WO2006054749A1 - 低損失Mn-Znフェライト及びこれを用いた電子部品並びにスイッチング電源 - Google Patents
低損失Mn-Znフェライト及びこれを用いた電子部品並びにスイッチング電源 Download PDFInfo
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- WO2006054749A1 WO2006054749A1 PCT/JP2005/021385 JP2005021385W WO2006054749A1 WO 2006054749 A1 WO2006054749 A1 WO 2006054749A1 JP 2005021385 W JP2005021385 W JP 2005021385W WO 2006054749 A1 WO2006054749 A1 WO 2006054749A1
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- loss
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- ferrite
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- 229910000859 α-Fe Inorganic materials 0.000 title claims abstract description 91
- 230000005291 magnetic effect Effects 0.000 claims abstract description 60
- 239000013078 crystal Substances 0.000 claims abstract description 56
- 230000004907 flux Effects 0.000 claims abstract description 39
- 239000002184 metal Substances 0.000 claims abstract description 15
- 229910052751 metal Inorganic materials 0.000 claims abstract description 15
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 9
- 229910052742 iron Inorganic materials 0.000 claims abstract description 7
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 7
- 150000002739 metals Chemical class 0.000 claims abstract description 4
- 230000035699 permeability Effects 0.000 claims description 19
- 229910052715 tantalum Inorganic materials 0.000 claims description 11
- 229910052735 hafnium Inorganic materials 0.000 claims description 10
- 229910052758 niobium Inorganic materials 0.000 claims description 10
- 229910052718 tin Inorganic materials 0.000 claims description 10
- 229910052719 titanium Inorganic materials 0.000 claims description 10
- 229910052720 vanadium Inorganic materials 0.000 claims description 10
- 229910052726 zirconium Inorganic materials 0.000 claims description 10
- 239000004071 soot Substances 0.000 claims description 2
- 230000001747 exhibiting effect Effects 0.000 abstract description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 abstract 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 abstract 2
- 229910000019 calcium carbonate Inorganic materials 0.000 abstract 2
- 235000010216 calcium carbonate Nutrition 0.000 abstract 2
- UBEWDCMIDFGDOO-UHFFFAOYSA-N cobalt(II,III) oxide Inorganic materials [O-2].[O-2].[O-2].[O-2].[Co+2].[Co+3].[Co+3] UBEWDCMIDFGDOO-UHFFFAOYSA-N 0.000 abstract 1
- 229910052681 coesite Inorganic materials 0.000 abstract 1
- 229910052906 cristobalite Inorganic materials 0.000 abstract 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 abstract 1
- 239000000377 silicon dioxide Substances 0.000 abstract 1
- 235000012239 silicon dioxide Nutrition 0.000 abstract 1
- 229910052682 stishovite Inorganic materials 0.000 abstract 1
- PBCFLUZVCVVTBY-UHFFFAOYSA-N tantalum pentoxide Inorganic materials O=[Ta](=O)O[Ta](=O)=O PBCFLUZVCVVTBY-UHFFFAOYSA-N 0.000 abstract 1
- 229910052905 tridymite Inorganic materials 0.000 abstract 1
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 38
- 239000000203 mixture Substances 0.000 description 20
- 229910021645 metal ion Inorganic materials 0.000 description 15
- 238000010304 firing Methods 0.000 description 11
- 230000001965 increasing effect Effects 0.000 description 11
- 238000005259 measurement Methods 0.000 description 11
- 230000007423 decrease Effects 0.000 description 10
- 239000011029 spinel Substances 0.000 description 10
- 229910052596 spinel Inorganic materials 0.000 description 10
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 9
- 229910052760 oxygen Inorganic materials 0.000 description 9
- 239000001301 oxygen Substances 0.000 description 9
- 238000002844 melting Methods 0.000 description 7
- 230000008018 melting Effects 0.000 description 7
- 238000000034 method Methods 0.000 description 6
- 239000011261 inert gas Substances 0.000 description 5
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- 238000005245 sintering Methods 0.000 description 4
- 230000002159 abnormal effect Effects 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 3
- 239000012535 impurity Substances 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- 238000004804 winding Methods 0.000 description 3
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- 241001201614 Prays Species 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000000460 chlorine Substances 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 238000011160 research Methods 0.000 description 2
- 238000007088 Archimedes method Methods 0.000 description 1
- 238000012935 Averaging Methods 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- 229910018605 Ni—Zn Inorganic materials 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 229910052801 chlorine Inorganic materials 0.000 description 1
- 230000002301 combined effect Effects 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 235000019800 disodium phosphate Nutrition 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 230000005674 electromagnetic induction Effects 0.000 description 1
- 238000002003 electron diffraction Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 230000001939 inductive effect Effects 0.000 description 1
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- 230000010354 integration Effects 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 230000005389 magnetism Effects 0.000 description 1
- 239000002075 main ingredient Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 238000010295 mobile communication Methods 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
Classifications
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B35/26—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on ferrites
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Definitions
- the present invention relates to an Mn-Zn flight used for electronic components such as transformers and choke coils such as switching power supplies, and in particular, has low power loss at a high frequency of 1 MHz or more, and power loss (core loss) has temperature dependency.
