KR910002375B1 - Magnetic core component and manufacture thereof - Google Patents

Abstract

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Description

Magnetic core and its manufacturing method

1 is a graph showing the effective transmittance μo _1K of a magnetic core changed with time.

2 is a graph showing the X-ray diffraction pattern of the Fe-based alloy ribbon prepared by the single roll method in Example 1. FIG.

Figure 3a is a graph showing the X-ray diffraction pattern of the Fe-base alloy heat-treated in Example 1.

3b is a transmission electron micrograph of the Fe-base alloy ribbon heat treated in Example 1. FIG.

4a to 4h are graphs showing various heat treatment shapes in which 'a' is fast heating and 'b' is air cooling.

FIG. 5 is a perspective view showing the toroidal winding core of the Fe-base alloy ribbon in Example 1. FIG.

6 is a schematic diagram showing a circuit for measuring the controlled magnetization properties of a magnetic core.

7 is a graph showing the characteristics of a magnetic core as a saturation reactor.

8 is a graph showing the relationship between ΔB and magnetic H. FIG.

9 is a graph showing the relationship between core loss and frequency.

10 is a graph showing the relationship between ΔB _b , ΔB, and magnetic field H.

11 is a graph depicting the relationship between B ₁₀ , Br / B ₁₀ , core loss and Hc, and temperature.

12 is a graph showing the relationship between the output voltage and the temperature increase ΔT at the core case surface, and current at a 12V load.

13a to 13c are graphs each showing a DC B-H curve.

14 is a graph showing the relationship between a specific core gain Go and X (atomic%).

FIG. 15 is a graph showing the relationship between a specific core gain Go and α (atomic%). FIG.

16 is a schematic diagram showing a semiconductor circuit reactor.

FIG. 17 is a schematic diagram showing a basic circuit of a switching source using the semiconductor circuit reactor of FIG.

Fig. 18 is a graph showing a wave in which a load current is formed in which A represents a case where the semiconductor circuit reactor of the present invention is used and B represents a case where a reactor is used.

19 is a schematic diagram illustrating an embodiment of a semiconductor circuit reactor including the reactor of the present invention.

FIG. 20 is a schematic diagram illustrating an embodiment of a hollow component choke. FIG.

21 is a graph showing the relationship between noise level and frequency.

22A is a schematic diagram showing a toroidal winding core.

22B is a schematic diagram showing a magnetic core produced from the toroidal winding core of FIG. 22A.

FIG. 23a is a graph depicting the DC B-H curve. FIG.

FIG. 23B is a graph showing the relationship between the pulse transmittance [mu] and [Delta] B. FIG.

와 주파수 사이를 관계를 도시한 그래프.24 is the absolute value of the composite transmittance of 1μ

A graph showing the relationship between and frequency.

25A is a perspective view of an E core;

25B is a schematic diagram showing an E-type magnetic core for a transformer.

26A is a schematic diagram illustrating a circuit for evaluating pulse reduction characteristics.

FIG. 26B is a graph showing the relationship between the output pulse peak voltage and the input pulse peak voltage. FIG.

FIG. 27A is a schematic diagram illustrating a circuit for measuring a tendency of a decrease in frequency. FIG.

27B is a graph showing the relationship between reduction and frequency.

28A is a perspective view of a toroidal wound core.

28B is a perspective view of the cutting core.

29 is a graph showing the relationship between core loss and frequency.

FIELD OF THE INVENTION The present invention relates to magnetic cores having good magnetic properties that change less with time, in particular magnetic cores for use in semiconductor circuit reactors, common component chokes, transformers, motors and the like.

Magnetic cores for such applications generally require magnetostriction, high effective permeability, high saturation flux density, and the magnetic properties require good durability and less change over time.

In addition to the above characteristics, especially when used as a saturation reactor for a magnetic amplification circuit, a magnetic core is required to have low core loss and good controlled magnetization characteristics (low uncontrolled magnetic flux density).

The semiconductor circuit reactor prevents an error due to noise caused by a current larger than the rated value and prevents damage to the semiconductor circuit, thereby causing the semiconductor circuit to be caused by a current spark or electric ranking generated by "on" and "off" of the semiconductor circuit. Used to prevent flow through. Thus, such a reactor requires high effective permeability and high spherical ratio to suppress the abnormal current.

For common component chokes, the magnetic core must have a large effective magnetic flux range operable to prevent single poles and have a small area ratio of the DC B-H curve.

In transformers, magnetic cores must have a small area ratio of the DC BH curve to prevent single poles, as in common component chokes, and are required to have good high-frequency characteristics, especially small core losses at high frequencies, so recent switching sources have to be operated at higher frequencies. do.

Care should be taken with Fe-base and Co-base amorphous alloys, such as these materials with recent saturation flux densities. Co-based amorphous alloys have low magnetization and high effective permeability. Use in saturation reactors has been proposed by Japanese Patent Application Laid-Open Nos. 57-210612 and 57-21512. On the other hand, the Fe-based amorphous alloy has a higher saturation magnetic flux density than the Fe-based amorphous alloy, as disclosed in Japanese Patent Application No. 58-1183, and the Co-based amorphous alloy is also heat-treated under an oxygen-free atmosphere. It has a high spherical ratio.

Although Fe-based amorphous alloys have a higher saturation magnetic flux density than Co-base alloys, Fe-base alloys saturate core loss and control magnetization characteristics, especially in magnetic amplification circuits of switching sources where they operate at high frequencies of 20 KHz or higher. Inferior to Co-base alloys when used for reactors. Since the Fe-base amorphous alloy has a large total control magnetizing power, a large control magnetization current requires a control output voltage which induces an increase in the temperature of the magnetic core, and also increases the load of the control circuit, decreases the efficiency of the vicinity The other part of has less durability. In addition, spark currents and the like cannot be effectively prevented since the semiconductor circuit reactor shows extremely high magnetization and low effective permeability when formed of an Fe-based amorphous alloy.

In the meantime, the switching source transformer was proposed by the Telecommunications Technical Report to use a Fe-based amorphous alloy for a switching source transformer made of conventional Hn-Zn ferrite but usable at high frequencies. However, as pointed out in the technical report, when the Fe-based amorphous alloy is used, the core shows large magnetization which induces a decrease in magnetic properties by mechanical stress, and also the deterioration of high frequency magnetic properties causes the core to be cut or Occurs when the resin is included.

Accordingly, it is desirable to provide a material having low magnetization and high effective permeability compared to Co-based amorphous alloys and a high saturation flux density compared to Fe-based amorphous alloys, which characteristics are almost invariant with time. do.

Japanese Patent Application Laid-Open No. 62-101008 discloses an auxiliary having less transparent dispersion or 0.1 μm of highly transparent particles on an amorphous matrix in a volume larger than the matrix phase to be used as a magnetic core for magnetic properties that are almost invariant with time in a magnetic circuit. Posted a transparent material.

Therefore, it is an object of the present invention to provide a magnetic core having high saturation magnetic flux density, effective transmittance and low core loss. As a result of severe studies, the inventors found that the magnetic core is made of a Fe-based soft magnetic alloy consisting essentially of Fe, Cu and M, where M is selected from the group consisting of Nb, W, Ta, Zr, Hf, Ti and Mo. It was found that at least one element, at least 50% of the alloy structure, is occupied by fine crystalline particles, and the magnetic core has a change in effective transmittance over time X of 0.3 to less.

The magnetic core of the present invention essentially has a rate of change of the effective permeability for 0.3 to less than a time (X) made of Fe-based soft magnetic alloy comprising Fe, Cu and M, wherein M is Nb, At least one element selected from the group consisting of W, Ta, Zr, Hf, Ti and Mo, and at least 50% of the alloy structure is occupied by fine crystalline particles.

In particular, the Fe-based soft magnetic alloy uses a magnetic core according to the present invention which generally has a composition expressed by the general formula,

(Fe ₁ … _a M _a ) _100-xyz-α Cu _M Si _y B _z M ' _α

a

0.5, 0.1

x

3, 0

y

30, 0

25, 5

y+z

30, 그리고 0.1

α

30이며, 상기 합금 구즈의 최소 50%는 미세한 결정질 입자에 의해 점유된다.M in it is at least one element selected from the group consisting of Co and / or Ni, M 'constitutes Nb, W, Ta, Zr, Hf, Ti and Mo, and a, x, y, z and α are each satisfactorily 0

a

0.5, 0.1

x

3, 0

y

30, 0

25, 5

y + z

30, and 0.1

α

30, at least 50% of the alloy goose is occupied by fine crystalline particles.

Another form of Fe-based soft magnetic alloy suitable for the present invention has a composition expressed by the general formula.

