WO2002058085A1 - Noyau agglomere et procede de production dudit noyau - Google Patents
Noyau agglomere et procede de production dudit noyau Download PDFInfo
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- WO2002058085A1 WO2002058085A1 PCT/JP2002/000296 JP0200296W WO02058085A1 WO 2002058085 A1 WO2002058085 A1 WO 2002058085A1 JP 0200296 W JP0200296 W JP 0200296W WO 02058085 A1 WO02058085 A1 WO 02058085A1
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- iron
- dust core
- powder
- magnetic
- molding
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/147—Alloys characterised by their composition
- H01F1/14766—Fe-Si based alloys
- H01F1/14775—Fe-Si based alloys in the form of sheets
- H01F1/14783—Fe-Si based alloys in the form of sheets with insulating coating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/102—Metallic powder coated with organic material
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
- H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
- H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/08—Cores, Yokes, or armatures made from powder
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49071—Electromagnet, transformer or inductor by winding or coiling
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49073—Electromagnet, transformer or inductor by assembling coil and core
Definitions
- the present invention relates to a dust core having excellent electrical characteristics such as specific resistance and magnetic characteristics such as magnetic permeability, and a method for producing the same. ⁇ .
- the magnetic core By arranging the magnetic core in a magnetic field, a large magnetic flux density can be obtained, and the size and performance of electromagnetic equipment can be reduced.
- the magnetic core is inserted into an electromagnetic coil (hereinafter simply referred to as a coil) to increase the local magnetic flux density or form a magnetic circuit by being interposed in a plurality of coils.
- a coil an electromagnetic coil
- Such a magnetic core is required to have a high magnetic permeability in order to increase the magnetic flux density, and is also required to have a low high-frequency loss (or iron loss) since it is often used in an alternating magnetic field.
- High-frequency loss includes hysteresis loss, eddy current loss, and residual loss, but the main problems are hysteresis loss and eddy current loss.
- Hysteresis loss is proportional to the frequency of the alternating magnetic field, whereas eddy current loss is proportional to the square of the frequency. For this reason, reduction of eddy current loss is required especially when used in a high frequency range. In order to reduce the eddy current loss, it is necessary to reduce the current flowing through the magnetic core due to the induced electromotive force. In other words, it is desired to increase the specific resistance of the magnetic core.
- the magnetic core formed by pressing the iron-based magnetic powder coated with the insulating film in this manner is referred to as a “dust core”.
- the dust core has a large specific resistance and a large degree of shape freedom, but the conventional dust core has a low density and magnetic properties such as magnetic permeability are not always sufficient.
- the present invention has been made in view of such circumstances, and it is an object of the present invention to provide a dust core having excellent magnetic properties as compared with the related art while securing a large specific resistance. It is another object of the present invention to provide a method for manufacturing a dust core suitable for manufacturing such a dust core.
- the inventors of the present invention have conducted intensive research to solve this problem, and through repeated trial and error, have succeeded in forming an iron-based magnetic powder coated with an insulating film at a higher pressure than ever before, and completed the present invention. That is what led to it.
- the dust core of the present invention is a dust core obtained by press-molding an iron-based magnetic powder covered with an insulating film.
- the magnetic properties such as the magnetic flux density and the like are superior to the conventional one while having a sufficient specific resistance.
- a dust core was obtained.
- a magnetic flux density of B 2k is 1.1 T or more at a low magnetic field (or in a low magnetic field) of 2 kA / m, and a large magnetic flux density of 1.6 T or more at a high magnetic field (or in a high magnetic field) of 1 OkAZm.
- a dust core was obtained. That is, a dust core having high magnetic permeability was obtained in a wide range of magnetic fields.
- the saturation magnetization Ms is as large as 1.9 T (in a magnetic field of 1.6 MA / m), a large magnetic flux density can be stably obtained even in a high magnetic field.
- the powder magnetic core of the present invention a sufficiently high specific resistance and a high magnetic flux density in a wide range of magnetic fields are combined, so that eddy current loss is reduced and high output and high performance of electromagnetic devices are achieved. It is possible to reduce the size or size and weight.
- the powder magnetic core of the present invention has a four-point bending strength and a high strength of 5 OMPa or more, it can be advantageously applied to various products in various fields.
- the method for producing a dust core according to the present invention includes a coating step of coating an insulating coating on the surface of an iron-based magnetic powder, and a coating step of applying a higher fatty acid-based lubricant to the inner surface of a molding die.
- a molding step of hot pressing the magnetic powder is a coating step of coating an insulating coating on the surface of an iron-based magnetic powder, and a coating step of applying a higher fatty acid-based lubricant to the inner surface of a molding die.
