KR20170018939A - Powder core, electric/electronic component, and electric/electronic device - Google Patents

Abstract

1. A compacted particulate core excellent in heat resistance, wherein the resin for providing the resin-based material (R) comprises an acrylic resin as a compaction core (1) comprising a soft magnetic powder (M) and an insulating resin- (1) is measured by TOF-SIMS under the following conditions, and a peak based on a first ion composed of at least one kind of ions represented by C _n H _2n-1 O ₂ ^- (n = 11 to 20) An electric / electronic part having such a compacted core and an electric / electronic device in which the electric / electronic part is mounted are also provided.
Investigation ion: Bi ³⁺
Acceleration voltage: 25 keV
Survey current: 0.3 ㎀
Investigation mode: bunching mode

Description

[0001] POWDER CORE, ELECTRIC / ELECTRONIC COMPONENT, AND ELECTRIC / ELECTRONIC DEVICE [0002]

The present invention relates to a compacted core using soft magnetic powder, an electric / electronic component having the compacted core, and an electric / electronic device in which the electric / electronic component is mounted.

A compact cored core used as a component of an electric / electronic component such as an inductance element, a reactor, a transformer or a choke coil can be obtained by compacting a large number of soft magnetic powders together with a resin and heat-treating the obtained compact. Patent Document 1 below discloses an example of a compact cored core.

Japanese Laid-Open Patent Publication No. 2012-212853

The compacted powder core obtained by the above production method is a composite of a soft magnetic powder and a resin-based material. The soft magnetic powder in the compacted core is thermally stable if it is up to about 300 캜, usually in the air. However, when the compaction core is heated to such a temperature, the thermal degradation of the resin-based material becomes present and the magnetic characteristic of the compaction core changes.

As a measure for evaluating the thermal stability of such a cored core, a heating test in which the substrate is left in an atmosphere at 250 캜 for 1,000 hours in the atmosphere (the "heating test" in this specification means the heating test). ) Is the change rate of the core loss in the case of the compacting core. In this specification, using the core loss Pc ₀ (unit: kW / m 3) of the compaction core measured before the heating test and the core loss Pc ₁ (unit kW / m 3) of the compaction core measured after the heating test, (Unit:%) of the core loss defined by "%" is small, and the compacted core is referred to as " excellent in heat resistance ".

? Pc = (Pc ₁ - Pc ₀ ) / Pc ₀ 100

An object of the present invention is to provide a compacted core excellent in heat resistance, an electric / electronic component having such a compacted core, and an electric / electronic appliance in which the electric / electronic component is mounted.

In order to solve the above problems, the inventors of the present invention have found that a compact cored core in which a peak based on a specific ion is measured by TOF-SIMS has excellent heat resistance.

The present invention completed on the basis of the above finding is, as an embodiment, a compacting core comprising a soft magnetic powder and an insulating resin material, wherein the resin providing the resin material contains an acrylic resin, , A peak based on a first ion composed of at least one kind of ions represented by C _n H _2n-1 O ₂ ^- (n = 11 to 20) is measured by TOF-SIMS under the condition To provide a compost core.

Investigation ion: Bi ³⁺

Acceleration voltage: 25 keV

Survey current: 0.3 ㎀

Investigation mode: bunching mode

The first intensity ratio, which is the ratio of the peak intensity based on the first ion to the intensity of the peak based on C ₃ H ₃ O ₂ ^- measured when the compact cores are measured by TOF-SIMS under the above conditions, is 0.03 or more .

When the compacted core was measured by TOF-SIMS under the above conditions, the maximum value of the peak based on the ion was found to be larger than mass / u where the peak based on the first ion had a maximum value, 0.5 at least one mass / u, wherein at least one peak based on a second ion which is an ion other than the first ion is measured, and the ratio of the peak intensity of the first ion The second intensity ratio, which is the ratio of the peak intensity, is preferably 0.1 or more.

According to another aspect of the present invention, there is provided a compaction core comprising a soft magnetic powder and an insulating resin-based material, wherein the resin providing the resin-based material contains an acrylic resin and the compacted core is subjected to TOF- , A peak based on a third ion represented by C ₅ H ₇ O ₃ ^- is measured.

Investigation ion: Bi ³⁺

Acceleration voltage: 25 keV

Survey current: 0.3 ㎀

Investigation mode: bunching mode

The third intensity ratio, which is the ratio of the peak intensity based on the third ion to the intensity of the peak based on C ₃ H ₃ O ₂ ^- measured when the compact cores are measured by TOF-SIMS under the above conditions, is 0.05 or more .

According to another aspect of the present invention, there is provided a compaction core comprising a soft magnetic powder and an insulating resin-based material, wherein the resin providing the resin-based material contains an acrylic resin and the compacted core is subjected to TOF- The fourth ion represented by C ₇ H ₁₁ O ₂ ^- is measured.

Investigation ion: Bi ³⁺

Acceleration voltage: 25 keV

Survey current: 0.3 ㎀

Investigation mode: bunching mode

Wherein the ratio of the peak intensity based on the fourth ion to the intensity of the peak based on C ₃ H ₃ O ₂ ^- measured when the compacted core is measured by TOF-SIMS under the above conditions is 0.02 or more .

The compacting core according to the present invention may further comprise at least one of the following features.

The fifth strength, which is the ratio of the peak intensity based on C ₂ HO ^- to the intensity of the peak based on C ₂ H ₃ O ₂ ^- measured when the compact core was measured by TOF-SIMS under the conditions described above The ratio is 10 or less.