- the present invention relates to a small Mn-Zn ferrite, an electronic component having a strong Mn-Zn ferrite, and a switching power supply.
- Switching power supplies are used in various circuits that require power supply.
- a DC-DC converter is mounted next to a DSP (Digital Signal Processor), MPU (Micro-Processing Unit), etc. Yes.
- DSP Digital Signal Processor
- MPU Micro-Processing Unit
- LSIs Large-scale Integration
- DC-DC converters have been responding to lower output voltages and higher currents. Since a drop in operating voltage leads to unstable operation of the LSI against fluctuations in output voltage (ripple), measures are taken to increase the switching frequency of the DC-DC converter.
- Inductive elements such as transformers and choke coils are used in switching power supply circuits. Higher switching frequency reduces the number of wires in the ferrite core that make up the inductance element. Therefore, the power of reducing the switching power supply circuit size and reducing copper loss is also preferred. From this point of view, the switching frequency is expected to be higher.
- Switching power supply circuits are used in various environments such as mounted on EVs (electric vehicles), HEVs (hybrid electric vehicles), etc., and mounted on mobile communication devices such as mobile phones.
- the environmental temperature and the load state change variously.
- the switching power supply circuit may reach nearly 100 ° C due to the heat generated by other peripheral circuits and the ambient temperature.
- the switching power supply circuit has a high frequency and various environments. Therefore, the ferrite core in the core is also required to have a low power loss at a high frequency, a wide temperature range and an operating magnetic flux density range, and to be hard to be magnetically saturated to a high current value.
- Freight power loss includes eddy current loss, hysteresis loss, and residual loss.
- Eddy current loss occurs due to the electromotive force generated by the eddy current generated by electromagnetic induction, and increases in proportion to the square of the frequency.
- Hysteresis loss is caused by DC hysteresis and increases in proportion to the frequency.
- Residual loss is the remaining loss, which is caused by domain wall resonance, natural resonance, diffusion resonance, and the like. It is well known that power loss behaves in a quadratic curve with respect to temperature and is usually minimized when the magnetocrystalline anisotropy constant K is zero.
- K is 0
- the temperature at which 1 1 is reached is also the temperature at which the initial permeability i is maximized, and is also called the secondary peak of the initial permeability / zi.
- An Mn-Zn ferrite core having a high saturation magnetic flux density is used in the switching power supply circuit so as to have low power loss under various environments.
- Fe 0 exceeds 50 mol%
- the Mn-Zn ferrite has a significantly lower volume resistivity than the Ni-Zn ferrite due to the presence of Fe 2+ in the spinel. As the switching frequency increases, the power loss due to eddy current loss increases. Therefore, there is a problem that the efficiency of the switching power supply circuit having Mn-Zn ferrite decreases as the frequency increases.
- the Mn-Zn flight has been reduced to some extent by a low power loss. Since the efficiency of the switching power supply is greatly influenced by the power loss of the ferrite core, to further increase the efficiency of the switching power supply, the low power loss key of the ferrite core is required.
- the switching frequency of switching power supplies has been increased from 1 MHz to 2 MHz, and even higher frequencies of about 4 MHz have been proposed. At present, the switching frequency is high and the loss is low over a wide temperature range.
- An Mn-Zn ferrite that satisfies the requirements for high saturation magnetic flux density is desired.
