以下,對本發明之實施形態進行詳細說明。 1.壓粉磁芯 圖1所示之本發明之一實施形態之壓粉磁芯1係其外觀為環狀之環形磁芯,且含有結晶質磁性材料之粉末以及非晶質磁性材料之粉末。本實施形態之壓粉磁芯1係藉由具備包括對包含該等粉末之混合物進行加壓成形之成形處理的製造方法所製造者。作為不受限定之一例,本實施形態之壓粉磁芯1含有使結晶質磁性材料之粉末以及非晶質磁性材料之粉末相對於壓粉磁芯1所含有之其他材料(有為同種材料之情形,亦有為不同種材料之情形)結著的結著成分。 (1)結晶質磁性材料之粉末 提供本發明之一實施形態之壓粉磁芯1含有之結晶質磁性材料之粉末之結晶質磁性材料只要滿足為結晶質(藉由一般之X射線繞射測定,可獲得具有能夠特定出材料種類之程度之明確之峰值之繞射光譜)、以及為強磁性體、尤其是軟磁性體,則不限定具體之種類。作為結晶質磁性材料之具體例,可列舉Fe-Si-Cr系合金、Fe-Ni系合金、Fe-Co系合金、Fe-V系合金、Fe-Al系合金、Fe-Si系合金、Fe-Si-Al系合金、羰基鐵以及純鐵。上述結晶質磁性材料可由1種材料構成,亦可包含複數種材料。提供結晶質磁性材料之粉末之結晶質磁性材料較佳為選自由上述材料所組成之群中之1種或2種以上之材料,其中,較佳為含有Fe-Si-Cr系合金,更佳為包含Fe-Si-Cr系合金。Fe-Si-Cr系合金係結晶質磁性材料中能夠使鐵損Pcv相對較低之材料,因此,即便提高壓粉磁芯1中之結晶質磁性材料之粉末之含量相對於結晶質磁性材料之粉末之含量與非晶質磁性材料之粉末之含量之總和的質量比率(於本說明書中亦稱為「第一混合比率」),具備壓粉磁芯1之電感器之鐵損Pcv亦不易升高。Fe-Si-Cr系合金中之Si之含量以及Cr之含量不受限定。作為不受限定之例示,可列舉將Si之含量設為2~7質量%左右,將Cr之含量設為2~7質量%左右。 本發明之一實施形態之壓粉磁芯1含有之結晶質磁性材料之粉末之形狀不受限定。粉末之形狀可為球狀,亦可為非球狀。於為非球狀之情形時,可為鱗片狀、橢圓球狀、液滴狀、針狀之類之具有形狀各向異性之形狀,亦可為不具有特別之形狀各向異性之不定形。作為不定形之粉體之例,可列舉複數個球狀粉體相互接觸地結合、或者以局部埋沒於其他粉體中之方式結合之情形。此種不定形之粉體容易於羰基鐵中被觀察到。 粉末之形狀可為於製造粉末之階段獲得之形狀,亦可為藉由對所製造之粉末進行二次加工而獲得之形狀。作為前者之形狀,可例示球狀、橢圓球狀、液滴狀、針狀等,作為後者之形狀,可例示鱗片狀。 本發明之一實施形態之壓粉磁芯1含有之結晶質磁性材料之粉末之粒徑不受限定。結晶質磁性材料之粉末中的於體積基準之粒度分佈中自小粒徑側起之累計粒徑分佈成為50%之粒徑(於本說明書中亦稱為「中值粒徑」)D50
C有較佳為15 μm以下之情形。與非晶質磁性材料之粉末相比,結晶質磁性材料之粉末為軟質,因此,結晶質磁性材料之粉末於壓粉磁芯1之內部變形之可能性較高。因此,粒徑之大小對壓粉磁芯1之特性造成之影響相對較低。結晶質磁性材料之粉末之中值粒徑D50
A有較佳為10 μm以下之情形,有更佳為5 μm以下之情形,有特佳為2 μm以下之情形。 壓粉磁芯1中之結晶質磁性材料之粉末之含量係第一混合比率成為40質量%以上且90質量%以下之量。藉由第一混合比率為40質量%以上且90質量%以下,與僅由非晶質磁性材料構成之情形相比,壓粉磁芯1之絕緣耐壓特性提高。認為該絕緣耐壓特性之提高之原因在於,藉由壓粉磁芯1以上述範圍包含結晶質磁性材料之粉末,而絕緣擊穿能量分散於整體。就使壓粉磁芯1之絕緣耐壓特性穩定地提高之觀點而言,第一混合比率更佳為45質量%以上且85質量%以下,特佳為50質量%以上且80質量%以下。藉由將第一混合比率設定於上述範圍內,例如,可使用D50
A為3 μm以上且20 μm左右之非晶質磁性材料而製作絕緣耐壓特性良好之壓粉磁芯1。 壓粉磁芯1之絕緣耐壓值較佳為僅含有非晶質磁性材料之粉末作為磁性粉末之壓粉磁芯之絕緣耐壓值之1.2倍以上,更佳為1.25倍以上,最佳為1.3倍以上。此處,「磁性粉末」係指壓粉磁芯1所含有之結晶質磁性材料之粉末以及非晶質磁性材料之粉末。「僅含有上述非晶質磁性材料之粉末作為磁性粉末之壓粉磁芯」係指除了將壓粉磁芯中之結晶質磁性材料全部置換為非晶質磁性材料以外,以相同之成分及條件製造的壓粉磁芯。 較佳為結晶質磁性材料之粉末之至少一部分包含經實施表面絕緣處理之材料,更佳為結晶質磁性材料之粉末包含經實施表面絕緣處理之材料。於對結晶質磁性材料之粉末實施表面絕緣處理之情形時,觀察到壓粉磁芯1之絕緣電阻提高之傾向。對結晶質磁性材料之粉末實施之表面絕緣處理之種類不受限定。可例示磷酸處理、磷酸鹽處理、氧化處理等。 (2)非晶質磁性材料之粉末 提供本發明之一實施形態之壓粉磁芯1含有之非晶質磁性材料之粉末之非晶質磁性材料只要滿足為非晶質(根據一般之X射線繞射測定,無法獲得具有能夠特定出材料種類之程度之明確之峰值之繞射光譜)、以及為強磁性體、尤其是軟磁性體,則不限定具體之種類。作為非晶質磁性材料之具體例,可列舉Fe-Si-B系合金、Fe-P-C系合金以及Co-Fe-Si-B系合金。上述非晶質磁性材料可由1種材料構成,亦可包含複數種材料。構成非晶質磁性材料之粉末之磁性材料較佳為選自由上述材料所組成之群中之1種或2種以上之材料,其中,較佳為含有Fe-P-C系合金,更佳為包含Fe-P-C系合金。 作為Fe-P-C系合金之具體例,可列舉組成式由Fe100 原子 %-a-b-c-x-y-z-t
Nia
Snb
Crc
Px
Cy
Bz
Sit
表示且為0原子%≦a≦10原子%、0原子%≦b≦3原子%、0原子%≦c≦6原子%、6.8原子%≦x≦13原子%、2.2原子%≦y≦13原子%、0原子%≦z≦9原子%、0原子%≦t≦7原子%的Fe基非晶質合金。於上述組成式中,Ni、Sn、Cr、B以及Si為任意添加元素。 Ni之添加量a較佳為設為0原子%以上且6原子%以下,更佳為設為0原子%以上且4原子%以下。Sn之添加量b較佳為設為0原子%以上且2原子%以下,亦可於1原子%以上且2原子%以下之範圍內添加。Cr之添加量c較佳為設為0原子%以上且2原子%以下,更佳為設為1原子%以上且2原子%以下。P之添加量x亦有較佳為設為8.8原子%以上之情形。C之添加量y較佳為設為4原子%以上且10原子%以下,亦有較佳為設為5.8原子%以上且8.8原子%以下之情形。B之添加量z較佳為設為0原子%以上且6原子%以下,更佳為設為0原子%以上且2原子%以下。Si之添加量t較佳為設為0原子%以上且6原子%以下,更佳為設為0原子%以上且2原子%以下。 本發明之一實施形態之壓粉磁芯1含有之非晶質磁性材料之粉末之形狀不受限定。關於粉末之形狀之種類,由於與結晶質磁性材料之粉末之情形相同,因而省略說明。亦有因製造方法之關係而非晶質磁性材料容易形成為球狀或者橢圓球狀之情形。又,一般而言,非晶質磁性材料與結晶質磁性材料相比為硬質,因此,亦有較佳為使結晶質磁性材料為非球狀而使之於加壓成形時容易變形之情形。 本發明之一實施形態之壓粉磁芯1含有之非晶質磁性材料之粉末之形狀可為於製造粉末之階段獲得之形狀,亦可為藉由對所製造之粉末進行二次加工而獲得之形狀。作為前者之形狀,可例示球狀、橢圓球狀、針狀等,作為後者之形狀,可例示鱗片狀。 本發明之一實施形態之壓粉磁芯1含有之非晶質磁性材料之粉末之粒徑有非晶質磁性材料之粉末之中值粒徑D50
A較佳為50 μm以下之情形。藉由非晶質磁性材料之粉末之中值粒徑D50
A為50 μm以下,而有容易提高壓粉磁芯1之絕緣電阻並且使鐵損Pcv降低之情形。就更穩定地實現提高壓粉磁芯1之絕緣電阻並且使鐵損Pcv降低之觀點而言,非晶質磁性材料之粉末之中值粒徑D50
A有較佳為20 μm以下之情形,有為10 μm以下、進而較佳為7 μm以下更佳之情形,有特佳為5 μm以下之情形。 (3)結著成分 壓粉磁芯1亦可含有使結晶質磁性材料之粉末以及非晶質磁性材料之粉末相對於壓粉磁芯1所含有之其他材料結著之結著成分。結著成分只要為有助於固定本實施形態之壓粉磁芯1所含有之結晶質磁性材料之粉末以及非晶質磁性材料之粉末(於本說明書中,有時亦將該等粉末總稱為「磁性粉末」)之材料,則其組成不受限定。作為構成結著成分之材料,可例示樹脂材料以及樹脂材料之熱分解殘渣(於本說明書中,將該等總稱為「基於樹脂材料之成分」)等有機系之材料、無機系之材料等。作為樹脂材料,可例示丙烯酸系樹脂、聚矽氧樹脂、環氧樹脂、酚樹脂、尿素樹脂、三聚氰胺樹脂等。包含無機系之材料之結著成分可例示水玻璃等玻璃系材料。結著成分可由一種材料構成,亦可包含複數種材料。結著成分亦可為有機系之材料與無機系之材料之混合體。 作為結著成分,通常使用絕緣性之材料。藉此,可提高作為壓粉磁芯1之絕緣性。 2.壓粉磁芯之製造方法 上述之本發明之一實施形態之壓粉磁芯1之製造方法並無特別限定,但若採用以下說明之製造方法,則可實現更有效率地製造壓粉磁芯1。 本發明之一實施形態之壓粉磁芯1之製造方法具備以下說明之成形步驟,亦可進而具備熱處理步驟。 (1)成形步驟 首先,準備包含磁性粉末、以及於壓粉磁芯1中提供結著成分之成分之混合物。提供結著成分之成分(於本說明書中亦稱為「黏合劑成分」)既有為結著成分本身之情形,亦有為與結著成分不同之材料之情形。作為後者之具體例,可列舉黏合劑成分為樹脂材料,且結著成分為其熱分解殘渣之情形。 可藉由包含該混合物之加壓成形之成形處理而獲得成形製造物。加壓條件不受限定,基於黏合劑成分之組成等適當地決定。例如,於黏合劑成分包含熱硬化性之樹脂之情形時,較佳為於加壓之同時進行加熱,於模具內使樹脂之硬化反應進行。另一方面,於壓縮成形之情形時,雖然加壓力較高,但加熱並非必要條件,而成為短時間之加壓。 以下,對混合物為造粒粉且進行壓縮成形之情形稍微詳細地進行說明。造粒粉由於處理性優異,故而可提高成形時間短且生產性優異之壓縮成形之步驟之作業性。 (1-1)造粒粉 造粒粉含有磁性粉末以及黏合劑成分。造粒粉中之黏合劑成分之含量並無特別限定。於上述含量過低之情形時,黏合劑成分難以保持磁性粉末。又,於黏合劑成分之含量過低之情形時,於經過熱處理步驟而獲得之壓粉磁芯1中,由黏合劑成分之熱分解殘渣構成之結著成分難以使複數個磁性粉末彼此與其他粉末絕緣。另一方面,於上述黏合劑成分之含量過高之情形時,經過熱處理步驟而獲得之壓粉磁芯1所含有之結著成分之含量容易變高。若壓粉磁芯1中之結著成分之含量變高,則壓粉磁芯1之磁氣特性變得容易下降。因此,造粒粉中之黏合劑成分之含量較佳為設為相對於造粒粉整體而成為0.5質量%以上且5.0質量%以下之量。就更穩定地減少壓粉磁芯1之磁氣特性下降之可能性之觀點而言,造粒粉中之黏合劑成分之含量較佳為設為相對於造粒粉整體而成為1.0質量%以上且3.5質量%以下之量,更佳為設為成為1.2質量%以上且3.0質量%以下之量。 造粒粉亦可含有除上述磁性粉末及黏合劑成分以外之材料。作為此種材料,可例示潤滑劑、矽烷耦合劑、絕緣性之填料等。於含有潤滑劑之情形時,其種類並無特別限定。可為有機系之潤滑劑,亦可為無機系之潤滑劑。作為有機系之潤滑劑之具體例,可列舉硬脂酸鋅、硬脂酸鋁等金屬皂。認為此種有機系之潤滑劑於熱處理步驟中氣化而幾乎不會殘留於壓粉磁芯1中。 造粒粉之製造方法並無特別限定。可將提供上述造粒粉之成分直接混煉,並將所獲得之混煉物以公知之方法粉碎等而獲得造粒粉,亦可藉由製備於上述成分中添加分散介質(可列舉水作為一例)而成之漿料,使該漿料乾燥並粉碎而獲得造粒粉。亦可於粉碎後進行篩分或分級而控製造粒粉之粒度分佈。 作為利用上述漿料獲得造粒粉之方法之一例,可列舉使用噴霧乾燥器之方法。如圖2所示,於噴霧乾燥器裝置200內設置有轉子201,自噴霧乾燥器裝置200之上部朝向轉子201注入漿料S。轉子201以特定之轉速旋轉,於噴霧乾燥器裝置200內部之腔室內利用離心力將漿料S呈小滴狀進行噴霧。進而,向噴霧乾燥器裝置200內部之腔室導入熱風,藉此使小滴狀之漿料S中所含有之分散介質(水)於維持小滴形狀之狀態下揮發。其結果,利用漿料S形成造粒粉P。自噴霧乾燥器裝置200之下部回收該造粒粉P。轉子201之轉速、向噴霧乾燥器裝置200內導入之熱風溫度、腔室下部之溫度等各參數適當設定即可。作為該等參數之設定範圍之具體例,作為轉子201之轉速可列舉4000~8000 rpm,作為向噴霧乾燥器裝置200內導入之熱風溫度可列舉130~170℃,作為腔室下部之溫度可列舉80~90℃。又,腔室內之氣氛及其壓力亦適當設定即可。作為一例,可列舉將腔室內設為大氣(空氣)氣氛,並將其壓力設為以與大氣壓之差壓計為2 mmH2
O(約0.02 kPa)。亦可藉由篩分等而進一步控制所獲得之造粒粉P之粒度分佈。 (1-2)加壓條件 壓縮成形時之加壓條件並無特別限定。考慮造粒粉之組成、成形品之形狀等進行適當設定即可。於壓縮成形造粒粉時之加壓力過低之情形時,成形品之機械強度降低。因此,容易產生成形品之處理性下降、自成形品獲得之壓粉磁芯1之機械強度降低等問題。又,亦有壓粉磁芯1之磁氣特性降低或者絕緣性降低之情形。另一方面,於壓縮成形造粒粉時之加壓力過高之情形時,製作能夠耐受該壓力之成形模具變得困難。就更穩定地減少壓縮加壓步驟對壓粉磁芯1之機械特性或磁氣特性造成不良影響之可能性而容易工業化地進行大量生產之觀點而言,壓縮成形造粒粉時之加壓力較佳為設為0.3 GPa以上且2 GPa以下,更佳為設為0.5 GPa以上且2 GPa以下,特佳為設為0.8 GPa以上且2 GPa以下。 於壓縮成形時,可一面加熱一面進行加壓,亦可於常溫下進行加壓。 (2)熱處理步驟 藉由成形步驟而獲得之成形製造物可為本實施形態之壓粉磁芯1,亦可如以下所說明般對成形製造物實施熱處理步驟而獲得壓粉磁芯1。 於熱處理步驟中,藉由對利用上述成形步驟而獲得之成形製造物進行加熱,而藉由修正磁性粉末間之距離而進行磁氣特性之調整,且使成形步驟中對磁性粉末賦予之應變緩和而進行磁氣特性之調整,從而獲得壓粉磁芯1。 熱處理步驟如上所述以調整壓粉磁芯1之磁氣特性為目的,因此,以使壓粉磁芯1之磁氣特性成為最良好之方式設定熱處理溫度等熱處理條件。作為設定熱處理條件之方法之一例,可列舉使成形製造物之加熱溫度變化,而將升溫速度以及加熱溫度下之保持時間等其他條件設為固定。 設定熱處理條件時之壓粉磁芯1之磁氣特性之評價基準並無特別限定。作為評價項目之具體例,可列舉壓粉磁芯1之鐵損Pcv。於該情形時,以壓粉磁芯1之鐵損Pcv成為最低之方式設定成形製造物之加熱溫度即可。鐵損Pcv之測定條件適當地設定,作為一例,可列舉將頻率設為100 Hz且將有效最大磁通密度Bm設為100 mT之條件。 熱處理時之氣氛並無特別限定。於為氧化性氣氛之情形時,黏合劑成分之熱分解過度進行之可能性或磁性粉末進行氧化之可能性提高,因此,較佳為於氮、氬等惰性氣氛、或氫等還原性氣氛下進行熱處理。 3.電感器、電子・電氣機器 本發明之一實施形態之電感器具備上述之本發明之一實施形態之壓粉磁芯1、線圈以及與該線圈之各端部連接之連接端子。此處,壓粉磁芯1之至少一部分係以位於當經由連接端子對線圈流通電流時藉由該電流而產生之感應磁場內的方式配置。本發明之一實施形態之電感器由於具備上述之本發明之一實施形態之壓粉磁芯1,故而絕緣耐壓特性優異,並且即便於高頻下鐵損亦不易增大。因此,與先前技術之電感器相比,亦能夠小型化。 作為此種電感器之一例,可列舉圖3所示之環形線圈10。環形線圈10具備藉由在環狀之壓粉磁芯(環形磁芯)1上捲繞被覆導電線2而形成之線圈2a。可於位於包含所捲繞之被覆導電線2之線圈2a與被覆導電線2之端部2b、2c之間之導電線之部分定義線圈2a之端部2d、2e。如此,本實施形態之電感器中構成線圈之構件與構成連接端子之構件亦可利用同一構件構成。 作為本發明之一實施形態之電感器之另一例,可列舉圖4所示之線圈埋設型電感器20。線圈埋設型電感器20可形成為數mm見方之小型之晶片狀,具備具有箱型形狀之壓粉磁芯21,且於其內部埋設有被覆導電線22之線圈部22c。被覆導電線22之端部22a、22b位於壓粉磁芯21之表面並露出。壓粉磁芯21之表面之一部分由彼此電性獨立之連接端部23a、23b覆蓋。連接端部23a與被覆導電線22之端部22a電性連接,連接端部23b與被覆導電線22之端部22b電性連接。於圖4所示之線圈埋設型電感器20中,覆導電線22之端部22a由連接端部23a覆蓋,覆導電線22之端部22b由連接端部23b覆蓋。 被覆導電線22之線圈部22c埋設至壓粉磁芯21內之方法不受限定。可將捲繞有被覆導電線22之構件配置於模具內,進而將包含磁性粉末之混合物(造粒粉)供給至模具內,並進行加壓成形。或者,亦可準備預先對包含磁性粉末之混合物(造粒粉)進行預成形而成之複數個構件,並將該等構件組合,於此時劃分形成之空隙部內配置被覆導電線22而獲得組裝體,對該組裝體進行加壓成形。包含線圈部22c之被覆導電線22之材質不受限定。例如,可列舉設為銅合金。線圈部22c亦可為扁立繞法線圈。連接端部23a、23b之材質亦不受限定。就生產性優異之觀點而言,有較佳為具備由銀膏等導電膏形成之金屬化層及形成於該金屬化層上之鍍覆層之情形。形成該鍍覆層之材料不受限定。作為該材料含有之金屬元素,可例示銅、鋁、鋅、鎳、鐵、錫等。 本發明之一實施形態之電子・電氣機器係安裝有上述之本發明之一實施形態之電感器者,且利用上述連接端子連接於基板。本發明之一實施形態之電子・電氣機器由於安裝有本發明之一實施形態之電感器,故而即便有時向機器內施加高電壓、或者施加高頻信號,亦不易產生因電感器之功能下降或發熱引起之故障,機器之小型化亦較為容易。 以上所說明之實施形態係為了使本發明易於理解而記載者,並非為了限定本發明而記載者。因此,上述實施形態中所揭示之各要素,其旨趣為亦包含屬於本發明之技術範圍之所有設計變更及均等物。 [實施例] 以下,藉由實施例等對本發明更具體地進行說明,但本發明之範圍不受該等實施例等限定。 (實施例1) (1)Fe基非晶質合金粉末之製作 以成為Fe其餘部分