- the manufacturing method of the present invention it is possible to perform molding at a higher pressure than ever before, while avoiding damage to the molding die and an increase in ejection pressure, so that sufficient lubrication is possible without performing internal lubrication.
- the moldability of the iron-based magnetic powder can be obtained.
- FIG. 1 is a graph showing the relationship between the molding pressure and the ejection pressure.
- FIG. 2 is a graph showing the relationship between the molding pressure and the density of the obtained powder compact (compact density).
- Figure 3 is a schematic diagram of a pulse test time measurement test device using a solenoid valve. is there.
- FIG. 4 is a bar graph comparing pulse control times of the example and the comparative example.
- the specific resistance is a unique value for each dust core that does not depend on its shape. With a dust core having the same shape, the higher the resistivity, the smaller the eddy current loss. If the specific resistance / 0 is less than 1.5 ⁇ , the eddy current loss cannot be sufficiently reduced, so that the specific resistance 0 is preferably 1.5 ⁇ or more, and more preferably 7 ⁇ or more. It is more preferable that it is ⁇ or more.
- Permeability is determined by permeability (magnetic flux density ⁇ ) / (magnetic field strength ⁇ ), but in general: // is not constant as can be seen from the ⁇ - ⁇ curve. Therefore, instead of directly evaluating the magnetic properties of the dust core of the present invention based on the magnetic permeability, the magnetic properties were evaluated based on the magnetic flux density generated when the core was placed in a magnetic field having a specific strength. In other words, as an example, a low magnetic field (2 kA / m) and a high magnetic field (10 kA / m) are selected, and the magnetic flux densities B 2k and B 10k generated when the powder magnetic core is placed in those magnetic fields are used. We decided to evaluate the magnetic properties of the magnetic core.
- the saturation magnetization Ms is small, a large magnetic flux density cannot be obtained in a high magnetic field.
- the saturation magnetization Ms ⁇ 1.9 T in a magnetic field of 1.6 MAZm, Furthermore, because it is 1.95 mm or more, it exceeds 10 kA / m (4) Even in a magnetic field, a large magnetic flux density can be obtained stably.
- Dust cores unlike cores sintered or sintered at high temperatures, consist of a powder compact of iron-based magnetic powder in which the surface of each particle is covered with an insulating coating. Therefore, the bond of each particle is mainly a mechanical bond accompanying plastic deformation, not a chemical bond. For this reason, in the case of the conventional powdered magnetic core, which had a low molding pressure, the strength was insufficient, and the range of application was limited.
- the bonding of each particle of the iron-based magnetic powder becomes strong, and, for example, the four-point bending strength is 50 MPa or more, and more preferably 10 OMPa or more. High strength could be obtained.
- the four-point bending strength is not specified in JIS, but can be determined by a test method for a green compact.
- the dust core of the present invention is excellent not only in bending strength but also in tensile and compressive strength.
- the strength of the dust core of the present invention may be indexed not only by the four-point bending strength but also by the radial crushing strength or the like.
- the iron-based magnetic powder is an iron powder made of pure iron.
- the purity is preferably 99.5% or more, and more preferably 99.8% or more.
- iron powder for example, AGC 100.30 manufactured by Höganäs can be used.
- This iron powder has components other than Fe: C: 0.001, Mn: 0.02, 0: 0.08 (unit: mass%) or less, and has extremely few impurities compared to other iron powders for sale. Iron powder with excellent compressibility.
- the iron-based magnetic powder may be an iron alloy powder containing a ferromagnetic material (element) such as cobalt (Co) and nickel (Ni) in addition to pure iron.
- a ferromagnetic material such as cobalt (Co) and nickel (Ni) in addition to pure iron.
- the entire dust core is 100% by mass, (0 is 50% by mass or less or 30% by mass or less, and 5% by mass or more (for example, 5 to 30% by mass) Good in terms of high magnetic flux density.
- the iron-based magnetic powder may be an iron alloy powder containing silicon (Si). It became clear. In this case, for example, if 3; 1 is 7% by mass or less, 4% by mass or less, or 2% by mass or less, and 0.3% by mass or more (for example, 0.3 to 4% by mass), Good in terms of magnetic flux density and low coercive force. However, when Si exceeds 7% by mass, the iron-based magnetic powder becomes hard, and it becomes difficult to improve the density of the dust core. Note that A1 has the same effect as Si.
- the iron-based magnetic powder may be a mixed powder obtained by mixing a plurality of powders suitable for the magnetic core material.
- mixed powders of pure iron powder and Fe—49Co—2V (particle) powder, pure iron powder and Fe—3Si powder can be used.