(Fe _1-a M _a ) _{100-xyz-α-β-γ} Cu _M Si _y B _z M ' _α M " _β X _γ

a

0.5, 0.1

x

3, 0

y

30, 0

z

25, 5

y+z

30, 0.1

α

30, β

10, 그리고 γ

10이며 상기 합금 구조의 최소 50%는 1000Å 또는 그 이하의 평균 입자 직경을 갖는 미세한 결정입자이다.In which M is Co and / or Ni and M 'is at least one element selected from the group consisting of Nb, W, Ta, Zr, Hf, Ti and Mo, and M "is a group consisting of V, Cr, Mn, Al At least one element selected from platinum, the elements Sc, Y rare earth elements Au, Zn, Sn and Re, X in the platinum group are at least one selected from the group consisting of C, Ge, P, Ga, Sb, In, Be and As and , x, y, z, α, β and γ are each satisfying 0

a

0.5, 0.1

x

3, 0

y

30, 0

z

25, 5

y + z

30, 0.1

α

30, β

10, and γ

10 and at least 50% of the alloy structure is fine crystal grains having an average particle diameter of 1000 mm 3 or less.

In each of the Fe-based soft self-alloys Fe will be replaced by Co and / or Ni in the range up to 0.3. When M (Co and / or Ni) exceeds 0.3, the controlled magnetization of the magnetic core decreases. However, in order to have good magnetic properties such as low core loss and magnetization, the content of Co and / or Ni is appropriately represented by 0 to 0.1. In particular, the range of "a" is suitably 0 to 0.05 to provide a low magnetization alloy.

Cu is an essential element and its content "X" is 0.1 to 3 atomic%. When it is less than 0.1 atomic%, there is little effect on the increase in the transmittance and the reduction of the core loss which will be obtained by the addition of Cu. On the other hand, when it exceeds 3 atomic%, the final magnetic core controlled magnetization property is lower than that containing no Cu. Suitable content of Cu in the present invention is 0.5 to 2 atomic%, and the magnetic core in the above range has a controlled magnetization property as compared with that of a Co-based amorphous alloy magnetic core.

It is not entirely clear as the core loss is reduced and the transmittance is increased by the addition of Cu, but it will be expected as one.

Since Cu and Fe are positive interaction parameters, their solubility is low. Thus, the alloy is heated but it is amorphous and the zinc or copper atoms gather to form agglomerates by the compositional wave generation. This yields many domains that are going to be crystalline to provide to the nucleus to produce fine crystalline particles. The crystalline particles accumulate on Fe, and since Cu hardly dissolves in Fe, the Cu content in the vicinity of the crystalline particles becomes high. This, in turn, inhibits the growth of the positive particles.

Due to the addition of Cu, most of the nuclei are formed and crystal grains grow, so the crystal grains become fine and the phenomenon is accelerated by the inclusion of Nb, Ta, W, Mo, Zr, Hf, Ti and the like.

Without Nb, Ta, W, Mo, Zr, Hf, Ti, etc., the crystal grains do not become completely fine and fall into the soft magnetic properties of the final alloy. Nb and Mo are particularly effective and in particular, Nb acts to retain fine grains, thereby providing very soft magnetic properties. Since fine crystalline particles are formed on Fe, the Fe-based soft magnetic alloy has a smaller magnetization than the Fe-based amorphous alloy, and the Fe-based soft magnetic alloy has a small magnetic anisotropy due to the change of internal stress, resulting in soft Improve magnetic properties

It is not easy to refine the crystal grains without adding Cu. Instead, the compound phase is easily formed and crystallized, which deteriorates the magnetic properties.

Si and B are the elements that make especially fine alloy structures. The Fe-based soft magnetic alloy is preferably prepared by adding Si and B to form an amorphous alloy and then heat treating to form fine crystalline particles.

y

30원자%, 0

z

25원자% 및 5

y+z

30원자%로 하는데, 그 이유는 만일 그렇게 하지 않으면 합금이 상당히 감소된 포화자속 밀도를 갖게 되기 때문이다.The content of Si ("y") and the content of B ("z") are 0

y

30 atomic%, 0

z

25 atomic% and 5

y + z

30 atomic percent, because otherwise the alloy will have a significantly reduced saturation flux density.

y

25, 3

z

18, 그리고 18

y+z

28일때, 이러한 범위는 탁월한 연자성 성질 특히, -5×10^-6내지 +5×10^-6범위의 포화 자기 변형을 갖는 합금을 제공한다. 특히 양호한 범위는 11

y

24, 3

z

9 및 18

y+z

27이고, 이러한 범위는 -1.5×10^-6내지 +1.5×10^-6범위의 포화 자기 변형을 갖는 합금을 제공한다.In the present invention, the preferred range of y is 6 to 25 atomic%, the preferred range of z is 2 to 25 atomic%, and the preferred range of y + z is 14 to 30 atomic%. When y exceeds 25 atomic%, the final alloy has a relatively large magnetic strain under conditions that provide good soft magnetic properties, and when y is 6 atomic% or less, sufficient soft magnetic properties are not necessarily obtained. The reason for limiting the content of B ("z") is that since a uniform grain structure cannot be easily obtained when z is 2 atomic% or less, when soft magnetic properties deteriorate to some extent, and z exceeds 25 atomic%, The final alloy will have a relatively large magnetostriction under heat treatment conditions that provide good soft magnetic properties. With respect to the total amount of Si + B (y + z), when y + z is 14 atomic% or less, it is often difficult to make the alloy amorphous, thereby providing relatively inferior magnetic properties. When y + z exceeds 30 atomic%, an extreme decrease in the saturation flux density and an increase in the deterioration magnetostriction of the soft magnetic properties occur. In particular, the content of Si and B is 10

y

25, 3

z

18, and 18

y + z

When 28, this range provides alloys with excellent soft magnetic properties, in particular saturated magnetostrictions in the range of -5x10 ^-6 to + 5x10 ^-6 . A particularly good range is 11

y

24, 3

z

9 and 18

y + z

27 and this range provides alloys with a saturated magnetostriction in the range of -1.5 × 10 ⁻⁶ to + 1.5 × 10 ⁻⁶ .

In the present invention, when added together with Cu, M 'acts to make the precipitated crystal grains fine. M 'is at least one element selected from the group consisting of Nb, W, Ta, Zr, Hf, Ti and Mo. These elements have a function of raising the crystallization temperature of the alloy. By interacting with Cu, which has a function of lowering the crystal temperature by forming a lump, Nb or the like suppresses the growth of precipitated crystal grains, thereby making the crystal grains fine.

Content of M '((alpha)) is 0.1-30 atomic%. When the content of M 'is 0.1 atomic% or less, a sufficient effect of making the grains fine can not be obtained, and when the content of M' exceeds 30 atomic%, an extreme decrease in the saturation magnetic flux density occurs. A good content of M 'is 0.1 to 10 atomic%, more preferable α is 2 to 8 atomic%, and particularly excellent soft magnetic properties are obtained in this range. Often, the best as M 'is Nb or Mo, in particular Nb is very good in terms of magnetic properties. The addition of M 'provides a Fe-based soft magnetic alloy with a magnetic permeability as high as that of a Co-based high permeability material.

At least one element selected from the group consisting of platinum group elements, V, Cr, Mn, Al, rare earth elements Sc, Y, and Au, Zn, Sn and Re, for the purpose of improving corrosion resistance or magnetic properties and controlling magnetic deformation Phosphorus M "may be added, but its content is at most 10 atomic%. When the content of M" exceeds 10 atomic%, an extreme decrease in saturation magnetic flux density occurs. A particularly good amount of M ″ is up to 5 atomic percent.

Among them, at least one element selected from the group consisting of Ru, Rh, Pd, Os, Ir, Pt, Au, Cr, and V can provide an alloy having very good corrosion resistance and wear resistance, so that an alloy suitable for a magnetic head or the like can be obtained. I can make it.

The Fe-based soft magnetic alloy may contain 10 atomic% or less of at least one element X selected from the group consisting of C, Ge, P, Ga, Sb, In, Be, and As. These elements are effective in making the alloy amorphous, and when Si and B are added, they not only help to make the alloy amorphous, but also control the alloy's Curie temperature and magnetostriction.