· Pepper core contains P (phosphorus). The carbon powder core tends to be easily measured for at least one of the first ion, the third ion and the fourth ion by containing P in some cases.

The soft magnetic powder has a portion made of amorphous material.

The soft magnetic powder is a Fe-based amorphous alloy which is composed of 0 atomic% or more and 10 atomic% or less of Ni, 0 atomic% or more and 3 atomic% or less of Sn, 0 atom% or more and 6 atomic% or less of Cr, At least 3.0 atomic% and not more than 11 atomic%, C at least 1.0 atomic% and not more than 10 atomic%, B at 0 atomic% and not more than 9 atomic%, and Si at not less than 0 atomic% and not more than 6 atomic%. Fe-based amorphous alloys may contain P, which may tend to be easily measured for at least one of the first, third, and fourth ions.

The compact cored core is obtained by press-forming a composition containing the soft magnetic powder and the resin to obtain a molded body, and heating the obtained molded body. The heating of the molded body preferably includes heating in an oxidizing atmosphere and heating in a non-oxidizing atmosphere. The composition may contain an inorganic component, and the inorganic component preferably contains P. The inclusion of P in the inorganic component may tend to make measurement easier for at least one of the first, third, and fourth ions.

According to another aspect of the present invention, there is provided an electric / electronic component comprising a compaction core, a coil, and a connection terminal connected to each end of the coil, wherein at least a part of the compaction core includes: And an electric / electronic part arranged so as to be located in an induction magnetic field generated by the current when a current is passed through the coil.

According to another aspect of the present invention, there is provided an electric / electronic device in which the electric / electronic component is mounted, wherein the electric / electronic component is connected to the substrate by the connection terminal.

The compact cored core according to the present invention is excellent in heat resistance. According to the present invention, there is provided an electric / electronic part having such a compacted core and an electric / electronic device having the electric / electronic part mounted.

1 is a perspective view conceptually showing the shape of a compacting core according to an embodiment of the present invention.
Fig. 2 is a view showing a cross-sectional observation result of a compacting core according to an embodiment of the present invention. Fig.
3 is a diagram showing a part of the spectrum (mass / u is near 185, near 199 and near 213) obtained by measuring TOF-SIMS with respect to each of the compaction cores prepared in Example 1 and Comparative Examples 1 to 3 .
4 is a perspective view conceptually showing the shape of a toroidal core, which is an electric / electronic part having a compacted core according to an embodiment of the present invention.
Fig. 5 is a perspective view showing a part of an overall configuration of an inductance element which is an electric / electronic component having a compacted core according to another embodiment of the present invention. Fig.
6 is a partial front view showing a state in which the inductance element shown in Fig. 5 is mounted on a mounting substrate.
Fig. 7 is a view showing another part (mass / u near 115 and near 127) of the spectrum obtained by TOF-SIMS measurement for each of the compaction cores prepared in Example 1 and Comparative Examples 1 to 3. Fig.

Hereinafter, embodiments of the present invention will be described in detail.

1. Popcorn core

The compact powder core 1 according to an embodiment of the present invention shown in Fig. 1 has a ring-shaped outer appearance, and as shown in Fig. 2, the soft magnetic powder M and the insulating Based resin (R).

(1) Ions measured by TOF-SIMS

The compact carbon core 1 according to one embodiment of the present invention has a peak based on at least one of the first ion, the third ion and the fourth ion described below when measured by TOF-SIMS under the conditions described below Is measured.

(1-1) First ion

The compact carbon core 1 according to one embodiment of the present invention is characterized in that when measured by TOF-SIMS under the following conditions (hereinafter also referred to as "measurement condition 1"), C _n H _2n-1 O ₂ ^- (n = 11 to 20) is measured based on a first ion composed of at least one kind of ions. The first ions may be one kind or a plurality of kinds. The first ions are usually plural kinds.

Investigation ion: Bi ³⁺

Acceleration voltage: 25 keV

Survey current: 0.3 ㎀

Investigation mode: bunching mode

Here, the bunching mode is a mode in which the pulse width of the ion beam irradiated to the sample is narrowed, and the resolution is increased by narrowing the pulse width (time difference between the tip of the beam and the subsequent time).

3 is a diagram showing a part of the spectrum obtained by TOF-SIMS measurement for each of the compacted core 1 produced by Example 1 and Comparative Examples 1 to 3 to be described later. In Fig. 3, C ₁₁ H ₂₁ O ₂ ^- , C ₁₂ H ₂₃ O ₂ ^- , C ₁₃ H ₂₅ O ₂ ^- Are shown.

In the present specification, when the first intensity ratio described below is 0.01 or less, it is determined that the peak based on the first ion does not exist because the peak of the first ion can not be distinguished from the measurement noise.

By measuring the peak based on the first ion, a compacted powder core having excellent heat resistance is obtained. The reason is not clear. There is a possibility that a material having a carbon-hydrogen bond, which is more so-called an organic material, exists as a resin-based material. The first ion may have a chemical structure represented by the following formula (1).

CH ₃ - (CH ₂ ) _x -CH ₂ -COO ^- (1)

x is an integer between 8 and 17 inclusive

Since the resin for providing the resin-based material (R) in the compacting core (1) according to one embodiment of the present invention includes acrylic resin, when the compacting core (1) is measured by TOF-SIMS, The peak at which mass / u of the value is 71.02 is measured. The formula assumed from mass / u of the maximum value of this peak is C ₃ H ₃ O ₂ ^- . From this formula, it is considered that the anion which gives this peak corresponds to the acrylic acid ion. The ratio of the peak intensity based on the first ion to the intensity of the peak (referred to as " first reference intensity " in this specification) (referred to as " first intensity ratio " , It is preferably 0.03 or more, more preferably 0.05 or more, and particularly preferably 0.10 or more. The first ions having a first intensity ratio of 0.03 or more are preferably two or more, more preferably three or more, and particularly preferably four or more. The first ions having a first intensity ratio of 0.05 or more are preferably two or more, more preferably three or more, and particularly preferably four or more. It is preferable that the number of the first ions having a first intensity ratio of 0.10 or more is two or more.