- high-hardness sendust (F e — 9 Si — 6 A 1) powder and pure iron powder, which were conventionally difficult to mold, are used. Mixed powders have become available. In particular, it is preferable to use a commercially available iron-based magnetic powder because the cost of the dust core can be reduced.
- the iron-based magnetic powder may be made of granulated powder or elementary powder.
- the particle size is preferably from 20 to 300 m, and more preferably from 50 to 200 / m.
- the present inventor further conducted additional tests and the like, and newly found that it is preferable to reduce the particle size of the iron-based magnetic powder, particularly in the case of reducing eddy current loss.
- the particle size is preferably not more than 105 ⁇ m, more preferably not more than 53 xm.
- the particle size be 53 ⁇ m or more, and more preferably 105 ⁇ m or more.
- the classification of the iron-based magnetic powder can be easily performed by a sieving method or the like.
- the insulating coating is coated on the surface of each particle of the iron-based magnetic powder. Due to the presence of the insulating coating, a dust core having a large specific resistance can be obtained.
- the insulating coating has the following characteristics: (1) high electrical resistance; (2) high adhesion to the magnetic powder so that it does not peel off when the powders contact each other during molding; and (3) when the powders come into contact with each other during molding. , High slidability and low friction so that powders tend to slip and plastically deform. It is required to have a friction coefficient and, if possible, a ferromagnetic material.
- an insulating coating applicable to a dust core material satisfying the above condition (1) has not been found. Therefore, the present inventor has set forth as a phosphate-based insulating film or S i 0 2 , AI 2 O 3, T i 0 2 , Z r 2 and their composite oxide-based insulating films were used. These coatings may be obtained by coating themselves or by reacting a component (eg, Fe, Si, etc.) in iron-based magnetic powder with phosphoric acid, etc. But it is good. Phosphate-based insulating coatings are excellent in (1) and (3) and are difficult to peel off even during high-pressure molding, so that it is easy to achieve both high electrical resistance and high magnetic flux density and high magnetic permeability due to high density.
- a phosphate-based insulating film or S i 0 2 , AI 2 O 3, T i 0 2 , Z r 2 and their composite oxide-based insulating films were used. These coatings may be obtained by coating themselves or by reacting a component (eg
- the oxide-based insulating film has high heat resistance, and thus has an advantage that it is easy to perform annealing (annealing) after molding, which will be described later. Therefore, whether to use a phosphate-based insulating film or an oxide-based insulating film is preferably selected according to the intended use of the dust core.
- the iron-based magnetic powder when the iron-based magnetic powder is warm-pressed as in the production method of the present invention, a new lubricant having a very high lubricity between the inner wall of the molding die and the iron-based magnetic powder ( A lubricating film of metal stone (2) is formed.
- This lubricant exhibits the best lubricity when it contains Fe (eg, in the case of an iron salt coating of higher fatty acids). Therefore, from the viewpoint of promoting the formation of such an iron salt film, it is preferable that the insulating film itself also has a composition containing Fe to improve the lubricity between the inner wall of the molding die and the iron-based magnetic powder. Is more effective.
- the insulating coating for example, iron phosphate if phosphate-based, if the oxide-based F e S I_ ⁇ 3, F e A l 2 ⁇ 4, such as N i F e 2 0 4 A composite oxide with Fe is preferred.
- a dust core of the present invention is newly provided with a coating process in which an insulating film containing Fe is coated on the surface of the iron-based magnetic powder; A coating step of applying a higher fatty acid-based lubricant on the inner surface; and a filling step of filling the iron-based magnetic powder coated with the insulating film in a molding die coated with the higher fatty acid-based lubricant. And pressing the iron-based magnetic powder filled in the molding die at a warm pressure, and reacting Fe in the insulating film with the higher fatty acid-based lubricant. And a forming step of forming a metal stone film by the following method.
- the manufacturing method includes a coating step in which an insulating film containing Fe is coated on the surface of the iron-based magnetic powder, and a higher fatty acid-based lubricant on the inner surface of the molding die.
- the iron-based magnetic powder thus obtained is subjected to pressure molding in a warm state, and a molding process in which a metal stone film is formed by a reaction between Fe in the insulating film and the higher fatty acid-based lubricant. It is preferable if it becomes.
- the coating step is a step of coating an insulating film on the surface of the iron-based magnetic powder.
- phosphate films are particularly preferable in terms of adhesion, slidability, and electric resistance. Therefore, it is preferable that the coating step is a step in which phosphoric acid is brought into contact with the iron-based magnetic powder to form a phosphate coating (particularly, iron phosphate coating) on the surface of the iron-based magnetic powder.