a

0.5, 0.1

x

3, 0

y

30, 0

z

25, 5

y+z

30, 0.1

α

30이고, 그들의 양호한 범위는 0

a

0.3, 0.1

x

3, 6

y

25, 2

z

25, 14

y+z

30, 0.1

α

10이고, 보다 양호한 범위는 0

a

0.1, 0.5

x

2, 10

y

25, 3

z

18, 18

y+z

28, 2

α

8이고, 가장 양호한 범위는 0

a

0.05, 0.5

x

2, 11

y

24, 3z

9, 18

y+z

27 2

α

8이고, 일반식 (Fe_1-aM_a)_{100-x-y-z-α-β-γ}Cu_xSi_yB_zM'_αM"_βX_γ를 갖는 Fe-베이스 연사성 합금에 있어서, a, x, y, z, α, β 및 γ의 일반적인 범위는 0

a

0.5, 0.1

x

3, 0

y

30, 0

z

25, 5

y+z

30, 0.1

α

30, β

10, γ

10이고, 양호한 범위는 0

a

0.3, 0.1

x

3, 6

y

25, 2

z

25, 14

y+z

30, 0.1

α

10,β

5, γ

5이고, 보다 양호한 범위는 0

a

0.1, 0.5

x

2, 10

y

25, 3

z

18, 18

y+z

28, 2

α

8, β

5, γ

5이고, 가장 양호한 범위는 0

a

0.05, 0.5

x

2, 11

y

24, 3

z

9, 18

y+z

27, 2

α

8, β

5, γ

5이다.Taken together, in the Fe _- base soft magnetic alloy having the general formula (Fe _1-a M _a ) _100-xyz-α Cu _x Si _y B _z M ' _α , the general ranges of a, x, y, z and α Is 0

a

0.5, 0.1

x

3, 0

y

30, 0

z

25, 5

y + z

30, 0.1

α

30, their preferred range is 0

a

0.3, 0.1

x

3, 6

y

25, 2

z

25, 14

y + z

30, 0.1

α

10, with a better range of 0

a

0.1, 0.5

x

2, 10

y

25, 3

z

18, 18

y + z

28, 2

α

8, the best range is 0

a

0.05, 0.5

x

2, 11

y

24, 3 z

9, 18

y + z

27 2

α

8, and in the Fe _- based twistable alloy having the general formula (Fe _1-a M _a ) _{100-xyz-α-β-γ} Cu _x Si _y B _z M ' _α M " _β X _γ , a, x The general range of, y, z, α, β, and γ is 0

a

0.5, 0.1

x

3, 0

y

30, 0

z

25, 5

y + z

30, 0.1

α

30, β

10, γ

10, the preferred range is 0

a

0.3, 0.1

x

3, 6

y

25, 2

z

25, 14

y + z

30, 0.1

α

10, β

5, γ

5, the better range is 0

a

0.1, 0.5

x

2, 10

y

25, 3

z

18, 18

y + z

28, 2

α

8, β

5, γ

5, the best range is 0

a

0.05, 0.5

x

2, 11

y

24, 3

z

9, 18

y + z

27, 2

α

8, β

5, γ

5.

The Fe-based soft magnetic alloy having the above composition has an alloy structure in which at least 50% is composed of fine grains. These crystal grains are based on α-Fe having a bcc structure in which Si, B and the like are dissolved. These grains have an extremely small average particle diameter of 1000 mm 3 or less, and are uniformly distributed in the alloy structure. Often, the average particle diameter of the grains is determined by measuring the maximum size of each particle and averaging them. When the average particle diameter exceeds 100 mm 3, excellent soft magnetic properties are not obtained. The average particle diameter is preferably 500 kPa or less, more preferably 200 kPa or less, and particularly preferably 50 to 200 kPa. The remainder of the alloy structure other than the fine grains may be mainly amorphous. Even when fine grains occupy nearly 100% of the alloy structure, the Fe-based soft magnetic alloy has sufficiently good magnetic properties.

Often, with regard to unavoidable impurities such as N, O, S, and the like, containing them in an amount such that they do not degrade desirable properties is not considered to change the alloy composition suitable for the magnetic core of the present invention.

Now, a method of manufacturing the Fe-based soft magnetic alloy will be described in detail.

First, the alloy melt of the composition is quenched by a known liquid cooling method such as a single roll method, a double roll method, or the like to form an amorphous alloy ribbon. Typically, amorphous alloy ribbons produced by the single roll method or the like have a thickness of about 5 to 100 μm, and amorphous alloy ribbons having a thickness of about 25 μm are particularly suitable as magnetic core materials for use at high frequencies.

These amorphous alloys may contain a crystalline phase, but the alloy structure is preferably amorphous so that uniform and fine grains can be surely formed by a heat treatment to be followed. Often, Fe-soft magnetic alloys containing fine grains can be produced directly by the liquid phase cooling method without depending on the heat treatment, as long as suitable conditions are selected.

Because amorphous ribbons have good processability in the amorphous state, they can be wound, punched, etched, or any other process in the desired form prior to heat treatment, but once crystallized, they lose such processability.

The heat treatment is carried out by heating the amorphous alloy ribbon processed in the desired form in an inert gas atmosphere such as hydrogen, nitrogen, argon or the like or in a vacuum. The temperature and time of the heat treatment vary depending on the composition of the amorphous alloy ribbon and the shape and size of the magnetic core made from the amorphous alloy ribbon or the like, but is generally preferably 450 to 700 ° C. and 5 minutes to 24 hours. If the heat treatment temperature is lower than 450 ° C., crystallization does not easily occur, and thus requires too much time for heat treatment. On the other hand, when the heat treatment temperature exceeds 700 ° C, coarse crystal grains are sometimes formed, so that it is difficult to obtain fine grains. Regarding the heat treatment time, if the heat treatment time is shorter than 5 minutes, it is difficult to heat the whole winding core at a uniform temperature, so that non-uniform magnetic properties are obtained, and if the heat treatment time is longer than 24 hours, the productivity is too low Rather, grains grow excessively, resulting in a decrease in magnetic properties. Preferred heat treatment conditions are 500 to 650 DEG C and 5 minutes to 6 hours, especially considering uniform temperature control and the like.

The heat treatment atmosphere is preferably an inert gas atmosphere, but may be an oxidizing atmosphere such as air or the like. Cooling can be carried out appropriately in air or in the furnace. In addition, the heat treatment may be performed in several steps.

In order to provide magnetic anisotropy, the heat treatment may be performed in a magnetic field. In the heat treatment step, when a magnetic field parallel to the magnetic path of the magnetic core of the present invention is applied, the heat treated final magnetic cores have a good spherical ratio in their BH curves, as a result of which they are saturated reactors, magnetic switches, pulse compression cores. It is particularly suitable for reactors for preventing spike voltages. On the other hand, when the heat treatment is performed while a magnetic field perpendicular to the magnetic path of the magnetic core is applied, the B-H curve is inclined to provide a small spherical ratio and a constant permeability. In addition, it has a wider operating range, making it suitable for transformers, noise filters, choke coils, and the like.

The magnetic field need not always be applied during the heat treatment, only the alloys need to be at a temperature lower than their Curie temperature Tc. In the case of the present invention, since the alloy is crystalline and has a higher Curie temperature than the amorphous pair, the heat treatment in the magnetic field can be carried out at a temperature higher than the Curie temperature of the corresponding amorphous alloy. In the case of heat treatment in a magnetic field, it may be carried out in two or more steps. In addition, a rotating magnetic field may be applied during the heat treatment.

The magnetic core of the present invention preferably has a saturated magnetic flux density (Bs) of 10KG or more and an effective permeability (μo _1KHz ) of 5 × 10 ³ or more.

In the present invention, the effective permeability change rate (x) with respect to time is represented by the following equation x = 1-μ _b / μ _a . In transplantation, μ _a is the effective permeability at 1 before testing the sample, and μ _b is the effective permeability at 1 KHz after heating the sample to 100 ° C. for 1000 hours in air. The heating test can be carried out in a constant temperature furnace.

This rate of change x should be less than 0.3, preferably less than 0.1, and more preferably less than 0.05.

As described above, in order to avoid deterioration of the magnetic properties of the magnetic core due to the internal stress generated when infiltrating or coating with the resin, the magnetic core has a magnetic strain of + 5 × 10 ^-6 to -5 × 10 ^-6 It is preferable to have (λs), and it is particularly preferable to have a magnetostriction (λs) of + 1.5 × 20 ⁻⁶ to -1.5 × 10 ⁻⁶ .

By using the Fe-base soft magnetic alloy having the above composition and properties, a saturated reactor, a semiconductor circuit reactor, a normal mode choke, a standard mode choke, a high frequency transformer, a motor core, and the like can be provided.

In the case of a saturation reactor or a semiconductor reactor, the saturation reactor must have a large control range, and the semiconductor reactor must prevent spike current without reducing the voltage applied to the circuit. Therefore, the magnetic cores for the two reactors should have a spherical ratio B _r / B ₁₀ of the DC BH curve, preferably 8% or more, preferably 70% or more. Frequently, B _r means residual magnetic flux density, and B ₁₀ means magnetic flux density at ₁₀ De which corresponds to almost saturated magnetic flux density. Such large spherical ratios can be obtained by heat treatment while applying a magnetic field parallel to the magnetic path of the magnetic core.

In the case of a saturated reactor, the magnetic core preferably has an unregulated magnetic flux density (ΔB _b ) of 3KG or less at 50KHz to prevent the voltage from changing when the load current increases.

When the magnetic core of the present invention is used as a reactor for a semiconductor circuit, it shows an excellent function of preventing the spike voltage from flowing through the semiconductor circuit.

When the magnetic core of the present invention is used for a conventional mode choke or high frequency transformer, a large effect magnetic flux density can be obtained for a single polarity pulsed voltage input. Therefore, the DC BH curve preferably has a spherical ratio B _r / B ₁₀ of 30% or less.

