KR20170061586A - Compressed powder core, method of manufacturing the compressed powder core, inductor comprising the compressed powder core and electronic-electric device mounted with the inductor - Google Patents

Abstract

Disclosed is a compacted core containing a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, and provides a compacted core capable of improving direct current superimposition characteristics and reducing iron loss in an inductor having such compacted core .
A compact powder core (1) comprising a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, wherein a median diameter (D ₅₀ A) of the powder of the amorphous magnetic material is 15 μm or less, Wherein the median diameter (D ₅₀ C) of the powder satisfies the following formula (1).
_{1 ≤ D 50 A / D 50} C ≤ 3.5 (1)

Description

TECHNICAL FIELD [0001] The present invention relates to a compacted core, a method of manufacturing the compacted core, an inductor having the compacted core, and an electronic or electric device in which the inductor is mounted. BACKGROUND OF THE INVENTION 1. Field of the Invention [0002] ELECTRIC DEVICE MOUNTED WITH THE INDUCTOR}

The present invention relates to a compaction core, a method for manufacturing the compaction core, an inductor having the compaction core, and an electronic / electric device in which the inductor is mounted. In this specification, the term " inductor " means a passive element having a core material including a compacted core and a coil, and includes the concept of a reactor.

A compacting core used for a boosting circuit such as a hybrid car, a reactor used for power generation, a substation facility, and an inductor such as a transformer or a choke coil can be obtained by compacting a soft magnetic powder. An inductor having such a compacted core is required to have both low iron loss and excellent DC superposition characteristics.

Patent Literature 1 discloses a means for solving the above-mentioned problem (having a combination of a low iron loss and an excellent direct superposition property) as a means for pressing a mixed powder obtained by mixing a magnetic powder and a binder, An inductor in which a powder obtained by mixing 5 to 20 wt% of a carbon powder with a sendust powder is used as the magnetic powder.

Patent Literature 2 discloses an inductor capable of further reducing iron loss, wherein a mixture of an amorphous soft magnetic powder of 90 to 98 mass% and a crystalline soft soft powder of 2 to 10 mass% And a magnetic core (compaction core) containing the magnetic core. In such magnetic cores (compact cores), the amorphous soft magnetic powder is a material for lowering the core loss of the inductor. The crystalline soft magnetic powder improves the filling ratio of the mixed powder and increases the magnetic permeability, And serves as a binder for bonding magnetic powders to each other.

Japanese Laid-Open Patent Publication No. 2006-13066 Japanese Laid-Open Patent Publication No. 2010-118486

Patent Document 1 aims at improving direct current superimposition characteristics by using powder of a different kind of crystalline magnetic material as a raw material of a cored core, and in Patent Document 2, aiming at further reduction of iron loss, Powder and powders of an amorphous magnetic material are used as a raw material for a cored core. However, in Patent Document 2, the evaluation of the direct current superposition characteristic is not carried out.

SUMMARY OF THE INVENTION Accordingly, the present invention is directed to a compactor core containing powder of a crystalline magnetic material and powder of an amorphous magnetic material, wherein, with respect to the inductor having such a compactor core, the direct current superimposition characteristic is improved and the compactor core And to provide the above-mentioned objects. It is another object of the present invention to provide a method of manufacturing the compacted core as described above, an inductor having the compacted core, and an electronic / electric apparatus in which the inductor is mounted.

In order to solve the above problems, the inventors of the present invention have found that by appropriately adjusting the particle diameter distribution of the crystalline magnetic material powder and the particle diameter distribution of the amorphous magnetic material powder contained in the dust compact core, In a preferred embodiment, it is preferable that the ratio of the powder of the crystalline magnetic material contained in the powder compact core to the powder of the amorphous magnetic material exceeds the range estimated from the mixing ratio of the powder of the crystalline magnetic material and the powder of the amorphous magnetic material, It is possible to improve the direct current superimposition characteristic of the inductor having the core and to reduce the iron loss.

The inventions completed by these findings are as follows.

One embodiment of the present invention is a compost core containing a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, wherein the median diameter (D ₅₀ A) of the powder of the amorphous magnetic material is 15 μm or less, (D ₅₀ C) of the powder of the powder compact and the following formula (1).

_{1 ≤ D 50 A / D 50} C ≤ 3.5 (1)

When the particle diameter distribution of the powder of the crystalline magnetic material contained in the dust compact core and the particle diameter distribution of the powder of the amorphous magnetic material satisfy the above relationship, the powder of the crystalline magnetic material contained in the powder compact core and the powder of the amorphous magnetic material It is possible to improve the direct current superimposition characteristic of the inductor having the compact core and nonlinearly to reduce the iron loss.

The median diameter (D ₅₀ A) of the powder of the amorphous magnetic material may preferably satisfy the median diameter (D ₅₀ C) of the crystalline magnetic material powder and the following formula (2). As shown in the following embodiments, by satisfying the following expression (2), it is easy for both of the two parameters (mu 0 x mu 5500 x Isat / rho and mu 0 x Isat / rho) showing the direct current superposition characteristic to be satisfactory.

_{1.2 ≤ D 50 A / D 50} C ≤ 2.5 (2)

The median diameter (D ₅₀ A) of the amorphous magnetic material powder is preferably 7 탆 or less from the viewpoints of improving the direct current superimposition characteristic of the inductor having the compaction core and reducing the iron loss more stably have.

It is preferable that the first mixing ratio, which is the mass ratio of the content of the crystalline magnetic material powder to the total of the content of the powder of the crystalline magnetic material and the content of the powder of the amorphous magnetic material contained in the dust compact core is 40 mass% Is preferable from the standpoint of more stably realizing reduction of iron loss of the inductor as compared with an inductor having a compact core comprising only a powder of an amorphous magnetic material.

The first mixing ratio may be 2 mass% or more.

The crystalline magnetic material may be at least one selected from the group consisting of Fe-Si-Cr alloys, Fe-Ni alloys, Fe-Co alloys, Fe-V alloys, Fe-Al alloys, Fe- And may contain one or more materials selected from the group consisting of alloys, carbonyl iron and pure iron.

The crystalline magnetic material is preferably made of an Fe-Si-Cr-based alloy.

The amorphous magnetic material may contain one or more materials selected from the group consisting of Fe-Si-B alloys, Fe-P-C alloys and Co-Fe-Si-B alloys.

The amorphous magnetic material is preferably made of an Fe-P-C alloy.

The powder of the crystalline magnetic material is preferably made of a material subjected to an insulation treatment. By performing the insulation treatment, the insulation resistance of the compaction core can be improved and the iron loss in the high frequency band can be reduced more stably.

The compacting core may contain a binder component that binds the powder of the crystalline magnetic material and the powder of the amorphous magnetic material to another material contained in the compacting core. In this case, it is preferable that the binder component contains a component based on a resin material.

Another aspect of the present invention is a method for producing the compact cored core, comprising the steps of: forming a mixture containing the powder of the crystalline magnetic material and the powder of the amorphous magnetic material, and a binder component comprising the resin material; And a shaping step of obtaining a molded product by the shaping step. With this manufacturing method, it is possible to more efficiently manufacture the compact cored core.

In the above manufacturing method, the molded product obtained by the molding step may be the compacted core. Or a heat treatment step of obtaining the compacted core by heat treatment for heating the molded product obtained by the molding step.

