The analysis of Fig. 14 was carried out for all the samples. Here, the analysis results of the comparative example are shown in Fig. 14 (a) in Example 1 and Fig. 14 (b).

In Example 1 of Fig. 14 (a), it was found that the O1 _S peak position was 531.08 eV, the Metal-OH ratio was 43.01%, and the Metal-Oxide ratio was 56.99%.

In the comparative example of 14 (b) and FIG O1 _S 530.61eV peak position is, the ratio is 15.26% Metal-OH, Metal-Oxide found that the ratio of 84.74%.

The XPS analysis results of Examples 1 to 7 and Comparative Examples are shown in Table 2 below.

Table 2 also shows the powder characteristics and the magnetic core characteristics shown in Table 1.

15 is a graph showing the relationship between the O1 _S peak position in Examples 1 to 7 and the comparative example and the electrical resistivity of the green compact.

17 is a graph showing the relationship between the O concentration (XPS) of the surface of the powders of Examples 1 to 7 and Comparative Examples and the electric resistivity of the powder magnetic core.

As shown in FIG. 15, it was recognized that the electric resistivity tends to increase as the O1 _S peak position shifts to the high energy side.

Lowering of electric resistivity due to shift of the low-energy side of the peak position O1 _S, as shown in 15 is a Metal-OH from the state of the O atoms is changed to cause a Metal-Oxide state is, I think. Thus, as shown in Fig. 14, analysis of the state of the peak position of O1 _S (waveform separation) was performed in each sample.

16 is a graph showing the relationship between the Metal-OH ratio in Examples 1 to 7 and Comparative Examples obtained by analyzing the state of the peak position of O1 _S and the electrical resistivity of the green compact.

As shown in Fig. 16, it was found that the electrical resistivity increases as the metal-OH ratio increases. That is, it was recognized that the electrical resistivity tends to decrease as the number of O atoms in the metal-OH state of the powder surface decreases. It is presumed that the change of the metal-OH state of the powder surface to the metal-oxide state due to the oxidation of the powder surface affects the electrical resistivity of the powder magnetic core.

Then, the presence of metal-OH by XPS analysis was confirmed by FT-IR analysis.

For the FT-IR analysis, FTS-40A manufactured by BIO-RAD was used as the apparatus. The diffuse reflection attachment made of BIO-RAD was used as the attachment. For the detector, Mid-IR DTGS was used. Further, the measurement area 4000~600cm ^-1, resolution of the 8cm ^-1, the cumulative number of times was 100 circuit. Further, the FT-IR analysis was carried out in the same manner as in Example 1. The results of the experiment are shown in Fig.

17 shows FT-IR analysis results obtained by setting the FT-IR spectrum at 4000 to 600 cm ^-1 . 18 is an FT-IR analysis result in which the FT-IR spectrum is changed to 3800 to 3000 cm ^-1 and is shown in an enlarged scale.

When the peak of the spectrum is observed at around 3690 cm ^{-1 and} around 3630 cm ^-1 , it is an isolated surface hydroxyl group bonded to the quadrature coordination Fe ion at the 6-coordinate of the spinel crystal of γ-iron oxide and has a spectrum peak of 3660 cm ^-1 , it is an isolated surface hydroxyl group bonded with a 6-valence Fe ion of a spinel crystal of α-iron oxide, and when the peak of the spectrum is seen to be 3600 cm ^-1 or less, it is a perturbation of the hydrogen bond ). For FT-IR analysis, H. Watanabe and J. Seto, Bull. Chem. Soc. Jpn., 66.395 (1993) were used as references.

As shown in Figure 18, is that the peak of the hydroxyl group shown in the vicinity of 3690cm ^-1, 3660cm ^-1 vicinity, 3630cm ^-1 vicinity. These were recognized as peaks of hydroxyl groups bonded to Fe on the powder surface by chemical adsorption (see FIGS. 5 and 6), and it was confirmed that Metal-OH was present.

As described above, it was found that the metal-OH (chemisorbed water) is related to the electric resistivity.

Therefore, the hydroxyl group density shown in the following formula (4) is used as an index for distinguishing the example and the comparative example.