In order to reduce core loss, it is desirable that one or both of the ribbon surfaces be partially or wholly covered with an insulating layer. This insulating layer may be formed in various ways. For example, it may be formed by attaching insulating powders such as SiO ₂ , MgO, Al ₂ O ₃ , to the ribbon surface by dipping, spraying, and electrophoresis. A thin layer such as SiO ₂ may be formed by sputtering or vacuum plating. Alternatively, a mixture of solutions of the improved alkylsilicates in alcohols with acids can be added to the ribbon. In addition, the forsterite (MgSiO ₄ ) layer may be formed by heat treatment. In addition, the sol obtained by partially hydrating the SiO ₂ —TiO ₂ metal alkoxide may be mixed with various ceramic powders and the final mixture may be added to the ribbon. In addition, a solution mainly containing polytitanocarbosilane can be added to the ribbon and then heated. In addition, it can be heated by adding a phosphoric acid solution. In addition, the insulating layer may be formed by heating by applying an oxidizing agent to the ribbon.

In order to fabricate a saturation reactor or the like from the winding core, the winding core may be composed of an alloy ribbon and insulating tape positioned between adjacent ribbon layers. Such winding cores can be formed by placing insulating tape on the ribbon and winding them. This insulating tape may be polyamide tape, ceramic fiber insulating tape, polyester tape, aramid tape, glass fiber tape, or the like.

When a high thermal insulating tape is used, the winding core containing such tape can be heat treated.

In the case of a laminated core, an insulating thin film is inserted between adjacent layers to insulate between alloy plate layers. In this case, materials that have no solubility such as ceramic, glass, mica or the like can be used for the insulating thin film. When these materials are used, heat treatment may be performed after lamination.

In the case of the winding core, the inner and outer ends of the ribbon can be secured to the winding core body to prevent loosening of the winding core. The fixation of the ribbon ends can be done by applying a laser beam or electron energy to the fixation point or by using an adhesive or adhesive tape.

Often, the Fe-based soft magnetic alloy is preferably plated or coated to prevent corrosion. In addition, the winding core can be housed in an insulating case, and materials such as grease can be used to fill the space between the winding core and the case to prevent insulation and corrosion of the winding core. Since the magnetic core of the present invention can be made of Fe-based alloys, it is particularly important to isolate it from air.

Without limiting the scope of the invention, the present invention will be described in more detail by the following examples.

Example 1

A melt having a composition of 1 atomic% Cu, 13.5 atomic% Si ₁ , 7.2 atomic% B, 2.5 atomic% Nb, and the balance Fe was molded into a ribbon of 18 탆 thickness 18 탆 by a single roll method. X-ray diffraction of this ribbon showed a halo pattern unique to the amorphous alloy of FIG. Transmission electrophotography of this ribbon showed no crystal grains in the alloy structure. As can be seen from the X-ray diffraction and transmission electrophotography, the final ribbon was almost completely amorphous.

Next, this amorphous ribbon was formed into a toroidal winding core having an inner diameter of 10 mm and an outer diameter of 13 mm as shown in FIG. 5, and then heat-treated at 550 DEG C for 1 hour in a nitrogen gas atmosphere.

The toroidal winding core was embedded in a core case made of phenol resin and wound around the wire 10 times on both the first and second sides around it. This magnetic core was placed in a constant temperature furnace at 100 ° C. and its change in effective permeability was measured at each time. The results are shown in FIG. ₁ , where A ₁ represents the magnetic core of this example. For comparison, an amorphous alloy with 0.4 atomic% Fe, 5.9 atomic% Mn, 15 atomic% Si, 9 atomic% B, and the balance Co, and an unheated Fe base amorphous having the same composition as A ₁ (in this example) The alloy was molded into a magnetic core in the same manner as above and its effective permeability was measured over time. The results are also shown in FIG. 1, where B ₁ is a magnetic core made of Co base amorphous alloy, and C ₁ is a non-heat treated Fe base amorphous alloy (Fe balance Cu ₁ Nb _2.5 Si _3.5 B _7.2 A magnetic core made of

As can be seen from FIG. 1, in the magnetic core of the present invention, the effective permeability hardly changed with time (the effective permeability change rate with time x = 0.02), but the Co-based amorphous alloy (Comparative Example) In the case of the magnetic core, X was as high as 0.73. In the case of Fe-based amorphous alloys having the same composition, X was as low as 0.03 but its effective permeability was too low to be used as a magnetic core. Thus, this indicates that the magnetic core of the present invention has excellent durability because of the low rate of change of effective permeability over time.

The magnetic core of the present invention was decomposed to analyze the metal structure of the ribbon by X-ray diffraction and transmission electrophotography. Figure 3 (a) shows the X-ray diffraction pattern of the Fe base alloy of the present embodiment and Figure 3 (b) shows a transmission electron photograph of the same Fe base alloy, 1 is a fine crystal grain 2 is a matrix Indicates. It can be expected from this that the matrix phase is amorphous but may be converted into a fine crystalline phase when the heat treatment temperature is high. X-ray diffraction and transmission electrophotography showed that the Fe base alloy of this example contains crystalline ultrafine particles made of bcc Fe solid solution having a particle size of 50 to 200 GPa.

Example 2

This example shows the measurement of the standard magnetization characteristics of the magnetic core.

Figure 6 shows a circuit for measuring standard magnetization characteristics, which is equivalent to that for evaluating a saturated reactor. 7 schematically shows the characteristics of the saturation reactor when the Dc regulating current Ic flows through the regulating circuit. In FIG. 6 the specimen S is a saturated reactor consisting of a magnetic core and three windings N _L , N _C , N _V.

N _L , which corresponds to the output winding of the saturation reactor used in the magnetic amplifier, is connected to an Ac power supply (Eg) having a frequency f (period: Tp) via a resistor (R _L ) and a rectifier (D). The value of Eg is set so that the magnetic core saturates at a phase angle within 90 ° of the applied sinusoidal voltage in the half period Tg of the gate.

N _C is the regulating winding, which is connected to the Dc power source Ec via an inductor Lc having a sufficiently large inductance to give Dc magnetization to the magnetic core as compared to the inductance of the magnetic core.

N _V is the winding for measuring the reset flux Δøcm corresponding to the regulating input, which is connected to a standard rectifier type Ac voltmeter.

7 schematically shows a standard magnetization curve measured by this circuit.

defining a β ₀ by the inverse of the standard full magnetizing force (H _r) By a β ₀ = 1 / H _r.

In the case of a saturated reactor, when β ₀ is large (when H _r is small), the regulating current is smaller and has better characteristics.

On the other hand, the factor (alpha) ₀ which shows the squareness ratio of the magnetization curve of a magnetic core is prescribed | regulated as follows.

α ₀ = 1-△ B _b / △ B _m

In the case of a saturated reactor, when α ₀ is large, the unregulated magnetic flux density ΔB _b becomes smaller and has better characteristics.

The product of α ₀ and β ₀ represents the unit core gain G ₀ .

G ₀ = α ₀ · β ₀

Larger G ₀ makes the magnetic core more suitable for the saturated reactor as a whole.

The maximum value (β _m ) of the magnetic flux density corresponds to the maximum value of the gate magnetic field.

₀………………………………………………… (1) _{H rm = N L · i L} (max) /

₀ …. … … … … … … … … … … … … … … … … … … (One)

₀는 샘플의 평균 자기 통로 길이이다.At this time,

₀ is the average magnetic path length of the sample.

The magnetic flux density (B _c ) is determined by the standard magnetic field:

₀……………………………………………………… (2)H = (N _{CI C} ) /

₀ …. … … … … … … … … … … … … … … … … … … … … (2)

The difference between the maximum value B _m and the magnetic flux density B _C is expressed as ΔB _cm , and the reading (Ev) of the magnetic flux voltmeter _V in the N _V circuit is as follows.

Ev alpha f, Nv, A, ΔB _cm ... … … … (3)

Where f is frequency and A is the effective cross-sectional area of the magnetic core.

In actual saturation reactor, it is necessary to know the H _{Lm -ΔB b} characteristic in the positive region of the magnetic field H and the H _{Lm -ΔB b} characteristic in the negative region of the magnetic field H.

ΔB _b = B _m -B _r . … … … … … … … … … … … … … … … … … … … … … … (4)

Evd alpha f, Nv, A, DELTA B _b . … … … … … … … … … … … … … … … … … … (5)

DELTA B = DELTA B _cm -DELTA B _b . … … … … … … … … … … … … … … … … … … … … (6)

In the case of a saturated reactor, the curve in FIG. 8 is preferably low in one quadrant and located near the axis in the quadrant, and is rapidly inclined.

Example 3

1 at.% Was formed into Cu and 13.5 at.% Si, 9 at% B, 3 at% N _b and the balance of Fe width of the melt to a single roll method 4.5mm, the thickness of the ribbon 18㎛. This ribbon was almost completely amorphous. The ribbon was molded into a toroidal winding coil having an inner diameter of 10 mm and an outer diameter of 13 mm. The alloy had a crystal temperature of 508 ° C. and a anneal temperature of about 310 ° C. when measured at a heating rate of 10 ° C./min.