Ni5 ~ 7 原子 %
Cr2 ~ 4 原子 %
P10 ~ 13 原子 %
C5 ~ 6 原子 %
B2 ~ 4 原子 %
之組成之方式稱量原料,使用水霧化法而製作非晶質磁性材料之粉末(非晶粉末)。使用日機裝公司製「Microtrac粒度分佈測定裝置 MT3300EX」以體積分佈之形式測定所獲得之非晶質磁性材料之粉末之粒度分佈。於體積基準之粒度分佈中自小粒徑側起之累計粒徑分佈成為50%之粒徑(中值粒徑)D50
A為5 μm。 又,作為結晶質磁性材料之粉末,準備Fe-Si-Cr系合金,具體而言,準備由Si之含量為6~7質量%、Cr之含量為3~4質量%且其餘部分包含Fe以及不可避免之雜質的合金構成、且中值粒徑D50
C為2 μm的粉末。 (2)造粒粉之製作 將上述非晶質磁性材料之粉末以及結晶質磁性材料之粉末以成為表1所示之第一混合比率之方式進行混合而獲得磁性粉末。將磁性粉末97.2質量份、包含丙烯酸系樹脂或者酚樹脂之絕緣性結著材料2~3質量份、以及包含硬脂酸鋅之潤滑劑0~0.5質量份混合至作為溶劑之水中而獲得漿料。 使用圖2所示之噴霧乾燥器裝置200以上述條件對所獲得之漿料進行造粒,而獲得造粒粉。 (3)壓縮成形 將所獲得之造粒粉填充至模具內,並以面壓0.5~1.5 GPa進行加壓成形,而獲得具有外徑20 mm×內徑12 mm×厚度3 mm之環形狀之成形體。 (4)熱處理 進行熱處理而獲得包含壓粉磁芯之環形磁芯,於該熱處理中,將所獲得之成形體載置於氮氣流氣氛之爐內,將爐內溫度自室溫(23℃)以10℃/分之升溫速度加熱至作為最佳磁芯熱處理溫度之200~400℃,並於該溫度下保持1小時,然後,於爐內冷卻至室溫。 製作下述表1所示之第一混合比率不同之環形磁芯,並藉由下述測定方法測定磁芯密度、絕緣電阻、絕緣耐壓、磁導率以及鐵損Pcv。 (試驗例1)絕緣耐壓之測定 使用Kikusui公司製「TOS5051A」之耐壓測定器作為測定裝置,利用平行板電極夾持作為樣品之環形磁芯,以AC(Alternating Current,交流電)(50 Hz)施加外加電壓。求出產生絕緣擊穿之電壓作為絕緣耐壓。 針對如上述般測定出之實施例1-2~實施例1-8之絕緣耐壓值,求出以僅含有非晶質磁性材料之粉末作為磁性粉末之實施例1-1之環形磁芯之絕緣耐壓值為基準(100%)之情形時的絕緣耐壓比(非晶質100%基準)、以及以僅含有結晶質磁性材料之粉末作為磁性粉末之實施例1-8之環形磁芯之絕緣耐壓值為基準(100%)之情形時的絕緣耐壓比(結晶質100%基準)。 (試驗例2)絕緣電阻之測定 使用原Agilent(現Keysight)公司「4339B」之高電阻測定器作為測定裝置,於外加電壓20 V下利用兩端子法測定。 (試驗例3)磁芯密度ρ之測定 對實施例1中所製作之環形磁芯之尺寸以及重量進行測定,並根據該等數值計算出各環形磁芯之密度ρ(單位:g/cc)。 (試驗例4)磁導率之測定 針對在實施例1中所製作之環形磁芯上將被覆銅線分別於一次側捲繞40次且於二次側捲繞10次而獲得的環形線圈,使用阻抗分析儀(HP公司製「4192A」),以100 kHz之條件測定初磁導率μ0。 (試驗例5)鐵損Pcv之測定 針對在實施例1中所製作之環形磁芯上將被覆銅線分別於一次側捲繞15次且於二次側捲繞10次而獲得的環形線圈,使用BH分析儀(岩崎通信機公司製「SY-8217」),於將有效最大磁通密度Bm設為15 mT之條件下,以測定頻率2 MHz測定鐵損Pcv(單位:kW/m3
)。 將使用上述試驗例1~5之方法測定出之結果示於表1。 [表1]
圖5係表示關於實施例1之絕緣耐壓對第一混合比率之依存性之曲線圖。如該圖之絕緣耐壓之曲線圖所示,於實施例1中,藉由在非晶質磁性材料之粉末中混合結晶質磁性材料之粉末,與單獨使用各磁性粉末之情形相比,絕緣耐壓特性提高。即,藉由將上述不同之磁性粉末進行混合,而獲得協同地使壓粉磁芯之絕緣耐壓值增加之效果。於實施例1中,自第一混合比率為30質量%~40質量%附近絕緣耐壓值急遽上升,於40質量%~70質量%之範圍內絕緣耐壓比達到120%以上,於50質量%~70質量%之範圍內絕緣耐壓比達到130%以上,以實施例1-1之非晶質磁性材料之粉末單體為基準(100%)之絕緣耐壓比之值提高了30%以上。 (實施例2) 使用非晶質磁性材料之粉末之粒徑、結晶質磁性材料之粉末之表面處理以及粒徑與實施例1中所使用之磁性粉末不同的磁性粉末,以與實施例1相同之方式獲得包含壓粉磁芯之環形磁芯。 具體而言,作為非晶質磁性材料之粉末,製作組成與實施例1相同且中值粒徑D50
A為15 μm之Fe基非晶質合金粉末。再者,實施例2中所使用之非晶質磁性材料之粉末係藉由連續地進行氣體霧化與水霧化之霧化法而製作。 作為結晶質磁性材料之粉末,準備Fe-Si-Cr系合金,具體而言,準備由Si之含量為6~7質量%、Cr之含量為3~4質量%且其餘部分包含Fe以及不可避免之雜質的合金構成、且中值粒徑D50
C為4 μm的粉末。結晶質磁性材料之粉末使用經實施磷酸鹽系之表面絕緣處理者。 加壓成形之加壓力為0.5~1.5 GPa,於熱處理中,於氮氣氛內以200~400℃加熱1小時。 製作下述表2所示之第一混合比率不同之環形磁芯,並測定絕緣耐壓、絕緣電阻、磁芯密度、磁導率以及鐵損Pcv。 (試驗例1~5) 以與實施例1相同之方式進行絕緣耐壓之測定、絕緣電阻之測定、磁芯密度ρ之測定、磁導率之測定以及鐵損Pcv之測定。 求出以僅含有非晶質磁性材料之粉末之實施例2-1之環形磁芯之絕緣耐壓值為基準(100%)之情形時的絕緣耐壓比(非晶質100%基準)、以及以僅含有結晶質磁性材料之粉末作為磁性粉末之實施例2-7之環形磁芯之絕緣耐壓值為基準(100%)之情形時的絕緣耐壓比(結晶質100%基準)。 關於磁導率,除測定了初磁導率μ0以外,亦測定了對環形磁芯以100 kHz之條件疊加直流電流而因此產生之直流外加磁場為5500 A/m時之相對磁導率μ5500。將測定結果示於表2。 [表2]
圖6係表示關於實施例2之絕緣耐壓對第一混合比率之依存性之曲線圖。如圖6之絕緣耐壓之曲線圖所示,於實施例2中亦與實施例1同樣,藉由在非晶質磁性材料之粉末中混合結晶質磁性材料之粉末,與單獨使用各粉末之情形相比,絕緣耐壓特性提高,確認到協同效果。於實施例2中,自第一混合比率為40質量%附近,絕緣耐壓值高於非晶質磁性材料之粉末,於70質量%~90質量%之範圍內絕緣耐壓比達到180%以上,以實施例2-6之非晶質磁性材料之粉末單體為基準(100%)之絕緣耐壓比之值提高了80%以上。 圖7係表示實施例1及實施例2之絕緣耐壓對第一混合比率之依存性之曲線圖。根據該圖之結果可知,藉由在非晶質磁性材料之粉末中混合結晶質磁性材料之粉末,與單獨使用各粉末之情形相比,可獲得絕緣耐壓較高之壓粉磁芯。即,圖7表示超出基於壓粉磁芯中包含之結晶質磁性材料之粉末與非晶質磁性材料之粉末之混合比率所期待地、即藉由超過單純之相加性之協同效果,獲得絕緣耐壓特性優異之壓粉磁芯。 圖8係表示實施例1及實施例2之以非晶質磁性材料之粉末單體為基準時之各第1混合比率下之絕緣耐壓比的曲線圖,圖9係表示實施例1及實施例2之以結晶質材料之粉末單體為基準時之各第1混合比率下之絕緣耐壓比的曲線圖。 根據圖5~圖9之結果可知,使該絕緣耐壓之值提高之效果係藉由適當調整非晶質磁性材料之中值粒徑D50
A,並且將第一混合比率設定於40質量%以上且90質量以下之範圍內,而穩定地發揮。又,藉由將第1混合比率設為50~70質量%,無論於非晶質磁性材料之中值粒徑D50
A較大時還是較小時,均可提高壓電磁芯之絕緣耐壓特性。進而,根據圖9可知,若為如上所述之第1混合比率(50~70質量%),則可獲得以僅含有結晶質材料粉末作為磁性粉末之壓粉磁芯為基準(100%)之情形時之絕緣耐壓比之值為110%以上、或者125%以上的壓粉磁芯。 圖10~圖12係依次表示關於實施例1之絕緣電阻、磁芯密度、以及磁導率對第一混合比率之依存性的曲線圖。 圖13~圖15係依次表示關於實施例2之絕緣耐壓、絕緣電阻、磁芯密度以及磁導率對第一混合比率之依存性的曲線圖。 如表1及表2以及圖5~圖15所示,藉由在非晶質磁性材料之粉末中混合結晶質磁性材料之粉末而獲得之優異之壓粉磁芯不僅能夠提高絕緣耐壓特性,而且能夠於鐵損Pcv幾乎未增加之狀態下使絕緣耐壓增加,從而提供良好之電感器。 根據本發明,可獲得提供絕緣耐壓特性優異並且鐵損降低之良好之電感器的壓粉磁芯,根據本實施例確認到,其良好之程度為超出基於壓粉磁芯所含有之結晶質磁性材料之粉末與非晶質磁性材料之粉末之混合比率之期待之程度。 [產業上之可利用性] 具備本發明之壓粉磁芯之電感器可較佳地用作油電混合車等之升壓電路之構成零件、發電・變電設備之構成零件、變壓器或扼流圈等之構成零件等。Hereinafter, embodiments of the present invention will be described in detail. 1. Powder magnetic core The powder magnetic core 1 of one embodiment of the present invention shown in Fig. 1 is a ring-shaped magnetic core having a ring shape and containing a powder of a crystalline magnetic material and a powder of an amorphous magnetic material. . The powder magnetic core 1 of the present embodiment is manufactured by a production method including a molding process including press forming a mixture containing the powders. The powder magnetic core 1 of the present embodiment contains the powder of the crystalline magnetic material and the powder of the amorphous magnetic material with respect to the other materials contained in the powder magnetic core 1 (there is the same material). In the case of a different kind of material, there is also a binding component. (1) Powder of crystalline magnetic material The crystal magnetic material which provides the powder of the crystalline magnetic material contained in the powder magnetic core 1 of one embodiment of the present invention is determined to be crystalline (by general X-ray diffraction measurement) A diffraction spectrum having a sharp peak to the extent that the material type can be specified can be obtained, and a ferromagnetic material, particularly a soft magnetic material, is not limited to a specific type. Specific examples of the crystalline magnetic material include Fe-Si-Cr alloy, Fe-Ni alloy, Fe-Co alloy, Fe-V alloy, Fe-Al alloy, Fe-Si alloy, and Fe. -Si-Al alloy, carbonyl iron and pure iron. The crystalline magnetic material may be composed of one material or a plurality of materials. The crystalline magnetic material which provides the powder of the crystalline magnetic material is preferably one or more selected from the group consisting of the above materials, and preferably contains a Fe-Si-Cr alloy, preferably. It is an alloy containing Fe-Si-Cr. In the Fe-Si-Cr alloy-based crystalline magnetic material, a material having a relatively low iron loss Pcv can be obtained, and therefore, even if the content of