According to still another aspect of the present invention, there is provided an inductor including 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 is disposed in the induction magnetic field generated by the current when the current is passed through the coil. Such an inductor can achieve excellent direct current superimposition characteristics and low loss based on excellent characteristics of the compact dust core.

Still another aspect of the present invention is an electronic or electric device in which the inductor is mounted, wherein the inductor is an electronic or electric device connected to the substrate by the connection terminal. Examples of such electronic / electric apparatuses include a power supply apparatus having a power supply switching circuit, a voltage raising and lowering circuit, a smoothing circuit, etc., and a small portable communication apparatus. The electronic / electric apparatus according to the present invention includes the above-described inductor, so it is easy to cope with a large current and a high frequency.

The compact powder core according to the present invention has the particle diameter distribution of the powder of the crystalline magnetic material and the particle diameter distribution of the powder of the amorphous magnetic material appropriately adjusted and therefore it is possible to improve the direct current superimposition characteristic for the inductor having such a compacted core And iron loss can be reduced. Further, according to the present invention, there is provided a method of manufacturing the compacted core, an inductor having the compacted core, and an electric / electric device in which the inductor is mounted.

1 is a perspective view conceptually showing a shape of a compacting core according to an embodiment of the present invention.
2 is a view conceptually showing a spray dryer apparatus and its operation used in an example of a method of manufacturing granulated powder.
Fig. 3 is a perspective view conceptually showing the shape of a toroidal coil, which is one type of inductor having a compacted core according to an embodiment of the present invention. Fig.
4 is a perspective view conceptually showing the shape of a coil-embedded type inductor, which is one type of inductor having a compacted core according to an embodiment of the present invention.
5 is a graph showing the dependency of Relative Pcv on the first mixing ratio in Example 1. FIG.
FIG. 6 is a graph showing the dependency of Relative Pcv on the first mixing ratio in Example 2. FIG.
7 is a graph showing the dependency of relative Pcv on the first mixing ratio in Example 3. Fig.
8 is a graph showing the dependency of Relative Pcv on the first mixing ratio in Example 4. Fig.
9 is a graph showing the dependency of Relative Pcv on the first mixing ratio in Example 5. Fig.
10 is a graph showing the dependency of relative Pcv on the first mixing ratio in Example 6. Fig.
11 is a graph showing the dependency of relative Pcv on the first mixing ratio in Example 7. Fig.
12 is a graph showing the dependency of relative Pcv on the first mixing ratio in Example 8. Fig.
13 is a graph showing the dependency of relative Pcv on the first mixing ratio in Example 9. Fig.
14 is a graph showing the dependency of relative Pcv on the first mixing ratio in Example 10. Fig.
15 is a graph showing the dependency of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in Example 1. Fig.
16 is a graph showing the dependence of μ0 x μ5500 × Isat / ρ on the first mixing ratio in the second embodiment.
17 is a graph showing the dependency of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in the third embodiment.
18 is a graph showing the dependency of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in the fourth embodiment.
19 is a graph showing the dependency of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in the fifth embodiment.
Fig. 20 is a graph showing the dependence of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in Example 6. Fig.
Fig. 21 is a graph showing the dependence of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in Example 7. Fig.
22 is a graph showing the dependence of μ0 × μ5500 × Isat / ρ on the first mixing ratio in the eighth embodiment.
Fig. 23 is a graph showing the dependency of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in Example 9. Fig.
24 is a graph showing the dependence of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in the tenth example.
25 is a graph showing the dependence of mu 0 x Isat / rho on the first mixing ratio in Example 1. Fig.
26 is a graph showing the dependency of mu 0 x Isat / rho on the first mixing ratio in Example 2. Fig.
27 is a graph showing the dependence of mu 0 x Isat / rho on the first mixing ratio in Example 3. Fig.
28 is a graph showing the dependency of mu 0 x Isat / rho on the first mixing ratio in the fourth embodiment.
Fig. 29 is a graph showing the dependence of mu0 x Isat / rho on the first mixing ratio in Example 5. Fig.
30 is a graph showing the dependence of mu0 x Isat / rho on the first mixing ratio in Example 6. Fig.
31 is a graph showing the dependency of mu 0 x Isat / rho on the first mixing ratio in Example 7. Fig.
32 is a graph showing the dependence of μ0 × Isat / ρ on the first mixing ratio in the eighth embodiment.
Fig. 33 is a graph showing the dependence of mu 0 x Isat / rho on the first mixing ratio in Example 9. Fig.
Fig. 34 is a graph showing the dependency of mu 0 x Isat / rho on the first mixing ratio in Example 10. Fig.
35 is a graph showing the results of plotting the relationship between iron loss (Pcv) and mu 0 x mu 5500 x Isat / r against the results of Example 1. Fig.
FIG. 36 is a graph showing the results of plotting the relationship between iron loss (Pcv) and 占 0 占 Isat /? With respect to the results of Example 1. FIG.
Fig. 37 is a view showing the relationship between the iron loss (Pcv) and mu0 (mu m) of the first mixed ratio in the case where the first mixing ratio is 30% by mass, in view of comparing the results of Examples 1 to 8 and Example 10, is a graph showing the results of plotting the relationship of 占 5500 占 Isat / ?.
Fig. 38 is a graph showing the relationship between the iron loss (Pcv) and mu0 (x), where the first mixing ratio in each example is 30% by mass from the viewpoint of comparing the results of Examples 1 to 8 and Example 10, Isat / rho < / RTI >
39 is a graph showing the results of plotting the relationship between iron loss (Pcv) and mu 0 x mu 5500 x Isat / r against the results of Example 10. Fig.
FIG. 40 is a graph showing the results of plotting the relationship between iron loss (Pcv) and 占 0 占 Isat /? With respect to the result of Example 10. FIG.
41 is a graph showing the relationship between the Example 11 results in terms of the written μ0 × μ5500 × Isat / ρ and D ₅₀ A / D ₅₀ C based on, and μ0 × Isat / ρ and D ₅₀ A / D ₅₀ C to be.

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

1. Popcorn core

The compact powder core 1 according to one embodiment of the present invention shown in Fig. 1 contains a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, whose outer appearance is a ring-shaped toroidal core. The compact powder cores 1 according to the present embodiment are manufactured by a manufacturing method including a forming process comprising press-forming a mixture containing these powders. As an example which is not limiting, the compact powder core 1 according to the present embodiment is a powder compact in which powder of a crystalline magnetic material and powder of an amorphous magnetic material are mixed with another material contained in the press compaction core 1 (which may be the same kind of material, Or may be a heterogeneous material).

