TWI771395B - 錳鋅系鐵氧體燒結體 - Google Patents

錳鋅系鐵氧體燒結體 Download PDF

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TWI771395B
TWI771395B TW107110687A TW107110687A TWI771395B TW I771395 B TWI771395 B TW I771395B TW 107110687 A TW107110687 A TW 107110687A TW 107110687 A TW107110687 A TW 107110687A TW I771395 B TWI771395 B TW I771395B
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mass
manganese
sintered body
core loss
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TW107110687A
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TW201840512A (zh
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三吉康晴
多田智之
小湯原德和
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日商日立金屬股份有限公司
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Abstract

本發明是一種錳鋅系鐵氧體燒結體，其含有：主成分，其由以Fe2 O3 換算為53.30～53.80莫耳%的Fe(鐵)、以ZnO換算為6.90～9.50莫耳%的Zn(鋅)及以MnO換算的剩餘部分的Mn(錳)所構成；以及，副成分，其相對於前述換算後的前述主成分的合計100質量份，由以SiO2 換算為0.003～0.020質量份的Si(矽)、以CaCO3 換算為超過0質量份且0.35質量份以下的Ca(鈣)、以Co3 O4 換算為0.30～0.50質量份的Co(鈷)、以ZrO2 換算為0.03～0.10質量份的Zr(鋯)及以Ta2 O5 換算為0～0.05質量份的Ta(鉭)所構成；並且，平均結晶粒徑為3μm以上且未滿8μm；燒結體密度為4.65g/cm3 以上。

Description

錳鋅系鐵氧體燒結體
本發明關於一種錳鋅系鐵氧體燒結體，其適合用於各種電源裝置的變壓器、電感器、反應器、扼流圈等電子零件的磁心。
在近年開始急速普及的EV(電動車)、PHEV(插電式油電混合動力車)等的電動運輸機器之一也就是電動汽車中，設有大輸出的電動馬達或充電器等的機器，且在該等機器中使用能夠承受高電壓、大電流的電子零件。電子零件是以線圈與磁心來作為基本結構，且磁心是由錳鋅系鐵氧體燒結體等的磁性材料所構成。
在這樣的用途中，不僅會在行進時對電子零件產生各式各樣的機械性和電性的負載，並且所使用的環境溫度也有各種情況。通常會預見由磁心損耗帶來的發熱，而利用結晶磁異向性常數K1來調整磁心損耗變成極小的溫度，以將該溫度設定成稍微高於電子零件所曝露的環境最高溫度，來防止鐵氧體因熱失控而失去磁性的情形。 又，家庭用電子機器所使用的電子零件中，使用了被設計成例如磁心損耗(也稱作電力損耗)的極小溫度在100℃以下的錳鋅系鐵氧體，因此被要求在寬廣的溫度範圍中為低磁心損耗。