the powder of the crystalline magnetic material in the powder magnetic core 1 is increased relative to the crystalline magnetic material The mass ratio of the content of the powder to the sum of the contents of the powder of the amorphous magnetic material (also referred to as "the first mixing ratio" in the present specification), and the iron loss Pcv of the inductor having the powder magnetic core 1 is not easy to rise. high. The content of Si and the content of Cr in the Fe-Si-Cr alloy are not limited. The content of Si is about 2 to 7 mass%, and the content of Cr is about 2 to 7 mass%, as an example of the invention. The shape of the powder of the crystalline magnetic material contained in the powder magnetic core 1 according to the embodiment of the present invention is not limited. The shape of the powder may be spherical or non-spherical. In the case of being non-spherical, it may be a shape having an anisotropic shape such as a scaly shape, an elliptical shape, a droplet shape, or a needle shape, or an amorphous shape having no abnormal shape anisotropy. Examples of the powder of the amorphous shape include a case where a plurality of spherical powders are bonded to each other or combined in such a manner as to be partially buried in other powders. Such an amorphous powder is easily observed in carbonyl iron. The shape of the powder may be a shape obtained at the stage of producing the powder, or may be a shape obtained by secondary processing of the produced powder. The shape of the former may be, for example, a spherical shape, an elliptical shape, a droplet shape, or a needle shape, and the shape of the latter may be scaly. The particle size of the powder of the crystalline magnetic material contained in the powder magnetic core 1 according to the embodiment of the present invention is not limited. The particle size distribution in the volume-based particle size distribution of the powder of the crystalline magnetic material is 50% of the particle size distribution from the small particle diameter side (also referred to as "median particle diameter" in the present specification) D 50 C It is preferably 15 μm or less. Since the powder of the crystalline magnetic material is soft compared with the powder of the amorphous magnetic material, the powder of the crystalline magnetic material is highly likely to be deformed inside the powder magnetic core 1. Therefore, the influence of the particle size on the characteristics of the powder magnetic core 1 is relatively low. The powder of the crystalline magnetic material has a median diameter D 50 A of preferably 10 μm or less, more preferably 5 μm or less, and particularly preferably 2 μm or less. The content of the powder of the crystalline magnetic material in the powder magnetic core 1 is such that the first mixing ratio is 40% by mass or more and 90% by mass or less. When the first mixing ratio is 40% by mass or more and 90% by mass or less, the insulating withstand voltage characteristics of the powder magnetic core 1 are improved as compared with the case where only the amorphous magnetic material is used. The reason why the improvement in the withstand voltage characteristic is considered to be that the powder magnetic core 1 contains the powder of the crystalline magnetic material in the above range, and the dielectric breakdown energy is dispersed throughout. The first mixing ratio is more preferably 45% by mass or more and 85% by mass or less, and particularly preferably 50% by mass or more and 80% by mass or less, from the viewpoint of stably improving the insulation withstand voltage characteristics of the powder magnetic core 1 . By setting the first mixing ratio within the above range, for example, an amorphous magnetic material having a D 50 A of about 3 μm or more and about 20 μm can be used to produce a powder magnetic core 1 having excellent insulation withstand voltage characteristics. The insulating withstand voltage value of the powder magnetic core 1 is preferably 1.2 times or more, more preferably 1.25 times or more, more preferably 1.25 times or more, of the powder containing only the amorphous magnetic material as the powder magnetic core of the magnetic powder. More than 1.3 times. Here, the "magnetic powder" refers to a powder of a crystalline magnetic material contained in the powder magnetic core 1 and a powder of an amorphous magnetic material. "Powder containing only the above-mentioned amorphous magnetic material as a powder magnetic core of magnetic powder" means the same composition and conditions except that all of the crystalline magnetic material in the powder magnetic core is replaced with an amorphous magnetic material. A powder magnetic core manufactured. Preferably, at least a part of the powder of the crystalline magnetic material comprises a material subjected to surface insulation treatment, and more preferably a powder of the crystalline magnetic material comprises a material subjected to surface insulation treatment. In the case where the surface of the crystalline magnetic material was subjected to surface insulation treatment, the tendency of the insulation resistance of the powder magnetic core 1 to be improved was observed. The kind of surface insulating treatment performed on the powder of the crystalline magnetic material is not limited. Phosphoric acid treatment, phosphate treatment, oxidation treatment, and the like can be exemplified. (2) Powder of amorphous magnetic material The amorphous magnetic material which provides the powder of the amorphous magnetic material contained in the powder magnetic core 1 of one embodiment of the present invention is amorphous (according to general X-rays) In the diffraction measurement, it is not possible to obtain a diffraction spectrum having a sharp peak to the extent that the material type can be specified, and a ferromagnetic material, particularly a soft magnetic material, is not limited to a specific type. Specific examples of the amorphous magnetic material include an Fe-Si-B based alloy, an Fe-PC based alloy, and a Co-Fe-Si-B based alloy. The amorphous magnetic material may be composed of one material or a plurality of materials. The magnetic material constituting the powder of the amorphous magnetic material is preferably one or more selected from the group consisting of the above materials, and preferably contains a Fe-PC-based alloy, more preferably contains Fe. -PC alloy. Specific examples of the Fe-PC-based alloy include a composition formula of Fe 100 atom %-abcxyzt Ni a Sn b Cr c P x C y B z Si t and 0 atom% ≦a ≦ 10 atom%, 0 atom. %≦b≦3 atom%, 0 atom%≦c≦6 atom%, 6.8 atom%≦x≦13 atom%, 2.2 atom%≦y≦13 atom%, 0 atom%≦z≦9 