(1-2) Second ion

When the compacted core 1 according to one embodiment of the present invention is measured by TOF-SIMS, the peak based on the second ions described below may be measured. In the present specification, the second ion means that the mass / u of the maximum value of the peak based on the ion is larger than the mass / u of the maximum value of the peak based on the first ion and the mass / quot; u " means an ion other than the first ion. A plurality of second ions may be defined for one type of first ion. In this case, a plurality of peaks are measured in the region of mass / u.

As shown in Fig. 3, the compact cored core 1 manufactured according to the embodiment of the present invention and the compacted cores prepared by the comparative example also had the second The peak based on the ion was measured. As shown in FIG. 3, there are clearly two peaks of the second ion corresponding to C ₁₁ H ₂₁ O ₂ ^{- which} is one kind of the first ions.

The compacted core 1 according to one embodiment of the present invention preferably has a second intensity ratio of 0.1 or more and a ratio of the peak intensity of the first ion to the total sum of the peak intensities of the second ions of 0.2 or more desirable.

The specific chemical structure of the second ion is not clear. As will be described later, the second ion is likely to be a fragment of a compound produced by bonding an acrylic resin to Fe, which is a constituent element of the soft magnetic powder. That is, the carboxyl group (-COOH) of the acrylic resin used as the binder chemically bonds to the surface of the soft magnetic powder by dehydration reaction with the hydroxyl group (-OH) bonded to Fe present on the surface of the soft magnetic powder . There is a possibility that a part of the acrylic resin chemically bonded to the surface of the soft magnetic powder is fragmented with Fe and become the second ion.

The second ion can also be measured in a compaction core other than the compaction core 1 according to the embodiment of the present invention, but in such compaction cores, the peak based on the first ion becomes a noise level, 0.1 or more.

(1-3) Third ion

The compacting core (1) according to one embodiment of the present invention measures a peak based on a third ion represented by C ₅ H ₇ O ₃ ^- when measured by TOF-SIMS under the measurement condition 1.

In the present specification, when the third intensity ratio to be described later is 0.01 or less, it is determined that the peak based on the third ion does not exist because the peak of the third ion can not be distinguished from the measurement noise.

By measuring the peak based on the third ion, a compacted powder core having excellent heat resistance is obtained. The reason is not clear. Although the specific chemical structure of the tertiary ion (C ₅ H ₇ O ₃ ^- ) is not clear, it has a carboxyl ion ((COO) ^- ) and a carbonyl group (> C = O) And so on.

In the compaction core 1 according to the embodiment of the present invention, the ratio of the peak intensity based on the third ion to the first reference intensity (referred to as " third intensity ratio " in this specification) More preferably 0.15 or more, and particularly preferably 0.20 or more.

(1-4) Fourth ion

The compacted core (1) according to one embodiment of the present invention, when measured by TOF-SIMS under the measurement condition 1, measures a peak based on a fourth ion represented by C ₇ H ₁₁ O ₂ ^- .

In the present specification, when the fourth intensity ratio to be described later is 0.01 or less, it is determined that the peak based on the third ion does not exist because the peak of the third ion can not be distinguished from the measurement noise.

By measuring the peak based on the fourth ion, a compacted powder core having excellent heat resistance is obtained. The reason is not clear. The specific chemical structure of the fourth ion (C ₇ H ₁₁ O ₂ ^- ) is not clear, but there is a possibility of a heptenoic acid ion having an ethylenic unsaturated bond at any of positions 2 to 6.

In the compaction core 1 according to the embodiment of the present invention, the ratio of the peak intensity based on the fourth ion to the first reference intensity (also referred to as " fourth intensity ratio " in the present specification) More preferably 0.04 or more, and particularly preferably 0.06 or more.

The compact powder core 1 according to one embodiment of the present invention may preferably contain P (phosphorus). Although the reason is not clear, it is easy to measure at least one of the first ion, the third ion and the fourth ion by the Peps core 1 containing P (phosphorous), and the heat resistance of the green compact 1 . The P (phosphorus) contained in the compaction core 1 may affect the physical properties and composition of the resin-based material R and contribute to generation of the above-mentioned ions. The method of containing P (phosphorus) in the press compaction core 1 is not limited. P (phosphorous) may be contained in the soft magnetic powder M or a phosphorus-containing glass or the like-containing material may be used in the production process of the dust compact core 1. It is particularly preferable to contain P in the soft magnetic powder (M).

(1-5) Fifth ion

In the compaction core 1 according to the embodiment of the present invention in which the peak based on the first ion is measured, an ion represented by C ₂ HO ^- , which is thought to be produced by decomposition of the acrylic resin in an oxidizing atmosphere Of the maximum value of the peak (mass / u of the peak is 41.01) of the peak (also referred to as " fifth ion " However, the intensity of the fifth peak tends to be smaller than the intensity of the peak of the fifth ion measured in the compaction core in which the peak based on the first ion is not substantially measured. Therefore, the compacted powder cores 1 according to one embodiment of the present invention may be in a state where decomposition by the oxidation of the resin-based material is not progressed relatively.