(1) Powder of crystalline magnetic material

The crystalline magnetic material which imparts the powder of the crystalline magnetic material contained in the compacted powder core 1 according to the embodiment of the present invention is a crystalline one (it is preferable that the crystalline magnetic material is crystalline A diffraction spectrum having a peak is obtained), and a specific kind is not limited as long as it satisfies a ferromagnetic substance, particularly a soft magnetic material substance. 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. The crystalline magnetic material may be composed of one kind of material or may be composed of plural kinds of materials. The crystalline magnetic material imparting the powder of the crystalline magnetic material is preferably one or more kinds of materials selected from the group consisting of the above materials, and among them, it is preferable that the crystalline magnetic material contains an Fe-Si-Cr based alloy, And more preferably made of an Fe-Si-Cr-based alloy. Since the Fe-Si-Cr-based alloy is a material capable of relatively lowering the iron loss (Pcv) in the crystalline magnetic material, the content of the crystalline magnetic material powder and the content of the powder of the amorphous magnetic material The iron loss Pcv of the inductor having the compaction core 1 becomes high even if the mass ratio (also referred to as " first mixing ratio " in the present specification) of the content of the crystalline magnetic material powder to the total of the sum Do not. The content of Si and the content of Cr in the Fe-Si-Cr alloy are not limited. As a non-limiting example, the content of Si is set to about 2 to 7 mass% and the content of Cr is set to about 2 to 7 mass%.

The shape of the powder of the crystalline magnetic material contained in the compacted powder cores 1 according to one embodiment of the present invention is not limited. The shape of the powder may be spherical or non-spherical. In the case of the non-spherical shape, it may be a shape having a shape anisotropy such as a scaly shape, an elliptic spherical shape, a liquid droplet shape, a needle shape, or a pseudo shape having no particular shape anisotropy. Examples of the amorphous powder include a case in which pluralities of spherical powder are bonded to each other or combined so as to be partially buried in another powder. Such irregular powder is liable to be observed in carbonyl iron.

The shape of the powder may be a shape obtained in the step of producing the powder, or a shape obtained by secondary working the produced powder. Examples of the former shape include spherical shape, elliptical spherical shape, droplet shape, needle shape and the like, and the latter shape exemplifies a scaly shape.

The grain size of the powder of the crystalline magnetic material contained in the compacted powder cores 1 according to the embodiment of the present invention is set in relation to the grain size of the powder of the amorphous magnetic material contained in the compacted core 1 do.

The content of the crystalline magnetic material powder in the compacting core (1) is preferably such that the first mixing ratio is 40 mass% or less. The iron loss Pcv of the inductor having the compaction core 1 is easily lowered as compared with the case where the magnetic material contained in the compaction core is composed only of the amorphous magnetic material because the first mixing ratio is 40 mass% or less. The first mixing ratio is preferably 35 mass% or less, more preferably 30 mass% or less, and most preferably 25 mass% or less, from the viewpoint of more stably realizing reduction of the iron loss (Pcv) of the inductor having the compaction core % Or less by mass.

It is preferable that at least a part of the powder of the crystalline magnetic material is made of a material subjected to the surface insulation treatment, and the powder of the crystalline magnetic material is more preferably made of the material subjected to the surface insulation treatment. When the powder of the crystalline magnetic material is subjected to the surface insulation treatment, the insulation resistance of the compaction core 1 tends to be improved. The kind of the surface insulation treatment to be performed on the powder of the crystalline magnetic material is not limited. Phosphoric acid treatment, phosphate treatment, oxidation treatment and the like.

(2) Powder of amorphous magnetic material

The amorphous magnetic material imparting the powder of the amorphous magnetic material contained in the dust compact core 1 according to the embodiment of the present invention is an amorphous magnetic material which is amorphous (by general X-ray diffraction measurement, A diffraction spectrum having a peak can not be obtained), and a specific kind is not limited as far as it is a ferromagnetic substance, particularly a soft magnetic material substance. Specific examples of the amorphous magnetic material include Fe-Si-B alloys, Fe-P-C alloys and Co-Fe-Si-B alloys. The amorphous magnetic material may be composed of one kind of material or a plurality of kinds of materials. The magnetic material constituting the powder of the amorphous magnetic material is preferably one or more kinds of materials selected from the group consisting of the above materials, and among them, it is preferable to contain an Fe-PC based alloy, and Fe-PC Based alloy is more preferable.

As a specific example of the Fe-PC-based alloy, the composition formula is represented by _{100 atom%} Fe- _abcxyzt Ni _a Sn _b Cr _c P _x C _y B _z Si _t , 0 atom% _≤a ≤ 10 atom%, 0 atom% b ≤ 3 at%, 0 at% ≤ c ≤ 6 at%, 6.8 at% ≤x ≤ 13 at%, 2.2 at% ≤y ≤ 13 at%, 0 at% ≤z≤9 at%, 0 at% t ≤ 7 atomic%. In the above composition formula, Ni, Sn, Cr, B, and Si are optional additional elements.

The addition amount a of Ni is preferably 0 atomic% or more and 6 atomic% or less, more preferably 0 atomic% or more and 4 atomic% or less. The addition amount b of Sn is preferably 0 atomic% or more and 2 atomic% or less, and may be added in a range of 1 atomic% or more and 2 atomic% or less. The addition amount c of Cr is preferably 0 atomic% or more and 2 atomic% or less, more preferably 1 atomic% or more and 2 atomic% or less. The addition amount x of P is preferably 8.8 atomic% or more. The addition amount y of C is preferably 5.8 at.% Or 8.8 at.% Or less. The addition amount z of B is preferably 0 atomic% or more and 3 atomic% or less, more preferably 0 atomic% or more and 2 atomic% or less. The addition amount t of Si is preferably 0 atomic% or more and 6 atomic% or less, more preferably 0 atomic% or more and 2 atomic% or less.

The shape of the powder of the amorphous magnetic material contained in the compacted powder 1 according to one embodiment of the present invention is not limited. Since the shape of the powder is the same as that of the powder of the crystalline magnetic material, the description is omitted. The amorphous magnetic material may be spherical or ellipsoidal in some cases in terms of the manufacturing method. In general, since the amorphous magnetic material is harder than the crystalline magnetic material, it is preferable that the crystalline magnetic material is made non-spherical and easily deformed during the pressure molding.

The shape of the powder of the amorphous magnetic material contained in the compacted powder cores 1 according to the embodiment of the present invention may be a shape obtained at the stage of producing the powder or a shape obtained by secondary working the produced powder. Examples of the former shape include spherical shape, elliptical spherical shape, needle shape, and the latter shape exemplifies a scaly shape.

The particle diameter of the powder of the amorphous magnetic material contained in the compacted powder 1 according to the embodiment of the present invention is such that the particle size distribution in which the cumulative particle size distribution on the small particle size side is 50% Median diameter "). D ₅₀ A is 15 占 퐉 or less. When the median diameter (D ₅₀ A) of the amorphous magnetic material powder is 15 μm or less, it is easy to reduce the iron loss (Pcv) while improving the direct current superimposition characteristic of the dust compact core (1). From the viewpoint of more stably realizing reduction of the iron loss Pcv while improving the direct current superimposition characteristic of the compaction core 1, the case where the median diameter (D ₅₀ A) of the powder of the amorphous magnetic material is preferably 10 탆 or less And it is more preferable that it is not more than 7 탆, and it is particularly preferable that it is not more than 5 탆.

The particle diameter of the powder of the amorphous magnetic material contained in the compacted powder 1 according to the embodiment of the present invention has the following relationship with the particle diameter of the powder of the amorphous magnetic material contained in the powdered core 1. That is, the median diameter (D ₅₀ A) of the powder of the amorphous magnetic material satisfies the following formula (1) with the median diameter (D ₅₀ C) of the powder of the crystalline magnetic material.