atom%, 0 atom %≦t≦ 7 atom% of Fe-based amorphous alloy. In the above composition formula, Ni, Sn, Cr, B, and Si are arbitrary added elements. The amount of addition of a is preferably 0 atom% or more and 6 atom% or less, and more preferably 0 atom% or more and 4 atom% or less. The amount b of Sn added is preferably 0 atom% or more and 2 atom% or less, and may be added in a range of 1 atom% or more and 2 atom% or less. The amount c of addition of Cr is preferably 0 atom% or more and 2 atom% or less, and more preferably 1 atom% or more and 2 atom% or less. The addition amount x of P is also preferably set to 8.8 atom% or more. The amount of addition y of C is preferably 4 atom% or more and 10 atom% or less, and is preferably 5.8 atom% or more and 8.8 atom% or less. The amount of addition z of B is preferably 0 atom% or more and 6 atom% or less, and more preferably 0 atom% or more and 2 atom% or less. The amount t of Si added is preferably 0 atom% or more and 6 atom% or less, and more preferably 0 atom% or more and 2 atom% or less. The shape of the powder of the amorphous magnetic material contained in the powder magnetic core 1 according to the embodiment of the present invention is not limited. The type of the shape of the powder is the same as that of the powder of the crystalline magnetic material, and thus the description thereof will be omitted. There is also a case where the amorphous magnetic material is easily formed into a spherical shape or an ellipsoidal shape due to the relationship between the manufacturing methods. Further, in general, since the amorphous magnetic material is harder than the crystalline magnetic material, it is preferable that the crystalline magnetic material is non-spherical and is easily deformed during press molding. The shape of the powder of the amorphous magnetic material contained in the powder magnetic core 1 of one embodiment of the present invention may be a shape obtained at the stage of producing the powder, or may be obtained by secondary processing of the produced powder. The shape. The shape of the former may be, for example, a spherical shape, an elliptical shape, or a needle shape, and the shape of the latter may be scaly. The particle size of the powder of the amorphous magnetic material contained in the powder magnetic core 1 according to the embodiment of the present invention is such that the powder of the amorphous magnetic material has a median diameter D 50 A of preferably 50 μm or less. When the powder of the amorphous magnetic material has a median diameter D 50 A of 50 μm or less, the insulation resistance of the powder magnetic core 1 can be easily increased and the iron loss Pcv can be lowered. The powder of the amorphous magnetic material has a median diameter D 50 A of preferably 20 μm or less from the viewpoint of more stably achieving an increase in the insulation resistance of the powder magnetic core 1 and a decrease in the iron loss Pcv. It is preferably 10 μm or less, more preferably 7 μm or less, and particularly preferably 5 μm or less. (3) The binding component The powder magnetic core 1 may contain a binding component in which the powder of the crystalline magnetic material and the powder of the amorphous magnetic material are adhered to the other materials contained in the powder magnetic core 1. The binding component is a powder which is used to fix the crystalline magnetic material contained in the powder magnetic core 1 of the present embodiment and a powder of an amorphous magnetic material (in the present specification, the powders are also collectively referred to as The material of "magnetic powder" is not limited in its composition. Examples of the material constituting the constituent component include organic materials such as a resin material and a thermal decomposition residue of the resin material (referred to collectively as "components based on the resin material" in the present specification), inorganic materials, and the like. Examples of the resin material include an acrylic resin, a polyoxyxylene resin, an epoxy resin, a phenol resin, a urea resin, and a melamine resin. A glass-based material such as water glass can be exemplified as the binding component of the inorganic material. The binding component may be composed of one material or a plurality of materials. The binding component may also be a mixture of an organic material and an inorganic material. As the binding component, an insulating material is usually used. Thereby, the insulation property as the powder magnetic core 1 can be improved. 2. Method for Producing Powder Magnetic Core The method for producing the powder magnetic core 1 according to the embodiment of the present invention is not particularly limited. However, if the manufacturing method described below is employed, the powder can be more efficiently produced. Magnetic core 1. The method for producing the powder magnetic core 1 according to the embodiment of the present invention includes the molding step described below, and may further include a heat treatment step. (1) Forming Step First, a mixture containing a magnetic powder and a component which provides a constituent component in the powder magnetic core 1 is prepared. The component providing the binding component (also referred to as "adhesive component" in the present specification) is either a case of the component itself or a material different from the component of the composition. Specific examples of the latter include a case where the binder component is a resin material and the binder component is a thermal decomposition residue. The shaped article can be obtained by a press forming process comprising the mixture. The pressurization conditions are not limited, and are appropriately determined based on the composition of the binder component and the like. For example, when the binder component contains a thermosetting resin, it is preferred to carry out heating while pressurizing, and to carry out a hardening reaction of the resin in the mold. On the other hand, in the case of compression molding, although the pressing force is high, heating is not a necessary condition, and it becomes a pressurization for a short time. Hereinafter, the case where the mixture is a granulated powder and compression-molded will be described in some detail. Since the granulated powder is excellent in handleability, the workability of the step of compression molding in which the molding time is short and the productivity is excellent can be improved. (1-1) Granulated powder The granulated powder contains a magnetic powder and a binder component. The content of the binder component in the granulated powder is not