錳鋅系鐵氧體的磁心損耗具有溫度依存性(溫度相關性)，在結晶磁異向性常數K1成為0的溫度中，磁滯損耗較小，而對於溫度具有極小值。結晶磁異向性常數K1成為0的溫度，主要能夠藉由適當調整錳鋅系鐵氧體中的構成尖晶石的金屬離子中，表示正值的結晶磁異向性常數K1的金屬離子與表示負值的結晶磁異向性常數K1的金屬離子的量來加以變化。構成尖晶石的金屬離子中，表示正值的K1的金屬離子有Fe2+ 、Co2+ 等，表示負值的K1的金屬離子有Fe3+ 、Mn2+ 等。磁心損耗成為極小的溫度，能夠藉由調整Fe2+ 、Fe3+ 、Zn2+ 及Mn2+ 等的金屬離子來比較容易地加以變化，但僅靠這樣的方式難以改善磁心損耗的溫度依存性。因此，會導入具有比Fe2+ 更大得多的結晶磁異向性常數的Co2+ ，來進行磁心損耗的溫度依存性的改善。
這樣的鐵氧體的磁心損耗Pcv，一般是由磁滯損耗Ph、渦電流損耗Pe及剩餘損耗Pr所構成。磁滯損耗Ph源自直流磁滯，與頻率成比例地增加，渦電流損耗Pe源自因電磁感應作用而產生的電動勢所發生的渦電流，與頻率的平方成比例地增加。剩餘損耗Pr是起因於磁域壁共鳴等的剩餘損耗，在500kHz以上的頻率會變得明顯。亦即，磁滯損耗Ph、渦電流損耗Pe、剩餘損耗Pr會根據頻率而改變，並且在全體的磁心損耗中佔的比例也會根據頻率帶而有所不同。因此，會要求可適用於所使用的頻率或溫度之錳鋅系鐵氧體。
作為在寬廣的溫度範圍中為低磁心損耗的鐵氧體，例如在日本特開平05-198416號公報中，揭示了一種錳鋅系鐵氧體，其中在由52.0～54.7莫耳%的Fe2 O3 、31～40莫耳的MnO及6～15莫耳%的ZnO所構成的基本組成100重量%中，添加了0.001～0.030重量%的SiC及0.02～0.30重量%的CaO，並進一步添加從下述的群組中所選出的至少一種成分：0.01～0.08重量%的氧化鈮、0.05～0.40重量%的氧化鈦、0.005～0.08重量%的氧化銻、0.02～0.15重量%的氧化鉭、0.005～0.20重量%的氧化釩、0.02～0.15重量%的氧化鋯、0.02～0.50重量%的氧化錫、0.01～0.50重量%的氧化鋁、0.01～1.0重量%的氧化鈷、0.02～0.15重量%的氧化銅、0.05～1.0重量%的氧化鉿及0.001～0.030重量%的氧化矽。該錳鋅系鐵氧體，在100kHz的頻率、200mT的最大磁束密度及100℃的溫度中為低磁心損耗，但在更高的頻率(300～500kHz)中並不能在寬廣的溫度範圍中皆有足夠低的磁心損耗。
已知Co有助於改善磁心損耗的溫度依存性，但在含有Co之錳鋅系鐵氧體中，2價的金屬離子(Co2+ )容易經由晶格缺陷而移動，因此會導致磁異向性增大、磁心損耗增加及磁導率的降低等磁性特性的經時變化，且在高溫環境下該經時變化較大。因此，針對容易曝露於高溫中的電子零件中所使用的錳鋅系鐵氧體，會要求達成進一步的低磁心損耗化與抑制磁性特性的經時變化。
(發明所欲解決的問題) 因此，本發明的目的在於提供一種錳鋅系鐵氧體，其在300～500kHz的高頻率中，於寬廣的溫度範圍中為低磁心損耗，且在高溫環境下的磁心損耗的經時變化較小。
(用於解決問題的手段) 本發明的錳鋅系鐵氧體燒結體，其特徵在於，含有：主成分，其由以Fe2 O3 換算為53.30～53.80莫耳%的Fe(鐵)、以ZnO換算為6.90～9.50莫耳%的Zn(鋅)及以MnO換算的剩餘部分的Mn(錳)所構成；以及，副成分，其相對於前述換算後的前述主成分的合計100質量份，由以SiO2 換算為0.003～0.020質量份的Si(矽)、以CaCO3 換算為超過0質量份且0.35質量份以下的Ca(鈣)、以Co3 O4 換算為0.30～0.50質量份的Co(鈷)、以ZrO2 換算為0.03～0.10質量份的Zr(鋯)及以Ta2 O5 換算為0～0.05質量份的Ta(鉭)所構成；並且，平均結晶粒徑為3μm以上且未滿8μm；燒結體密度為4.65g/cm3 以上。
本發明的錳鋅系鐵氧體燒結體中，較佳是Ta含量以Ta2 O5 換算為0.01質量份以上。
本發明的錳鋅系鐵氧體燒結體中，較佳是Fe含量以Fe2 O3 換算為53.40～53.70莫耳%，Zn含量以ZnO換算為7.00～9.40莫耳%，Si含量以SiO2 換算為0.004～0.015質量份，Co含量以Co3 O4 換算為0.30～0.45質量份，Zr含量以ZrO2 換算為0.05～0.09質量份。