_{1 ≤ D 50 A / D 50} C ≤ 3.5 (1)

Since the D ₅₀ A / D ₅₀ C is in the range of 1 to 3.5, it is easy to reduce the iron loss (Pcv) while improving the direct current superposition characteristic of the inductor having the compact core (1). Concretely, for the inductor having the compacted core 1 in a non-linear manner, the range exceeding the range estimated from the mixing ratio of the powder of the crystalline magnetic material and the powder of the amorphous magnetic material contained in the compacted core 1, It is possible to improve the direct current superimposition characteristic and to reduce the iron loss (Pcv).

The median diameter (D ₅₀ A) of the powder of the amorphous magnetic material may preferably satisfy the median diameter (D ₅₀ C) of the powder of the crystalline magnetic material and the following formula (2). As shown in the following embodiments, by satisfying the following expression (2), it is easy for both of the two parameters (mu 0 x mu 5500 x Isat / rho and mu 0 x Isat / rho) showing the direct current superposition characteristic to be satisfactory.

_{1.2 ≤ D 50 A / D 50} C ≤ 2.5 (2)

As compared with an inductor having a compaction core in which a magnetic material is made of an amorphous magnetic material and an inductor having a compaction core in which a magnetic material is made of a crystalline magnetic material, a basic tendency is that the magnetic material has a compact core made of an amorphous magnetic material The inductor has a low iron loss (Pcv) but also a low direct current superimposition characteristic. Therefore, in general, when the magnetic material contained in the dust compact core is made of an amorphous magnetic material only (when the first mixing ratio is 0 mass%), when the crystalline magnetic material is contained and the first mixing ratio is increased , The inductor having the compaction core tends to increase the core loss (Pcv) although the direct current superposition characteristic is improved.

However, in the inductor having the compacted core 1 according to the embodiment of the present invention, the improvement of the direct current superimposition characteristic takes precedence over the increase of the iron loss Pcv, and the inductance of the inductor having the compacted core 1 It is possible to improve the superposition characteristics and to reduce the iron loss (Pcv). In the compaction core 1 according to a preferred embodiment of the present invention, when the first mixing ratio is increased, the iron loss Pcv of the inductor having the compaction core 1 tends to decrease inversely. Therefore, in the compacting powder core 1 according to the embodiment of the present invention, when the first mixing ratio is about 40% by mass or more, the magnetic material contained in the compacting core 1 is only the amorphous magnetic material (1), when the crystalline magnetic material is contained and the first mixing ratio is increased, the iron loss (Pcv) is not increased for the inductor having the compaction core (1) It may be possible to improve the characteristics.

From the viewpoint of more stably obtaining such a compact powder core 1, the first mixing ratio is preferably 1% by mass or more and 40% by mass or less, and more preferably 2% by mass or more and 40% And more preferably 5 mass% or more and 40 mass% or less, and more preferably 5 mass% or more and 35 mass% or less.

(3) Binder component

The compaction core 1 may contain a binder component which binds the powder of the crystalline magnetic material and the powder of the amorphous magnetic material to another material contained in the pressor core 1. The binder component is a powder of the crystalline magnetic material and the powder of the amorphous magnetic material contained in the compact powder core 1 according to the present embodiment (these powders may be collectively referred to as " magnetic powder " The composition is not limited as long as it contributes to fixation. Examples of materials constituting the binder component include organic materials and inorganic materials such as resin materials and pyrolysis residues of the resin materials (herein, these are collectively referred to as " components based on a resin material "). As the resin material, an acrylic resin, a silicone resin, an epoxy resin, a phenol resin, a urea resin, a melamine resin and the like are exemplified. Examples of the binder component made of an inorganic material include glass-based materials such as water glass. The binder component may be composed of one kind of material or may be composed of a plurality of materials. The binding component may be a mixture of an organic-based material and an inorganic-based material.

As a binder component, an insulating material is usually used. As a result, it becomes possible to improve the insulating property as the dust compact core (1).

2. Manufacturing method of potato core

The method for producing the compacted core 1 according to the embodiment of the present invention is not particularly limited, but the compacted powder core 1 can be produced more efficiently by employing the production method described below.

The compacting powder core 1 according to the embodiment of the present invention may be provided with the following shaping step and further include a heat treatment step.

(1) Molding process

First, a mixture containing a magnetic powder and a component imparting a binding component in the pression core (1) is prepared. The component for imparting a binding component (also referred to as " binder component " in the present specification) may be a binder component itself or may be a material different from the binding component. As a concrete example of the latter, the case where the binder component is a resin material and the binder component is a pyrolysis residue.

A molded product can be obtained by a molding process including press molding of the mixture. The pressurizing conditions are not limited, but are appropriately determined based on the composition of the binder component and the like. For example, when the binder component is made of a thermosetting resin, it is preferable to heat the resin together with the pressurization to advance the curing reaction of the resin in the mold. On the other hand, in the case of compression molding, the pressing force is high, but heating is not a necessary condition and the pressing is performed for a short time.

Hereinafter, the case where the mixture is subjected to compression molding as granulated powder will be described in some detail. Since the granulated powder is excellent in handling property, the molding time is short and the workability of a compression molding process excellent in productivity can be improved.

(1-1) granulated powder

The granulated powder contains a magnetic powder and a binder component. The content of the binder component in the granulated powder is not particularly limited. When such a content is excessively low, it is difficult for the binder component to retain the magnetic powder. When the content of the binder component is excessively low, in the compacted core 1 obtained through the heat treatment process, the binder component composed of the residue of the thermal decomposition of the binder component can not sufficiently isolate the plurality of magnetic powders from each other do. On the other hand, when the content of the binder component is excessively high, the content of the binder component contained in the compacting core 1 obtained through the heat treatment process tends to be high. If the content of the binder component in the press powder core 1 is increased, the magnetic powder characteristic of the press powder core 1 is likely to be lowered. Therefore, it is preferable that the content of the binder component in the granulated powder is 0.5 mass% or more and 5.0 mass% or less with respect to the whole granulated powder. The content of the binder component in the granulated powder is such that the content of the binder component in the granulated powder is 1.0% by mass or more and 3.5% by mass or less with respect to the whole granulated powder from the viewpoint of more stably reducing the possibility that the magnetic powder characteristic of the powder compact core 1 is lowered , More preferably not less than 1.2 mass% and not more than 3.0 mass%.

The granulated powder may contain a material other than the magnetic powder and the binder component. Examples of such a material include a lubricant, a silane coupling agent, and an insulating filler.

In the case of containing a lubricant, the kind thereof is not particularly limited. The lubricant may be an organic lubricant or an inorganic lubricant. Specific examples of the organic lubricant include metallic soaps such as zinc stearate and aluminum stearate. It is considered that such an organic lubricant is vaporized in the heat treatment process and hardly remains in the pressoluble core 1.

The method for producing the granulated powder is not particularly limited. The granulated powder may be kneaded as it is and the obtained kneaded product may be pulverized by a known method to obtain a granulated powder. A slurry obtained by adding a dispersion medium (water as an example) to the above- , And the slurry is dried and pulverized to obtain a granulated powder. After the pulverization, sieving or classifying may be performed to control the particle size distribution of the granulated powder.