- Examples of methods for bringing phosphoric acid into contact with the iron-based magnetic powder include a method of spraying a phosphoric acid solution in which phosphoric acid is mixed in water or an organic solvent onto the iron-based magnetic powder, and a method of bringing the iron-based magnetic There is a method of immersing the powder.
- the organic solvent includes ethanol, methanol, isopropyl alcohol, acetone, glycerin and the like.
- the concentration of the phosphoric acid solution is preferably, for example, 0.1 to 10% by mass, and more preferably 0.1 to 2% by mass.
- the application step is a step of applying a higher fatty acid-based lubricant to the inner surface of the molding die.
- the higher fatty acid-based lubricant is preferably a metal salt of the higher fatty acid in addition to the higher fatty acid itself.
- Metal salts of higher fatty acids include lithium salts, calcium salts and zinc salts. is there. In particular, lithium stearate, calcium stearate, and zinc stearate are preferred. In addition, barium stearate, lithium normitate, lithium oleate, calcium noremitate, calcium oleate and the like can also be used.
- the application step is preferably a step of spraying a higher fatty acid-based lubricant dispersed in water or an aqueous solution into a heated molding die.
- the higher fatty acid-based lubricant When the higher fatty acid-based lubricant is dispersed in water or the like, it becomes easier to uniformly spray the higher fatty acid-based lubricant on the inner surface of the molding die. Further, when sprayed into the heated molding die, the water evaporates quickly, and the higher fatty acid-based lubricant can be uniformly attached to the inner surface of the molding die.
- the heating temperature of the molding die needs to consider the temperature of the molding step described later, but it is sufficient to heat it to, for example, 10 ° C. or more. However, in order to form a uniform film of the higher fatty acid-based lubricant, it is preferable that the heating temperature be lower than the melting point of the higher fatty acid-based lubricant. For example, when lithium stearate is used as the higher fatty acid-based lubricant, the heating temperature is preferably set to less than 220 ° C.
- the higher fatty acid-based lubricant when the higher fatty acid-based lubricant is dispersed in water or the like, when the total weight of the aqueous solution is 100% by mass, the higher fatty acid-based lubricant is 0.1 to 5% by mass, and more preferably 0.1 to 5% by mass. When the content is 5 to 2% by mass, a uniform lubricating film is preferably formed on the inner surface of the molding die.
- a surfactant when a higher fatty acid-based lubricant is dispersed in water or the like, a surfactant is added to the water, whereby uniform dispersion of the higher fatty acid-based lubricant can be achieved.
- surfactants include alkylphenol-based surfactants, polyoxyethylene nonyl phenyl ether (E 0) 6, polyoxyethylene nonyl phenyl ether (E 0) 10, and anionic nonionic type Surfactants, borate-based emalbon T-80, and the like can be used. These may be used in combination of two or more.
- lithium stearate when lithium stearate is used as the higher fatty acid-based lubricant, polyoxyethylene nonylphenyl ether (EO) 6, polyoxyethylene nonyl phenyl ether (EO) 10 and borate ester Emalbon T-8 0 It is preferable to use the three types of surfactants simultaneously. Compared to adding only one of them This is because, in the case where the composite is added, the dispersibility of lithium stearate in water or the like is further activated.
- the ratio of the surfactant is 1.5 to 15% by volume. preferable. .
- an antifoaming agent for example, a silicon-based antifoaming agent
- an antifoaming agent for example, a silicon-based antifoaming agent
- the addition ratio of the defoaming agent may be, for example, about 0.1 to 1% by volume when the total volume of the aqueous solution is 100% by volume.
- the particles of the higher fatty acid-based lubricant dispersed in water or the like have a maximum particle size of less than 30 zm.
- the maximum particle size is 3 O ⁇ m or more, the particles of the higher fatty acid-based lubricant easily precipitate in the aqueous solution, and it becomes difficult to uniformly apply the higher fatty acid-based lubricant to the inner surface of the molding die. Because.
- the application of the aqueous solution in which the higher fatty acid-based lubricant is dispersed can be performed, for example, by using a spray gun for coating or an electrostatic gun.
- the filling step is a step of filling an iron-based magnetic powder coated with an insulating film into a molding die coated with a higher fatty acid-based lubricant.
- This filling step is preferably a step of filling the heated iron-based magnetic powder into a heated molding die. If both the iron-based magnetic powder and the molding die are heated, in the subsequent molding step, the iron-based magnetic powder and the higher fatty acid-based lubricant react stably and provide uniform lubrication between the two. A film is easily formed. Therefore, for example, it is preferable to heat both to 10 ° C. or more.
- the molding step is a step of hot-pressing the iron-based magnetic powder filled in the molding die.