本發明的錳鋅系鐵氧體燒結體，較佳是(a)在300kHz的頻率和100mT的勵磁磁束密度中，該錳鋅系鐵氧體燒結體在20℃時的磁心損耗Pcv20為300kW/m3 以下，並且在100℃時的磁心損耗Pcv100為320kW/m3 以下；並且，(b)在500kHz的頻率和100mT的勵磁磁束密度中，該錳鋅系鐵氧體燒結體在20℃時的磁心損耗Pcv20為650kW/m3 以下，並且在100℃時的磁心損耗Pcv100為850kW/m3 以下。
本發明錳鋅系鐵氧體燒結體，較佳是由下述式(1)來表示的磁心損耗的變化率Ps為5%以下： Ps(%)=[(Pcv100B－Pcv100A)/Pcv100A]×100．．．(1)； 其中，Pcv100A為在保持於200℃前，在100℃時的磁心損耗；Pcv100B為在200℃保持96小時後，在100℃時的磁心損耗；兩者皆是在300kHz的頻率和100mT的最大磁束密度中所測量到的數值。
以下，詳細地說明本發明的實施型態，但本發明並不限定於此實施型態，可在本發明的技術性思想的範圍內加以適當變化。
[1]錳鋅系鐵氧體燒結體 (A)組成 本發明的錳鋅系鐵氧體燒結體，含有由Fe、Mn及Zn所構成的主成分；以及，由Si、Ca、Co及Zr所構成的副成分。本發明的錳鋅系鐵氧體燒結體，可進一步含有作為副成分的Ta。主成分是主要構成尖晶石鐵氧體的元素，而副成分是對於尖晶石鐵氧體的形成加以補助的元素。Co雖然可構成尖晶石鐵氧體，但在本發明中其含量相較於主成分為顯著地少，因此作為副成分。
(1)主成分 為了減低在希望的溫度中的磁心損耗Pcv，必須要適當地對構成尖晶石的離子中，表示正值的結晶磁異向性常數K1的金屬離子與表示負值的結晶磁異向性常數K1的金屬離子的量加以調整。然而，由於也需要滿足飽和磁束密度Bs、居里溫度Tc、初始磁導率μi等的磁心損耗Pcv以外的磁性特性的要求，所以組成的選擇自由度較小。又，為了在寬廣的溫度範圍中減少磁心損耗，必須要設定磁心損耗成為極小的溫度。於是，將主成分的組成作成以Fe2 O3 換算為53.30～53.80莫耳%的Fe、以ZnO換算為6.90～9.50莫耳%的Zn，並且將以MnO換算的Mn作為剩餘部分，使得具有500mT以上的飽和磁束密度Bs、230℃以上的居里溫度Tc及1500以上的初始磁導率μi，而能夠用於要承受高溫下之高電壓和大電流的使用之電子零件用磁心，並且藉由將磁心損耗的極小溫度例如作成100℃以下，更佳是80℃以下，而在寬廣的溫度範圍中為低磁心損耗。
(a)Fe：53.30～53.80莫耳%(以Fe2 O3 換算) 若Fe含量未滿53.30莫耳%，則磁心損耗的極小溫度變高，且低溫側的磁心損耗增大，而無法充分獲得在20～100℃的溫度範圍中的磁心損耗的減低效果。又若超過53.80莫耳%，則磁心損耗的極小溫度變低，且高溫側的磁心損耗增大，而無法充分獲得在20～100℃的溫度範圍中的磁心損耗的減低效果。Fe含量的下限較佳是53.40莫耳%，更佳是53.45莫耳%。另一方面，Fe含量的上限較佳是53.70莫耳%，更佳是53.65莫耳%。
(b)Zn：6.90～9.50莫耳%(以ZnO換算) 若Zn含量未滿6.90莫耳%，則磁心損耗的溫度變化會增大而較不佳，又若超過9.50莫耳%，則不容易獲得足夠的飽和磁束密度。Zn含量的下限較佳是7.00莫耳%，更佳是8.0莫耳%，最佳是9.10莫耳%。另一方面，Zn含量的上限較佳是9.40莫耳%，更佳是9.30莫耳%。
(c)Mn：剩餘部分(MnO換算) Mn含量，是自主成分(Fe、Zn及Mn)的總量減去Fe含量和Zn含量後的剩餘部分。
(2)副成分 本發明的錳鋅系鐵氧體燒結體，作為副成分至少含有Si、Ca、Co及Zr，且可任意決定是否要含有Ta。副成分的組成是以質量份來表示，並且是相對於前述換算過之前述主成分的合計100質量份。
(a)Si：0.003～0.020質量份(以SiO2 換算) Si會偏析於結晶粒邊界而將結晶粒加以絕緣(提高晶粒邊界電阻)，縮小相對損耗係數tanδ/μi，並減低渦電流損耗。結果，錳鋅系鐵氧體燒結體在高頻區域中的磁心損耗減低。若Si含量太少，則提高結晶粒邊界電阻的效果較小，而若Si含量太多，反而會誘發結晶的肥大化，而使磁心損耗劣化。