- the conventional Mn-Zn ferrite cannot satisfy these requirements.
- the object of the present invention is to achieve low power loss over a wide temperature range and operating magnetic flux density and high saturation magnetic flux density even at a high frequency of 1 MHz or higher, particularly 2 MHz or higher.
- Another object of the present invention is to provide an electronic component such as a transformer coil using such a low-loss Mn-Zn ferrite.
- Yet another object of the present invention is to provide a switching power supply having such an electronic component.
- the low-loss Mn-Zn ferrite of the present invention includes at least one of Fe, Mn, and Zn as main components, Co, Ca, and Si as first subcomponents, and a Va group metal as a second subcomponent. Containing, before The total amount of the main components is 100 mol%, 53 to 56 mol% in terms of Fe force Fe 0, Zn is converted to ZnO
- the quantity ratio is 2 or more in terms of CaCO and SiO, respectively, and Ta is Ta 0
- the Va group metal is at least one selected from the group force consisting of Ta, Nb, and V, and the total amount of the Va group metal is Ta 0, Nb 0 on a mass basis with respect to the total amount of the main components.
- the low-loss Mn-Zn ferrite of the present invention contains at least one kind selected from the group force consisting of Zr, Hf, Sn and Ti as a third subcomponent, and is based on the total amount of the main components.
- Zr is converted to 1500 ppm or less in terms of ZrO
- Sn is converted to SnO
- Ti 2 2 2 2 is preferably 10000 ppm or less, and Ti is preferably 10000 ppm or less in terms of soot.
- the low loss Mn-Zn flight of the present invention preferably has an initial permeability ⁇ i at 100 kHz and 20 ° C. of 400 or more and a saturation magnetic flux density Bm at 100 ° C. of 400 mT or more. .
- the low-loss Mn-Zn ferrite of the present invention has 54 to 55 mol of Fe as the main component in terms of Fe 0.
- Ta is 500-2000 ppm in terms of Ta 0, frequency 2 MHz and magnetic flux density
- power loss Pcv at 20 m to 120 ° C. at 50 mT is 1500 kW / m 3 or less.
- Si is 40 ppm or more in terms of SiO, Ca force CaCO
- SiO and CaCO is preferably 750 ppm or more.
- the low-loss Mn-Zn ferrite of the present invention preferably contains at least one kind of Group I metal oxide together with Si and Ca in the grain boundary layer. It is also preferable that at least one of Zr, Hf, Sn and Ti be dissolved in the crystal grains! /.
- the average crystal grain size is preferably 1.0 ⁇ m to 3.0 ⁇ m. In order to achieve low loss even at a high operating magnetic flux density (50 mT), the average crystal grain size is preferably 1.2 m to 3.0 ⁇ m.
- the electronic component of the present invention is characterized in that the low-loss Mn-Zn ferrite is used as a magnetic core, and a winding is applied to the magnetic core.
- the switching power supply according to the present invention is characterized in that the electronic component is used as a transformer and Z or a choke coil.
- the low-loss Mn-Zn ferrite of the present invention has a low power loss over a wide temperature range and operating magnetic flux density, and a high saturation magnetic flux density even at a high frequency of 1 MHz or higher, particularly 2 MHz. For this reason, the switching power supply having electronic components such as a transformer and a choke coil using the low-loss Mn-Zn ferrite of the present invention can operate with high efficiency, and the mounted electronic device can be reduced in size and reduced in consumption. It can be electric power.
- FIG. 1 is a TEM photograph showing a crystal structure of Mn—Zn ferrite according to an example of the present invention.
- FIG. 2 is a perspective view showing a U-type magnetic core using Mn—Zn ferrite according to one embodiment of the present invention.
- FIG. 3 is a perspective view showing a transformer in which a U-type magnetic core using Mn-Zn ferrite according to an embodiment of the present invention is wire-bonded and combined with an I-type magnetic core.
- FIG. 4 is a block diagram showing a circuit of a DC-DC converter having the transformer shown in FIG. BEST MODE FOR CARRYING OUT THE INVENTION
- power loss Pcv is given by the following formula (1):
- Hysteresis loss Ph is determined solely by the saturation magnetism and coercivity of Mn-Zn ferrite, and increases in proportion to the frequency.
