TW201621933A - Powder core, electric/electronic component, and electric/electronic device - Google Patents

Abstract

Provided is a powder core (1) having excellent heat resistance and equipped with a soft magnetic powder (M) and an insulating resin-based material (R), with the resin providing the resin-based material (R) containing an acrylic resin. Also provided is an electric/electronic component equipped with this powder core, and an electric/electronic device in which this electric/electronic component is installed. When the powder core (1) is measured by means of TOF-SIMS under the following conditions, a peak based on first ions is measured, with said first ions comprising at least one species of ion represented by CnH2n-1O2 - (where n = 11-20). Radiated ions: Bi3+ Acceleration voltage: 25 keV Radiation current: 0.3 pA Radiation mode: Bunching mode.

Description

Powder core, electrical and electronic parts and electrical and electronic equipment

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

The powder core portion used as a constituent element of an electrical component such as an inductance element, a reactor, a transformer, or a turbulent flow can be heat-treated by forming a large amount of soft magnetic powder together with a resin or the like. obtain. An example of a powder core is disclosed in Patent Document 1 below.

[Previous Technical Literature] [Patent Literature]

[Patent Document 1] Japanese Patent Laid-Open Publication No. 2012-212853

The powder core portion obtained by the above production method is a composite of a soft magnetic powder and a resin material, and the soft magnetic powder in the powder core portion is usually thermally stable even in the atmosphere as long as it reaches about 300 ° C or so. . However, when the powder core portion is heated to such a temperature, the thermal deterioration of the resin-based material is remarkable, and the magnetic properties of the powder core portion are changed.

As one of the dimensions for evaluating the thermal stability of the core of the powder, a heating test in which the core of the powder is placed in an atmosphere at 250 ° C for 1,000 hours is used (in the present specification, the heating test is not described). "The rate of change in core loss in the case of the heating test". In this specification, the core loss Pc ₀ (unit: kW/m ³ ) of the powder core measured before the heating test and the core loss Pc _{1 of the} powder core measured after the heating test will be used (unit kW) /m ³ ) The change rate ΔPc (unit: %) of the core loss defined by the following formula is referred to as "excellent heat resistance" of the powder core portion.

_{△ Pc = (Pc 1 -Pc 0} ) / Pc 0 × 100

An object of the present invention is to provide a powder core having excellent heat resistance, an electrical and electronic component including the core of the powder, and an electrical and electronic device in which the electronic component of the electrical component is mounted.

In order to solve the above problem, the inventors of the present invention conducted research and obtained the following findings: a peak based on a specific ion was measured when measured by TOF-SIMS (Time Of Flight Secondary Ion Mass Spectrometry). The powder core has excellent heat resistance.

In one aspect of the invention, the present invention provides a powder core having a soft magnetic powder and an insulating resin material, and the resin to which the resin material is applied contains an acrylic resin. When the powder core portion is measured by TOF-SIMS under the following conditions, the first ion based on at least one of ions including C _n H _2n-1 O ₂ ^- (n = 11 to 20) is measured. peak.

Irradiation ion: Bi ³⁺

Acceleration voltage: 25keV

Irradiation current: 0.3pA

Illumination mode: cluster mode

The ratio of the intensity of the peak based on the first ion measured by the TOF-SIMS measured by the TOF-SIMS to the intensity of the peak based on C ₃ H ₃ O ₂ ^- , that is, the first intensity is preferably 0.03 or more. .

When the powder core portion is measured by TOF-SIMS under the above-described conditions, the maximum value of the peak based on the ion is located at the mass/u which is the maximum value based on the peak of the first ion and is smaller than the mass/u of 0.5. Between mass/u, at least one is determined based on the above The peak of the second ion of the ion other than the ion is preferably 0.1 or more as the ratio of the peak intensity of the first ion to the sum of the intensities of the peaks of the second ion, that is, the second intensity.

In another aspect, the present invention provides a powder core having a soft magnetic powder and an insulating resin material, and the resin to which the resin material is applied contains an acrylic resin and is used under the following conditions. When the powder core was measured by TOF-SIMS, a peak based on the third ion indicated by C ₅ H ₇ O ₃ ^{- was} measured.

Irradiation ion: Bi ³⁺

Acceleration voltage: 25keV

Irradiation current: 0.3pA

Illumination mode: cluster mode

The ratio of the intensity of the peak based on the third ion measured by the TOF-SIMS measured by the TOF-SIMS to the intensity of the peak based on C ₃ H ₃ O ₂ ^- , that is, the third intensity is preferably 0.05 or more. .

According to another aspect of the invention, there is provided a powder core comprising a soft magnetic powder and an insulating resin material, wherein the resin to which the resin material is applied contains an acrylic resin, When the powder core was measured by TOF-SIMS, the fourth ion represented by C ₇ H ₁₁ O ₂ ^{- was} measured.

Irradiation ion: Bi ³⁺

Acceleration voltage: 25keV

Irradiation current: 0.3pA

Illumination mode: cluster mode

The ratio of the intensity of the peak based on the fourth ion measured by the TOF-SIMS measured by the TOF-SIMS to the intensity of the peak based on C ₃ H ₃ O ₂ ^- , that is, the fourth intensity is preferably 0.02 or more. .

The powder core of the present invention described above may further have at least one of the following features.

‧ The ratio of the intensity of the C ₂ HO ⁻ -based peak measured by the TOF-SIMS measured by the TOF-SIMS to the intensity of the peak based on the C ₂ H ₃ O ₂ ^- , that is, the fifth intensity ratio is 10 the following.