若含有以SiO2 換算為0.003～0.020質量份的Si，藉由與其他副成分的組合能夠確保足夠用來減低渦電流損耗的晶粒邊界電阻，且能夠在300kHz以上的高頻區域中將錳鋅系鐵氧體燒結體作成低損耗。Si含量的下限以SiO2 換算較佳是0.004質量份，更佳是0.005質量份。另一方面，Si含量的上限以SiO2 換算較佳是0.015質量份，更佳是0.012質量份。
(a)Ca：超過0質量份且0.35質量份以下(以CaCO3 換算) Ca會偏析於結晶粒邊界而將結晶粒加以絕緣(提高晶粒邊界電阻)，縮小相對損耗係數tanδ/μi，並減低渦電流損耗。結果，錳鋅系鐵氧體燒結體在高頻區域中的磁心損耗減低。若Ca含量太少，則提高晶粒邊界電阻的效果較小，而若Ca含量太多，反而會誘發結晶的肥大化，而使磁心損耗劣化。
若含有以CaCO3 換算為超過0質量份且0.35質量份以下的Ca，藉由與其他副成分的組合能夠確保足夠用來減低渦電流損耗的晶粒邊界電阻，且能夠在300kHz以上的高頻區域中將錳鋅系鐵氧體燒結體作成低損耗。Ca含量的下限以CaCO3 換算較佳是0.05質量份，更佳是0.07質量份。另一方面，Ca含量的上限以CaCO3 換算較佳是0.30質量份，更佳是0.20質量份。
(c)Co：0.30～0.50質量份(以Co3 O4 換算) Co是有助於改善磁心損耗的溫度依存性的元素。Co2+ 與Fe2+ 皆作為具有正值的結晶磁異向性常數K1的金屬離子，而具有調整磁心損耗成為最小值之溫度的效果。又，Co可減低殘留磁束密度Br，而減低磁滯損耗Ph。另一方面，因為Co2+ 具有比Fe2+ 更大的結晶磁異向性常數K1，所以若Co的含量太多，則磁化曲線容易變成恆磁導率合金(perminvar)型，又在低溫側中的結晶磁異向性常數容易變得太偏向正值側，使得低溫度域中的損耗顯著增加，且磁心損耗的溫度依存性也會惡化。另一方面，若Co含量太少，則改善溫度依存性的效果較小。
若含有以Co3 O4 換算為0.30～0.50質量份的Co，則藉由與其他副成分的組合，能夠在實用溫度範圍中減低磁心損耗，且能夠改善溫度依存性。Co含量的上限以Co3 O4 換算較佳是0.45質量份，更佳是0.40質量份。
(d)Zr：0.03～0.10質量份(以ZrO2 換算) 以ZrO2 換算為0.03～0.10質量份的Zr，與Si和Ca一起主要偏析於結晶粒邊界層以提高晶粒邊界電阻，藉此來幫助達成低損耗化，並且縮小磁心損耗的變化率Ps。若Zr的含量太少，則磁心損耗與磁心損耗的變化率Ps的減低效果較小，而若Zr的含量太多，則會產生粗大晶粒的成長而使磁心損耗增大。Zr含量的下限以ZrO2 換算較佳是0.05質量份，更佳是0.06質量份。又，Zr含量的上限以ZrO2 換算較佳是0.09質量份，更佳是0.08質量份。
(e)Ta：0～0.05質量份(以Ta2 O5 換算) 因為Ta會偏析於結晶粒邊界層而提高晶粒邊界電阻，所以可含有以0.05質量份作為上限的量，但亦可含有0質量份(不含有)。若Ta含量太多，則Ta會侵入結晶粒內，而使得錳鋅系鐵氧體燒結體的磁心損耗增大。藉由含有以Ta2 O5 換算為0～0.05質量份的Ta，能夠確保足夠用來減低渦電流損耗的晶粒邊界電阻，而在500kHz以上的高頻區域中，減低特別在高溫(100℃)時的磁滯損耗和剩餘損耗，而在高頻區域中實現寬廣的溫度範圍中的低損耗化。含有Ta的情況中，含量的下限以Ta2 O5 換算較佳是0.01質量份。Ta含量的上限以Ta2 O5 換算較佳是0.04質量份，更佳是0.03質量份。
副成分中，Si主要偏析在結晶粒邊界和三相點，Ca、Zr及Ta在燒結步驟的途中有時會固溶於尖晶石相，且在燒結後仍有一部分殘留於結晶粒內。若固溶於尖晶石相中的Ca、Zr及Ta變多，則結晶粒內的電阻會變高，並且體積電阻率ρ會增加，但晶粒邊界的Ca、Zr及Ta的含量會減少。若要一邊提高體積電阻率一邊作成低磁心損耗的錳鋅系鐵氧體燒結體，有效的方式是調整固溶於尖晶石相中的Ca、Zr及Ta的比例與偏析於結晶粒邊界的Ca、Zr及Ta的比例，以提高結晶粒內的電阻並形成高電阻的結晶粒邊界。此調整，能夠藉由後述的燒結溫度與燒結環境的控制來進行。