After that, various types of heat treatments shown in FIGS. 4A to H were performed on each winding coil in a magnetic field. When the magnetic field was applied, it was parallel to the magnetic path of the magnetic core at 10e. This shows that the alloy after the heat treatment has crystalline fine particles of 100 to 200 kPa composed of bcc Fe solid solution and forming a main alloy structure.

Each winding core was embedded in a phenolic resin core case and wound 10 times with a wire around each magnetic core on both the first and second sides to provide a saturated reactor as shown in FIG. The properties of each magnetic core were measured. The results are shown in Table 1.

TABLE 1

As shown in FIG. 1, each type of heat treatment shown in FIG. 4 can provide a final magnetic core with a high spherical ratio, with its core loss (W ₂ / 100K) at 2KG and 100KHz being Co-based. Less than the amorphous alloy magnetic core (W ₂ / 100K = 200-900). In addition, the magnetic flux density at 10Oe (sB _s ) is 12.4KG, which is considerably higher than that of Co-based amorphous alloys and 80% Ni permalloy.

The alloy heat-treated with the pattern (b) of FIG. 4 has a Gurley temperature (Tc) of 570 ° C. and a saturation magnetostriction (λ _s ) of 3.8 × 10 ⁻⁶ .

Example 4

A melt of 1 atomic% Cu, 13.5 atomic% Si, 9 atomic% B, 5 atomic% Nb and the balance Fe was formed into a ribbon having a thickness of 18 μm and a width of 5 mm by a single roll method. This alloy had a crystal temperature of 533 ° C. when a heating rate of 10 ° C./min was measured. The glass temperature was 260 degreeC.

After that, the ribbon was coated with MgO powder by electrophoresis and molded into a winding core having an inner diameter of 15 mm and an outer diameter of 19 mm. This winding core was heated at 610 ° C. for 1 hour in an N ₂ gas atmosphere, and cooled to 250 ° C. at a cooling rate of 5 ° C./min in 50e and a magnetic field parallel to the magnetic core of the magnetic core. After maintaining at 250 ° C. for 4 hours, it was cooled to room temperature at a cooling rate of about 60 ° C./min.

Another winding coil having the same composition and the same structure was heated at 610 ° C. for 1 hour, after which it was cooled to room temperature at a cooling rate of 100 ° C./min in a 50 e magnetic field parallel to the magnetic passage of the magnetic core.

Each core was embedded in a phenolic resin core case and the wire was wound ten times around each magnetic core on both the first and second sides to provide a saturated reactor. The characteristics of each saturated reactor were examined. The results are shown in Table 2.

TABLE 2

As can be seen from Table 2, this magnetic core has a high spherical ratio suitable for a saturated reactor. The alloy heat-treated in the pattern (b) has a main phase having a Gurley temperature of 550 ° C. and a saturated magnetic strain (λ _s ) of 1 × 10 ⁻⁶ .

In addition, it was observed that crystalline ultrafine particles predominantly exist in the alloy structure in Example 1.

Example 5

The saturated reactor was made of Fe _73.5 Cu ₁ Nb ₃ Si _13.5 B ₉ alloy (A ₂ , Type 1), Fe _71.5 Cu ₁ Nb ₅ Si _13.5 B ₉ alloy (A ₃ ), and Fe _71.5 Cu ₁ Nb ₅ Si _13.5 B ₉ alloy (A ₄ ), high spherical ratio Fe base amorphous alloy (C ₂ : Fe _69.3 Ni _7.7 Si ₁₃ B ₁₀ ), and two high spherical ratio Co base amorphous alloys (B ₂ , B ₃ : Co _69.7 Fe _0.4 Mn _5.9 Si ₁₅ B ₉ , Co ₆₇ Fe ₄ Mo _1.5 Si _16.5 B ₁₁ ) were used. The alloy (A ₂ ) was heated at 550 ° C. for 1 hour, cooled to 280 ° C., and maintained at that temperature for 1 hour, followed by heat treatment by applying a magnetic field of 2e in the direction of the magnetic path, and alloy (A ₃ ) at 610 ° C. for 1 hour. while heating and cooling to 250 ℃ and held for a further 2 hours at that temperature in that only after it in was heat treated by applying a magnetic field of 15Oe in the magnetic path direction, the alloy (a ₄₎ is while heating the air cooled in 610 ℃ for one hour self-direction Was heated by adding a magnetic field of 20e. The B _r / B ₁₀ of each alloy is as follows.

The core loss of the magnetic core of each alloy (A ₂ to B ₃ ) was measured at 2KG. The result is shown in FIG. According to this, the magnetic cores (A ₂ , A ₃ , A ₄ ) using the saturation reactor of the present invention exhibit lower core loss than the conventional high spherical ratio Co base amorphous alloys (B ₂ , B ₃ ). Thus, it is suitable for saturated reactors. It also exhibited half or less core loss than the conventional high spherical ratio Fe base amorphous alloy C ₂ .

Example 6

The alloys (A ₂ , A ₃ , A ₄ , B ₂ , B ₄ ) shown in FIG. 9 were used to provide a saturation reactor, and their standard magnetization characteristics were evaluated by the circuit of FIG. 6. In this case, the primary winding N _V and the secondary winding N _L were 17 turns each, and the regulating winding N _C was 5 turns. The result is shown in FIG. As can be seen in FIG. 10, the saturation reactor of the present invention has a standard magnetization force comparable to that of the high aperture ratio Co base amorphous alloy in the case of the same ΔB, but is 1.5 to 2 times higher than the Co base amorphous alloy saturation reactor. It had an overall standard magnetic density of ΔB _m . Therefore, the saturation reactor of the present invention can be miniaturized under the condition that the temperature rise of the core does not cause a big problem.

Example 7

Saturated reactors were prepared from microcrystalline alloys containing 1 atomic% Cu, 13.5 atomic% Si, 9 atomic B, 3 atomic% Nb and the balance Fe, and the temperature characteristics of the magnetic properties were measured. The result is shown in FIG.

In the range from room temperature to 150 ° C., no change in spherical ratio, B _r / B ₁₀ , core loss, and coercivity occurred. Regarding B ₁₀ , the decrease in temperature was increased by about 1 KG from room temperature to 150 ° C., but this does not cause a substantial problem. Thus, saturated reactors made from such microcrystalline alloys have good durability.

Example 8

The alloy melt having the composition shown in Table 3 was molded into an amorphous ribbon having a thickness of 8 탆 and a width of 5 mm by a single roll method. Each ribbon was molded into a winding core having an inner diameter of 15 mm and an outer diameter of 19 mm. Each winding core was heat treated to form crystalline ultrafine particles in the alloy structure. Heat treatment conditions are according to the heat treatment pattern (b) of FIG.

Each winding core is embedded in a phenolic resin core case and the wire is wound around each winding core 10 times on both the first and second sides to provide a saturated reactor as in Example 1. In the case of the magnetic core was measured DC BH curve and ACB-H curve, and standard 100KHz magnetization curve in the core loss (W ₂ / 100K), 50KHz in 2KG. The standard magnetization curve of the saturated reactor of the same tissue as in Example 7 was measured by the method shown in Example 2.

Magnetic flux density (B ₁₀ ) at ₁₀ Oe magnetic field density, spherical ratio of DC BH curve, HC (Dc), B _r / B ₁ (Ac), Hc (Ac), W ₂ of ACB-H curve at 20 KHz / 100K, total standard magnetization force (Hr) and unregulated magnetic density (ΔB _b ) are shown in Table 3.

TABLE 3

The saturation reactor of the present invention had a Co base amorphous alloy and B ₁₀ higher than 80 wt% Ni permalloy, and had a high spherical ratio. In addition, the saturation reactor of the present invention had good characteristics in terms of Hc, core loss and ΔBb when compared to Co base amorphous alloy. The saturated reactor of the present invention had a low core loss compared to that made with 50% by weight Ni Permalloy and Fe base amorphous alloy, which means that the saturated reactor of the present invention has good standard magnetization properties.

Because of this characteristic, the saturation reactor of the present invention can be operated with a small standard current, increasing the efficiency of the circuit. In addition, since ΔBb is small, it has a wide range of adjustment.

Example 9

An alloy melt having the composition shown in Table 4 was used to prepare a winding core with crystalline ultrafine particles as in Example 8, and each winding core was molded into a saturated reactor. For each saturated reactor, the magnetic pole density at 10Oe (B ₁₀ ), core loss at 100 KHz and 2 kG (W ₂ / 100K), unregulated magnetic flux density (ΔBb) and saturation magnetostriction (λs) were measured. The results are shown in Table 4.

TABLE 4

Note * Sample 9 is a comparative example

As can be seen from Table 4, the saturation reactor of the present invention had a higher spherical ratio, lower Hc, lower core loss, and lower uncontrolled magnetic flux density (ΔBb) than the Fe base amorphous alloy. In addition, by having a low lambda s, deterioration of magnetic properties due to coating or the like can be avoided.