‧The powder core contains P (phosphorus). When the powder core portion contains P, it is indicated that at least one of the first ion, the third ion, and the fourth ion is likely to be measured.

‧ The soft magnetic powder described above has an amorphous portion.

‧ The soft magnetic powder-based Fe-based amorphous alloy contains (Ni 0 atom% or more and 10 atom% or less, Sn 0 atom% or more and 3 atom% or less), Cr 0 atom% or more, and 6 atom% or less, P 3.0 atom% or more and 11 atom% or less, C 1.0 atom% or more and 10 atom% or less, B 0 atom% or more and 9 atom% or less, and Si 0 atom% or more and 6 atom% or less. When the Fe-based amorphous alloy contains P, it tends to be easy to measure at least one of the first ion, the third ion, and the fourth ion.

‧ The powder core portion is obtained by press-forming a composition containing the soft magnetic powder and the resin to obtain a molded body, and heating the obtained molded body. The heating of the above shaped body preferably includes heating in an oxidizing environment and heating in a non-oxidizing environment thereafter. The composition may further contain an inorganic component, and the inorganic component preferably contains P. When P is contained in the inorganic component, it is indicated that at least one of the first ion, the third ion, and the fourth ion tends to be easily measured.

In still another aspect, the present invention provides an electrical and electronic component comprising: the powder core, the coil, and an electrical and electronic component connected to each end of the coil, and at least a portion of the powder core It is disposed in an induced magnetic field generated by the current when a current flows through the connection terminal via the connection terminal.

In still another aspect, the present invention provides an electrical and electronic device that is an electrical and electronic device in which the above-described electrical and electronic components are mounted, and the electrical and electronic components are connected to the substrate by using the connection terminal.

The powder core of the above invention is excellent in heat resistance. Moreover, according to the present invention, an electrical and electronic component including the powder core and an electrical and electronic device having the electrical component of the electrical component are provided.

1‧‧‧Powder core

2‧‧‧coated wire

2a‧‧‧ coil

2b, 2c‧‧‧ covered end of wire 2

2d, 2e‧‧‧ end of coil 2a

3‧‧‧Powder core

3a‧‧‧Installation surface of the powder core 3

3b, 3c‧‧‧ side of the powder core 3

4‧‧‧ Terminals

5‧‧‧Air core coil

5a‧‧‧Winding section of air core coil 5

5b‧‧‧End of the air core coil 5

10‧‧‧Inductors for toroidal cores

20‧‧‧Inductive components

30‧‧‧ Storage recess

40‧‧‧Connecting end

42a‧‧‧1st bend

42b‧‧‧2nd bend

100‧‧‧Installation substrate

110‧‧‧pad parts

120‧‧‧ solder layer

M‧‧‧ soft magnetic powder

R‧‧‧Resin materials

Fig. 1 is a perspective view conceptually showing the shape of a powder core of an embodiment of the present invention.

Fig. 2 is a view showing a cross-sectional observation result of a powder core portion according to an embodiment of the present invention.

Fig. 3 is a view showing a part of the spectrum (mass/u is around 185, near 199, and around 213) obtained by measuring the powder cores produced in Example 1 and Comparative Examples 1 to 3 by TOF-SIMS.

Fig. 4 is a perspective view conceptually showing the shape of an inductor which is a toroidal core of an electric and electronic component having a powder core of an embodiment of the present invention.

Fig. 5 is a perspective view showing a part of an overall configuration of an inductance element of an electric and electronic component having a powder core of another embodiment of the present invention.

Fig. 6 is a partial front elevational view showing a state in which the inductance element shown in Fig. 5 is mounted on a mounting substrate.

Fig. 7 is a view showing another portion of the spectrum obtained by measurement of TOF-SIMS by the powder cores produced in Example 1 and Comparative Examples 1 to 3 (mass/u is in the vicinity of 115 and in the vicinity of 127).

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

1. Powder core

The powder core unit 1 according to the embodiment of the present invention shown in Fig. 1 has an outer ring shape, and as shown in Fig. 2, it has a soft magnetic powder M and an insulating resin containing a component based on an acrylic resin. Material R.

(1) Ions measured by TOF-SIMS

When the powder core unit 1 according to an embodiment of the present invention is measured by the TOF-SIMS under the following conditions, a peak based on at least one of the first ion, the third ion, and the fourth ion described below is measured.

(1-1) first ion

When the powder core unit 1 according to an embodiment of the present invention is measured by TOF-SIMS under the following conditions (hereinafter also referred to as "measurement condition 1"), the measurement is based on the inclusion of C _n H _2n-1 O ₂ ^- (n= The peak of the first ion of at least one of the ions shown in 11 to 20). The first ion may be one type or plural types. The first ions are usually plural.

Irradiation ion: Bi ³⁺

Acceleration voltage: 25keV

Irradiation current: 0.3pA

Illumination mode: cluster mode

Here, the cluster mode is a mode in which the ion beam irradiated to the sample is pulsed, and the pulse width (the time difference between the front end and the rear end of the beam) is narrowed to improve the decomposition ability.

Fig. 3 is a view showing a part of a spectrum obtained by measuring each of the powder core portions 1 produced in the following Example 1 and Comparative Examples 1 to 3 by TOF-SIMS. Fig. 3 shows peaks based on C ₁₁ H ₂₁ O ₂ ^- , C ₁₂ H ₂₃ O ₂ ^- , and C ₁₃ H ₂₅ O ₂ ^- belonging to the first ion, respectively.