(3)雜質 構成錳鋅系鐵氧體燒結體的原料中，有時包含硫(S)、氯(Cl)、磷(P)、硼(B)等的雜質。該等雜質中，特別是S會與Ca形成化合物，該化合物作為異物而偏析於結晶粒邊界，而使體積電阻率ρ降低並使渦電流增加。經驗上已知，若減低該等雜質的含量，能夠減低磁心損耗及提高磁導率。因此，為了進一步減低磁心損耗，相對於前述換算後的主成分的合計100質量份，較佳是將S作成0.03質量份以下，將Cl作成0.01質量份以下，將P作成0.001質量份以下，以及將B作成0.0001質量份以下。
主成分、副成分及雜質的定量，能夠藉由螢光X射線分析和ICP(感應耦合電漿)發光分光分析來進行。預先藉由螢光X射線分析來進行含有元素的定性分析，然後藉由將各元素與標準樣本加以比較之檢量(calibration curve method)線法來加以定量。
(B)平均結晶粒徑 本發明的錳鋅系鐵氧體燒結體，具有3μm以上且未滿8μm的平均結晶粒徑。若平均結晶粒徑成為8μm以上，渦電流損耗和剩餘損耗的減低效果便不足，且500kHz以下的高頻區域中的磁心損耗會增大。另一方面，若平均結晶粒徑未滿3μm，則晶粒邊界作為磁壁的磁釘點來發揮作用，並且又因為反磁場的影響，會誘發磁導率的降低和磁心損耗的增加。平均結晶粒徑較佳為4～7μm。此外，平均結晶粒徑是藉由以下實施例所記載的方法來求出。
(C)燒結體密度 本發明的錳鋅系鐵氧體燒結體具有4.65 g/cm3 以上的密度。若燒結體密度未滿4.65 g/cm3 ，則機械性強度不佳，容易產生缺損或破裂。較佳的燒結體密度為4.75 g/cm3 以上。此外，燒結體密度是藉由以下實施例所記載的方法來求出。
[2]錳鋅系鐵氧體燒結體的製造方法 第1圖表示用來獲得本發明的錳鋅系鐵氧體燒結體之燒結步驟的溫度條件。前述燒結步驟具有升溫步驟、高溫保持步驟及降溫步驟。燒結步驟中，是藉由調整氧氣分壓來使Ca、Zr等偏析於晶粒邊界，並對固溶於結晶粒內的情形加以適當控制，來減低磁心損耗。
(A)升溫步驟 升溫步驟中，自室溫至400～950℃的溫度之間的第1升溫步驟中，是在大氣中進行升溫，以從成形體除去黏結劑。自第1升溫步驟以後到高溫保持步驟為止之間的第2升溫步驟中，較佳是將環境中的氧氣濃度降低到0.01～0.5體積%。升溫步驟中，對應於脫黏結劑中的碳殘留的程度、組成等，來適當選擇升溫速度。平均升溫速度較佳是在50～200℃/小時的範圍內。
(B)高溫保持步驟 高溫保持步驟，較佳是將環境中的氧氣濃度調整成0.1～0.5體積%，並以1150～1250℃的溫度來進行。高溫保持步驟中的環境中的氧氣濃度，較佳是設定成比第2升溫步驟中的氧氣濃度更高。
(C)降溫步驟 降溫步驟中，若氧氣濃度太高，燒結體的氧化狀況進展，會從尖晶石結構析出氧化鐵(III)(赤鐵礦)。另一方面，若氧氣濃度太低，會析出氧化鐵(II)(方鐵礦)，產生結晶變形而使得磁心損耗增加。較佳是將降溫步驟中的氧氣濃度控制成不會發生赤鐵礦的析出和方鐵礦的析出。具體而言，較佳是對降溫步驟中的氧氣濃度加以控制以使得氧濃度PO2 (體積分率)與溫度T(℃)滿足下述式(2)： logPO2 =a-b/(T+273)．．．(2) 此處，a為3.1～12.8的常數，b為6000～20000的常數。a是由高溫保持步驟的溫度與氧氣濃度所規定。若b未滿6000，則即便溫度降低後氧氣濃度仍然高，使得氧化進展，有時會自尖晶石結構析出赤鐵礦。另一方面，若b大於20000，則氧氣濃度降低，會使得方鐵礦析出，並且結晶粒和晶粒邊界層未被充分氧化而使得電阻變小。a更佳是6.4～11.5，且b更佳是10000～18000。
藉由上述燒結步驟所得到的錳鋅系鐵氧體燒結體，在室溫中具有5Ω．m以上的體積電阻率。更進一步，體積電阻率為了減低渦電流損耗Pe而較佳是作成10Ω．m以上。