- Eddy current loss Pe is proportional to the square of crystal grain size Z2 and the square of frequency, and inversely proportional to volume resistivity. Residual loss Pr becomes apparent at frequencies above 500 kHz.
- Hysteresis loss Ph, eddy current loss Pe, and residual loss Pr vary depending on the frequency used, and the ratio of each loss in the total power loss varies depending on the frequency band. Therefore, in order to reduce power loss, it is necessary to reduce power loss according to the frequency used as well as reducing each loss.
- a suitable composition and microstructure that is wide even at high frequencies of 1 MHz or higher, especially 2 MHz or higher, has low power loss in the temperature range, and has high saturation magnetic flux density.
- the amount of metal ion exhibiting 1 and the metal ion exhibiting negative magnetocrystalline anisotropy constant ⁇ are appropriately determined.
- the temperature at which the power loss of ferrite is minimized varies depending on the composition of metal ions in the ferrite.
- the total amount of crystal magnetic anisotropy constant K of metal ions is determined by the composition of metal ions.
- the total amount of ⁇ determines the magnetic anisotropy of the entire ferrite.
- Fe 2+ and other metal ions increase or decrease.
- ferrite for electronic components such as choke coils and transformers has a magnetocrystalline anisotropy constant K ⁇ 0 on the low temperature side in the temperature range to be used.
- the composition has a temperature at which the power loss is minimized.
- Co 2+ has a larger magnetocrystalline anisotropy constant and magnetostriction constant than other metal ions.
- the composition of the Mn-Zn ferrite of the present invention is 100 mole 0/0, respectively Fe 0, Mn 0 and terms of ZnO Fe, the total amount of Mn and Zn as main components , Fe 5
- the mass ratio of Ca and Si is 2 or more in terms of CaCO and SiO, respectively, and
- Ta was 250 ppm or more in terms of Ta 0.
- the magnetocrystalline anisotropy constant K is low.
- the temperature dependence was improved by reducing 2 5 1.
- the power loss Pcv from 0 ° C to 120 ° C was 350 kW / m 3 or less at a frequency of 2 MHz and a magnetic flux density of 25 mT.
- the average crystal grain size is less than 3.2 ⁇ m, especially 1.2 ⁇ m to 3 ⁇ m
- the volume resistivity p is 1 ⁇ 'm or more
- the initial permeability i at 100 kHz and 20 ° C is 400 or more
- the saturation magnetic flux density Bm at ° C is preferably 400 mT or more
- the Curie temperature Tc is preferably 200 ° C or more.
- the resonance frequency of the initial permeability is set higher than the operating frequency of the switching power supply.
- the operating frequency power of the switching power supply is 3 ⁇ 4 MHz. Therefore, the composition and permeability of the flight are selected so that the resonance frequency is 4 MHz or more and the domain wall resonance frequency is 8 MHz or more.
- the Mn-Zn ferrite of the present invention contains a first subcomponent consisting of Co, Ca, and Si.
- Si and Ca are impurities contained in the raw material.
- Si and Ca contained in the Mn-Zn ferrite are within a predetermined range, and Si and Ca are contained in the ferrite sintered body.
- the volume resistivity P is increased by making it exist at the grain boundary and insulating the crystal grains.
- Si and Ca are iron oxide and low melting point complex oxide (2FeO SiO,
- the amount of addition can inhibit densification of the ferrite sintered body, increase the crystal grain size, and broaden the distribution.
- the formation of a low-melting-point composite oxide can be prevented by a composite additive with Ta or the like.
- Ca also helps prevent low melting point metals from evaporating during sintering.
- Si is 40 ppm or more in terms of SiO and Ca is 3000 ppm or less in terms of CaCO.
- the total of SiO and CaCO is 750 ppm or more, and the mass ratio of CaCO and SiO is 2 or more.
- the crystal grain boundary is very thin and its crystal state is difficult to confirm.
- CaCO / Mn-Zn Ferri with a total of SiO and CaCO of 750 ppm or more.
- SiO and CaCO are more than the above range, abnormal sintering such as abnormal growth of crystal grains may occur.
- Mn-Zn ferrite that is easy to occur and low loss and / or low loss is difficult to obtain.
- volume resistivity p decreases due to the occurrence of a typical defect.