In the present specification, when the first intensity ratio is 0.01 or less, since the peak of the first ion cannot be distinguished from the measurement noise, it is determined that there is no peak based on the first ion.

By measuring the peak based on the first ion, a powder core having excellent heat resistance can be obtained. The reason is not clear. A substance having a bond of carbon and hydrogen and having a property as a so-called organic substance may exist as a resin-based material. The first ion has a possibility of having a chemical structure represented by the following formula (1).

CH ₃ -(CH ₂ ) _x -CH ₂ -COO ^- (1)

x is an integer of 8 or more and 17 or less

The resin to which the resin-based material R is provided in the powder core portion 1 according to the embodiment of the present invention contains an acrylic resin. Therefore, when the powder core portion 1 is measured by TOF-SIMS, the maximum value of the peak/mass is determined. The peak of 71.02. The chemical formula assumed by mass/u of the maximum value of the peak is C ₃ H ₃ O ₂ ^- , and according to the chemical formula, it is considered that the negative ion imparting the peak corresponds to an acrylic ion. It is preferable that at least one of the ratio of the intensity of the peak of the first ion to the intensity of the peak (also referred to as "the first reference intensity" in the present specification) (referred to as "the first intensity ratio" in the present specification) is preferable. It is 0.03 or more, more preferably 0.05 or more, and particularly preferably 0.10 or more. Further, the first ions having a first intensity ratio of 0.03 or more are preferably two or more, more preferably three or more, and still more preferably four or more. The first ions having a first intensity ratio of 0.05 or more are preferably two or more, more preferably three or more, and particularly preferably four or more. The first ions having a first intensity ratio of 0.10 or more are preferably two or more types.

(1-2) second ion

When the powder core unit 1 according to an embodiment of the present invention is measured by TOF-SIMS, the peak of the second ion based on the following description can also be measured. In the present specification, the term "second ion" means that the mass/u based on the maximum value of the peak of the ion is between the mass/u based on the maximum value of the peak of the first ion and the mass/u which is smaller than 0.5 of the mass/u. Ions other than the first ion. There are also cases where a plurality of second ions are defined with respect to one type of first ion. In this case, a complex peak is measured in the above mass/u region.

As shown in Fig. 3, in the powder core portion 1 according to the embodiment of the present invention produced in the examples, when the powder core portion produced in the comparative example was measured by TOF-SIMS, the measurement was based on the second The peak of ions. As shown in FIG. 3, two peaks of the second ion corresponding to C ₁₁ H ₂₁ O ₂ ^{- which is one} of the first ions are clearly present.

In the powder core portion 1 according to the embodiment of the present invention, the ratio of the peak intensity of the first ion to the sum of the peak intensities of the second ions, that is, the second intensity is preferably 0.1 or more, more preferably 0.2 or more.

The specific chemical structure of the second ion is not clear. As explained below, the second ion can be A fragment of a compound formed by binding an acrylic resin to Fe which is a constituent element of the soft magnetic powder. That is, the carboxyl group (-COOH) of the acrylic resin used as the binder is dehydrated with the Fe-bonded hydroxyl group (-OH) present on the surface of the soft magnetic powder, whereby the acrylic resin and the soft magnetic powder are used. Surface chemical bonding. There is a possibility that a part of the acrylic resin chemically bonded to the surface of the soft magnetic powder is partially fragmented with Fe to become a second ion.

The second ion can also be measured in the core of the powder other than the powder core 1 according to the embodiment of the present invention. In the core of the powder, the peak of the first ion becomes a noise level, so the second intensity The ratio does not become 0.1 or more.

(1-3) third ion

When the powder core portion 1 of one embodiment of the present invention was measured by TOF-SIMS under the measurement condition 1, a peak based on the third ion indicated by C ₅ H ₇ O ₃ ^{- was} measured.

In the present specification, when the third intensity ratio is 0.01 or less, since the peak of the third ion cannot be distinguished from the measurement noise, it is determined that there is no peak based on the third ion.

By measuring the peak based on the third ion, a powder core having excellent heat resistance can be obtained. The reason is not clear. The specific chemical structure of the third ion (C ₅ H ₇ O ₃ ^- ) is not clear, and may have a carboxyl ion ((COO) ^- ) and a carbonyl group (> C = O), and further contains hydrogen, a methylene group, a methyl group and the like.

In the powder core unit 1 according to the embodiment of the present invention, the ratio of the intensity of the peak of the third ion to the first reference intensity (also referred to as "the third intensity ratio" in the present specification) is preferably 0.10 or more. Preferably, it is 0.15 or more, and particularly preferably 0.20 or more.

(1-4) 4th ion

When the powder core portion 1 according to an embodiment of the present invention was measured by TOF-SIMS under the measurement condition 1, a peak based on the fourth ion indicated by C ₇ H ₁₁ O ₂ ^{- was} measured.

In the present specification, when the fourth intensity ratio is 0.01 or less, the peak of the third ion cannot be distinguished from the measurement noise, and therefore it is determined that there is no peak based on the third ion.

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

In the powder core unit 1 according to the embodiment of the present invention, the ratio of the intensity of the peak of the fourth ion to the first reference intensity (also referred to as "the fourth intensity ratio" in the present specification) is preferably 0.02 or more. More preferably, it is 0.04 or more, and it is especially preferably 0.06 or more.