藉由實施例來更詳細對本發明加以說明，但本發明並不限定於該等實施例。
(實施例1～50及比較例1～8) 根據如表1所示的調配比例對作為主成份的Fe2 O3 粉末、ZnO粉末及Mn3 O4 粉末加以溼式混合並乾燥，並在900℃進行3小時的初步煅燒。此外，表1中是以MnO換算來表示Mn3 O4 粉末的添加量。針對所獲得到的初步煅燒粉100質量份，根據表1所示的調配比例來將SiO2 粉末、CaCO3 粉末、Co3 O4 粉末、ZrO2 粉末及Ta2 O5 粉末添加球磨機中，進行表2所示的時間的粉碎、混合直到平均粉碎粒徑成為1.2～1.4μm為止。將作為黏結劑的聚乙烯醇添加至所獲得到的混合物中，並在研鉢中加以顆粒化後，進行加壓成形而獲得環狀的成形體。
各成形體，藉由燒結步驟來加以燒結，燒結步驟由升溫步驟、高溫保持步驟及降溫步驟所構成，其中升溫步驟自室溫升溫至表2所示的保持溫度為止，高溫保持步驟以保持溫度來保持5小時，降溫步驟自保持溫度冷卻至室溫。升溫步驟中，將升溫速度設成：到400℃為止是50℃/小時，然後自400℃至保持溫度為止是100℃/小時；並且，將煅燒環境中的氧氣濃度設成：自室溫到700℃為止是21體積%(使用大氣)，到達700℃以後是0.1體積%。將高溫保持步驟中的氧氣濃度表示於表2。降溫步驟中，將冷卻速度設成：自保持溫度至900℃為止是100℃/小時，之後是150℃/小時。降溫步驟中，到1000℃為止將氧氣濃度(體積%)調節成平衡氧氣分壓。900℃以後在N2 的流動氣體中冷卻，最終的氧氣濃度降低至約0.003體積%。如此，便獲得外徑25mm×內徑15mm×厚度5mm的圓環狀錳鋅系鐵氧體燒結體(磁心)。
針對各錳鋅系鐵氧體燒結體，是藉由下述方法來測量密度、體積電阻率ρ、平均結晶粒徑、飽和磁束密度Bs、初始磁導率μi及磁心損耗Pcv。
(1)燒結體密度 從各錳鋅系鐵氧體燒結體的尺寸和重量，藉由體積重量法來算出密度。將結果表示於表3。
(2)體積電阻率ρ 自各錳鋅系鐵氧體燒結體切割出平板狀的試料，在對向的二平面上設置銀糊電極，使用日置電機股份有限公司製的毫歐姆高階測試器3224來測量電阻R(Ω)。自電極形成面的面積A(m2 )與厚度t(m)，藉由下述式(3)來算出體積電阻率ρ(Ω．m)。將結果表示於表3。 ρ(Ω．m)=R×(A/t)．．．(3)
(3)平均結晶粒徑 對各錳鋅系鐵氧體燒結體的鏡面研磨面中的結晶粒邊界加以熱蝕刻(1100℃、1小時、在N2 中處理)，然後利用光學顯微鏡(400倍)來拍攝照片，並在顯微鏡照片的100μm×100μm的正方形區域中，作為藉由求積法之圓等效徑長來求出平均結晶粒徑。將結果表示於表3。
(4)飽和磁束密度Bs 將各錳鋅系鐵氧體燒結體作為磁心，將一次側繞線和二次側繞線分別卷繞40圈之後，施加1.2kA/m的磁場，使用直流磁化測量試驗裝置(Metron技研股份有限公司製的SK-110型)在23℃測量飽和磁束密度Bs。將結果表示於表3。
(5)初始磁導率μi 將各錳鋅系鐵氧體燒結體作為磁心，卷繞10圈之後，施加0.4A/m的磁場，使用惠普製的HP-4285A，以23℃且100kHz的條件來測量初始磁導率μi。將結果表示於表3。
(6)磁心損耗Pcv 將各錳鋅系鐵氧體燒結體作為磁心，將一次側繞線和二次側繞線分別卷繞4圈，使用岩崎通訊機股份有限公司製的B-H(磁化)分析儀(SY-8232)，以300kHz和500kHz的各頻率及100mT的勵磁磁束密度的條件，測量在20℃、40℃、60℃、80℃、100℃、120℃及140℃時的磁心損耗Pcv。將結果表示於表4。
[表1-1]
Figure 107110687-A0304-0001
[表1-2]
Figure 107110687-A0304-0002
[表1-3]
Figure 107110687-A0304-0003
[表2-1]
Figure 107110687-A0304-0004
 註：(1)高溫保持步驟中的環境中的氧氣濃度(體積%)。
[表2-2]