- the iron-based magnetic powder (especially, the insulating film) and the higher fatty acid-based lubricant are chemically bonded to each other, and the metal lithographic film (eg, the iron salt film of the higher fatty acid) is converted into the iron-based magnetic powder. Formed on the surface of the powder compact. Then, the metal stone coating is firmly bonded to the surface of the powder compact, and exhibits much better lubricating performance than the higher fatty acid-based lubricant adhered to the inner surface of the molding die. I do. As a result, it is considered that the frictional force between the contact surface between the inner surface of the molding die and the outer surface of the powder compact was significantly reduced.
- the metal lithographic film eg, the iron salt film of the higher fatty acid
- the insulating film itself contains an element (for example, Fe) that promotes the formation of the metal stone. It is preferred to contain. Thereby, the metal stone film can be more reliably formed on the inner surface of the molding die.
- the molding temperature in the molding process is determined in consideration of the type of iron-based magnetic powder, insulating film and higher fatty acid-based lubricant, and molding pressure. Therefore, in the molding process
- “Warm” means that the molding process is performed under appropriate heating conditions according to each situation. However, in order to promote the reaction between the iron-based magnetic powder and the higher fatty acid-based lubricant, it is generally preferable to set the molding temperature to 100 ° C. or higher. Further, in order to prevent the destruction of the insulating film and the deterioration of the higher fatty acid-based lubricant, it is generally preferable to set the molding temperature to 200 ° C. or lower. It is more preferable to set the molding temperature to 120 to 180 ° C.
- the degree of “pressing” in the molding process depends on the desired properties of the dust core, iron-based magnetic powder, It is appropriately determined according to the type of the insulating film, the higher fatty acid-based lubricant, the material of the molding die, the inner surface properties, and the like.
- the manufacturing method of the present invention is used, molding can be performed under a high pressure exceeding the conventional molding pressure. For this reason, for example, the molding pressure
- the present inventor has conducted an additional test, and has found that even when the molding pressure is set to about 200 OMPa, it is possible to manufacture a dust core without any problem.
- the molding pressure is preferably set to 2000 MPa or less, more preferably to 1500 MPa or less.
- the molding pressure is 686 MP.
- the pressure for extracting the powder magnetic core from the molding die was lower when setting the pressure to a than when setting the molding pressure to 588 MPa. This was a discovery that overturned the conventional belief that the higher the molding pressure, the higher the ejection pressure.
- pressure molding was possible even when the molding pressure was increased to 98 IMPa, and discovered that iron stearate was attached to the surface of the powder compact.
- the above-mentioned molding pressure is a pressure at which the iron-based magnetic powder and the higher fatty acid-based lubricant are chemically bonded to form a metal stone coating.
- a film of metal stone for example, a film of an iron salt of a higher fatty acid such as a monomolecular film of iron stearate
- the film reduced the frictional force between the inner surface of the molding die and the press-molded body, and reduced the extraction pressure of the press-molded body.
- the present inventor performed additional tests and confirmed that when the manufacturing method of the present invention was used, the forming pressure was about 60 OMPa, and the withdrawal pressure was maximum, Above that, it was found that the withdrawal pressure was rather reduced. It was also found that even when the molding pressure was changed in the range of 900 to 200 OMPa, the ejection pressure maintained a very low value of about 5 MPa.
- the annealing step is a step of heating the powder compact obtained after the compacting step.
- the annealing step By performing the annealing step, the residual stress or strain of the powder compact is removed, and the magnetic properties can be improved. Therefore, it is preferable to perform an annealing step after the forming step.
- this annealing step preferably includes a heating step in which the heating temperature is 300 to 600 ° C. and the heating time is 1 to 300 minutes. More preferably, the heating temperature is 350 to 500 ° C and the heating time is 5 to 60 minutes.
- the heating time is less than 300 ° C, the effect of removing residual stress and strain is poor, and if it exceeds 600 ° C, the insulating film is destroyed. Also, if the heating time is less than 1 minute, the effect of removing residual stress and strain is poor, and even if heating is performed for more than 300 minutes, the effect is not further improved.
- the method for manufacturing a dust core of the present invention comprises: a coating step of coating an insulating coating on the surface of an iron-based magnetic powder; and a high-grade fatty acid-based coating on the inner surface of a molding die.
- a coating step of applying a lubricant, a filling step of filling the iron-based magnetic powder coated with the insulating film in a molding die coated with the higher fatty acid-based lubricant, and a molding die A molding step of hot-pressing the iron-based magnetic powder filled in a magnetic field, and a saturation magnetization Ms ⁇ 1.9 T in a magnetic field of 1.6 MA / m, and a specific resistance ⁇ ⁇ 1-5 ⁇ .