As an example of a method for obtaining the granulated powder from the above slurry, a method using a spray dryer may be mentioned. 2, a rotor 201 is formed in the spray drier 200, and the slurry S is injected toward the rotor 201 from the top of the apparatus. The rotor 201 is rotated by a predetermined number of rotations and the slurry S is sprayed from the chamber inside the spray dryer apparatus 200 into a small droplet shape by centrifugal force. Also, hot air is introduced into the chamber inside the spray dryer apparatus 200, whereby the dispersion medium (water) contained in the slurry S in the droplet phase is volatilized while maintaining the droplet shape. As a result, the granulated powder (P) is formed from the slurry (S). This granulated powder (P) is recovered from the lower part of the apparatus (200). The parameters such as the number of rotations of the rotor 201, the temperature of hot air to be introduced into the spray drier 200, and the temperature of the lower portion of the chamber may be appropriately set. As a specific example of the setting range of these parameters, the rotational speed of the rotor 201 is 4000 to 8000 rpm, the hot air temperature to be introduced into the spray drier 200 is 130 to 170 DEG C, the temperature of the lower portion of the chamber is 80 to 90 DEG C . The atmosphere in the chamber and its pressure may be set appropriately. As an example, the inside of the chamber is made to be an air (air) atmosphere, and the pressure is set to 2 mmH ₂ O (about 0.02 mm) by a pressure difference with the atmospheric pressure. The particle size distribution of the obtained granulated powder (P) may further be controlled by a sieve or the like.

(1-2) Pressurizing conditions

The pressing condition in the compression molding is not particularly limited. The composition of the granulated powder, the shape of the molded product, and the like. When the pressing force at the time of compression molding of the granulated powder is excessively low, the mechanical strength of the molded article is lowered. For this reason, there is a tendency that a problem that the mechanical strength of the compacting core 1 obtained from the molded article decreases, which reduces the handling property of the molded article. In some cases, the magnetic properties of the dust compact core 1 may be deteriorated or the insulating property may be deteriorated. On the other hand, when the pressing force at the time of compression molding of the granulated powder is excessively high, it becomes difficult to manufacture a molding die capable of withstanding the pressure. From the viewpoint of more stably reducing the possibility that the compression pressurizing process adversely affects the mechanical properties and magnetic properties of the press compaction core 1 and facilitating mass production on an industrial scale, the pressing force at the time of compression- , More preferably not less than 0.3 ㎬ and not more than 2 ㎬, more preferably not less than 0.5 ㎬ and not more than 2 ㎬, and particularly preferably not less than 0.8 ㎬ and not more than 2..

In the compression molding, pressing may be performed while heating, or may be performed at room temperature.

(2) Heat treatment process

The compacted product obtained by the molding process may be the compacted powder core 1 according to the present embodiment, and the compacted powder 1 may be obtained by subjecting the compacted product to a heat treatment process as described below.

In the heat treatment step, the molded product obtained by the above-mentioned molding step is heated to adjust the magnetic properties by modifying the distance between the magnetic powders and moderate the magnetic properties by modifying the strain imparted to the magnetic powder in the molding step To obtain a compact powder core (1).

Since the heat treatment step is for the purpose of adjusting the magnetic properties of the dust compact core 1 as described above, the heat treatment conditions such as the heat treatment temperature are set so as to make the magnetic powder characteristic of the dust compact core 1 the best. As an example of a method for setting the heat treatment conditions, it is possible to change the heating temperature of the molded product to keep the other conditions such as the heating rate and the holding time at the heating temperature constant.

The criteria for evaluating the magnetic properties of the dust compact core 1 when setting the heat treatment conditions are not particularly limited. As a concrete example of the evaluation item, iron loss (Pcv) of the press compaction core (1) can be mentioned. In this case, the heating temperature of the molded product may be set so that the iron loss (Pcv) of the compacted core (1) is the lowest. The measurement conditions of the iron loss (Pcv) are appropriately set and, as an example, a condition is set such that the frequency is 100 kHz and the maximum magnetic flux density (Bm) is 100 mT.

The atmosphere at the time of heat treatment is not particularly limited. In the case of an oxidizing atmosphere, it is preferable to conduct the heat treatment in an inert atmosphere such as nitrogen or argon or a reducing atmosphere such as hydrogen because the possibility that the binder component is excessively decomposed or the oxidation of the magnetic powder is likely to proceed .

3. Inductors, electronic and electric devices

An inductor according to one 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 disposed 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. Since the inductor according to the embodiment of the present invention is provided with the compacted core 1 according to the embodiment of the present invention described above, the direct current superimposition characteristic is excellent and the iron loss is not increased even if it is a high frequency. Therefore, the inductor can be downsized as compared with the related art inductor.

An example of such an inductor is the toroidal coil 10 shown in Fig. The toroidal coil 10 is provided with a coil 2a formed by winding a coated conductive line 2 on a ring-shaped compacted cores 1 (toroidal core). 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, the inductor according to the present embodiment may be configured such that the member constituting the coil and the constituent member constituting the connection terminal are made of the same member.

As another example of the inductor according to the embodiment of the present invention, the coil embedded type inductor 20 shown in Fig. 4 can be mentioned. The coil embedded type inductor 20 can be formed as a small chip with a length of several millimeters and includes a compaction core 21 having a box shape. In the coiled inductor 20, A coil portion 22c of the coil spring 22 is buried. The end portions 22a and 22b of the coated conductive line 22 are located on the surface of the dust compact core 21 and are exposed. A part of the surface of the compacting core 21 is covered by the connection ends 23a and 23b which are electrically independent of each other. The connecting end portion 23a is electrically connected to the end portion 22a of the coated conductive wire 22 and the connecting end portion 23b is electrically connected to the end portion 22b of the coated conductive wire 22. [ The end portion 22a of the covered conductive wire 22 is covered by the connecting end portion 23a and the end portion 22b of the coated conductive wire 22 is covered by the connecting end portion 23b ) ≪ / RTI >

The method of embedding the coil portion 22c of the coated conductive wire 22 into the press compaction core 21 is not limited. It is also possible to arrange a member wound with the coated conductive wire 22 in a metal mold and supply a mixture (granulated powder) containing a magnetic powder into the metal mold, and perform press molding. Alternatively, a plurality of members obtained by preliminarily molding a mixture (granulated powder) containing a magnetic powder are prepared, and these members are assembled. In this case, a coated conductive line 22 is formed in a void portion To obtain an assembly, and this assembly may be pressure-molded. The material of the coated conductive line 22 including the coil portion 22c is not limited. For example, a copper alloy. The coil portion 22c may be an edge-wise coil. The material of the connecting ends 23a, 23b is not limited either. From the viewpoint of excellent productivity, it is preferable to include a metallization layer formed of a conductive paste such as silver paste and a plating layer formed on the metallization layer. The material for forming the plating layer is not limited. Examples of the metal element contained in the material include copper, aluminum, zinc, nickel, iron, and tin.

An electronic or electric device according to an embodiment of the present invention is an electronic or electric device in which an inductor according to an embodiment of the present invention is mounted, and is connected to the substrate with the connection terminal. Since the inductor according to the embodiment of the present invention is mounted in the electronic or electric device according to the embodiment of the present invention, even if a large current is flowed in the device or a high frequency is applied, the function of the inductor Problems caused by heat generation are not easily generated, and the size of the device can be easily reduced.