Specifically, when the compacted core 1 according to one embodiment of the present invention is measured by TOF-SIMS, the ratio of the peak intensity based on the fifth ion to the first reference intensity (in this specification, " 5 intensity ratio ") is preferably 10 or less, more preferably 7 or less, and particularly preferably 5 or less.

(2) Soft magnetic powder

The material constituting the soft magnetic powder (M) included in the dust compact core (1) according to one embodiment of the present invention is not limited. As such a material, a crystalline magnetic material and an amorphous magnetic material and a material having a crystalline portion and an amorphous portion are exemplified. The material constituting the soft magnetic powder M may be one kind or a plurality of kinds. In the case where the soft magnetic powder (M) is composed of a plurality of kinds of materials, the composition and the mixing ratio of each constituent material are not limited.

The crystalline magnetic material is not particularly limited as long as it is a crystalline material (a material capable of obtaining a diffraction spectrum having a clear peak so as to specify a material type by general X-ray diffraction measurement) and a soft magnetic material Do not. Examples of the crystalline magnetic material include Fe-Si-Cr alloys, Fe-Ni alloys, Fe-Co alloys, Fe-V alloys, Fe-Al alloys, Fe- Al-based alloys, carbonyl iron and pure iron. It is particularly preferable that these crystalline magnetic materials contain P in order to facilitate measurement of at least one of the first ion, the third ion and the fourth ion.

The amorphous magnetic material may be amorphous (as long as it is a soft magnetic material) that is amorphous (that is, it can not obtain a diffraction spectrum having a clear peak to such an extent that a material type can be specified by general X-ray diffraction measurement) It does not. Specific examples of the amorphous magnetic material include Fe-P-C-B-Si alloys, Fe-Si-B alloys, Fe-P-C alloys and Co-Fe-Si-B alloys. It is particularly preferable that these amorphous magnetic materials include P in order to facilitate measurement of at least one of the first ion, the third ion and the fourth ion.

As a more specific example of the amorphous magnetic material, it is preferable that the composition formula is represented by Fe _{100 at% -abcxyzt} Ni _a Sn _b Cr _c P _x C _y B _z Si _t where 0 at% ≤ a ≤ 10 at%, 0 at% ≤ b ≤ 0 at% ≤ c ≤ 6 at%, 6 at% ≤ x ≤ 10.8 at%, 2.2 at% ≤ y ≤ 9.8 at%, 0 at% ≤ z ≤ 4.2 at%, 0 at% ≤ t ≤ And 7 at% of Fe-based amorphous alloys. In the above composition formula, Ni, Sn, Cr, B, and Si are optional additional elements.

The preferable amount of each element of the Fe-based amorphous alloy is as follows. The addition amount a of Ni is preferably 0 at% to 6 at%, more preferably 0 at% to 4 at%. The addition amount b of Sn is preferably 0 at% to 2 at%, more preferably 1 at% to 2 at%. The addition amount c of Cr is preferably 0 at% or more and 2 at% or less, and more preferably 1 at% or more and 2 at% or less. The addition amount x of P is preferably 8.8 at% or more in order to facilitate measurement of at least one of the first ion, the third ion and the fourth ion. The addition amount y of C is preferably 5.8 at% or more and 8.8 at% or less. The addition amount z of B is preferably 0 at% to 3 at%, more preferably 0 at% to 2 at%. The addition amount t of Si is preferably 0 at% to 6 at%, more preferably 0 at% to 2 at%.

The material having a crystalline portion and an amorphous portion may be a mixture of a crystalline magnetic material and an amorphous magnetic material, or may be a material having an amorphous phase and a crystalline phase. As the latter material, an Fe-based alloy containing an element promoting crystal precipitation, such as Nb, Cu, Si or the like, may be exemplified as a crystalline seed crystal dispersed and precipitated in an amorphous phase.

The shape of the soft magnetic powder (M) contained in the press powder core (1) according to one embodiment of the present invention is not limited. The shape of the soft magnetic powder M may be spherical or non-spherical. In the case of the non-spherical shape, the shape may be a shape having a shape anisotropy such as a flat shape, a scaly shape, an elliptic sphere shape, a droplet shape, a needle shape, or a pseudo shape having no particular shape anisotropy.

The shape of the soft magnetic powder M may be a shape obtained in the step of manufacturing the soft magnetic powder M (the atomization method may be a concrete example), and the shape of the soft magnetic powder M Or may be a shape obtained by car machining (flat machining with atlite or the like is a concrete example). Examples of the former shape include spherical shape, elliptical spherical shape, droplet shape, needle shape and the like, and examples of the latter shape include a flat shape and a scaly shape.

The particle size of the soft magnetic powder (M) contained in the compacted powder (1) according to one embodiment of the present invention is not limited. Such a particle diameter is defined by the average particle diameter D50 (particle diameter when the volume cumulative value in the volume distribution of the particle diameter of the soft magnetic powder (M) measured by the laser diffraction scattering method is 50%), 20 mu m. The average particle size D50 of the soft magnetic powder (M) is preferably 2 mu m or more and 15 mu m or less in view of enhancing the handling property and enhancing the packing density of the soft magnetic powder (M) More preferably from 3 탆 to 10 탆, and particularly preferably from 4 탆 to 7 탆.

The content of the soft magnetic powder (M) in the compacted core (1) according to one embodiment of the present invention is not limited. It is properly set in consideration of the composition of the resin-based material, the manufacturing process, and the like.