- Si is difficult to dissolve in the spinel phase, and is ubiquitous exclusively at grain boundaries and triple points.
- Ca is also segregated at the grain boundaries and triple points. Ca is dissolved in the spinel phase during the firing process, and part of the Ca is dissolved and remains in the crystal grains after firing. When the amount of Ca dissolved in the spinel phase increases, naturally the Ca in the grain boundary layer decreases, and in some cases it is insufficient. On the other hand, Ca dissolved in the spinel phase causes a decrease in Fe 2+ in the spinel. Since Fe 2+ decreases as the amount of Ca dissolved increases, volume resistivity p can be increased by increasing the resistance in the crystal grains.
- Ca is dissolved in the spinel phase to reduce Fe 2+ and Ca dissolved in the spinel phase. It is effective to adjust so that the amount of Ca segregated at the crystal grain boundary increases to increase the resistance within the crystal grain and to form a high-resistance crystal grain boundary.
- the mass ratio of Ca and Si must be 2 or more in terms of CaCO and SiO, respectively.
- the power loss Pcv at 0 to 120 ° C at a frequency of 2 MHz and a magnetic flux density of 25 mT is set to 350 kW / m 3 or less, and further at a frequency of 2 MHz and a magnetic flux density of 50 mT at 20 to 120 ° C.
- Co is preferably 1000 to 5000 ppm in terms of Co 0, more preferably 2000 to 5000 ppm.
- Ca is preferably 500 to 3000 ppm in terms of CaCO. 600 to 2500 ppm
- Si is preferably 40-700 ppm in terms of SiO 50-600 pp
- the total of SiO and CaCO is preferably 1000 ppm or more.
- CaCO 3 / SiO is preferably 10 or more.
- the Mn-Zn ferrite of the present invention contains at least one group Va metal as a second subcomponent.
- Va group metal is at least one selected from the group power consisting of Ta, Nb and V.
- the Va group metal enters the grain boundary layer together with Si and Ca, and reduces the power loss by increasing the resistance of the grain boundary layer.
- Ta is preferable because it has a higher melting point than Nb and V, and can effectively prevent lowering of the melting point due to oxides of Ca and Si and Fe.
- the total of Ta, Nb and V is preferably 250 to 2000 ppm in terms of Ta 0, Nb 0 and V 0 on a mass basis, respectively 500 to 2000 pp
- the total amount of Ta, Nb and V exceeds 2000 ppm, power loss Increases, and the initial permeability / zi decreases, which is not preferable. If the total amount of Ta, Nb and V is less than 250 ppm, the effect of reducing power loss cannot be exhibited effectively.
- the Ta oxide has a higher melting point than the Nb oxide, it is effective in forming a grain boundary layer.
- Ta and Nb have a uniform crystal structure by suppressing the growth of crystal grains, and are effective in reducing power loss.
- V is effective in improving the workability of the sintered body and suppressing the occurrence of chipping and the like.
- V oxide has a melting point and a lower melting point than those of Ta and Nb oxides, and has the function of promoting the growth of crystal grains. For this reason, V is preferably 300 ppm or less in terms of V0.
- Ta is preferably 250 ppm or more in terms of Ta 0, more preferably 500 to 2000 ppm.
- Nb and V are preferably 300 ppm or less in terms of Nb 0 and V 0, respectively.
- the Mn-Zn ferrite of the present invention may further contain at least one selected from the group force consisting of Zr, Hf, Sn and Ti as a third subcomponent.
- Zr, Hf, Sn, and Ti become tetravalent stable metal ions in the ferrite and dissolve together with Ca in the crystal grains to increase volume resistivity and reduce power loss Pcv.
- at least one additive of Zr, Hf, Sn, and Ti changes Mn 3+ in the spinel to Mn 2+ and improves the initial permeability / zi.
- at least one of Zr, Hf, Sn, and Ti may have a part of the force that exists exclusively in the crystal grains.
- Zr, Hf, Sn and Ti are masses in terms of ZrO, HfO, SnO and TiO, respectively.
- the standard is preferably 1500 ppm or less, 1500 ppm or less, 10000 ppm or less, and 10000 ppm or less, more preferably 1000 ppm or less, 1000 ppm or less, 5000 ppm or less, and 5000 ppm or less. If the contents of Zr, Hf, Sn and Ti exceed the above upper limits, abnormal grain growth is likely to occur, and power loss is deteriorated and saturation magnetic flux density is lowered.