It is preferable that the powder core portion 1 according to an embodiment of the present invention contains P (phosphorus). The reason is not determined, and it is easy to measure at least one of the first ion, the third ion, and the fourth ion by the powder core portion 1 containing P (phosphorus), and the heat resistance of the powder core portion 1 becomes Easy to improve. The P (phosphorus) contained in the powder core portion 1 affects the physical properties or composition of the resin material R, and contributes to the possibility of the above-described ion formation. The method of causing the powder core portion 1 to contain P (phosphorus) is not limited. The soft magnetic powder M may contain P (phosphorus), and a phosphorus-containing substance such as phosphoric acid glass may be used in the production process of the powder core portion 1. It is especially preferable to make the soft magnetic powder M contain P.

(1-5) 5th ion

The powder core unit 1 according to an embodiment of the present invention in which the peak of the first ion is measured is also measured as an ion represented by C ₂ HO ⁻ which is formed by decomposition of an acrylic resin in an oxidizing atmosphere. (In this specification, also referred to as "5th ion"), the peak (mass/u of the peak value is 41.01). However, the intensity of the fifth peak tends to be smaller than the intensity of the peak of the fifth ion measured by the core of the powder based on the peak of the first ion. Therefore, there is a possibility that the decomposition of the powder core portion 1 according to the embodiment of the present invention in a state in which decomposition by oxidation or the like of the resin-based material is relatively undeveloped.

Specifically, when the powder core unit 1 according to an embodiment of the present invention is measured by TOF-SIMS, the ratio of the intensity of the peak of the fifth ion to the first reference intensity is also referred to as “the fifth in the present specification. The strength ratio ") is preferably 10 or less, more preferably 7 or less, and particularly preferably 5 or less.

(2) Soft magnetic powder

The soft magnetic powder M which is provided in the powder core portion 1 which is one embodiment of the present invention There is no limit to the material. As such a material, a crystalline magnetic material, an amorphous magnetic material, and a material having a crystalline portion and an amorphous portion are exemplified. The material constituting the soft magnetic powder M may be one type or plural kinds. In the case where the soft magnetic powder M contains a plurality of materials, the composition and the blending ratio of each constituent material are not limited.

The crystalline magnetic material is not limited as long as it satisfies the crystal quality (a diffraction spectrum which can be determined by a usual X-ray diffraction to have a specific peak to the extent of the specific material type) and a soft magnetic material. The specific type. Specific examples of the crystalline magnetic material include an Fe—Si—Cr alloy, an Fe—Ni alloy, an Fe—Co alloy, an Fe—V alloy, an Fe—Al alloy, and an Fe—Si alloy. Fe-Si-Al alloy, carbonyl iron and pure iron. In order to facilitate the measurement of at least one of the first ion, the third ion, and the fourth ion, it is particularly preferable that the crystalline magnetic material contains P.

The amorphous magnetic material is a soft magnetic material as long as it is amorphous (a diffraction spectrum which can be determined by a usual X-ray diffraction to have a specific peak to a specific material type) and a soft magnetic material The specific type is not limited. Specific examples of the amorphous magnetic material include an Fe-P-C-B-Si alloy, an Fe-Si-B alloy, an Fe-P-C alloy, and a Co-Fe-Si-B alloy. In order to facilitate the measurement of at least one of the first ion, the third ion, and the fourth ion, it is particularly preferable that the crystalline magnetic material contains P.

Further, as an example of the amorphous magnetic material, a composition formula is represented by Fe _{100at%-abcxyzt} Ni _a Sn _b Cr _c P _x C _y B _z Si _t , 0at%≦a≦10at%, 0at%≦ b≦3at%, 0at%≦c≦6at%, 6.8at%≦x≦10.8at%, 2.2at%≦y≦9.8at%, 0at%≦z≦4.2at%, 0at%≦t≦7at% Fe-based amorphous alloy. In the above composition formula, Ni, Sn, Cr, B, and Si are arbitrary added elements.

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

The material having a crystalline portion and an amorphous portion may be a mixture of a crystalline magnetic material and an amorphous magnetic material, or may be a material having an amorphous phase and a crystalline phase. As the material of the latter, an element which promotes crystal precipitation by using Nb, Cu, Si or the like as an Fe-based alloy is exemplified, and a sub-phase of crystallinity is dispersed and precipitated in the mother phase of the amorphous material.

The shape of the soft magnetic powder M contained in the powder core portion 1 according to the embodiment of the present invention is not limited. The shape of the soft magnetic powder M may be spherical or non-spherical. In the case of being non-spherical, it may have a shape having an anisotropic shape such as a flat shape, a scale shape, an ellipsoid shape, a droplet shape, or a needle shape, or may have a shape anisotropy. Indefinite.

The shape of the soft magnetic powder M may be a shape obtained at the stage of producing the soft magnetic powder M (the atomization method is exemplified as a specific example), or may be secondary processing by using the manufactured soft magnetic powder M (exemplified by the use of a mill) The shape obtained by flat processing of a crusher or the like as a specific example). The shape of the former is exemplified by a spherical shape, an ellipsoidal shape, a droplet shape, a needle shape, or the like, and the shape of the latter is exemplified by a flat shape and a scaly shape.

The particle diameter of the soft magnetic powder M contained in the powder core portion 1 according to the embodiment of the present invention is not limited. When the particle diameter is specified by the average particle diameter D50 (particle diameter when the volume distribution value of the particle diameter of the soft magnetic powder M measured by the laser diffraction scattering method is 50%), it is usually set to 1 μm. To the range of 20 μm. The average particle diameter D50 of the soft magnetic powder M is preferably 2 μm or more and 15 μm or less, and more preferably from the viewpoint of improving the workability and increasing the packing density of the soft magnetic powder M of the powder core portion 1 . Set to 3 μm or more and 10 μm In the following, it is particularly preferably 4 μm or more and 7 μm or less.