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 embodiment is intended to include all design modifications and equivalents falling within the technical scope of the present invention.

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)

(1) Preparation of Fe-based amorphous alloy powder

Fe _{71 atomic%} Ni _{6 atomic%} Cr _{2 atomic%} P _{11 atomic%} C _{8 atomic%} B Composition of _{2 atomic%}

(Amorphous powder) having different particle size distributions were prepared by using a water atomization method. The particle size distribution of the obtained amorphous magnetic material powder was measured by volume distribution using "Microtrack particle size distribution measuring apparatus MT3300EX" manufactured by Nikkiso Co., Ltd. The particle size (median diameter) (D ₅₀ A) in which the cumulative particle size distribution on the small particle size side was 50% in the particle size-based particle size distribution was 5 μm. Further, as the powder of the crystalline magnetic material, an Fe-Si-Cr alloy, specifically, an alloy containing 6.4% by mass of Si and 3.1% by mass of Cr with the balance consisting of Fe and inevitable impurities And a median diameter (D ₅₀ C) of 2 탆 was prepared.

(2) Manufacture of granulated powder

The amorphous magnetic material powder and the crystalline magnetic material powder were mixed so as to have a first mixing ratio shown in Table 1 to obtain a magnetic powder. 97.2 parts by mass of magnetic powder, 2 to 3 parts by mass of an insulating binder made of an acrylic resin and a phenol resin, and 0 to 0.5 parts by mass of a lubricant composed of zinc stearate were mixed with water as a solvent to obtain a slurry.

The obtained slurry was granulated using the spray dryer apparatus 200 shown in Fig. 2 under the above-mentioned conditions to obtain granulated powder.

(3) Compression molding

The resulting granular powder was filled in a metal mold and subjected to pressure molding at a surface pressure of 0.5 to 1.5 mm to obtain a molded body having a ring shape having an outer diameter of 20 mm x inner diameter of 12 mm x thickness of 3 mm.

(4) Heat treatment

The obtained molded body was placed in a furnace in a nitrogen atmosphere and the furnace temperature was heated from room temperature (23 DEG C) to a temperature of the optimum core heat treatment of 200 to 400 DEG C at a heating rate of 10 DEG C / For 1 hour, and then subjected to a heat treatment in which the furnace was cooled to room temperature to obtain a toroidal core comprising a compacted core.

(Test Example 1) Measurement of core density?

The dimensions and weight of the toroidal core produced in Example 1 were measured and the density? (Unit: g / cc) of each toroidal core was calculated from these values. The results are shown in Table 1.

(Test Example 2) Measurement of permeability

The toroidal cores obtained by winding the coated copper wires of Example 1 on the primary side 40 times and the secondary side 10 times were wound on the toroidal core under conditions of 100 kHz using an impedance analyzer ("4192A" manufactured by HP) The initial permeability μ0 was measured. The DC current was superimposed on the toroidal coil under the condition of 100 kHz, and the relative permeability 占 5500 when the direct current applied magnetic field was 5500 A / m was measured. The results are shown in Table 1.

(Test Example 3) Measurement of direct current superposition characteristics

Using a toroidal coil formed of the toroidal core produced in Example 1, a DC current was superimposed on the toroidal coil in accordance with JIS C2560-2. Applying current Isat (unit: A) when the inductance ratio (ΔL / L ₀₎ of the amount of change ΔL of the L for the inductance L L ₀ of the applied before (initial) of the superposed current that is 30% by direct current The superposition characteristics were evaluated. This direct current superimposition characteristic was measured using " 4284 " The results are shown in Table 1.

(Test Example 4) Measurement of iron loss (Pcv)

Using a BH analyzer (" SY-8217 " manufactured by Iwasaki Kikai KK), a toroidal coil obtained by winding coated copper wires 15 times on the primary side and 10 times on the secondary side was coated on the toroidal core prepared in Example 1, The iron loss (Pcv) (unit: kW / m 3) was measured at a measurement frequency of 2 MHz under the condition that the maximum magnetic flux density (Bm) was 15 mT. The results are shown in Table 1.

(Evaluation Example 1) Relative Pcv

A value normalized by the case where the first mixing ratio was 0 mass% with respect to the iron loss (Pcv) measured by Test Example 4 was evaluated as Relative Pcv. Relative Pcv makes it possible to relatively evaluate the degree of change of the iron loss (Pcv) due to the change of the first mixing ratio even if the kind of the crystalline magnetic material and the amorphous magnetic material contained in the compaction core (toroidal core) are different . The evaluation results are shown in Table 2.

(Evaluation Example 2) 占 占 占 5500 占 Isat /?

Applying a second magnetic permeability μ0 and the direct current measured by the Test 2 magnetic field is 5500 A / m relative magnetic permeability μ5500, and Test Examples 1 and Isat / ρ (ΔL / L ₀ is 30 based on the measured result by the third when the %) Is a numerical value part of the product of the current density Isat and the core density? Measured in Test Example 1, mu 0 x mu 5500 x Isat / rho is suitable for relative evaluation of the direct current superimposition characteristic than Isat. The evaluation results are shown in Table 2.

The μ0 or μ5500 is a value that is standardized according to volume, while Isat is a value that is not standardized by volume or mass. For this reason, the size of the compact cored core (toroidal core) is influenced. Therefore, by making the parameter including Isat / rho divided by Is as an evaluation target, the direct current superimposition characteristic becomes generalized, and it becomes easy to prepare.

(Evaluation Example 3) 占 0 占 Isat /?

The numerical part of the product of Isat / rho based on the initial permeability mu0 measured by Test Example 2 and the result measured by Test Example 1 and Test Example 3 is mu0 x Isat / rho is mu0 x mu 5500 x Isat / rho Is suitable for relative evaluation of direct current superimposition characteristics than Isat. The evaluation results are shown in Table 2.

(Examples 2 to 10)

As shown in Table 3, the magnetic powder used in Example 1 was the same as Example 1, except that the magnetic powder having different diameters of the powder of the amorphous magnetic material, the composition of the powder of the crystalline magnetic material, To obtain a toroidal core composed of a compost core. The powder of the amorphous magnetic material used in Example 10 was produced by the atomization method in which gas atomization and water atomization were continuously performed. In the column of D ₅₀ C in Table 3, the particle size distribution of the powder of the crystalline magnetic material was measured using a "Microtrack particle size distribution analyzer MT3300EX" manufactured by Nikkiso Co., Ltd., (Median diameter, unit: 占 퐉) in which the cumulative particle diameter distribution is 50%.

The meanings of symbols in Table 3 are as follows.

· Type of composition

A-1: an Fe-Si-Cr alloy (the same composition as in Example 1) having a Si content of 6.4 mass%, a Cr content of 3.1 mass% and the balance of Fe and inevitable impurities;

A-2: Fe-Si-Cr alloy containing 6.3 mass% of Si, 3.2 mass% of Cr and balance of Fe and inevitable impurities

B-1: a Si content of 2.0 mass%, a Cr content of 3.5 mass%, and the balance of Fe and Si-Cr alloy

B-2: 3.5% by mass of Si, 4.5% by mass of Cr and the balance of Fe and Si-Cr based alloy consisting of Fe and inevitable impurities

C: Carbonyl iron

· Surface treatment type

I: No surface treatment (same as in Example 1)

II: With surface insulation treatment of zinc phosphate

III: Surface Insulation Treatment Containing Phosphorylation

The results of the test examples for Examples 2 to 10 are shown in Tables 4 to 12, and the results of the evaluation examples are shown in Tables 13 to 21. In these tables, the case where the first mixing ratio is 0% by mass and the case where the first mixing ratio is 100% by mass include those which give different embodiment numbers to the same results from the viewpoint of enhancing the viewability of the table (Examples 2-3 and 3-1, etc.).