- Raw materials constituting the flight include impurities such as sulfur S, chlorine Cl, phosphorus P, and boron B. By reducing these impurities, power loss can be reduced and magnetic permeability can be improved.
- S forms a compound with Ca and prays as a foreign substance at the grain boundary, which may decrease volume resistivity p and increase eddy current loss. Therefore, to further reduce power loss, S is 300 ppm or less, C1 is 100 ppm or less, P is 10 ppm or less on a mass basis, And B is preferably 1 ppm or less.
- the Mn-Zn ferrite of the present invention when the average crystal grain size is reduced to less than 3.2 ⁇ m and the crystal grain size is made uniform, the eddy current loss is reduced and the refinement of crystal grains is reduced. As a result, the domain wall is reduced, and the residual loss due to domain wall resonance is reduced.
- the calcined fluff powder to be fired is refined to an average crystal grain size of less than 1 ⁇ m and fired with the desired subcomponent composition and conditions. Do it.
- the ferrite calcined powder is refined, the ferrite can be densified even at a low firing temperature (for example, less than 1200 ° C), so that the crystal grain size in the obtained ferrite sintered body becomes small and uniform.
- Mn-Zn ferrite according to an embodiment of the present invention, 54-55 mole 0/0 of Fe (Fe 0 conversion
- a first subcomponent consisting of ppm Ca (CaCO equivalent) Ca and 40-700 ppm (SiO equivalent) Si
- Power loss Pcv is less than 1500 kW / m 3 at a frequency of 2 MHz and a magnetic flux density of 50 mT, and a large operating magnetic field. Even if given, the loss is low.
- the volume resistivity p is 1 ⁇ 'm or more, preferably 2 ⁇ 'm or more, and the initial permeability / at 100 kHz and 20 ° C zi is preferably 500 or more, and the saturation magnetic flux density Bm at 100 ° C. is preferably 400 mT or more.
- the power loss Pcv at 0 ° C to 120 ° C at a frequency of 2 MHz and a magnetic flux density of 25 mT is preferably 300 kW / m 3 or less, and 20 ° C to 120 ° at a frequency of 2 MHz and a magnetic flux density of 50 mT.
- the power loss Pcv in C is preferably 1200 kW / m 3 or less, more preferably 1000 kW / m 3 or less.
- a preferable firing step is, for example, raising the temperature in the atmosphere to a room temperature of 900 ° C, replacing the air in the furnace with an inert gas such as N at 900 ° C, and raising the temperature to 1150 ° C. With a holding process of 1150 ° C
- the oxygen concentration in the inert gas in the holding step is preferably 0.3 to 1.5%. Note that the above temperatures are merely examples and do not limit the present invention.
- the rate of temperature decrease from the holding temperature to 600 ° C. is preferably selected as appropriate depending on the composition within the range of 150 to 500 ° C./hr, although it depends on the content ratio of subcomponents such as Ca and Si.
- polybure alcohol was added as a binder and granulated with a spray dryer.
- the granules were formed into a predetermined shape and then fired to obtain a toroidal magnetic core having an outer diameter of 14 mm, an inner diameter of 7 mm, and a thickness of 5 mm.
- Firing was performed in the following two patterns.
- firing pattern A the temperature is raised from room temperature to 900 ° C in the atmosphere, the atmosphere in the firing furnace is replaced with N at 900 ° C, and the temperature is raised to 1150 ° C in N.
- the oxygen concentration in the N atmosphere was set at 0.5% and held at 1150 ° C. for 4 hours. Then 1150
- the temperature is lowered at an equilibrium oxygen partial pressure at a cooling rate of 100 ° C / hr, and below 900 ° C is N
- Firing pattern B was the same as Firing pattern A except that the oxygen concentration in the N atmosphere in the holding process was 0.1%.
- Table 1 shows the contents of main components and subcomponents and firing patterns of each sample. Sample 1 -4, 7, 9-11 are within the scope of the present invention, and samples 5, 6, 8, and 12-15 (with * after the sample number) are outside the scope of the present invention.
- Measurement was performed using a multimeter.