The content of the soft magnetic powder M of the powder core portion 1 according to the embodiment of the present invention is not limited. The composition of the resin-based material, the production steps, and the like are appropriately set depending on the application.

(3) Resin materials

The resin-based material R included in the powder core unit 1 according to the embodiment of the present invention is insulative, and the resin to which the material is applied contains an acrylic resin. In the present specification, the term "resin-based material R" means a material containing a resin and/or a resin-based component (exemplified as a component in which at least a part of the composition of the resin changes, and a (partial) thermal decomposition product of the resin is a specific example). In the resin material R of the present embodiment, the resin to which the resin material R is applied contains an acrylic resin.

The acrylic resin may be a homopolymer or a copolymer as long as it contains at least one structural unit based on acrylic acid and a derivative thereof. Examples of the acrylic acid derivative include acrylate, methacrylic acid and ester thereof, and acrylamide. In the case where the acrylic resin is a copolymer, the copolymer may contain a structural unit other than the structural unit based on at least one of acrylic acid and a derivative thereof, and the type of the compound to be imparted to the structural unit is not limited. Specific examples of the compound include an olefin such as ethylene and a vinyl ester such as vinyl acetate. The acrylic resin may also have a crosslinked structure. The crosslinking agent in this case is not limited, and a polyisocyanate compound or the like can be exemplified.

The resin to which the resin-based material is applied may also contain a resin other than the acrylic resin. Examples of such a resin include a polyfluorene oxide resin, an epoxy resin, a phenol resin, a urea resin, and a melamine resin.

As shown in FIG. 2, the resin-based material R is located between adjacent soft magnetic powders M, M in the powder core portion 1, and the soft magnetic powders M, M are fixed and insulated to contribute to the powder core 1 The shape and insulation are maintained. In general, when the powder core portion is subjected to a heating test, there is a concern that the fixing function and/or the insulating function of the resin-based material are lowered. However, the powder core unit 1 according to an embodiment of the present invention is as described above. Said, due to the use of TOF- When the resin material R of at least one of the first ion, the third ion, and the fourth ion is measured at the time of SIMS measurement, the magnetic properties are not easily lowered after the heating test.

(4) Method for manufacturing powder core

The method for producing the powder core unit 1 according to an embodiment of the present invention is not limited. When an example of the production method is exemplified, the obtained molded body can be heated by press-forming a composition containing a soft magnetic powder and a resin to obtain a green compact 1 .

In the production method, the pressurization conditions and the heating conditions are appropriately set depending on the mechanical properties or magnetic properties required for the powder core portion, the composition of the composition, and the like. Examples of the heating conditions include heating in an oxidizing atmosphere and heating in a non-oxidizing atmosphere. As described above, the powder core unit 1 according to the embodiment of the present invention includes the resin-based material R containing the component based on the acrylic resin. Therefore, the composition to be subjected to the above-described press molding contains an acrylic resin.

In order to easily obtain the resin-based material R of at least one of the first ion, the third ion, and the fourth ion when the powder core portion 1 is measured by TOF-SIMS, the composition is obtained from the composition containing the acrylic resin. The condition is preferably a heating in an oxidizing atmosphere, and the temperature is preferably 300 ° C or more and 400 ° C or less, more preferably 355 ° C or more and 400 ° C or less. Further, it is particularly preferably 360 ° C or more and 400 ° C or less. Further, from the viewpoint of more stably alleviating the strain applied to the soft magnetic powder M by press molding, it is preferable to perform heating at 400 ° C or higher. In this case, the powder core portion 1 can be appropriately formed. The resin-based material R is preferably heated in a non-oxidizing atmosphere. Therefore, in the case of heating in an oxidizing atmosphere and heating in a non-oxidizing atmosphere, it is preferred to heat at 300 ° C or higher and 400 ° C or lower in an oxidizing atmosphere, and thereafter, in a non-oxidizing atmosphere. Heating at 400 ° C or higher is performed.

The above composition for press molding may also contain components other than soft magnetic powder and resin. As such a component, an inorganic component such as glass or a lubricant such as a metal soap can be exemplified. There is also a use of TOF- by using a composition containing a P (phosphorus) component (for example, phosphoric acid glass). When the powder core unit 1 is measured by SIMS, it is easy to measure at least one of the first ion, the third ion, and the fourth ion. The preparation method of the composition is not limited. The material constituting the composition may be obtained by kneading only, or the slurry containing the material constituting the composition may be dried and pulverized to form a granulated powder.

2. Electrical and electronic parts

An electric and electronic component according to an embodiment of the present invention includes the powder core portion 1, the coil, and a connection terminal connected to each end portion of the coil according to an embodiment of the present invention. Here, at least a part of the powder core portion 1 is disposed in an induced magnetic field generated by the current when a current flows through the coil via the connection terminal.

An example of such an electrical and electronic component is the inductor portion 10 of the toroidal core shown in FIG. The inductor portion 10 of the toroidal core includes a coil 2a formed by winding the covered wire 2 around the annular powder core portion 1. The end portions 2d, 2e of the coil 2a can be defined in the portion of the wire between the coil 2a including the wound coated wire 2 and the end portions 2b, 2c of the covered wire 2. As described above, in the electric and electronic component of the embodiment, the member constituting the coil and the member constituting the connection terminal may include the same member.