- the powder magnetic core of the present invention can be used for various electromagnetic devices, for example, motors, actuators, transformers, induction heaters (IH), speakers, and the like. Since the dust core of the present invention has a large specific resistance and a high magnetic permeability, it is possible to achieve high performance, miniaturization, energy saving, and the like of various devices while suppressing energy loss. For example, if this dust core is built into a fuel injection valve of an automobile engine or the like, the dust core not only has excellent magnetic properties but also has a small high-frequency loss, so that it is possible to realize high response as well as small size and high output. .
- the powder magnetic core according to the present invention in a motor such as a DC machine, an induction machine, a synchronous machine, etc., because both miniaturization and high output of the motor can be achieved.
- the present inventor performed various new additional tests as described later, but first determined the effectiveness of the manufacturing method according to the present invention. At this time, the effectiveness was mainly examined from the viewpoint of the extraction pressure when the powder compact was extracted from the molding die and the density of the obtained powder compact. This will be specifically described below.
- a raw material powder (iron-based magnetic powder) used in the production of the dust core according to the present invention a commercially available Fe powder (Heganes ABC 100.30: purity 99.8% Fe) was prepared.
- the raw material powder was used as received without any particular classification. Its particle size was about 20-180 ⁇ m.
- This Fe powder was coated with a phosphate (insulating film) (coating process).
- This coating step was carried out by mixing phosphoric acid at a ratio of 1% by mass in an organic solvent (ethanol) and immersing 1000 g of Fe powder in 20 Oml of a coating solution containing vitreous acid. After leaving it for 10 minutes in that state, it was placed in a drying oven at 420 ° C. to evaporate ethanol. Thus, a phosphate coated Fe powder was obtained.
- lithium stearate dispersed in an aqueous solution was uniformly applied to the inner peripheral surface of the heated molding die at a rate of about 1 cm 3 / sec by a spray gun (application step).
- This aqueous solution is obtained by adding a surfactant and an antifoaming agent to water.
- a surfactant polyoxyethylene nonylphenol (EO) 6, (EO) 10 and borate ester Emalbon T-80 were used, and the entire aqueous solution (100 volume) was used. %) By volume.
- EO polyoxyethylene nonylphenol
- EO EO
- borate ester Emalbon T-80 borate ester Emalbon T-80
- the lithium stearate used had a melting point of about 25 ° C and an average particle size of 2 O jum.
- the amount of the dispersion was 25 g per 100 cm 3 of the aqueous solution.
- This was further refined with a ball mill-type pulverizer (Teflon-coated steel balls: 100 hours), and the obtained stock solution was diluted 20-fold to obtain an aqueous solution having a final concentration of 1%, and was subjected to the above coating step. Provided.
- a raw material powder for the comparative material As a raw material powder for the comparative material, a commercially available Fe powder (Soma1oy500 + 0.5kenol-bu made by Häganäs) premixed with a lubricant was prepared. Then, the powder as obtained was filled in the above molding die, and was subjected to pressure molding at room temperature. Of course, an aqueous solution of lithium stearate was not applied to the inner surface of the molding die.
- the pressure molding was performed by increasing the molding pressure sequentially from 392 MPa as in the case of the example.
- the forming pressure was limited to 100 OMPa because the forming die was damaged due to galling and the like.
- FIG. 1 shows the measurement results of the extraction pressure required for extracting the powder molded body from the molding die during the powder molding of each of the above Examples and Comparative Examples.
- Fig. 2 shows the measurement results of the density (compact density) of the powder compact obtained at that time.
- the extraction pressure is a value obtained by measuring the extraction load with a load cell and dividing the extraction load by the side area of the powder compact.
- the compact density is a value measured by the Archimedes method.
- the extraction pressure is significantly lower than when the internally lubricated Fe powder is pressed at room temperature. ing.
- the best value of the extraction pressure is at most about 1 IMPa.
- the manufacturing method according to the present invention after the molding pressure shows the maximum extraction pressure at 60 OMPa, the extraction pressure decreases with the increase of the molding pressure. Furthermore, even when the molding pressure is set to a high pressure of 1000 MPa to 2000 MPa, the ejection pressure is about
- the density of the obtained powder compact monotonically increases with an increase in the molding pressure. Also, at the same molding pressure, the powder compact obtained according to the present invention has a higher compact density than the comparative material. Specifically, in the case of the powder compact according to the present invention, the molding pressure
- the density of the compact reached 7.4 x 10 3 kg / m 3 , and at a molding pressure of 140 OMPa or more, the density was 7.8 X 10 3 kg / m 3 or more. Furthermore, when the forming pressure was further increased, the density of the formed body approached the true density of pure iron, 7.86 ⁇ 10 3 kg / m 3 .