Example 10

Amorphous alloy ribbons with 1 atomic% Cu, 13.5 atomic% Si, 9 atomic% B, 3 atomic% Nb and balance Fe, 13.5 atomic% Si, 9 atomic% B, 3 atomic% Nb and balance An amorphous alloy ribbon having a composition of Fe was prepared. The first amorphous alloy containing both Cu and Nb had a crystal temperature of 508 ° C. when measured at a heating rate of 10 ° C./min, while the second amorphous alloy without Cu was 583 ° C. when measured under the same conditions. It had a crystal temperature of.

Each amorphous alloy ribbon was molded into a winding core having an inner diameter of 15 mm and an outer diameter of 19 mm. The coil wound containing Cu-Nb according to the present invention was heated at 550 ° for 1 hour while applying a magnetic field of 10Oe in the direction of the magnetic path, and after that, 20 ° C./min to form crystalline ultrafine particles in the main alloy structure. It cooled to room temperature by the cooling rate of. On the other hand, the magnetic alloy of the comparative example was heated to 500 DEG C for 1 hour, cooled to 280 DEG C at a cooling rate of 5 DEG C / min while applying a magnetic field of 10 e in the magnetic direction thereof, and then held at 280 DEG C for 4 hours after that After cooling, the mixture was cooled to room temperature at a cooling rate of 20 ° C / min. The winding core of the comparative example had an amorphous structure. Each winding core was embedded in a phenolic resin core case and molded into a saturated reactor by winding the primary and secondary wires 20 times and the adjusting wire 5 times.

Each saturation reactor was mounted in a self-regulating switching power supply with a drive frequency of 100KHz. This switching power supply has two outputs: 12V output (self-amplification control) and 5V output (PWM control). The output characteristics of the saturation reactor were measured by this switching power supply. The input voltage was Ac 100V and the load current at the 12V output was varied while keeping the load current at the 5V output constant. In this case, the 12V output terminal voltage, power efficiency (η) and core case surface temperature increase (ΔT) were measured and compared between the two saturated reactors. The results are shown in FIG. 12, where A ₅ represents the saturated reactor of the present invention and C ₃ represents the saturated reactor of the Fe base amorphous alloy.

According to this, the saturation reactor of the present invention had a small temperature increase and a high power supply efficiency η without a change in the output voltage as compared with the comparative example (which is a Fe basic amorphous alloy).

Example 11

A melt having a composition of 0.8 atomic% Cu, 13.6 atomic% Si, 9 atomic% B, 3 atomic% Nb and the balance Fe, 1 atomic% Cu, 13.5 atomic% Si and 9 atomic% B, 5 atomic% Nb and The melt having a composition of addition Fe was molded into an amorphous ribbon by the single roll method. Each amorphous ribbon was heat-treated in an N ₂ gas atmosphere in a magnetic field of 100 e in the magnetic path direction. The heat treatment conditions were heated at 550 ° C. for 1 hour, cooled to 280 ° C., maintained at 280 ° C. for 1 hour for the first melt, and heated to 610 ° C. for 1 hour, cooled to 250 ° C. for 4 hours for the second alloy. The temperature was maintained at 250 ° C. A magnetic field was applied during the heat treatment. By this heat treatment, crystalline ultrafine particles were formed in the alloy structure.

Each winding coil was embedded in a Bakelite core case and the wire was wound ten times around each magnetic core on both the first and second sides to provide a saturation reactor. The characteristics of each saturated reactor were examined.

Figure 13 shows the DcB-H curves for each saturated reactor. (a) is for Fe _73.6 Cu _0.8 Nb ₃ Si _13.6 B ₉ alloy with B ₁₀ = 12.4 kG and Br / B ₁₀ = 93% and Hc = 0.004Oe, and (b) is B ₁₀ = 11.3 kG and For Fe _71.5 Cu ₁ Nb ₅ Si _13.5 B ₉ alloy with Br / B ₁₀ = 90% and Hc = 0.007Oe. For comparison, an amorphous alloy with 15 atomic% Si, 9 atomic% B, and 5.9 atomic% Mn balance was made of Co to form a saturated reactor. It had B ₁₀ = 7.8 kG, Br / B ₁₀ = 92% and Hc = 0.004Oe. FIG. 13C shows its Dc BH curve. As can be seen in FIG. 13, the saturation reactor of the present invention (a) (b) shows a higher B ₁₀ than the Co base amorphous alloy (C), which has a coercive force (Hc) and a spherical ratio (Br / B). _{The same} can be said for ₁₀ ). The maximum permeability (μ max) is 1450 K for Fe _73.6 Cu _0.8 Nb ₃ Si _13.6 B ₉ alloy and 1000 K for Fe _71.05 Cu ₁ Nb ₅ Si _13.5 B ₉ alloy.

Example 12

The alloy melt of Fe _72.5-X Cu _x Si _13.5 B ₉ Nb ₅ (alloy A ₆ ) and the alloy melt of Fe _77.5-x Cu _x Si _13.5 B ₉ (alloy A ₇ , Remarks) were amorphous by a single roll method. Molded with a ribbon. After that, each ribbon was molded into a winding core having an inner diameter of 15 mm and an outer diameter of 19 mm, and the final winding core was heat-treated under the same conditions as the heat treatment pattern of FIG. 4 while applying a magnetic field of 20Oe in the direction of the magnetic passage in a gas atmosphere. After that, the heat-treated winding core was embedded in the phenol resin core case and the wire was wound 10 times on the first and second sides to provide a saturated reactor. In the circuit shown in Example 2, the saturation reactor was measured with respect to the standard magnetization characteristics.

Figure 14 shows the unit core gain Go measured at 500 KHz. Go rapidly increases in the case of alloy (A ₆ ) when X exceeds 0.1 but Go unnecessarily decreases when X exceeds 3.

When Nd is not added (such as alloy A ₇ ), Go does not improve by addition of Cu. This means that the addition of both Cu and Nd is very effective in improving the standard magnetization properties of saturated reactors.

Example 13

The alloy melt of Fe _76.5-α Cu ₁ Si _15.5 B ₇ Nb ₅ (alloy A ₈ ) and the alloy melt of Fe _77.5-α Si _15.5 B ₇ Nb _α (alloy C ₆ ) were formed into an amorphous ribbon by a single roll method. Each ribbon was then formed from a winding core with an outer diameter of 19 mm and an inner diameter of 15 mm. Each winding core was heat-treated under the same condition as the heat treatment pattern (b) of FIG. 4 while applying a magnetic field of 20Oe in the direction of the magnetic passage in an N ₂ gas atmosphere, and a saturation reactor was made as in Example 12. The special core gain Go was measured at 50 KHz. The result is shown in FIG. The fact proved from FIG. 15 indicates that the saturation reactor of the present invention had a much larger Go than the comparative example, and that the addition of Cu and Nd was significantly effective in improving the control magnetization characteristics.

Example 14

The melt composed of 1 atomic% Cu, 13.5 atomic% Si, B9 atomic%, Nb 3 atomic%, and the balance Fe was formed into a ribbon having a width of 3 mm and a thickness of 18 μm by a single roll method. This ribbon was subjected to the heat treatment shown in Fig. 4 (b) in Example 8. This ribbon was then formed into a winding core and then poured into a phenolic resin case. A wire having a diameter of 0.4 mm was wrapped around 20 lines to provide a reactor for a semiconductor circuit shown in FIG. This reactor was measured for inductance at 1 KHz. The ratio of maximum inductance to initial inductance was 3.03, and the ratio of maximum inductance to residual inductance was 300. In addition, the residual inductance is the inductance measured when DC current is applied.

Due to the large ratio of maximum inductance to residual inductance, reactors are excellent at improving diode recovery characteristics.

17 shows the basic circuit of the switching power supply using the reactor. In FIG. 17, reference numeral 10 denotes a peripheral voltage, numerals 11, 12, and 13 denote respective diodes, and numeral 16 denotes a load. Both inputs and outputs were DC voltages. 18 shows the waveform of the load current. A is when no reactor is used, and B is when a reactor is inserted into a half-wave rectifier circuit operating at a pulse width of 10 μs and an input voltage of 100 VDC. By using the reactor of the present invention, current spikes are significantly reduced.

Example 15

1 mol% of Cu, 13.5 atomic% of Si, 7 atomic% of B, 2.5 atomic% of Nb, and the remainder of the melt were formed by an amorphous ribbon having a width of 3 mm and a thickness of 1 μm by a single roll method. The ribbon was applied with MgO powder in terms of contact with a single roll. Winding provides a toroidal winding core with an outer diameter of 4 mm and an inner diameter of 2 mm. This winding core is heat treated at 550 ° C. for 1 hour, the outer surface of which is coated with an epoxy resin and provided with a diode terminal to provide a semiconductor circuit reactor coupled with diodes 21, 22, represented by the reactor of the invention in FIG. 19. Connected.

This reactor is then used to smooth the circuit on the output side of the switching power supply to measure diode voltage and output noise.