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

The inductance element 20 shown in FIG. 5 includes a powder core portion 3, an air core coil 5 as a coil embedded in the interior of the powder core portion 3, and a connection terminal electrically connected to the air core coil 5 by welding. One of the pair of terminal portions 4 is configured.

The air-core coil 5 is formed by winding a wire of an insulating film into a spiral shape. The air-core coil 5 has a winding portion 5a and lead ends 5b and 5b drawn from the winding portion 5a. The number of windings of the air-core coil 5 is appropriately set in accordance with the required inductance.

As shown in FIG. 5, in the powder core portion 3, a housing recess 30 for accommodating one of the terminal portions 4 is formed on the mounting surface 3a of the mounting substrate. The housing recess 30 is formed on both sides of the mounting surface 3a, and is formed to be released toward the side faces 3b and 3c of the powder core unit 3. One of the terminal portions 4 protruding from the side faces 3b and 3c of the self-pressing powder core 3 is bent toward the mounting surface 3a, and is housed inside the housing recess 30.

The terminal portion 4 is formed of a thin Cu-shaped base material. The terminal portion 4 is embedded in the interior of the powder core portion 3, has a connection end portion 40 electrically connected to the lead ends 5b, 5b of the air core coil 5, and is exposed on the outer surface of the powder core portion 3 from the above pressure. The side faces 3b and 3c of the powder core portion 3 are formed by sequentially bending the first curved portion 42a and the second curved portion 42b formed on the mounting surface 3a. The connecting end portion 40 is a welded portion welded to the air core coil 5. The first bent portion 42a and the second bent portion 42b are solder joint portions that are soldered to the mounting substrate 100. The solder joint portion means a portion of the terminal portion 4 from which the self-pressing powder core portion 3 is exposed, at least toward the surface on the outer side of the powder core portion 3.

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

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

A conductor pattern that is electrically connected to an external circuit is formed on a surface of the mounting substrate 100, and one of the pair of inductive elements 20 is formed to mount the pair of pad portions 110 according to a portion of the conductor pattern.

As shown in FIG. 6, in the inductance element 20, the mounting surface 3a faces the mounting substrate 100 side, and the first bending portion 42a and the second bending portion 42b which are exposed from the powder core portion 3 to the outside are attached to the pad of the mounting substrate 100. The portions 110 are joined by a solder layer 120.

In the soldering step, after the paste portion 110 is applied with paste solder in the printing step, the second bent portion 42b faces the pad portion 110, and the inductor element 20 is mounted, and the solder is melted in the heating step. As shown in FIGS. 5 and 6, the second bent portion 42b faces the pad portion 110 of the mounting substrate 100, and the first bent portion 42a is exposed on the side faces 3b and 3c of the inductance element 20, so that the fillet-shaped solder layer 120 is formed. Fixed to the pad portion 110 and to the second bent portion 42b as a solder joint portion Both surfaces of the first curved portion 42a are sufficiently diffused and fixed.

Examples of the electric component and the electronic component other than the inductor portion 10 and the inductance element 20 of the toroidal core described above include a reactor or a transformer.

3. Electrical and electronic machines

An electric appliance according to an embodiment of the present invention is an electric and electronic component to which the powder core of the embodiment of the present invention is provided. As such an electric appliance, a power supply device such as a power supply switching circuit, a voltage raising circuit, a smoothing circuit, or a small portable communication device is exemplified.

When such an electric and electronic device is used for an in-vehicle use, it is strongly required to be excellent in motion stability even in a high-temperature environment for a long period of time. In order to cope with such a request, it is necessary to provide excellent electrical stability for each of the electrical and electronic components incorporated in the electrical and electronic equipment even in a high-temperature environment. As described above, since the electric and electronic component of the embodiment of the present invention has the powder core having excellent heat resistance, the electric and electronic device to which the component is attached can be easily applied to an in-vehicle use.

The embodiments described above are described in order to facilitate the understanding of the present invention, and are not intended to limit the present invention. Therefore, all the design changes or equivalents belonging to the technical scope of the present invention are also included in the gist of the present invention.

For example, according to the present invention, it is possible to judge whether or not the heat resistance of the powder core portion is excellent by using TOF-SIMS measurement. Further, by the TOF-SIMS measurement, it is possible to determine whether or not the powder core portion contains P (phosphorus) in each of the magnetic powder and the resin material.

[Examples]

Hereinafter, the present invention will be specifically described by way of Examples and the like, but the scope of the present invention is not limited to the Examples and the like.

(Example 1)

The amorphous soft magnetic powder obtained by weighing the composition of Fe _{74.43 at%} Cr _{1.96 at%} P _{9.04 at%} C _{2.16 at%} B _{7.54 at%} Si _{4.87 at%} was used as a soft water atomization method. Magnetic powder is produced. The particle size distribution of the obtained soft magnetic powder was measured by volume distribution using "Microtrac particle size distribution measuring apparatus MT3300EX" manufactured by Nikkiso Co., Ltd. As a result, the average particle diameter (D50) which is a particle diameter of 50% in the volume distribution was 10.6 μm.

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

The obtained slurry was pulverized after drying, and a fine powder of 300 μm or less and a coarse powder of 850 μm or more were removed using a mesh of 300 μm mesh and a sieve of 850 μm to obtain a granulated powder.