particularly limited. When the above content is too low, it is difficult for the binder component to retain the magnetic powder. Further, when the content of the binder component is too low, in the powder magnetic core 1 obtained by the heat treatment step, the binder component composed of the thermal decomposition residue of the binder component is difficult to make the plurality of magnetic powders mutually different. Powder insulation. On the other hand, when the content of the above-mentioned binder component is too high, the content of the binding component contained in the powder magnetic core 1 obtained by the heat treatment step tends to be high. When the content of the binder component in the powder magnetic core 1 becomes high, the magnetic characteristics of the powder magnetic core 1 become easy to fall. Therefore, the content of the binder component in the granulated powder is preferably 0.5% by mass or more and 5.0% by mass or less based on the entire granulated powder. The content of the binder component in the granulated powder is preferably 1.0% by mass or more based on the entire granulated powder, from the viewpoint of more stably reducing the possibility of a decrease in the magnetic properties of the powder magnetic core 1 . The amount of 3.5% by mass or less is more preferably 1.2% by mass or more and 3.0% by mass or less. The granulated powder may also contain materials other than the above magnetic powder and binder components. As such a material, a lubricant, a decane coupling agent, an insulating filler, or the like can be exemplified. In the case of containing a lubricant, the kind thereof is not particularly limited. It can be an organic lubricant or an inorganic lubricant. Specific examples of the organic-based lubricant include metal soaps such as zinc stearate and aluminum stearate. It is considered that such an organic lubricant is vaporized in the heat treatment step and hardly remains in the powder magnetic core 1. The method for producing the granulated powder is not particularly limited. The granulated powder may be directly kneaded, and the obtained kneaded product may be pulverized by a known method to obtain a granulated powder, or a dispersion medium may be added to the above-mentioned components (water may be used as a For example, the slurry is formed, and the slurry is dried and pulverized to obtain a granulated powder. The particle size distribution of the granulated powder can also be controlled by sieving or grading after pulverization. As an example of the method of obtaining a granulated powder by the said slurry, the method of using a spray dryer is mentioned. As shown in FIG. 2, a rotor 201 is provided in the spray dryer device 200, and the slurry S is injected from the upper portion of the spray dryer device 200 toward the rotor 201. The rotor 201 is rotated at a specific number of revolutions, and the slurry S is sprayed in a droplet shape by centrifugal force in a chamber inside the spray dryer device 200. Further, hot air is introduced into the chamber inside the spray dryer device 200, whereby the dispersion medium (water) contained in the droplet-shaped slurry S is volatilized while maintaining the shape of the droplet. As a result, the granulated powder P is formed by the slurry S. The granulated powder P is recovered from the lower portion of the spray dryer unit 200. The parameters such as the number of revolutions of the rotor 201, the temperature of the hot air introduced into the spray dryer device 200, and the temperature of the lower portion of the chamber may be appropriately set. As a specific example of the setting range of the parameters, the number of rotations of the rotor 201 is 4,000 to 8,000 rpm, and the temperature of the hot air introduced into the spray dryer device 200 is 130 to 170 ° C, and the temperature at the lower portion of the chamber can be exemplified. 80 to 90 ° C. Moreover, the atmosphere in the chamber and its pressure can be appropriately set. As an example, an atmosphere (air) atmosphere is used in the chamber, and the pressure is set to 2 mmH 2 O (about 0.02 kPa) at a pressure difference from atmospheric pressure. The particle size distribution of the obtained granulated powder P can be further controlled by sieving or the like. (1-2) Pressurization Conditions The pressurization conditions at the time of compression molding are not particularly limited. The composition of the granulated powder, the shape of the molded article, and the like may be appropriately set. When the pressing force at the time of compression molding of the granulated powder is too low, the mechanical strength of the molded article is lowered. Therefore, problems such as a decrease in the rationality of the molded article and a decrease in the mechanical strength of the powder magnetic core 1 obtained from the molded article are likely to occur. Further, there is a case where the magnetic characteristics of the powder magnetic core 1 are lowered or the insulation property is lowered. On the other hand, in the case where the pressing force at the time of compression molding of the granulated powder is too high, it becomes difficult to produce a molding die capable of withstanding the pressure. In view of more stably reducing the possibility that the compression and pressurization step has an adverse effect on the mechanical properties or magnetic gas characteristics of the powder magnetic core 1, and it is easy to industrially mass-produce, the pressure at the time of compression molding the granulated powder is higher. It is preferably set to 0.3 GPa or more and 2 GPa or less, more preferably 0.5 GPa or more and 2 GPa or less, and particularly preferably 0.8 GPa or more and 2 GPa or less. At the time of compression molding, it may be pressurized while being heated, or may be pressurized at normal temperature. (2) Heat Treatment Step The molded article obtained by the forming step may be the powder magnetic core 1 of the present embodiment, or the powdered magnetic core 1 may be obtained by subjecting the shaped article to a heat treatment step as described below. In the heat treatment step, by heating the shaped article obtained by the above-described forming step, the magnetic properties are adjusted by correcting the distance between the magnetic powders, and the strain relief imparted to the magnetic powder in the forming step is performed. The magnetic characteristics are adjusted to obtain the powder magnetic core 1. Since the heat treatment step is for the purpose of adjusting the magnetic characteristics of the powder magnetic core 1 as described above, the heat treatment conditions such as the heat treatment