(3) Resin material

The resin-based material (R) included in the compacted core (1) according to one embodiment of the present invention is an insulating material, and the resin for providing the material contains an acrylic resin. In the present specification, the term " resin material (R) " refers to a resin and / or a resin-based component (a component of which at least part of the resin is changed in composition, Based material (R) according to the present embodiment, the resin for providing the resin-based material (R) includes an acrylic resin.

The acrylic resin may contain a constituent unit based on at least one of acrylic acid and its derivatives, and may be a homopolymer or a copolymer. As the derivative of acrylic acid, acrylic acid ester, methacrylic acid and its ester, acrylamide and the like are exemplified. When the acrylic resin is a copolymer, the copolymer may contain a constituent unit other than the constituent unit based on at least one of acrylic acid and its derivatives, and the kind of the compound imparting the constituent unit is not limited. Specific examples of such compounds include olefins such as ethylene and vinyl esters such as vinyl acetate. The acrylic resin may have a crosslinked structure. In this case, the crosslinking agent is not limited, and examples thereof include polyisocyanate compounds and the like.

The resin for providing the resin-based material may contain a resin other than the acrylic resin. Examples of such resins include silicone resins, epoxy resins, phenol resins, urea resins, and melamine resins.

As shown in Fig. 2, the resin-based material R is placed between neighboring soft magnetic powders M and M in the compaction core 1 and fixes and insulates the soft magnetic powders M and M, Contributes to maintaining the shape and insulating properties of the compact powder core 1. In general, when the compacting core is provided in the heating test, the fixing function and / or the insulating function of the resin-based material may be degraded. However, the compacting core 1 according to the embodiment of the present invention, Based material R in which at least one of the first ion, the third ion and the fourth ion is measured when measured by TOF-SIMS, the magnetic properties do not deteriorate well after the heating test.

(4) Manufacturing method of potted core

The production method of the compacted powder cores 1 according to the embodiment of the present invention is not limited. As an example of such a manufacturing method, the compact powder core 1 can be obtained by press-molding a composition containing a soft magnetic powder and a resin, and heating the obtained molded body.

In this production method, the pressurizing condition and the heating condition are appropriately set according to mechanical characteristics, magnetic properties, composition of the composition and the like required for the press compaction core. Examples of the heating conditions include heating in an oxidizing atmosphere and heating in a non-oxidizing atmosphere. As described above, since the compacting core 1 according to one embodiment of the present invention is provided with the resin-based material (R) containing a component based on an acrylic resin, the composition to be subjected to the pressure molding is an acrylic resin .

(R) in which at least one of the first ion, the third ion and the fourth ion is measured when the green compact core (1) is measured by TOF-SIMS is obtained from a composition containing an acrylic resin, The heating conditions include heating in an oxidizing atmosphere, and the temperature is preferably 300 ° C to 400 ° C, more preferably 355 ° C to 400 ° C. Further, it is particularly preferable to set the temperature to 360 ° C or more and 400 ° C or less. In this case, it is preferable that heating is performed at 400 DEG C or more from the viewpoint of more reliably modifying the strain applied to the soft magnetic powder (M) by press molding. In this case, the powder compact core (1) It is preferable to conduct heating in a non-oxidizing atmosphere. Therefore, in the case of heating in an oxidizing atmosphere and heating in a non-oxidizing atmosphere, it is preferable that heating is performed in an oxidizing atmosphere at 300 ° C or more and 400 ° C or less and then heating at 400 ° C or more in a non- desirable.

The composition to be pressure-molded may contain components other than the soft magnetic powder and the resin. As such a component, an inorganic component such as glass, a lubricant such as a metal soap, and the like are exemplified. At least one of the first ion, the third ion and the fourth ion is measured when the green compact core 1 is measured by TOF-SIMS by containing a component (for example, phosphoric acid glass) containing P (phosphorus) It may become easy to become. The method of preparing the composition is not limited. The material constituting the composition may be simply kneaded, or the granulated powder may be formed by drying and pulverizing the slurry containing the material constituting the composition.

2. Electric and electronic parts

An electric / electronic component according to an embodiment of the present invention includes a compacting core (1) according to one embodiment of the present invention, a coil, and a connection terminal connected to each end of the coil. Here, at least a part of the compaction core 1 is arranged so as to be located in the induction magnetic field generated by the current when the current is passed through the coil via the connection terminal.

An example of such an electric / electronic part is the toroidal core 10 shown in Fig. The toroidal core 10 has a coil 2a formed by winding a coated conductive wire 2 on a ring-shaped green compact core 1. The end portions 2d and 2e of the coil 2a are positioned at the portions of the conductive wire located between the coil 2a made of the wound coated conductive wire 2 and the end portions 2b and 2c of the coated conductive wire 2, Can be defined. As described above, in the electric / electronic part according to the present embodiment, the member constituting the coil and the member constituting the connection terminal may be constituted by the same member.

An electric / electronic part according to an embodiment of the present invention includes a compacting core having a shape different from that of the compacting core 1 according to the embodiment of the present invention. As a specific example of such an electric / electronic part, there is an inductance element 20 shown in Fig. 5 is a perspective view showing a part of the overall configuration of the inductance element 20 according to the embodiment of the present invention. In Fig. 5, the lower surface (mounting surface) of the inductance element 20 is shown in an upward posture. 6 is a partial front view showing a state in which the inductance element 20 shown in Fig. 5 is mounted on the mounting substrate 10. Fig.

The inductance element 20 shown in Fig. 5 includes a compaction core 3, an air core coil 5 as a coil buried in the compaction core 3, and an air core coil 5 electrically connected to the air core coil 5 by welding And a pair of terminal portions 4 as connection terminals.