Based on the above results, FIG. 5 to FIG. 24 show the dependence of the relative Pcv on the first mixing ratio and the dependence on the first mixing ratio of 占 0 占 5500 占 Isat /? In each example.

5 is a graph showing the dependency of Relative Pcv on the first mixing ratio in Example 1. FIG.

FIG. 6 is a graph showing the dependency of Relative Pcv on the first mixing ratio in Example 2. FIG.

7 is a graph showing the dependency of relative Pcv on the first mixing ratio in Example 3. Fig.

8 is a graph showing the dependency of Relative Pcv on the first mixing ratio in Example 4. Fig.

9 is a graph showing the dependency of Relative Pcv on the first mixing ratio in Example 5. Fig.

10 is a graph showing the dependency of relative Pcv on the first mixing ratio in Example 6. Fig.

11 is a graph showing the dependency of relative Pcv on the first mixing ratio in Example 7. Fig.

12 is a graph showing the dependency of relative Pcv on the first mixing ratio in Example 8. Fig.

13 is a graph showing the dependency of relative Pcv on the first mixing ratio in Example 9. Fig.

14 is a graph showing the dependency of relative Pcv on the first mixing ratio in Example 10. Fig.

15 is a graph showing the dependency of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in Example 1. Fig.

16 is a graph showing the dependence of μ0 x μ5500 × Isat / ρ on the first mixing ratio in the second embodiment.

17 is a graph showing the dependency of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in the third embodiment.

18 is a graph showing the dependency of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in the fourth embodiment.

19 is a graph showing the dependency of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in the fifth embodiment.

Fig. 20 is a graph showing the dependence of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in Example 6. Fig.

Fig. 21 is a graph showing the dependence of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in Example 7. Fig.

22 is a graph showing the dependence of μ0 × μ5500 × Isat / ρ on the first mixing ratio in the eighth embodiment.

Fig. 23 is a graph showing the dependency of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in Example 9. Fig.

24 is a graph showing the dependence of mu 0 x mu 5500 x Isat / rho on the first mixing ratio in the tenth example.

25 is a graph showing the dependence of mu 0 x Isat / rho on the first mixing ratio in Example 1. Fig.

26 is a graph showing the dependency of mu 0 x Isat / rho on the first mixing ratio in Example 2. Fig.

27 is a graph showing the dependence of mu 0 x Isat / rho on the first mixing ratio in Example 3. Fig.

28 is a graph showing the dependency of mu 0 x Isat / rho on the first mixing ratio in the fourth embodiment.

Fig. 29 is a graph showing the dependence of mu0 x Isat / rho on the first mixing ratio in Example 5. Fig.

30 is a graph showing the dependence of mu0 x Isat / rho on the first mixing ratio in Example 6. Fig.

31 is a graph showing the dependency of mu 0 x Isat / rho on the first mixing ratio in Example 7. Fig.

32 is a graph showing the dependence of μ0 × Isat / ρ on the first mixing ratio in the eighth embodiment.

Fig. 33 is a graph showing the dependence of mu 0 x Isat / rho on the first mixing ratio in Example 9. Fig.

Fig. 34 is a graph showing the dependency of mu 0 x Isat / rho on the first mixing ratio in Example 10. Fig.

In each of the graphs, a fitting is performed for the quadratic curve of the evaluation result, and a quadratic curve obtained as a result thereof is represented by a solid line in the graph. A function representing a quadratic curve (where x is a value of the first mixing ratio and y Is the value of Relative Pcv, the value of 占 占 55 5500 占 Isat /? Or the value of 占 占 占 5500 占 Isat /?) Is described in the vicinity of the graph. By comparing the coefficients of x ² , the non-linearity of the curve can be evaluated relative.

With respect to the results of Example 1, the relationship between iron loss (Pcv), 占 0 占 5500 占 Isat /? And iron loss (Pcv) and? 0 占 Isat /? Were plotted. The results are shown in Fig. 35 and Fig.

As shown in FIG. 35 and FIG. 36, until the first mixing ratio reaches 40% by mass, .mu. X 占 5500 占 Isat /? Or? 0 占 Isat /? Gradually increases with an increase in the first mixing ratio, The iron loss (Pcv) was equal to or less than the case where the first mixing ratio was 0 mass%. Therefore, it was confirmed that the compacted core produced by Example 1 was a compacted core which gave a very good inductor with particularly excellent direct current superposition characteristics and particularly low core loss (Pcv).

With respect to the results of Example 10, the relationship between iron loss (Pcv), mu 0 x mu 5500 x Isat / rho and iron loss (Pcv) and mu0 x Isat / rho were plotted. The results are shown in Fig. 39 and Fig.

As shown in FIG. 39 and FIG. 40, until the first mixing ratio reaches 30% by mass,? 0 占 5500 占 Isat /? Or? 0 占 Isat /? Gradually increases with an increase in the first mixing ratio, The iron loss (Pcv) was equal to or less than the case where the first mixing ratio was 0 mass%. However, the compacted core produced by Example 10 had a larger value of core loss (Pcv) than the compacted core produced by Example 1. This is considered to be due to the fact that the D ₅₀ A / D ₅₀ C is as large as 3.8.

From the viewpoint of contrasting the results of Examples 1 to 8 and Example 10 in which the composition of the crystalline magnetic material is Fe-Si-Cr based alloy, the first mixing ratio in these Examples is 30 mass% (Table 22), and the relationship between iron loss (Pcv), 占 占 占 5500 占 Isat /? And iron loss (Pcv) and 占 占 Isat /? Were plotted. The results are shown in Fig. 37 and Fig.

37 and Fig. 38 are as follows. A white circle (O) is a result when the first mixing ratio in each example is 30% by mass. The black rhombus () indicates the result when the first mixing ratio in Examples 1 to 9 is 0 mass%. The white rhombus (◇) is a result when the first mixing ratio in Example 10 is 0 mass%. Black triangles () are the results when the first mixing ratio in each example is 100% by mass. X shows the results when the crystalline magnetic material is carbonyl iron and the first mixing ratio is 5% by mass to 30% by mass (Examples 9-2 to 9-6).

The broken line in Figs. 37 and 38 is a line roughly connecting the result when the first mixing ratio is 0 mass% and the result when the first mixing ratio is 100 mass%, and on the broken line or the upper side , Preferably in the left upper side as indicated by white arrows in the drawings, it is preferable that the ratio of the powder of the crystalline magnetic material contained in the powder compact core to the powder of the amorphous magnetic material, That is, it is shown that a compaction core is obtained which gives an inductor with an excellent direct current superimposition characteristic and a reduced iron loss, exceeding simple simplicity.