Figure 107110687-A0304-0005
 註：(1)高溫保持步驟中的環境中的氧氣濃度(體積%)。
[表2-3]
Figure 107110687-A0304-0006
 註：(1)高溫保持步驟中的環境中的氧氣濃度(體積%)。
[表3-1]
Figure 107110687-A0304-0007
 註：(1)燒結體密度。 (2)體積電阻率。 (3)平均結晶粒徑。 (4)飽和磁束密度。 (5)100kHz和0.4A/m中的初始磁導率。
[表3-2]
Figure 107110687-A0304-0008
 註：(1)燒結體密度. (2)體積電阻率。 (3)平均結晶粒徑。 (4)飽和磁束密度。 (5)100kHz和0.4A/m中的初始磁導率。
[表3-3]
Figure 107110687-A0304-0009
 註：(1)燒結體密度。 (2)體積電阻率。 (3)平均結晶粒徑。 (4)飽和磁束密度。 (5)100kHz和0.4A/m中的初始磁導率。
[表4-1]
Figure 107110687-A0304-0010
[表4-2]
Figure 107110687-A0304-0011
[表4-3]
Figure 107110687-A0304-0012
[表5-1]
Figure 107110687-A0304-0013
[表5-2]
Figure 107110687-A0304-0014
[表5-3]
Figure 107110687-A0304-0015
從表3～5可明顯看出，實施例1～50的錳鋅系鐵氧體燒結體的初始磁導率μi皆在1800以上，且在300kHz和500kHz的任一頻率中，皆可在寬廣的範圍中成為低磁心損耗。相對於此，比較例1～8的錳鋅系鐵氧體燒結體，在300kHz或500kHz的磁心損耗偏高。根據以上可知，藉由本發明能夠獲得自低溫(20℃)至高溫(100℃)為止皆為低磁心損耗的錳鋅系鐵氧體燒結體。
(實施例51～53和比較例9～11) 採用表6所示的組成和表7所示的製造條件，除此以外，以與實施例1同樣的方式來製作出錳鋅系鐵氧體燒結體。針對各錳鋅系鐵氧體燒結體，以與實施例1同樣的方式來測量密度、體積電阻率ρ、平均結晶粒徑、初始磁導率μi及磁心損耗Pcv。此外，磁心損耗Pcv的評價，是以300kHz的頻率和100mT的勵磁磁束密度的條件來進行。將結果表示於表8～表10。
進一步，將各錳鋅系鐵氧體燒結體的磁心在高溫槽內於200℃中保持96小時，然後從高溫槽取出並使磁心的溫度降低至室溫，藉由與上述相同的條件在20℃、40℃、60℃、80℃、100℃、120℃及140℃中測量磁心損耗，並根據高溫環境(200℃)放置前後的磁心損耗來藉由下述式(1)來算出磁心損耗的變化率Ps。 Ps(%)=[(PcvB－PcvA)/PcvA]×100．．．(1) 其中，PcvA為在保持於高溫(200℃)前的磁心的磁心損耗，PcvB為在高溫(200℃)保持後的磁心的磁心損耗。
例如，若欲求出因高溫環境(200℃)放置所造成的在100℃時的磁心損耗的變化率Ps，便使用在保持於高溫(200℃)前，以100℃、300kHz的頻率和100mT的勵磁磁束密度的條件來測量到的磁心的磁心損耗(Pcv100A)來作為PcvA，並使用在高溫(200℃)保持後，以100℃、300kHz的頻率和100mT的勵磁磁束密度的條件來測量到的磁心的磁心損耗(Pcv100B)來作為PcvB。
高溫保持前的磁心損耗的測量中，雖然將磁心在140℃的環境的恆溫槽中放置了10～15分鐘的程度直到溫度穩定為止，但並未實質發生磁性特性的經時變化。
[表6]
Figure 107110687-A0304-0016
 註：*為了進行比較而表示比較例3的資料。
[表7]
Figure 107110687-A0304-0017
 註：*為了進行比較而表示比較例3的資料。 (1)高溫保持步驟中的環境中的氧氣濃度(體積%)。
[表8]
Figure 107110687-A0304-0018