When the reactor of the present invention is not used, the diode voltage is 61.0V and the output noise is 123mVp-p, but when the diode voltage is 33.5V, the output noise is 47.3mVp-p. Therefore, the reactor of the present invention has a superior smoothing effect and a noise reduction effect.

Example 16

Reactors are made from alloy ribbons having the composition of Table 5 in the same manner as in Example 14, and their initial inductance L _o and maximum inductance L _m are measured. After 1000 hours of heat treatment at 120 ° C., the initial inductance L ₀ ¹⁰⁰⁰ and the maximum inductance L _m ¹⁰⁰⁰ are measured to determine L _o ¹⁰⁰⁰ / L _o and L _m ¹⁰⁰⁰ / L _m . The results are shown in Table 5.

TABLE 5

Note * Samples 26 to 27 are comparative examples

From Table 5 the reactor for semiconductor circuits according to the invention has much less inductance variation than conventional Co-based amorphous alloys.

Example 17

The melt having a composition of 1 atomic% Cu, 14 atomic% Si, 8 atomic% B, 5 atomic% Nb and the balance Fe was prepared by using a single roll method for amorphous alloy ribbon having a width of 5 mm, a maximum thickness of 20 μm, and an average thickness of 17 μm. to make. The ribbon was wound 20 times to make a toroidal winding core of 6 mm inner diameter, and air-cooled by heat treatment at 600 ° C. for 1 hour in an argon gas atmosphere. Example 1 A magnetic core having the same structure as the alloy structure is formed.

20 turns are made around this magnetic core to provide a reactor for semiconductor circuits. This semiconductor circuit reactor is inserted into the switching power supply in series with the diode to determine the power supply efficiency. As a result, the power supply efficiency is 80%. In addition, the temperature increase of the reactor is 15 ° C. On the other hand, when a similar reactor made of an amorphous alloy of Fe-Si-B is used, the power supply efficiency is 77%, which means high efficiency of the reactor of the present invention.

Example 18

The alloy melt having the composition of Table 6 was rapidly cooled by a single roll process to produce an amorphous alloy ribbon, each of which produced a toroidal core having an outer diameter of 35 mm and an inner diameter of 25 mm. Each winding core is heat treated at a temperature above or equal to its crystal temperature in a 5000Oe magnetic field perpendicular to its magnetic path to form extremely good crystalline particles in the alloy structure.

Wire 2 is wound around this winding core as shown in FIG. 20 to form a common mode choke. These common mode chokes have DC magnetic field characteristics, core loss at 2kG W ₂ / _100k , absolute value of complex permeability at 100KHz│μ│ _100k , pulse width of 10μs and pulse permeability at ΔB and saturated magnetostriction λs of 4kG. Measured for μ. The results are shown in Table 6.

TABLE 6

Note * Samples 15 to 17 are comparative examples

These DC magnetic properties are compared with those of Fe-based amorphous alloys, and μ _100Z is compared with Co-based amorphous alloys. In the frequency band near 100 KHz, where the noise problem is most serious, the common mode choke of the present invention has a large common Morse noise attenuation effect. In addition, the core loss in the common mode choke of 2KG and 100KHz of the present invention is less than that of the Fe-base amorphous alloy, and for the saturation magnetostriction, the Fe-base magnetic alloy is less than that of the base amorphous alloy. Variable so that

Example 19

An alloy melt having a composition of 1 atomic% Cu, 16.5 atomic% Si, 6 atomic% B, 3 atomic% Nb, and the balance Fe was formed by an amorphous ribbon having a width of 7.5 mm and a thickness of 18 μm by a single roll method. This amorphous alloy ribbon is wound to form a toroidal core of 19.5 mm outer diameter 9.6 mm inner diameter. This winding core is heat-treated in a magnetic field of 3000Oe perpendicular to the magnetic path and the N ₂ gas atmosphere. In this heat treatment, it is maintained at 510 ° C. for 1 hour, heated at a heating rate of 10 ° C./min and cooled to room temperature at a cooling rate of 2.5 ° C./min.

This winding core is embedded into the phenolic resin core case, and also two wires of ten turns are wound around it as shown in FIG. 20 to provide a common mode choke. Its magnetic properties are measured. As a result, the _{B 10 = 12KG, Br / B} 10 = 14%, HC = 0.018Oe,, μ 01k = 28000, │μ│ 100k = 2200 and B ₁ = 11.5KG.

This common mode choke was then used as a line filter on an Ac 100V input line for a switching power supply that could operate at 50KHz. Common mode noise from the input of the power supply was measured. The result is shown in FIG. As is apparent from FIG. 21, the line filter using the common mode choke of the present invention (indicated by A ₉ ) has a greater noise level reduction effect at lower frequencies than using the Mn-Zn ferrite core (indicated by D). Shows.

Example 20

An alloy melt (alloy A ₁₀ ) having a composition of 1 atomic% Cu, 13.5 atomic% Si, 9 atomic% B, 3 atomic% Nb and the balance Fe was formed into an amorphous ribbon by a single roll method. This amorphous ribbon was wound to form a toroidal core having an outer diameter of 31 mm to 18 mm. This winding core was heat-treated in an N ₂ atmosphere by applying a magnetic field of 5000Oe perpendicular to its magnetic path to form crystalline ultrafine particles in its alloy structure.

This winding core was introduced into the Bakelite core case, and 10 turns of wire were wound around it on the primary and secondary sides to measure its creeping characteristics as follows; Dc B-H curve and pulse permeability μ.

The results are shown in Figures 23 (a) and (b), respectively. As can be seen from 23 (a), the magnetic core of this example is B ₁₀ = 12.4KG, Br / B ₁₀ = 11%, Hc = 0.011Oe, μ _01k = 3500 and core loss W _{2 / 100k} = 230mW / cc . For comparison, Mn-Zn ferrites (D) and Co-based amorphous alloys (Co _69.7 Fe _0.4 Mn _5.9 Si ₁₅ B ₉ , Alloy B ₄ ) are shown in 23 (b).

The magnetic core of the present invention shows high saturation magnetic flux density and permeability with no change in time, low spherical ratio and core loss, so it is a comparative implementation in dependence of the effective pulse permeability on the magnetic flux density change ΔB phase It proved to be superior to those of courtesy. Therefore, when used as a common mode choke, it is less saturated with high voltage noise and maintains high inductance. Thus, it is possible to provide a line filter having excellent high voltage pulse damping characteristics. In addition, the absolute value of the composite magnetic permeability of this magnetic core | The result is shown in FIG. In FIG. 24, A ₁₁ represents Fe _73.5 Cu ₁ Nb ₃ Si _13.5 B ₉ alloy of the present invention, B ₅ represents Co _70.7 Fe _0.3 Mn ₅ Si ₁₅ B ₉ amorphous alloy (comparative example), C ₅ represents Fe _77.5 Si ₉ B _13.5 amorphous alloy (comparative example), and D represents Mn-Zn ferrite.

The fact that A ₁₁ has a large μ means that it has a larger damping effect on the usual noise.

The magnetic core of the present invention has an | μ | equivalent to that of Co-based amorphous alloys. Therefore, when it is used for a converter core, it can reduce the excitation current of the converter and become less saturated at high ΔB, and this can be miniaturized if the temperature increase does not cause serious problems.

Therefore, a high efficiency converter can be achieved from this.

Example 21

An alloy melt having a composition of 1 atomic% Cu, 13.5 atomic% Si, 7.2 atomic% B, 2.5 atomic% Nb and the balance Fe is formed into an amorphous ribbon having a width of 6.5 mm by a single roll method. This amorphous ribbon is wound in the form of a toroidal core having an outer diameter of 20 mm and an inner diameter of 10 mm. This winding core is heat-treated under the following conditions. (a) Heating to 550 ° C. for 1 hour in Ar atmosphere without magnetic field. (b) Apply a 3000Oe magnetic field and heat to 550 ° C for 1 hour in the atmosphere as in (a) perpendicular to the paper passage.

Twelve windings of both wires are wound around each one winding core to have a common mode choke. Each common mode choke is measured with respect to the pulse attenuation characteristics using the circuit shown in FIG. 26 (a) representing the impulse noise simulator 25 of the oscilloscopes 26 and 27. The measured pulse attenuation characteristics are shown in 25 (b). Here, A ₁₂ represents the common mode choke generated from the magnetic core heat treatment according to (a), and A ₁₃ represents the common mode choke produced from the magnetic core heat treatment according to (b). FIG. 26 (b) also shows the pulse attenuation characteristics of the common mode chokes made of Mn-Zn ferrites (D) and the pulse attenuation characteristics of the Fe-based amorphous alloy (C ₆ ). Although the common mode choke (A ₁₂ ) heat-treated without magnetic field exhibits higher pulse damping characteristics than the Mn-Zn ferrite (D), the common mode choke (A ₁₃ ) heat-treated in the magnetic field is a Fe-ribbons amorphous alloy (C _6). Higher pulse attenuation than

Example 22

Independence of the attenuation with respect to frequency was measured with respect to the common mode choke produced in Example 21. In the used measurement circuit shown in 27 (a), 28 is a standard signal generator, 29 is a selection level meter, and 31 is a power divider. The input signal level is Odbm. The results are shown in Figure 2 (b) together with the results of Mn-Zn ferrites (D). This demonstrates that the common mode choke of the present invention exhibits a better attenuation effect than that of Mn-Zn ferrite (D) in all frequency domains.