- the molding pressure is set to a considerably high pressure.
- the ejection pressure was kept low, and no galling or the like occurred on the inner surface of the molding die. It was also found that a powder compact having a remarkably high density could be obtained, depending on the molding pressure.
- a high-density dust core can be efficiently produced at low cost while extending the life of the mold.
- test pieces a ring-shaped (outer diameter: 039 mm x inner diameter 030 mm x thickness 5 mm) and a plate-shaped (5 mm x 10 mm x 55 mm), were prepared for each sample. Made.
- the aforementioned raw material powder Heganes ABC 100.30 was classified and used. Specifically, (i) Samples Nos. 1 to 11 that have a particle size of more than 105 m are used, and (ii) Samples Nos. 12 to 28 that have a particle size of 105 zm or less are used. (Iii) For sample Nos. 29 to 32, those classified to 53 m or less were used.
- Each raw material powder was coated with a phosphate (insulating film) (coating process).
- phosphoric acid was mixed in an organic solvent (ethanol) at a ratio of 1% by mass, and 1000 g of each raw material powder was immersed in 200 ml of a coating solution containing viscous force. After leaving it in that state for 10 minutes, it was placed in a drying oven at 120 ° C to evaporate ethanol.
- ethanol organic solvent
- test pieces consisting of Sample Nos. 1 to 32 shown in Tables 1 to 3 were obtained.
- Sample Nos. 33 and 34 used water atomized powder (Fe-27 mass% Co, particle size 150 / zm or less) manufactured by Daido Steel Co., Ltd.
- the water atomized powder 20% by volume and the above-mentioned: Fe powder (Heganes ABC 100.30: particle size 20 to 180 / m) 80% by volume were mixed with a ball mill type rotation. It uses a mixed powder that is uniformly mixed for 30 minutes using a mixer.
- sample No. 39 a water atomized powder (Fe-1% by mass Si, particle size of 150 m or less) manufactured by Daido Steel Co., Ltd. was used.
- the coating of the phosphate coating on each powder was carried out in the same manner as in the above-mentioned embodiment.
- test pieces shown in Tables 1 to 4 were annealed to remove strain (annealing process). This process is performed at 300 ⁇ 500 ° Cx
- test pieces of sample Nos. C1 to C4 are dust cores obtained by pressing raw material powder
- test piece of sample No. C5 is a magnetic core made of ingot. Specifically, it is as follows.
- test piece of sample No. C2 is a test piece of sample No. C1 that has been subjected to heat treatment (anneal: cooling after heating) at 275 ° C for 1 hour.
- test piece of sample No. C4 is the test piece of sample No. C3 which has been subjected to heat treatment (anneal: cooling after heating) for 30 minutes at 500 ° C.
- test piece of sample No. C5 is a magnetic core made of a commercially available electromagnetic stainless steel (Aichi Steel, AUM-25, Fe-13Cr-A1-Si), which is frequently used in factories, etc.
- the static magnetic field characteristics were measured using a direct current magnetic flux meter (manufacturer: Toei Kogyo, model number: MODEL-TRF).
- the AC magnetic field characteristics were measured using an AC B-H curve tracer (mechanical force: RIKEN ELECTRONICS, model number: ACBH-100K).
- the AC magnetic field characteristics in the table are obtained by measuring the high-frequency loss when the dust core is placed in a 800 Hz, 1.0 T magnetic field.
- the magnetic flux density in the static magnetic field indicates the magnetic flux density that can be generated when the strength of the magnetic field is sequentially changed to 0.5, 1, 2, 5, 8, and 10 kA / m. B in each table. . Shown 5k, B lk, B 2k, B 5k, B 8k, as B 1 () k.
- the saturation magnetization was obtained by processing a formed body into a plate having a size of 3 mm x 3 mm x lmm and measuring it with VSM (Toei Kogyo, VSM-35-15).
- VSM Toei Kogyo, VSM-35-15.
- the magnetic field 1.6MA
- the magnetization values (emu / g) obtained in / m were converted to T units using the density.
- the specific resistance was measured by a four-terminal method using a micro ohm meter (manufacturer: Hypertopacard (HP), model number: 3442 OA).
- the density was measured by the Archimedes method.
- test specimens of the examples shown in Tables 1 to 4 are all sufficiently dense and exhibit better magnetic and electrical properties than the test specimens of the comparative examples. Also, the mechanical strength is sufficiently high.
- the magnetic flux density B 2k , B 1C) k and the saturation magnetization Ms are improved.
- the specific resistance can be maintained larger than when annealing is performed, and high-frequency loss can be reduced.
- the present inventors newly conducted the following additional tests in order to confirm the effectiveness of the dust core obtained as described above with an actual machine.