The obtained granulated powder was filled in a mold, and press-molded at a surface pressure of 1.8 GPa to obtain a molded body having a ring shape. The obtained molded body was heated at 360 ° C for 10 hours in the atmosphere (oxidizing atmosphere), and then heat-treated under a nitrogen atmosphere (non-oxidizing atmosphere) at 470 ° C for 1 hour to obtain an outer diameter of 20 mm. A ring-shaped powder core having an inner diameter of 12 mm and a thickness of 7 mm.

(Comparative Example 1)

The same operation as in Example 1 was carried out except that the phosphoric acid glass was not prepared at the time of preparation of the slurry, and a powder core portion was obtained.

(Comparative Example 2)

A powder core was obtained in the same manner as in Example 1 except that the type of the soft magnetic powder was changed to Fe-Si-B-Cr-based amorphous (average particle diameter (D50): 50 μm). Further, the Fe-Si-B-Cr-based amorphous alloy is an additive without P.

(Comparative Example 3)

The same operation as in Comparative Example 2 was carried out except that the phosphoric acid glass was not prepared at the time of preparation of the slurry, and a powder core portion was obtained.

(Test Example 1) Measurement using TOF-SIMS

The powder cores produced in the examples and the comparative examples were each measured by TOF-SIMS. The measurement device and measurement conditions are as follows.

Measuring device: TOF-SIMS5 (manufactured by ION-TOF)

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

Acceleration voltage: 25keV

Irradiation current: 0.3pA

Measurement mode: High current bunching mode

An anion having a mass/u in the range of 20 to 250 was measured.

The specific measurement items are as follows. The peak intensity is obtained by fitting assuming that each peak has a regular distribution.

‧Based on the presence or absence of peaks of acrylic acid (C ₃ H ₃ O ₂ ^- ) and peak intensity (first reference intensity)

‧Based on the presence or absence of the peak of the first ion and the determination of the peak intensity

‧Based on the presence or absence of the peak of the second ion and the determination of the peak intensity

‧Based on the presence or absence of the peak of the third ion and the determination of the peak intensity

‧Based on the presence or absence of the peak of the fourth ion and the determination of the peak intensity

‧Based on the presence or absence of the peak of the 5th ion and the determination of the peak intensity

One of the measured spectra is shown in Figures 3 and 7.

As a result of the measurement, the peak based on the acrylic acid was measured in any of the powder cores. Therefore, based on the measurement results, the first intensity ratio, the second intensity ratio, the third intensity ratio, the fourth intensity ratio, and the fifth intensity ratio can be obtained. These results are shown in Table 1 together with the chemical formula of each ion assumed by the value of mass/u.

The meanings of the numerical values and the like in the respective columns of Table 1 are as follows.

The line "mass/u of the maximum value of the peak" indicates the mass/u of the maximum value of each peak. The measured values of the peak intensities based on the above negative ions of Example 1 and Comparative Examples 1 to 3 are shown in the column of the hypothetical chemical formula C ₃ H ₃ O ₂ ^- (mass/u of the peak value is 71.01) (count value) ) is the first reference intensity.

The first ion ratio indicates the first intensity ratio. As described above, the first intensity ratio is a ratio of the intensity of the peak based on the first ion to the first reference intensity. When the first intensity ratio is 0.01 or less, the peak based on the first ion cannot be distinguished from the measurement noise, and therefore it is determined that there is no peak based on the first ion.

The second ion ratio indicates the second intensity ratio. As described above, the second intensity ratio is a ratio of the peak intensity of the first ion to the sum of the peak intensities of the second ions. When the second intensity ratio is less than 0.05, the peak based on the first ion cannot be distinguished from the measurement noise, and thus it is expressed as "<0.05".

The third ion column indicates the third intensity ratio. As described above, the third intensity ratio is a ratio of the intensity of the peak based on the third ion to the first reference intensity. When the third intensity ratio is 0.01 or less, the peak based on the third ion cannot be distinguished from the measurement noise, and therefore it is determined that there is no peak based on the third ion.

The fourth ion column indicates the fourth intensity ratio. As described above, the fourth intensity ratio is a ratio of the intensity based on the peak of the fourth ion to the first reference intensity. When the fourth intensity ratio is 0.01 or less, the peak based on the fourth ion cannot be distinguished from the measurement noise, and therefore it is determined that there is no peak based on the fourth ion.

The fifth intensity ratio indicates the fifth intensity ratio. As described above, the fifth intensity ratio is a ratio of the intensity based on the peak of the fifth ion to the first reference intensity.

(Test Example 2) Evaluation of heat resistance

Copper wire winding was performed on the powder core having a ring shape produced in the examples and the comparative examples, and a BH analyzer ("Yi-8217" manufactured by Iwasaki Co., Ltd.) was used at a frequency of 100 kHz and a maximum magnetic flux density of 100 mT. The condition measures the core loss Pc ₀ (unit: kW/m ³ ).

For the powder core having a copper wire wound, a heating test was carried out for 1000 hours in an atmosphere at 250 ° C in the atmosphere. After the heating test, the core loss Pc ₁ (unit: kW/m ³ ) was measured under the above conditions. The rate of change ΔPc (unit: %) of the core loss was calculated based on the following formula.

_{△ Pc = (Pc 1 -Pc 0} ) / Pc 0 × 100

The measurement results of the core loss and the rate of change of the core loss are shown in Table 2.

As shown in Table 2, the change rate ΔPc of the core loss of the powder core of Example 1 in which the first ion, the third ion, and the fourth ion were measured was small, and the heat resistance was excellent. On the other hand, the rate of change ΔPc of the core loss of the powder cores of Comparative Examples 1 to 3 which were not measured by any of the first ions, the third ions, and the fourth ions was large, and the heat resistance was inferior.