temperature are set such that the magnetic characteristics of the powder magnetic core 1 are the best. As an example of the method of setting the heat treatment conditions, the heating temperature of the molded product is changed, and other conditions such as the temperature increase rate and the holding time at the heating temperature are fixed. The evaluation criteria of the magnetic gas characteristics of the powder magnetic core 1 when the heat treatment conditions are set are not particularly limited. Specific examples of the evaluation item include the iron loss Pcv of the powder magnetic core 1. In this case, the heating temperature of the molded article may be set such that the iron loss Pcv of the powder magnetic core 1 is the lowest. The measurement conditions of the iron loss Pcv are appropriately set, and examples thereof include a condition in which the frequency is 100 Hz and the effective maximum magnetic flux density Bm is 100 mT. The atmosphere at the time of heat treatment is not particularly limited. In the case of an oxidizing atmosphere, the possibility of excessive thermal decomposition of the binder component or the possibility of oxidation of the magnetic powder is improved. Therefore, it is preferably an inert atmosphere such as nitrogen or argon or a reducing atmosphere such as hydrogen. Heat treatment is performed. 3. Inductor, Electronic/Electrical Apparatus An inductor according to an embodiment of the present invention includes the powder magnetic core 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 magnetic core 1 is disposed in such a manner as to be within an induced magnetic field generated by the current when a current flows through the connection terminal. Since the inductor according to the embodiment of the present invention includes the powder magnetic core 1 according to the embodiment of the present invention described above, it is excellent in insulation withstand voltage characteristics, and it is difficult to increase the iron loss even at a high frequency. Therefore, it is also possible to be miniaturized as compared with the inductor of the prior art. An example of such an inductor is the toroidal coil 10 shown in FIG. The toroidal coil 10 is provided with a coil 2a formed by winding a covered conductive wire 2 on a ring-shaped powder magnetic core (annular core) 1. The end portions 2d, 2e of the coil 2a can be defined in a portion of the conductive line between the coil 2a including the wound coated conductive wire 2 and the end portions 2b, 2c covering the conductive wire 2. As described above, in the inductor of the present embodiment, the member constituting the coil and the member constituting the connection terminal can be configured by the same member. Another example of the inductor according to an embodiment of the present invention includes the coil-embedded inductor 20 shown in Fig. 4 . The coil-embedded inductor 20 can be formed into a small wafer shape of several mm square, and has a powder magnetic core 21 having a box shape, and a coil portion 22c covering the conductive wire 22 is embedded therein. The end portions 22a, 22b of the coated conductive wire 22 are located on the surface of the powder magnetic core 21 and exposed. One of the surfaces of the powder magnetic core 21 is partially covered by connection ends 23a, 23b which are electrically independent from each other. The connection end portion 23a is electrically connected to the end portion 22a of the covered conductive wire 22, and the connection end portion 23b is electrically connected to the end portion 22b of the covered conductive wire 22. In the coil-embedded inductor 20 shown in Fig. 4, the end portion 22a of the covered conductive wire 22 is covered by the connecting end portion 23a, and the end portion 22b of the covered conductive wire 22 is covered by the connecting end portion 23b. The method of embedding the coil portion 22c of the covered conductive wire 22 into the powder magnetic core 21 is not limited. The member in which the coated conductive wire 22 is wound may be placed in a mold, and the mixture containing the magnetic powder (granulated powder) may be supplied into the mold and press-formed. Alternatively, a plurality of members obtained by pre-forming a mixture (granulated powder) containing magnetic powder may be prepared, and these members may be combined, and the coated conductive wires 22 may be disposed in the gap portion formed at this time to obtain assembly. The assembly is press-formed. The material of the covered conductive wire 22 including the coil portion 22c is not limited. For example, it is a copper alloy. The coil portion 22c may also be a flat wound coil. The material of the connecting end portions 23a and 23b is also not limited. From the viewpoint of excellent productivity, it is preferable to provide a metallized layer formed of a conductive paste such as a silver paste and a plating layer formed on the metallized layer. The material forming the plating layer is not limited. Examples of the metal element contained in the material include copper, aluminum, zinc, nickel, iron, tin, and the like. An electronic/electrical device according to an embodiment of the present invention is characterized in that the inductor of one embodiment of the present invention described above is attached to the substrate by the connection terminal. Since an inductor according to an embodiment of the present invention is mounted on an electronic/electrical device according to an embodiment of the present invention, even if a high voltage is applied to the device or a high-frequency signal is applied, the function of the inductor is less likely to occur. Or the failure caused by heat, the miniaturization of the machine is also easier. The embodiments described above are described in order to facilitate the understanding of the present invention and are not intended to limit the invention. Therefore, the various elements disclosed in the above-described embodiments are intended to include all design changes and equivalents of the technical scope of the invention. [Examples] Hereinafter, the present invention will be more specifically described by way of Examples and the like, but the scope of the present invention is not limited by the Examples and the like. Production (1) Fe-based amorphous alloy powder of (Example 1) so as to be the remainder of Fe Ni 5 ~ 7 atomic% Cr 2 ~ 4 atomic% P 10 ~ 13 atomic% C 5 ~ 6 atomic% B 2 ~ 4 The raw material was weighed so as to have a composition of atomic % , and a powder (amorphous powder) of an amorphous magnetic material was produced by a water atomization method. The particle size distribution of the powder of the obtained amorphous magnetic material was measured in the form of a volume distribution using a "Microtrac particle size distribution measuring apparatus MT3300EX" manufactured by Nikkiso Co., Ltd. The particle size distribution from the small particle size side in the volume-based particle size distribution was 50% (median diameter) D 50 A was 5 μm. Moreover, as a powder of a crystalline magnetic material, an Fe-Si-Cr-based alloy is prepared, specifically, a content of Si is 6 to 7% by mass, a content of Cr is 3 to 4% by mass, and the rest contains Fe and A powder having an alloy composition of unavoidable impurities and having a median diameter D 50 C of 2 μm. (2) Preparation of granulated powder The powder of the amorphous magnetic material and the powder of the crystalline magnetic material were mixed so as to have a first mixing ratio shown in Table 1, to obtain a magnetic powder. 