- Etch the sample with concentrated hydrochloric acid take a scanning electron microscope (SEM) photograph (3000 times) of the surface, draw five straight lines with a length equivalent to 30 m on the photograph, and It was determined by averaging the particle size.
- SEM scanning electron microscope
- Table 2 shows the measurement results for each characteristic.
- FIG. 1 is a TEM photograph showing the structure of grain boundary triple points and grain boundaries of Sample 10 within the scope of the present invention.
- 1 and 2 indicate the main layer
- 3 indicates the grain boundary triple point.
- a grain boundary layer with a uniform thickness of about 2 to 3 nm wrapped the crystal grains.
- Sample 10 had very low power loss.
- Sample 13 outside the scope of the present invention with a small amount of added Ca and Si was observed by TEM, and the grain boundary layer was clearly recognized.
- the volume resistivity of sample 12 was 0.7 ⁇ ⁇ ⁇ , and the power loss was much lower than 350 kW / m 3 at all measured temperatures from 0 to 140 ° C.
- Samples 1 to 4, 7, and 9 to 11 within the scope of the present invention had an average crystal grain size of 1.9 to 2.9 ⁇ m.
- Sample 8 containing a large amount of Ca had an average crystal grain size of 3.2 m. As the particle size increased, eddy current loss and residual loss increased, and power loss increased.
- Samples 1 to 4, 7, and 9 to 11 within the scope of the present invention are compared with Samples 5, 6, 8, and 12 to 15 outside the scope of the present invention in a temperature range of 0 to 120 ° C.
- Samples 3 and 10 had low power loss Pcv at 253 kW / m 3 and 257 kW / m 3 at 140 MHz.
- Such low power loss at high temperatures and reduction of the temperature dependence of power loss Pcv are suitable for electronic components (for example, for automobiles) exposed to various temperatures from low to high.
- Other samples within the scope of the present invention also had a temperature between 20-100 ° C where power loss was minimized.
- the Mn-Zn flight within the scope of the present invention had low power loss in a wider temperature range than that outside the scope of the present invention.
- the Mn-Zn ferrite within the scope of the present invention had a saturation magnetic flux density of more than 400 mT at 100 ° C.
- Table 3 shows the saturation magnetic flux density, residual magnetic flux density, and holding force of Sample 9.
- the Mn-Zn ferrite of the present invention has a high saturation magnetic flux density even at high temperatures, so it does not easily magnetically saturate even at high temperatures and has excellent DC superposition characteristics when used in a choke coil. can get.
- Mn-Zn ferrite toroidal cores having the compositions shown in Table 4 were produced in the same manner as in Example 1. Baking followed pattern A. [0074] Table 4
- the power loss Pcv, initial permeability ⁇ i, loss coefficient tan h / ix density, volume resistivity p, and average crystal grain size were measured in the same manner as in Example 1.
- the measurement conditions for power loss Pcv were 1 MHz and 50 mT, and 2 MHz and 50 mT, respectively, and the measurement temperatures were 20 ° C, 60 ° C, 80 ° C, 100 ° C, and 120 ° C. .
- Table 5 shows the measurement results.
- each sample consisted of an amorphous phase.
- the thickness of the grain boundary layer was several nm.
- the grain boundary triple point and grain boundary layer contained Ta and V together with Ca and Si.
- the volume resistivity p of each sample was 1 ⁇ 'm or more.
- Co is added to the main components (Fe, Mn and Zn).
- Samples 17 to 28 containing 2000 to 5000 ppm in terms of O have a frequency of 2 MHz and a magnetic flux density of 50.
- power loss Pcv from 20 ° C to 120 ° C was significantly lower than 1500 kW / m 3 .
- the power loss was sufficiently low even at a frequency of 1 MHz and a magnetic flux density of 50 mT.
- the power loss was large between ° C and 120 ° C, and the power loss Pcv above 100 ° C was more than 1500 kW / m 3 .
- the average crystal grain size was 1.1 ⁇ m.
- the average crystal grain size should not be too small.
- the power loss at a frequency of 2 MHz and a magnetic flux density of 25 mT may not be sufficiently low.
- the average crystal grain size is preferably 1.0 ⁇ m to 3 ⁇ m. More preferably, it is 1.2 ⁇ m to ⁇ 3 ⁇ m ".