As described above, it is considered that the ΔPc of the powder core portion of the first embodiment is small because the presence of the first ions, the third ions, and the fourth ions causes the soft magnetic powder in the core of the powder to be generated by heating. The generated stress is appropriately moderated, and the soft magnetic powder does not easily accumulate strain. Further, it is presumed that the P, which is present in the soft magnetic powder or the phosphoric acid glass, contributes to the formation of the first ions, the third ions, and the fourth ions of the resin-based material during the heat treatment in the atmosphere.

[Industrial availability]

The powder core of the present invention is preferably a power supply device including a power supply switching circuit, a voltage raising circuit, a smoothing circuit, and the like, and is particularly preferably a power supply device for a vehicle or a small portable communication device.

1‧‧‧Powder core

Claims (17)

A powder core having a soft magnetic powder and an insulating resin material, and the resin to which the resin material is applied contains an acrylic resin, and the powder core is measured by TOF-SIMS under the following conditions. At the time of measurement, a peak based on at least one of the ions including C _n H _2n-1 O ₂ ^- (n = 11 to 20) is irradiated, and the ion is irradiated: Bi ^{3 +} acceleration voltage: 25 keV irradiation current : 0.3pA illumination mode: cluster mode. The powder core of claim 1, wherein the intensity of the peak based on the first ion measured by measuring the core of the powder by TOF-SIMS under the condition of claim 1 is relative to that based on C ₃ H ₃ O ₂ ^- the ratio of the peak intensity of the intensity ratio of the first i.e. 0.03 or more. The powder core of claim 1, wherein when the powder core is measured by TOF-SIMS under the condition of claim 1, the mass/u based on the maximum value of the peak of the ion is located based on the first ion The mass/u of the maximum value of the peak is compared with the mass/u which is smaller than 0.5 of the mass/u, and at least one peak based on the second ion which is an ion other than the first ion is measured, and the peak of the first ion The ratio of the intensity to the sum of the intensities of the peaks of the second ions, that is, the second intensity ratio is 0.1 or more. A powder core having a soft magnetic powder and an insulating resin material, and the resin to which the resin material is applied contains an acrylic resin, and the powder core is measured by TOF-SIMS under the following conditions. At the time, a peak based on the third ion indicated by C ₅ H ₇ O ₃ ^{- was} measured, and the ion was irradiated: Bi ^{3 +} acceleration voltage: 25 keV irradiation current: 0.3 pA irradiation mode: cluster mode. The powder core of claim 4, wherein the intensity of the peak based on the third ion measured by measuring the core of the powder by TOF-SIMS under the condition of claim 4 is relative to that based on C ₃ H ₃ O ₂ ^- the ratio of the peak intensity of the intensity ratio that is the third of 0.05 or more. A powder core having a soft magnetic powder and an insulating resin material, and the resin to which the resin material is applied contains an acrylic resin, and the powder core is measured by TOF-SIMS under the following conditions. At the time, the fourth ion indicated by C ₇ H ₁₁ O ₂ ^{- was} measured, and the irradiation ion: Bi ^{3 +} acceleration voltage: 25 keV irradiation current: 0.3 pA irradiation mode: cluster mode. The powder core of claim 6, wherein the intensity based on the peak of the fourth ion measured by measuring the core of the powder by TOF-SIMS under the condition of claim 6 is relative to that based on C ₃ H ₃ O ₂ ^- ratio of peak intensity of the intensity ratio of the fourth i.e. 0.02 or more. The powder core according to any one of claims 1 to 7, wherein the C ₂ HO ^- based peak is determined by measuring the core of the powder by TOF-SIMS under the conditions of claim 1, 4 or 6. The ratio of the intensity to the intensity of the peak based on C ₂ H ₃ O ₂ ^- , that is, the fifth intensity ratio is 10 or less. The powder core of any one of claims 1 to 7, which contains P. A powder core according to any one of claims 1 to 7, which has a soft magnetic powder or an amorphous portion. The powder core according to any one of claims 1 to 7, wherein the soft magnetic powder is a Fe-based amorphous alloy containing (Ni 0 atom% or more and 10 atom% or less, Sn 0 atom% or more and 3 atoms) % or less), Cr 0 atom% or more and 6 atom% or less, P 3.0 atom% or more and 11 atom% or less, C 1.0 atom% or more and 10 atom% or less, B 0 atom% or more and 9 atom% or less, and Si 0 atom% or more and 6 atom% or less. The powder core of any one of Claims 1 to 7, wherein the powder core is obtained by press-forming a composition containing the soft magnetic powder and the resin to obtain a molded body, and the obtained molded body is obtained. Get it by heating. The powder core of claim 12, wherein the heating of the shaped body comprises heating in an oxidizing environment and heating in a non-oxidizing environment thereafter. The powder core of claim 12, wherein the composition contains an inorganic component. The powder core of claim 14, wherein the inorganic component contains P. An electrical and electronic component, comprising: the powder core of any one of claims 1 to 7, a coil, and an electrical and electronic component connected to each end of the coil, and at least the core of the powder A portion is disposed in an induced magnetic field generated by the current when a current flows through the connection terminal through the connection terminal. An electrical and electronic machine mounted with an electrical and electronic device such as the electrical and electronic component of claim 16, wherein the electrical and electronic component is connected to the substrate by using the connecting terminal.