- the pulse control time which is an index of responsiveness, was measured using a solenoid valve for hydraulic control incorporating a fixed iron core made of the above sample No. 16 added this time.
- the equipment used for this measurement mainly consists of a solenoid valve, a drive driver that performs PWM control of the solenoid valve, and a hydraulic pressure source that applies hydraulic pressure to the solenoid valve via an oil passage.
- the solenoid valve used here is a prototype prepared for this test.
- the solenoid valve basically responds to the fixed iron core, the coil wound around the bobbin and housed in the fixed iron core, and the intermittent magnetic field (alternating magnetic field) generated in the coil and the fixed iron core. It consists of a plunger (made of J IS SUYB 1) that is sucked and rejected, and a valve that opens and closes the oil hole by reciprocating the plunger.
- the fixed iron core has a cylindrical shape (035x10mm) with a U-shaped cross section, has an annular groove ( ⁇ 27mmx ⁇ 17mmx5mm) inside, and is formed by the above-described method of the present invention. Consists of a magnetic core.
- FIG. 4 shows a comparison of the pulse control times of the example and the comparative example thus obtained.
- the pulse control time is reduced to less than 1/2 compared to the comparative example which is a conventional product. In other words, it can be seen that the responsiveness of the solenoid valve is significantly improved.
- the fixed iron core of the embodiment has a high density and a high magnetic flux density, and is equivalent to that of electromagnetic soft iron. This was attributed to the attraction force and the high specific resistance of 1 l ⁇ ⁇ , which suppressed the generation of eddy currents and reduced iron loss as compared with those of soft magnetic iron.
- the powder magnetic core of the present invention it has been clarified that a high magnetic flux density can be obtained while reducing high-frequency loss. Further, by using the production method of the present invention, a dust core having excellent magnetic properties and electrical properties can be industrially mass-produced efficiently at low cost.
Description
Claims
Priority Applications (4)
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US10/466,101 US6903641B2 (en) | 2001-01-19 | 2002-01-17 | Dust core and method for producing the same |
CA002435149A CA2435149C (en) | 2001-01-19 | 2002-01-17 | Powder magnetic core and processes for producing the same |
EP02716314A EP1353341B1 (en) | 2001-01-19 | 2002-01-17 | Dust core and method for producing the same |
JP2002558286A JP3815563B2 (ja) | 2001-01-19 | 2002-01-17 | 圧粉磁心およびその製造方法 |
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JP2001012157 | 2001-01-19 | ||
JP2001-12157 | 2001-01-19 |
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WO2002058085A1 true WO2002058085A1 (fr) | 2002-07-25 |
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PCT/JP2002/000296 WO2002058085A1 (fr) | 2001-01-19 | 2002-01-17 | Noyau agglomere et procede de production dudit noyau |
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US (1) | US6903641B2 (ja) |
EP (1) | EP1353341B1 (ja) |
JP (1) | JP3815563B2 (ja) |
CA (1) | CA2435149C (ja) |
WO (1) | WO2002058085A1 (ja) |
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US7029769B2 (en) | 2002-03-20 | 2006-04-18 | Kabushiki Kaisha Toyota Chuo Kenkyusho | Insulation film, powder for magnetic core and powder magnetic core and processes for producing the same |
JP2005146315A (ja) * | 2003-11-12 | 2005-06-09 | Toyota Central Res & Dev Lab Inc | 磁心用粉末、圧粉磁心およびそれらの製造方法 |
WO2006035911A1 (ja) * | 2004-09-30 | 2006-04-06 | Sumitomo Electric Industries, Ltd. | 軟磁性材料、圧粉磁心、および軟磁性材料の製造方法 |
WO2007023627A1 (ja) * | 2005-08-25 | 2007-03-01 | Sumitomo Electric Industries, Ltd. | 軟磁性材料、圧粉磁心、軟磁性材料の製造方法、および圧粉磁心の製造方法 |
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US20230130266A1 (en) * | 2021-10-21 | 2023-04-27 | Tdk Corporation | Soft magnetic alloy powder, dust core, and magnetic device |
Also Published As
Publication number | Publication date |
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CA2435149C (en) | 2008-02-12 |
US20040061582A1 (en) | 2004-04-01 |
US6903641B2 (en) | 2005-06-07 |
JPWO2002058085A1 (ja) | 2004-05-27 |
EP1353341A4 (en) | 2007-10-31 |
CA2435149A1 (en) | 2002-07-25 |
JP3815563B2 (ja) | 2006-08-30 |
EP1353341A1 (en) | 2003-10-15 |
EP1353341B1 (en) | 2012-09-26 |
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