The air core coil (5) is formed by spirally winding an insulated conductor wire. The air core coil 5 is constituted of the winding section 5a and the leading end portions 5b and 5b drawn out from the winding section 5a. The number of turns of the coil 5 is appropriately set according to the required inductance.

5, in the compaction core 3, a housing recess 30 for accommodating a part of the terminal portion 4 is formed on the mounting surface 3a of the mounting board. The accommodating concave portion 30 is formed on both sides of the mounting surface 3a and is formed so as to be released toward the side surfaces 3b and 3c of the compaction core 3. A part of the terminal portion 4 protruding from the side surfaces 3b and 3c of the compaction core 3 is bent toward the mounting surface 3a and housed in the accommodating concave portion 30. [

The terminal portion 4 is formed of a thin Cu-base substrate. The terminal portion 4 is provided with a connection end portion 40 buried in the inside of the compaction core 3 and electrically connected to the lead-out end portions 5b and 5b of the air-core coil 5, And a first curved portion 42a and a second curved portion 42b that are formed in order from the sides 3b and 3c of the compaction core 3 to the mounting surface 3a. The connecting end portion 40 is a welded portion welded to the air-core coil 5. The first curved portion 42a and the second curved portion 42b are solder joint portions that are soldered to the mounting substrate 100. [ The solder joint portion is a portion of the terminal portion 4 exposed from the pressurized core 3 and means at least a surface directed toward the outside of the compaction core 3.

The connection end portion 40 of the terminal portion 4 and the lead-out end portion 5b of the air-core coil 5 are joined by resistance welding.

As shown in Fig. 6, the inductance element 20 is mounted on the mounting substrate 100. Fig.

On the surface of the mounting substrate 100, a conductor pattern that is in electrical communication with an external circuit is formed. A part of the conductor pattern forms a pair of land portions 110 for mounting the inductance element 20.

6, in the inductance element 20, the mounting surface 3a is directed toward the mounting board 100, and the first bending portion 42a and the second bending portion 42a, which are exposed to the outside from the presser core 3, The second curved portion 42b is bonded to the solder layer 120 between the land portions 110 of the mounting substrate 100. [

In the soldering process, after the paste-like solder is applied to the land portion 110 in the printing process, the inductance element 20 is mounted so that the second curved portion 42b faces the land portion 110, The solder is melted. 5 and 6, the second bending portion 42b is opposed to the land portion 110 of the mounting board 100, and the first bending portion 42a faces the side face 3b of the inductance element 20 The solder layer 120 on the fillet is fixed to the land portion 110 and the solder layer 120 on both surfaces of the second bending portion 42b and the first bending portion 42a, which are the solder joint portions, So that it is fixed.

Examples of the electric / electronic components other than the toroidal core 10 and the inductance element 20 described above include a reactor and a transformer.

3. Electrical and electronic equipment

An electric / electronic device according to an embodiment of the present invention is an electric / electronic device having a compacted core according to an embodiment of the present invention. Examples of such electric and electronic devices include a power supply device having a power supply switching circuit, a voltage raising and lowering circuit, a smoothing circuit, etc., and a small portable communication device.

When such electric / electronic devices are used for automotive applications, it is strongly demanded that they have excellent operation stability even when they are placed for a long time under a high temperature environment. In order to cope with such a demand, it is necessary that each of the electric and electronic parts mounted on the electric / electronic device has excellent operation stability even if it is placed under a high temperature environment for a long period of time. As described above, since the electric / electronic part according to the embodiment of the present invention is provided with the compacted powder core having excellent heat resistance, the electric / electronic device in which the component is mounted can be easily applied to the vehicle use.

The embodiments described above are provided for the purpose of facilitating understanding of the present invention and are not described for limiting the present invention. Therefore, each element disclosed in the above-mentioned embodiment is intended to include all design changes and bacteria belonging to the technical scope of the present invention.

For example, according to the present invention, it is possible to determine whether or not the compacted core has excellent heat resistance by measuring with TOF-SIMS. Further, by measuring with TOF-SIMS, it can be judged whether or not the dust compact core contains P (phosphorus) in each of the magnetic powder and the resin-based material.

Example

Hereinafter, the present invention will be described in more detail with reference to Examples and the like, but the scope of the present invention is not limited to these Examples and the like.

(Example 1)

The amorphous soft magnetic powder was obtained by weighing the amorphous soft magnetic powder to a composition 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%} using the water atomization method as a soft magnetic powder . The particle size distribution of the obtained soft magnetic powder was measured by volume distribution using "Microtrack particle size distribution measuring apparatus MT3300EX" manufactured by Nikkiso Co., Ltd. As a result, the average particle diameter (D50) of 50% in the volume distribution was 10.6 mu m.

100 parts by mass of the soft magnetic powder, 1.7 parts by mass of an acrylic resin, 0.6 parts by mass of an inorganic component comprising phosphoric acid glass and 0.3 part by mass of a lubricant comprising zinc stearate were mixed to obtain a slurry.

The obtained slurry was pulverized after drying, and fine powders of 300 탆 or less and coarse powders of 850 탆 or more were removed using a sieve body having a pitch of 300 탆 and a sieve of 850 탆 to obtain a granulated powder.

The resulting granulated powder was filled in a metal mold and subjected to pressure molding at a surface pressure of 1.8 mm to obtain a molded body having a ring shape. The obtained molded body was heated in the atmosphere (oxidizing atmosphere) at 360 캜 for 10 hours and then heat-treated in a nitrogen atmosphere (non-oxidizing atmosphere) at 470 캜 for one hour to obtain an outer diameter 20 mm x inner diameter 12 mm x A compacted powder core having a ring shape with a thickness of 7 mm was obtained.