97.2 parts by mass of the magnetic powder, 2 to 3 parts by mass of the insulating binder containing the acrylic resin or the phenol resin, and 0 to 0.5 parts by mass of the lubricant containing zinc stearate are mixed in water as a solvent to obtain a slurry. . The obtained slurry was granulated under the above conditions using the spray dryer device 200 shown in Fig. 2 to obtain a granulated powder. (3) Compression molding The obtained granulated powder was filled into a mold and press-formed at a surface pressure of 0.5 to 1.5 GPa to obtain a ring shape having an outer diameter of 20 mm × an inner diameter of 12 mm × a thickness of 3 mm. Shaped body. (4) heat treatment is performed by heat treatment to obtain a toroidal magnetic core including a powder magnetic core. In the heat treatment, the obtained shaped body is placed in a furnace of a nitrogen gas atmosphere, and the temperature in the furnace is from room temperature (23 ° C). The temperature was raised at a heating rate of 10 ° C /min to 200 to 400 ° C which is the optimum core heat treatment temperature, and maintained at this temperature for 1 hour, and then cooled to room temperature in a furnace. The toroidal cores having the first mixing ratios shown in Table 1 below were produced, and the core density, the insulation resistance, the insulation withstand voltage, the magnetic permeability, and the iron loss Pcv were measured by the following measurement methods. (Test Example 1) Measurement of the withstand voltage was performed using a pressure-resistant measuring device of "TOS5051A" manufactured by Kikusui Co., Ltd. as a measuring device, and a ring-shaped magnetic core as a sample was sandwiched by a parallel plate electrode, and AC (Alternating Current) (50 Hz) was used. Apply an applied voltage. The voltage at which insulation breakdown occurs is determined as the insulation withstand voltage. With respect to the insulation withstand voltage values of Examples 1-2 to 1-8 measured as described above, the toroidal core of Example 1-1 in which the powder containing only the amorphous magnetic material was used as the magnetic powder was determined. The insulation withstand voltage ratio (amorphous 100% standard) when the insulation withstand voltage is the reference (100%), and the toroidal core of the embodiment 1-8 with the powder containing only the crystalline magnetic material as the magnetic powder The insulation withstand voltage ratio (100% of crystallinity) when the insulation withstand voltage is the reference (100%). (Test Example 2) Measurement of Insulation Resistance A high-resistance measuring instrument of the original Agilent (now Keysight) "4339B" was used as a measuring device, and was measured by a two-terminal method at an applied voltage of 20 V. (Test Example 3) Measurement of Core Density ρ The size and weight of the toroidal core produced in Example 1 were measured, and the density ρ of each toroidal core was calculated based on the values (unit: g/cc) . (Test Example 4) Measurement of magnetic permeability The toroidal coil obtained by winding the coated copper wire 40 times on the primary side and winding 10 times on the secondary side on the toroidal magnetic core produced in the first embodiment, The initial permeability μ0 was measured at 100 kHz using an impedance analyzer ("4192A" manufactured by HP). (Test Example 5) Measurement of Iron Loss Pcv The loop coil obtained by winding the coated copper wire 15 times on the primary side and 10 times on the secondary side on the toroidal magnetic core produced in Example 1 was used. The iron loss Pcv (unit: kW/m 3 ) was measured at a measurement frequency of 2 MHz using a BH analyzer ("Yi-8217" manufactured by Iwasaki Communications Co., Ltd.) under the condition that the effective maximum magnetic flux density Bm was set to 15 mT. . The results of the measurement using the above Test Examples 1 to 5 are shown in Table 1. [Table 1] Fig. 5 is a graph showing the dependence of the insulation withstand voltage of Example 1 on the first mixing ratio. As shown in the graph of the insulation withstand voltage of the figure, in Example 1, the powder of the crystalline magnetic material was mixed in the powder of the amorphous magnetic material, and the insulation was compared with the case where the respective magnetic powders were used alone. The pressure resistance is improved. That is, by mixing the above different magnetic powders, an effect of synergistically increasing the insulation withstand voltage value of the powder magnetic core is obtained. In the first embodiment, the insulation withstand voltage value increases sharply from the first mixing ratio of 30% by mass to 40% by mass, and the insulation withstand voltage ratio of 120% or more in the range of 40% by mass to 70% by mass is 50% or more. The insulation withstand voltage ratio is more than 130% in the range of % to 70% by mass, and the value of the insulation withstand voltage is increased by 30% based on the powder monomer of the amorphous magnetic material of Example 1-1 (100%). the above. (Example 2) The particle diameter of the powder of the amorphous magnetic material, the surface treatment of the powder of the crystalline magnetic material, and the magnetic powder having a particle diameter different from that of the magnetic powder used in Example 1 were the same as in Example 1. In this way, a toroidal core comprising a powder magnetic core is obtained. Specifically, as the powder of the amorphous magnetic material, a Fe-based amorphous alloy powder having the same composition as in Example 1 and having a median diameter D 50 A of 15 μm was produced. Further, the powder of the amorphous magnetic material used in Example 2 was produced by continuously