On the other hand, in the case of being located on the lower side than the broken line in Figs. 37 and 38, particularly on the lower right side as indicated by a black arrow in each drawing, the powder of the crystalline magnetic material and the powder of the amorphous magnetic material It is possible to obtain a compacted core which gives an inductor in which the DC superposition characteristic is lowered and the iron loss is increased, As shown in Fig. 37 and Fig. 38, the result of Example 10-2 is located on the right lower side than the broken line, and the compacted core produced by Example 10 has an inductor with excellent direct current superimposition characteristic and reduced iron loss It can not be said to be a compact core. It is considered that D ₅₀ A / D ₅₀ C is affected by the fact that the value of D ₅₀ A / D ₅₀ C is as large as 3.8, as in the results of FIGS. 39 and 40 described above.

(Examples 11 and 12)

Fe _{71 atomic%} Ni _{6 atomic%} Cr _{2 atomic%} P _{11 atomic%} C _{8 atomic%} B Composition of _{2 atomic%}

(Amorphous powder) having different particle size distributions were prepared by using a water atomization method. The particle size distribution of the obtained amorphous magnetic material powder was measured by volume distribution using "Microtrack particle size distribution measuring apparatus MT3300EX" manufactured by Nikkiso Co., Ltd. The particle size (median diameter) (D ₅₀ A) in which the cumulative particle diameter distribution on the small particle size side was 50% in the particle size-based particle size distribution was 10 μm. This amorphous powder and amorphous powder having a median diameter (D ₅₀ A) of 5 탆, 7 탆 and 15 탆 used in Examples 2 to 10 were prepared.

The remainder is made of an Fe-Si-Cr alloy composed of Fe and inevitable impurities, and the surface treatment includes the above-mentioned surface treatment type II ( Phosphorus-zinc-based surface insulating treatment), and a powder of a crystalline magnetic material having a median diameter (D ₅₀ C) of 4 탆 and 6 탆 was prepared as a material for Example 11. Si-Cr-based alloy (the above-mentioned composition type A-1) composed of Fe and inevitable impurities, with the content of Si being 6.4 mass%, the content of Cr being 3.1 mass% A powder of a crystalline magnetic material having a median diameter (D ₅₀ C) of 2 탆, which was not conducted (corresponding to the surface treatment type I described above), was prepared as a material for Example 12.

The amorphous magnetic material powder and the crystalline magnetic material powder were mixed so as to have a first mixing ratio of 30% by mass to obtain the magnetic powders of Examples 11-1 to 11-5 and the magnetic powder of Example 12 Magnetic powder was obtained. These magnetic powders were subjected to the same tests and evaluations as in Examples 2 to 10. Table 23 shows the results.

Based on the results of Example 11 shown in Table 23, μ0 × μ5500 × Isat / ρ and D ₅₀ A / D of ₅₀ C relationships, and μ0 × Isat / ρ and D 41 the relationship between the ₅₀ A / D ₅₀ C Respectively. As shown in Figure 41, the D ₅₀ A / D ₅₀ C is a case of 1 or less than 3.5, μ0 × μ5500 × Isat / ρ and μ0 × Isat / result becomes ρ is good is obtained, and this tendency is D ₅₀ A / D ₅₀ C was not less than 1.2 and not more than 2.5.

According to the present invention, it is possible to obtain a compact cored core which gives a good inductor with excellent direct current superimposition characteristics and reduced iron loss, and the degree of the good compactness is obtained by a combination of the powder of the crystalline magnetic material and the powder of the amorphous magnetic material It has been confirmed by the present embodiment that the amount exceeded the expectation based on the mixing ratio.

INDUSTRIAL APPLICABILITY The inductor having the compacted core of the present invention can be preferably used as a component of a booster circuit of a hybrid vehicle or the like, a component of a power generation / substation facility, a component of a transformer or a choke coil, or the like.

One … Population core (toroidal core)
10 ... Toroidal coil
2 … Coated conductive wire
2a ... coil
2b, 2c ... The end of the coated conductive line 2
2d, 2e ... The end of the coil 2a
20 ... Coil embedded type inductor
21 ... Potato core
22 ... Coated conductive wire
22a, 22b ... End
23a, 23b ... Connecting end
22c ... Coil part
200 ... Spray dryer unit
201 ... Rotor
S ... Slurry
P ... Granulated powder

Claims (17)

Wherein a median diameter (D ₅₀ A) of the powder of the amorphous magnetic material is 15 μm or less and a median diameter (D ₅₀ A) of the powder of the crystalline magnetic material is 15 μm or less, ₅₀ C) and the following formula (1).
_{1 ≤ D 50 A / D 50} C ≤ 3.5 (1) The method according to claim 1,
The median diameter (D ₅₀ A) of the amorphous magnetic material powder satisfies the following formula (2) with the median diameter (D ₅₀ C) of the powder of the crystalline magnetic material.
_{1.2 ≤ D 50 A / D 50} C ≤ 2.5 (2) 3. The method according to claim 1 or 2,
Wherein the median diameter (D ₅₀ A) of the amorphous magnetic material powder is 7 탆 or less. 3. The method according to claim 1 or 2,
Wherein the first mixing ratio, which is a mass ratio of the content of the crystalline magnetic material powder to the total of the content of the crystalline magnetic material powder and the amorphous magnetic material powder, is 40 mass% or less. 5. The method of claim 4,
Wherein the first mixing ratio is 2% by mass or more. 3. The method according to claim 1 or 2,
The crystalline magnetic material may be at least one selected from the group consisting of Fe-Si-Cr alloys, Fe-Ni alloys, Fe-Co alloys, Fe-V alloys, Fe-Al alloys, Fe- Wherein the carbonaceous material contains one or more materials selected from the group consisting of an alloy, carbonyl iron and pure iron. The method according to claim 6,
Wherein the crystalline magnetic material is made of an Fe-Si-Cr-based alloy. 3. The method according to claim 1 or 2,
Wherein the amorphous magnetic material contains one or more materials selected from the group consisting of an Fe-Si-B alloy, an Fe-PC alloy, and a Co-Fe-Si-B alloy. 9. The method of claim 8,
Wherein the amorphous magnetic material is made of an Fe-PC based alloy. 3. The method according to claim 1 or 2,
Wherein the powder of the crystalline magnetic material is made of a material subjected to an insulation treatment. 3. The method according to claim 1 or 2,
And a binder component that binds the powder of the crystalline magnetic material and the powder of the amorphous magnetic material to another material contained in the press compaction core. 12. The method of claim 11,
Wherein the binding component contains a component based on a resin material. A method for producing a press compaction core according to claim 12, comprising the steps of: press forming a mixture containing the powder of the crystalline magnetic material, the powder of the amorphous magnetic material and the binder component of the resin material, And a shaping step of shaping the green compact to obtain a green compact. 14. The method of claim 13,
Wherein the molded product obtained by the molding step is the compacted core. 14. The method of claim 13,
And a heat treatment step of obtaining the compacted core by a heat treatment for heating the molded product obtained by the molding step. An inductor comprising a compaction core, a coil, and a connection terminal connected to each end of the coil according to claim 1 or claim 2, wherein at least a part of the compaction core is connected to the coil Is placed so as to be located in the induced magnetic field generated by the current. An electronic or electric device in which the inductor is mounted according to claim 16, wherein the inductor is connected to the substrate with the connection terminal.

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