(Comparative Example 1)

The same operation as in Example 1 was carried out except that phosphoric acid glass was not blended during the preparation of the slurry to obtain a compacted core.

(Comparative Example 2)

The same operation as in Example 1 was carried out except that the soft magnetic powder was changed to Fe-Si-B-Cr amorphous powder (average particle diameter (D50): 50 占 퐉). Further, the Fe-Si-B-Cr amorphous alloy did not contain P added.

(Comparative Example 3)

The same operation as in Comparative Example 2 was carried out except that phosphate glass was not blended during the preparation of the slurry to obtain a compacted core.

(Test Example 1) Measurement by TOF-SIMS

Measurement was carried out by TOF-SIMS for each of the compact cores prepared by the examples and the comparative examples. The measuring device and measurement conditions are as follows.

Measurement apparatus: TOF-SIMS5 (manufactured by ION-TOF)

Investigation ion: Bi ³⁺ (liquid metal ion source: Bi)

Acceleration voltage: 25 keV

Survey current: 0.3 ㎀

Measurement mode: High current bunching mode

and anions in the range of mass / u ranging from 20 to 250 were measured.

Specific measurement items were as follows. The peak intensity was obtained by fitting assuming that each peak had a normal distribution.

Measurement of presence or absence of peaks and peak intensity (first reference intensity) based on acrylic acid ions (C ₃ H ₃ O ₂ ^- )

The presence or absence of a peak based on the first ion and the measurement of the peak intensity

· Measurement of peak presence / absence and peak intensity based on the second ion

· Measurement of peak presence / absence and peak intensity based on the third ion

· Measurement of peak presence / absence and peak intensity based on the fourth ion

· Measurement of Peak Intensity and Peak Intensity Based on Fifth Ion

Some of the measured spectra are shown in Fig. 3 and Fig.

As a result of measurement, peaks based on acrylic acid ions were measured for any compaction core. Thus, from the measurement results, the first intensity ratio, the second intensity ratio, the third intensity ratio, the fourth intensity ratio, and the fifth intensity ratio were determined. These results are shown in Table 1 together with the formula of each ion assumed from the value of mass / u.

The meanings of numerical values in each column in Table 1 are as follows.

In the column of " mass / u " of the maximum value of the peaks, mass / u of the maximum value of each peak is shown. In the row of the anion (mass / u of the maximum of the peak / u of 71.01), which is the assumed C ₃ H ₃ O ₂ ^- , the peak intensities of the anion-based peaks in Example 1 and Comparative Examples 1 to 3 (Count number), that is, the first reference intensity.

A row of the first ions showed a first intensity ratio. As described above, the first intensity ratio is the ratio of the peak intensity based on the first ion to the first reference intensity. When the first intensity ratio was 0.01 or less, it was judged that there was no peak based on the first ion because the peak based on the first ion could not be distinguished from the measurement noise.

And a row of the second ions exhibited a second intensity ratio. As described above, the second intensity ratio is the ratio of the peak intensity of the first ion to the sum of the peak intensities of the second ions. When the second intensity ratio is less than 0.05, the peak based on the first ion can not be distinguished from the measurement noise, and therefore, " < 0.05 "

The row of the third ions showed a third intensity ratio. As described above, the third intensity ratio is the ratio of the peak intensity based on the third ion to the first reference intensity. When the third intensity ratio is 0.01 or less, it was judged that there was no peak based on the third ion since the peak based on the third ion can not be distinguished from the measured noise.

And a row of the fourth ions showed a fourth intensity ratio. As described above, the fourth intensity ratio is a ratio of the peak intensity based on the fourth ion to the first reference intensity. When the fourth intensity ratio was 0.01 or less, it was judged that there was no peak based on the fourth ion since the peak based on the fourth ion can not be distinguished from the measurement noise.

And the row of the fifth ions showed a fifth intensity ratio. As described above, the fifth intensity ratio is the ratio of the peak intensity based on the fifth ion to the first reference intensity.

(Test Example 2) Evaluation of heat resistance

Winding of a copper wire was carried out on a compact core having a ring-shaped shape produced by the examples and the comparative example, and the copper foil was wound using a BH analyzer ("SY-8217" manufactured by Iwasaki Communication Co., Ltd.) at a frequency of 100 kHz and a maximum magnetic flux density of 100 mT core loss Pc in the condition ₀ (unit: ㎾ / ㎥) was measured.

A heating test was performed in which the copper dust cored core was left in an atmosphere at 250 캜 for 1,000 hours in the atmosphere. After the heating test, the core loss Pc ₁ (unit: kW / m 3) was measured under the above conditions. The change rate? Pc (unit:%) of the core loss was calculated based on the following formula.

? Pc = (Pc ₁ - Pc ₀ ) / Pc ₀ 100

Table 2 shows the measurement results of the core loss and the rate of change of core loss.

As shown in Table 2, the pressed powder cores according to Example 1 in which the first ions, the third ions and the fourth ions were measured had a small change rate? Pc of core loss and excellent heat resistance. On the other hand, in the compaction cores according to Comparative Examples 1 to 3 in which neither the first ion, the third ion nor the fourth ion was measured, the rate of change ΔPc of core loss was large and the heat resistance was inferior.