- a toroidal magnetic core of Mn—Zn ferrite having the composition shown in Table 6 was produced in the same manner as in Example 1. Baking followed pattern A.
- the grain boundary triple point was formed from an amorphous phase.
- the thickness of the grain boundary layer was several nm. All samples contained Ta and V together with Ca and Si at the grain boundary triple point and at the grain boundary.
- the volume resistivity of each sample is 1 ⁇ 'm or more, the loss factor tan ⁇ / ⁇ i is 5.0 X 10 _6 or less, and the density ds is 4.80 X 10 3 kg / m 3 or more. Except for 24, the average crystal grain size was 1.4 to 1.6 / zm.
- the power loss at 1 MHz and 50 mT was less than 350 kW / m 3 at all temperatures from 20 to 120 ° C.
- Sample 29 with Fe 0 force less than 4.0 mol% has a frequency of 2 MHz and In addition, the power loss at 20 ° C to 120 ° C was large at a magnetic flux density of 50 mT, and the power loss Pcv at 100 ° C or higher was more than 1500 kW / m 3 . Sample 29 has an average crystal grain size of 1.1 ⁇ m.
- a toroidal magnetic core of Mn—Zn ferrite having the composition shown in Table 8 was produced in the same manner as in Example 1. Baking followed pattern A.
- the loss was well over 1500 kW / m 3 .
- FIG. 2 shows a U core 1 made of the Mn-Zn ferrite of the present invention and having outer dimensions of a width of 3.8 mm, a length of 5.0 mm, and a height of 4.5 mm.
- the low-loss Mn-Zn ferrite of the present invention has a low power loss over a wide temperature range, a wide operating magnetic flux density, and a high saturation magnetic flux density even at a frequency of 1 MHz or higher, particularly 2 MHz.
- Is suitable for magnetic cores of electronic parts such as transformers and choke coils. Switching power supplies with electronic parts having such Mn-Zn ferrite magnetic cores can operate with high efficiency, and the mounted electronic devices can be made compact. Power consumption can be reduced.
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Abstract
Description
Claims
Priority Applications (3)
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JP2006545197A JPWO2006054749A1 (ja) | 2004-11-19 | 2005-11-21 | 低損失Mn−Znフェライト及びこれを用いた電子部品並びにスイッチング電源 |
US11/718,792 US7790053B2 (en) | 2004-11-19 | 2005-11-21 | Loss-loss Mn-Zn ferrite and electronic part made thereof and switching power supply |
EP05809433A EP1816111A4 (en) | 2004-11-19 | 2005-11-21 | LOSS-RELIABLE MN-ZN-FERRITE AND THIS USE ELECTRONIC COMPONENT, ELECTRONIC COMPONENT AND SWITCHGEAR |
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JP2004335530 | 2004-11-19 | ||
JP2004-335530 | 2004-11-19 |
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WO2006054749A1 true WO2006054749A1 (ja) | 2006-05-26 |
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PCT/JP2005/021385 WO2006054749A1 (ja) | 2004-11-19 | 2005-11-21 | 低損失Mn-Znフェライト及びこれを用いた電子部品並びにスイッチング電源 |
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US (1) | US7790053B2 (ja) |
EP (1) | EP1816111A4 (ja) |
JP (1) | JPWO2006054749A1 (ja) |
KR (1) | KR20070084472A (ja) |
CN (1) | CN100528802C (ja) |
WO (1) | WO2006054749A1 (ja) |
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- 2005-11-21 KR KR1020077011632A patent/KR20070084472A/ko not_active Application Discontinuation
- 2005-11-21 CN CNB2005800396309A patent/CN100528802C/zh not_active Expired - Fee Related
- 2005-11-21 EP EP05809433A patent/EP1816111A4/en not_active Withdrawn
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Also Published As
Publication number | Publication date |
---|---|
CN101061080A (zh) | 2007-10-24 |
CN100528802C (zh) | 2009-08-19 |
US20080007377A1 (en) | 2008-01-10 |
US7790053B2 (en) | 2010-09-07 |
EP1816111A1 (en) | 2007-08-08 |
EP1816111A4 (en) | 2011-12-28 |
JPWO2006054749A1 (ja) | 2008-06-05 |
KR20070084472A (ko) | 2007-08-24 |
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