 註：*為了進行比較而表示比較例3的資料。 (1)燒結體密度。 (2)體積電阻率。 (3)平均結晶粒徑。 (4)100kHz和0.4A/m中的初始磁導率。
[表9]
Figure 107110687-A0304-0019
 註：*為了進行比較而表示比較例3的資料。
[表10]
Figure 107110687-A0304-0020
 註：*為了進行比較而表示比較例3的資料。
[表11]
Figure 107110687-A0304-0021
 註：*為了進行比較而表示比較例3的資料。
從表8～表11可明顯看出，實施例51～53的錳鋅系鐵氧體燒結體的任一者皆有高初始磁導率μi和體積電阻率，因此在寬廣的溫度範圍中為低磁心損耗，且磁心損耗的變化率Ps也較小。相對於此，比較例9的錳鋅系鐵氧體燒結體雖然初始磁導率μi高，但體積電阻率低，因此磁心損耗較高，磁心損耗的變化率Ps也較大。比較例10的錳鋅系鐵氧體燒結體雖然體積電阻率高，因為初始磁導率μi也高，所以磁心損耗高，磁心損耗的變化率Ps也較大。又，比較例3和11的錳鋅系鐵氧體的體積電阻率和初始磁導率μi都低，因此磁心損耗的變化Ps雖然小，但磁心損耗高。根據以上可知，藉由本發明能夠獲得自低溫(20℃)至高溫(100℃)為止皆為低磁心損耗的錳鋅系鐵氧體燒結體。
(發明的功效) 本發明的錳鋅系鐵氧體燒結體，在300～500kHz的高頻中於寬廣的溫度範圍中的磁心損耗低，且在高溫環境下的磁心損耗的經時變化也小，因此適合用於會被曝露在高溫中的電子零件。
無
第1圖是概略性表示用來獲得本發明的錳鋅系鐵氧體燒結體的燒結步驟的圖表。
國內寄存資訊 (請依寄存機構、日期、號碼順序註記) 無
國外寄存資訊 (請依寄存國家、機構、日期、號碼順序註記) 無

Claims (5)

  1. 一種錳鋅系鐵氧體燒結體，其特徵在於，含有：主成分，其由以Fe2O3換算為53.30~53.80莫耳%的Fe、以ZnO換算為6.90~9.50莫耳%的Zn及以MnO換算的剩餘部分的Mn所構成；以及，副成分，其相對於前述換算後的前述主成分的合計100質量份，由以SiO2換算為0.003~0.020質量份的Si、以CaCO3換算為超過0質量份且0.35質量份以下的Ca、以Co3O4換算為0.30~0.50質量份的Co、以ZrO2換算為0.03~0.10質量份的Zr及以Ta2O5換算為0~0.05質量份的Ta所構成；並且，平均結晶粒徑為3μm以上且未滿8μm；燒結體密度為4.65g/cm3以上。
  2. 如請求項1所述之錳鋅系鐵氧體燒結體，其中，Ta含量以Ta2O5換算為0.01質量份以上。
  3. 如請求項1或2所述之錳鋅系鐵氧體燒結體，其中，Fe含量以Fe2O3換算為53.40~53.70莫耳%，Zn含量以ZnO換算為7.00~9.40莫耳%，Si含量以SiO2換算為0.004~0.015質量份，Co含量以Co3O4換算為0.30~0.45質量份，Zr含量以ZrO2換算為0.05~0.09質量份。
  4. 如請求項1或2所述之錳鋅系鐵氧體燒結體，其中，在300kHz的頻率和100mT的勵磁磁束密度中，該錳鋅系鐵氧體燒結體在20℃時的磁心損耗Pcv20為300kW/m3以下，並且在100℃時的磁心損耗Pcv100為320kW/m3以下；進一步，在500kHz的頻率和100mT的勵磁磁束密度中，該錳鋅系鐵氧體燒結體在20℃時的磁心損耗Pcv20為650kW/m3以下，並且在100℃時的磁心損耗Pcv100為850kW/m3以下。
  5. 如請求項1或2所述之錳鋅系鐵氧體燒結體，其中，由下述式(1)表示的磁心損耗的變化率Ps為5%以下：Ps(%)=[(Pcv100B-Pcv100A)/Pcv100A]×100．．．(1)；其中，Pcv100A為在保持於200℃前，在100℃時的磁心損耗；Pcv100B為在200℃保持96小時後，在100℃時的磁心損耗；兩者皆是在300kHz的頻率和100mT的最大磁束密度中所測量到的數值。
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