performing atomization of gas atomization and water atomization. As a powder of a crystalline magnetic material, an Fe-Si-Cr-based alloy is prepared. Specifically, the content of Si is 6 to 7% by mass, the content of Cr is 3 to 4% by mass, and the rest contains Fe and is inevitable. A powder having an alloy of impurities and a median diameter D 50 C of 4 μm. The powder of the crystalline magnetic material is treated by a surface treatment of a phosphate system. The pressing pressure is 0.5 to 1.5 GPa, and is heated at 200 to 400 ° C for 1 hour in a nitrogen atmosphere during heat treatment. Ring-shaped cores having different first mixing ratios as shown in Table 2 below were produced, and insulation withstand voltage, insulation resistance, core density, magnetic permeability, and iron loss Pcv were measured. (Test Examples 1 to 5) Measurement of insulation withstand voltage, measurement of insulation resistance, measurement of core density ρ, measurement of magnetic permeability, and measurement of iron loss Pcv were carried out in the same manner as in Example 1. The insulation withstand voltage ratio (amorphous 100% basis) when the insulation withstand voltage value of the toroidal core of Example 2-1 containing only the powder of the amorphous magnetic material was used as a reference (100%), And the insulation withstand voltage ratio (crystallinity 100% standard) when the dielectric breakdown voltage of the toroidal core of Example 2-7 containing the powder containing only the crystalline magnetic material as the magnetic powder was based on the reference (100%). Regarding the magnetic permeability, in addition to the measurement of the initial magnetic permeability μ0, the relative magnetic permeability μ5500 when the DC magnetic field was superimposed on the toroidal core at a condition of 100 kHz and thus the DC applied magnetic field was 5500 A/m was also measured. The measurement results are shown in Table 2. [Table 2] Fig. 6 is a graph showing the dependence of the insulation withstand voltage of Example 2 on the first mixing ratio. As shown in the graph of the insulation withstand voltage of Fig. 6, in the same manner as in the first embodiment, in the same manner as in the first embodiment, the powder of the crystalline magnetic material is mixed in the powder of the amorphous magnetic material, and the powder is used alone. In comparison with the case, the insulation withstand voltage characteristics were improved, and a synergistic effect was confirmed. In the second embodiment, the insulation withstand voltage is higher than the powder of the amorphous magnetic material from the first mixing ratio of about 40% by mass, and the insulation withstand voltage ratio is more than 180% in the range of 70% by mass to 90% by mass. The value of the insulation withstand voltage ratio based on the powder monomer of the amorphous magnetic material of Example 2-6 was increased by 80% or more. Fig. 7 is a graph showing the dependence of the insulation withstand voltages of the first embodiment and the second embodiment on the first mixing ratio. As a result of the above-mentioned figure, it is understood that by mixing the powder of the crystalline magnetic material in the powder of the amorphous magnetic material, a powder magnetic core having a higher insulation withstand voltage can be obtained as compared with the case of using each powder alone. That is, FIG. 7 shows that the insulation ratio is obtained beyond the mixing ratio of the powder based on the crystalline magnetic material contained in the powder magnetic core and the powder of the amorphous magnetic material, that is, by the synergistic effect exceeding the simple addition property. Powder core with excellent pressure resistance. 8 is a graph showing insulation withstand voltage ratios at respective first mixing ratios based on powder monomers of amorphous magnetic materials in Examples 1 and 2, and FIG. 9 shows Example 1 and implementation. A graph showing the insulation withstand voltage ratio at each first mixing ratio in the case of the powder monomer of the crystalline material in Example 2. As can be seen from the results of FIGS. 5 to 9, the effect of increasing the value of the withstand voltage is to appropriately adjust the value of the amorphous magnetic material D 50 A and set the first mixing ratio to 40% by mass. It is stable in the range of 90 mass or less. In addition, when the first mixing ratio is 50 to 70% by mass, the insulation withstand voltage of the piezoelectric core can be improved regardless of whether the value of the amorphous magnetic material has a large value of the particle diameter D 50 A or is small. characteristic. Furthermore, as shown in FIG. 9, it is understood that the first mixing ratio (50 to 70% by mass) as described above can be obtained by using a powder magnetic core containing only a crystalline material powder as a magnetic powder (100%). In the case of the case, the insulation withstand voltage ratio is 110% or more, or 125% or more of the powder magnetic core. 10 to 12 are graphs showing, in order, the dependence of the insulation resistance, the core density, and the magnetic permeability on the first mixing ratio in the first embodiment. 13 to 15 are graphs showing, in order, the dependence of the dielectric withstand voltage, the insulation resistance, the core density, and the magnetic permeability on the first mixing ratio in the second embodiment. As shown in Tables 1 and 2 and FIGS. 5 to 15 , the excellent powder magnetic core obtained by mixing the powder of the crystalline magnetic material in the powder of the amorphous magnetic material can not only improve the insulation withstand voltage characteristics, Further, the insulation withstand voltage can be increased in a state where the iron loss Pcv hardly increases, thereby providing a good inductor. According to the present invention, it is possible to obtain a powder magnetic core which provides an excellent inductor having excellent dielectric withstand voltage characteristics and reduced iron loss, and it has been confirmed according to the present embodiment that the degree of goodness is beyond the crystallinity contained in the powder-based magnetic core. The degree of expectation of the mixing ratio of the powder of the magnetic material and the powder of the amorphous magnetic material. [Industrial Applicability] The inductor including the powder magnetic core of the present invention can be preferably used as a component of a booster circuit such as a hybrid electric vehicle, a component of a power generation/substation device, a transformer, or a crucible. Components such as flow coils, etc.