Example 23

The magnetic properties and high pressure pulse characteristics are shown in Table 7 for the common mode chokes using the conventional alloy and the microcrystalline alloy of the present invention. Each common cord choke has a winding of two wires of 12.5 mm wide wound core, 25 mm outer diameter and 15 mm inner diameter. The magnetic field is applied at 3000Oe perpendicular to the magnetic path during heat treatment if necessary.

TABLE 7

Note ^* Sample numbers 9 and 10 are comparative examples

^{* *} : Balance determination

In the present invention, the normal mode choke has a higher absolute value | μ | than the conventional non-crystalline alloy crystallized locally at 100 KHz and has better noise reduction characteristics. In addition, since the output voltage Vo is small with respect to a pulse voltage of 1000 V and 1 mu sec, a good line filter can be provided by using the common mode choke of the present invention. It was also confirmed that Geddy can improve | μ | by heat-treating in a magnetic field.

Example 24

Table 8 shows the magnetic characteristics and high voltage pulse characteristics of the common mode choke of the present invention having the structure of Example 23. In other words, the magnetic field of 3000Oe is applied perpendicular to the furnace during the heat treatment. In addition, as in Example 23, the combined permeability | mu | and the output voltage Vo at 100 KHz were measured for each common mode choke when combined with a line filter for a pulse voltage of 1000 V and 1 mu sec. The results are also shown in Table 8.

TABLE 8

Example 25

An amorphous alloy ribbon having a thickness of 20 μm and a width of 7.5 mm and having the same composition as in Example 19 was formed of a toroidal core as shown in Fig. 22 (a), and the toroidal core was formed in the alloy structure. In order to generate fine and crystal grains, heat treatment was performed while applying a magnetic field of 5000Oe in the direction perpendicular to the magnetic path during the entire heat treatment cycle. In other words, the heat treatment was heated at a heating rate of 20 ° C./min to 500 ° C., maintained at 500 ° C. for 1 hour, cooled to 280 ° C. at a cooling rate of 5 ° C./min, and held at 280 ° C. for 2 hours, and then 2 Cool down to room temperature at a cooling rate of ° C / min. The Kapton tape is wound around the winding core as shown in Figure 22 (b) to provide a transducer core. After winding wire was wound around this core, its magnetic properties were measured. As a result, B ₁₀ = 12KG, Br / B ₁₀ = 12%, Hc = 0.012Oe and W _{2 / 100k} = 240mW / cc. In addition, the converter core is wrapped in a winding core with epoxy resin in vacuum to form a casting core, and then the gaptone tape is wrapped around the casting core to convert the converter core into B ₁₀ = 12KG, Br / B ₁₀ = 18%, Hc = 0.018Oe And W _{2 / 100k} = 370 mW / cc.

In comparison, amorphous alloy ribbons of 13.5 atomic% Si, 9 atomic B, 3 atomic% Nb, and the balance Fe were formed from toroidal cores, and the Kapton tape was wound around them to make them into a transformer core (Comparative Example). 2), and the capton tape was wound around it so that the toroidal core was filled with epoxy resin and then made into a transformer core (Comparative Example 2). The transformer core of Comparative Example 1 showed that the core loss (W _{2 / 100k} ) was 1500 mW / cc, and Comparative Example 2 showed 3300 mW / cc, which is the extremely large core loss (W _{2 / 100k} ). As such, the transformer cores according to the invention show much less core loss, even though filled with resin.

Example 26

The fine crystalline alloy having the same component as in Example 20 was formed of the E core shown in 25 (a), and heat-treated at 550 ° C. in an argon atmosphere for one hour so as to generate extremely fine crystal grains in the alloy structure. An E-type transformer core is then formed as shown in 25 (b). The core has a magnetic property of saturation magnetic flux density of 12.6KG, which is more than twice that of Mn-Zn ferrite, and its core loss (W _{2 / 100k} ) is 280mW / cc.

Thirteen wires on the first side and six wires on the second side were wound around the core and mounted as a transformer to a switch power source operating at 200 KHz. The temperature increment ΔT of the core was measured. The results are shown in Table 9.

TABLE 9

The core of the present invention is subjected to less temperature increase than that of Mn-Zn ferrite, and shows less impact on other factors.

Example 27

An alloy melt of Fe _73.5 Cu ₁ Si _16.5 B ₆ Nb ₃ (atomic%) was formed of an amorphous alloy ribbon, which was coated with an MgO layer by electrophoresis. This was then wound in the form shown in 28 (a), heat treated at 530 ° C. for 1 hour and then cooled. After the heat treatment, the core is filled with varnish and cut at the center by an outer slicer. These cutouts were polished and wrapped to make the cutout core shown in FIG. 28 (b). Its core loss at 100KHz and 2KG was as low as 500mW / cc.

Such cut cores can be formed into transformers by inserting bobbins provided with wires into the cut cores. Therefore, there is an advantage that the winding operation is easy. In addition, by providing a gap, the effective permeability of the core can be adjusted.

Example 28

FIG. 29 shows the dependence of the core loss on the frequency of the magnetic core of Fe _73.5 Cu ₁ Si _13.5 B ₉ Nb ₃ (alloy A ₁₆ , the present invention) as shown in Example 14, along with those of conventional materials. Shows. B ₆ represents Co _69.7 Fe _0.4 Mn _5.9 Si ₁₅ B ₉ amorphous alloy, C ₇ represents Fe _76.5 Cr ₁ Si _13.5 B ₉ amorphous alloy, and D represents Mn-Zn ferrite. The magnetic core of the present invention has a core loss up to the high frequency which is less than or equal to that of Co-based amorphous alloy (B ₆ ) and much smaller than those of Fe-based amorphous alloy (C ₇ ) and Mn-Zn ferrite (D). Indicates. Thus, the magnetic core of the present invention is excellent as a transformer operable at high frequencies. With regard to the saturation magnetic flux density, the magnetic core of the present invention is much larger than those of Mn-Zn ferrite and Co-based amorphous alloys, which means that the magnetic core of the present invention can be used in miniaturized transformers.

Claims (15)

In a magnetic core made of a Fe basic soft magnetic alloy composed of Fe, Cu, and M, wherein M is at least one component selected from the group consisting of Nb, W, Ta, Zr, Hf, Ti, and Mo, and alloy structure At least 50% of the magnetic core is formed of crystalline fine particles, and the effective permeability of the magnetic core at a time of effective magnetic permeability at 1 KHz after μa is heated to 100 ° C. in air for 1000 hours at μ K at an effective permeability at 1 KHz. A magnetic core characterized in that the rate of change X is defined by the formula X = 1-μb / μa and the value is 0.3 or less. The magnetic core of claim 1 wherein the Fe base soft magnetic alloy has a saturation magnetic flux density Bs of 10 KG or more and an effective permeability μ ₁ KHz of 5 × 10 ³ or more. 2. The magnetic core of claim 1 wherein the Fe base soft magnetic alloy has a saturation magnetic strain lambda s of + 5 × 10 ⁻⁶ to -5 × 10 ⁻⁶ . A saturation reactor composed of the magnetic core according to claim 1. The saturation reactor according to claim 4, wherein the unregulated magnetic density ΔBb at 50 KHz is 3KG or less. A reactor for semiconductor circuits comprising the magnetic core according to claim 1. The reactor for semiconductor circuits according to claim 4, wherein the Fe base soft magnetic alloy has a spherical ratio Br / B ₁₀ of 70% or more of the Dc BH curve. The reactor for semiconductor circuits according to claim 6, wherein the Fe base soft magnetic alloy has a spherical ratio Br / B ₁₀ of a Dc BH curve of 70% or more. A common mode choke consisting of the magnetic core according to claim 1. 2. The magnetic density at 5kg or more of 10O, according to claim 1, wherein the spherical ratio Br / B ₁₀ of the Dc BH curve of 30% or less, the absolute value of the compound permeability at 1000 or more 100 KHz, and A magnetic core having B ₁ and a magnetic density B ₁₀ at ₁₀ KG or more of 10Oe. A line filter incorporating the common mode choke of claim 9. A high frequency converter core composed of the magnetic core according to claim 1. 13. The high frequency converter core of claim 12, wherein the basic soft magnetic alloy has a spherical ratio Br / B ₁₀ of a Dc BH curve of 30% or less. A high frequency converter comprising the magnetic core of claim 12 and two or more windings. Rapidly quenching an alloy melt composed of M, Fe, and Cu selected from the group consisting of Nb, W, Ta, Zr, Hf, Ti, and Mo to form an amorphous ribbon; Forming; and heat-treating the winding core so that, after its extension, the alloy has crystalline fine particles that occupy at least 50% of its structure.

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