As described above, the reason why ΔPc of the compacted core of Example 1 is reduced is because the stress generated in the soft magnetic powder in the compacted powder core caused by the heating due to the presence of the first ion, the third ion and the fourth ion is moderated And the strain is hardly accumulated in the soft magnetic powder. Although the reason is not clear, it is presumed that the presence of P in the soft magnetic powder or the phosphoric acid glass promotes the generation of the first ion, the third ion and the fourth ion in the resin material during the heat treatment in the atmosphere .

Industrial availability

INDUSTRIAL APPLICABILITY The compacted core of the present invention is preferable as a power supply device having a power supply switching circuit, a voltage rising and falling circuit, a smoothing circuit and the like, particularly a power supply device for vehicle use and a small portable communication device.

1: potato core
M: soft magnetic powder
R: resin-based material
10: Toroidal core
2: Coated conductive wire
2a: coil
2b, 2c: an end of the coated conductive line 2
2d, 2e: an end of the coil 2a
20: Inductance element
3:
3a: the seat of the compaction core (3)
3b, 3c: side surface of the presser core 3
4: Terminal portion
5: Coil coil
5a: winding part of the coils 5
5b: the withdrawal end of the air core coil 5
30:
40: connection end
42a:
42b:
100: mounting board
110: Land portion
120: solder layer

Claims (17)

A compact powder core comprising a soft magnetic powder and an insulating resin material,
Wherein the resin providing the resin-based material contains an acrylic resin,
A peak based on a first ion consisting of at least one kind of ions represented by C _n H _2n-1 O ₂ ^- (n = 11 to 20) measured by TOF-SIMS under the following conditions Wherein the compacting core is formed into a sheet shape.
Investigation ion: Bi ³⁺
Acceleration voltage: 25 keV
Survey current: 0.3 ㎀
Investigation mode: bunching mode The method according to claim 1,
A ratio of a peak intensity based on C ₃ H ₃ O ₂ ^- to a peak intensity based on C ₃ H ₃ O ₂ ^- measured when the compacted core is measured by TOF-SIMS under the conditions described in claim 1 1 intensity ratio of 0.03 or more. The method according to claim 1,
Wherein when the compacted core is measured by TOF-SIMS under the conditions described in claim 1, the mass / u of the maximum value of the peak based on the ion is larger than the mass / u of the maximum value of the peak based on the first ion, at least one peak based on a second ion which is an ion other than the first ion is measured between the mass of the first ion and a mass / u of 0.5 smaller than the mass / u, Wherein the ratio of the peak intensities of the first ions to the second ions is 0.1 or more. A compact powder core comprising a soft magnetic powder and an insulating resin material,
Wherein the resin providing the resin-based material contains an acrylic resin,
Wherein a peak based on a third ion represented by C ₅ H ₇ O ₃ ^- is measured when measured by TOF-SIMS under the following conditions.
Investigation ion: Bi ³⁺
Acceleration voltage: 25 keV
Survey current: 0.3 ㎀
Investigation mode: bunching mode 5. The method of claim 4,
The ratio of the peak intensity based on the third ion to the intensity of the peak based on C ₃ H ₃ O ₂ ^- measured when the compacted core is measured by TOF-SIMS under the conditions described in claim 4 3 Poppy core having a strength ratio of 0.05 or more. A compact powder core comprising a soft magnetic powder and an insulating resin material,
Wherein the resin providing the resin-based material contains an acrylic resin,
Wherein the compacted core is measured by TOF-SIMS under the following conditions, and a fourth ion represented by C ₇ H ₁₁ O ₂ ^- is measured.
Investigation ion: Bi ³⁺
Acceleration voltage: 25 keV
Survey current: 0.3 ㎀
Investigation mode: bunching mode The method according to claim 6,
The ratio of the peak intensity based on the fourth ion to the intensity of the peak based on C ₃ H ₃ O ₂ ^- measured when the compacted core is measured by TOF-SIMS under the conditions described in claim 6 4 intensity ratio of 0.02 or more. 8. The method according to any one of claims 1 to 7,
The method according to any one of claims 1 to 6, wherein the strength of the peak based on C ₂ H ₃ O ₂ ^- measured when the compacted core is measured by TOF-SIMS is measured by C ₂ HO ^- Wherein the fifth intensity ratio is 10 or less. 9. The method according to any one of claims 1 to 8,
P < / RTI > 10. The method according to any one of claims 1 to 9,
Wherein the soft magnetic powder has a portion made of amorphous. 11. The method according to any one of claims 1 to 10,
Wherein the soft magnetic powder is a Fe-based amorphous alloy containing 0 at% to 10 at% of Ni, 0 at% to 3 at% of Sn, 0 at% to 6 at% At least 11 atomic%, at least 1.0 atomic% and not more than 10 atomic% of C, at least 0 atomic% and not more than 9 atomic% of B, and at least 0 atomic% and not more than 6 atomic% of Si. 12. The method according to any one of claims 1 to 11,
Wherein the compacted powder core is obtained by press molding a composition containing the soft magnetic powder and the resin to obtain a molded body and heating the obtained molded body. 13. The method of claim 12,
The heating of the molded body includes heating in an oxidizing atmosphere and heating in a non-oxidizing atmosphere. The method according to claim 12 or 13,
Wherein the composition contains an inorganic component. 15. The method of claim 14,
Wherein the inorganic component contains P. An electric / electronic component comprising a compaction core, a coil, and a connection terminal connected to respective ends of the coil according to any one of claims 1 to 15, wherein at least a part of the compaction core has a connection terminal Wherein the coil is disposed so as to be positioned in the induction magnetic field generated by the current when the current is passed through the coil. An electric / electronic device in which the electric / electronic component according to claim 16 is mounted, wherein the electric / electronic component is connected to the substrate with the connection terminal.

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