The metal-OH ratio in the formula represents the ratio of the hydroxyl group to the O concentration on the powder surface, and the O concentration (at%) and the metal-OH ratio (%) are the analytical results measured by XPS, (At%), the metal-OH ratio, and the " properties of the powder after drying ", which are shown in Table 3 below, are the specific surface area (m 2 / g) Of the specific surface area of SA.

In Table 3, Example 8 was added. Example 8 was carried out under the same conditions as those of the other samples except that the waiting time until the Fe-based soft magnetic powder produced by the water atomization method was put into the drier was 20 minutes. In Embodiment 8, the waiting time is reduced to approximately the limit or to the theoretical value.

19 is a graph showing the relationship between the waiting time until the drying of each sample and the hydroxyl group density. However, the experiment results of Example 8 are not shown in Fig.

As shown in Fig. 19, it was found that the shorter the waiting time, the higher the hydroxyl group density.

20 is a graph showing the relationship between the hydroxyl group density of each sample and the electric resistivity of each of the green compacts. However, the experimental results of Example 8 are not shown in Fig.

As shown in FIG. 20, it was found that the electric resistivity of the magnetic powder magnetic core becomes higher as the hydroxyl group density becomes higher.

7, the higher the hydroxyl group density (the density of the chemisorbed material) of the powder surface is, the higher the density of the powder surface of the binder resin as the insulating material (the resin having polarity in a part of the molecular structure such as acrylic resin, It is presumed that the electrical resistivity of the green compact can be increased.

The hydroxyl group density was set to be not less than 20 (at% · g / cm 2) and not more than 100 (at% · g / cm 2) by the experimental results of Examples 1 to 8 shown in Table 3. The preferable range is 34 (at% · g / cm 2) or more and 96 (at% · g / cm 2) or less. A more preferable range is 50 (at% · g / cm 2) or more and 96 (at% · g / cm 2) or less.

Based on the experimental results shown in Table 3, the average particle diameter (D50) of the Fe-base soft magnetic powder was set to 10 μm or more and 12.5 μm or less. Also, the O concentration of the Fe-based soft magnetic powder by the infrared absorption method is 0.2 wt% or less, more preferably 0.17 wt% or less. Also, the O concentration by the infrared absorption method of the Fe-based soft magnetic powder was made larger than 0 wt%.

1: Fe-based soft magnetic powder 2: Coil encapsulating powder magnetic core
1a: Powder surface 3, 11: Pressure magnetic core
4: Coil 10: Composite magnetic powder

Claims (10)

Wherein the hydroxyl group density at the surface of the powder represented by the following formula (1) is within the range of 20 (at%. G / cm2) to 100 (at%. G / cm2) or less.
(1)

(The metal-OH ratio in the equation represents the ratio of the hydroxyl group to the O concentration on the powder surface and the O concentration (at%) and the metal-OH ratio (%) are the analytical results measured by XPS, (M 2 / g) of the powder surface) The method according to claim 1,
Wherein the hydroxyl group density is within the range of 28 (at% · g / cm 2) to 96 (at% · g / cm 2) or less. 3. The method according to claim 1 or 2,
An Fe-based soft magnetic powder having an average particle diameter (D50) of 10 占 퐉 or more and 12.5 占 퐉 or less. 3. The method according to claim 1 or 2,
An Fe-based soft magnetic powder having an O concentration of 0.2 wt% or less by the infrared absorption method. 3. The method according to claim 1 or 2,
The Fe-based soft magnetic powder is represented by Fe _{100 -abcxyz- t} Ni _a Sn _b Cr _c P _x C _y B _z Si _t, where 0at% ≤a ≤10at%, 0at% ≤b≤3at%, 0at% ? C? 6at%, 6.8at%? X? 10.8at%, 2.0at%? Y? 9.8at%, 0at%? Z? 8.0at%, 0at%? T? 5.0at%. A composite magnetic powder characterized by comprising a plurality of Fe-based soft magnetic powders according to any one of claims 1 to 3 bonded together by a binder resin. The method according to claim 6,
The binder resin is a composite magnetic powder having a functional group having polarity. 8. The method of claim 7,
Wherein the functional group is a hydroxyl group. The method according to claim 6,
The binder resin is an acrylic resin. A compact magnetic core obtained by compression molding the composite magnetic powder according to claim 6.

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