Classifications

• • 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
  • H01F1/26—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 by macromolecular organic substances
• • 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
• • 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
  • B22F1/16—Metallic particles coated with a non-metal
• • 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
  • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
  • B22F3/24—After-treatment of workpieces or articles
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C33/00—Making ferrous alloys
  • C22C33/02—Making ferrous alloys by powder metallurgy
• • 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
• • 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
  • B22F2998/10—Processes characterised by the sequence of their steps
• • 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
  • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
• • 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
• • 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
  • H01F1/33—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 mixtures of metallic and non-metallic particles; metallic particles having oxide skin

Definitions

• the present invention generally relates to a soft magnetic material and a dust core, and more particularly to a soft magnetic material and a dust core including a plurality of metal magnetic particles covered with an insulating film.
• the metal magnetic material is that having a high saturation magnetic flux density and magnetic permeability, since the electrical resistivity is low (10- 6 ⁇ 10- 4 Q cm) , a large eddy current loss in middle and high frequency range. For this reason, the magnetic properties are deteriorated and it is difficult to use the single substance.
• the metal oxide magnetic material has a higher electrical resistivity (1 ⁇ : L0 8 ⁇ cm) than the metal magnetic material, so that the eddy current loss is small and the magnetic characteristics are less deteriorated in the middle and high frequency range.
• the saturation magnetic flux density of the metal oxide magnetic material is 1Z3 ⁇ : LZ2 of the saturation magnetic flux density of the metal magnetic material, there is a limit to applications. Considering the actual situation, by combining metal magnetic material and metal oxide magnetic material, high saturation magnetic flux density, high magnetic permeability, high electrical resistivity, which compensate for the disadvantages of both, are achieved.
• a composite magnetic material is proposed.
• Patent Document Japanese Patent Publication No. 10-503807
• a composite magnetic material is obtained by bonding a plurality of composite magnetic particles having an iron phosphate film formed on the surface of iron powder with organic substances such as polyphenylene ether or polyetherimide and an amide oligomer. A method of forming is disclosed! Speak.
• Patent Document 1 Japanese Patent Publication No. 10-503807
• the composite magnetic material When a composite magnetic material is used in the control mechanism of an automobile engine, the composite magnetic material is required to have heat resistance because the engine that has only the above-described magnetic characteristics becomes high temperature.
• the soft magnetic material disclosed in 1) has a problem that the mechanical strength at high temperature is not sufficient.
• the present invention has been made to solve the above-described problems, and provides a soft magnetic material and a powder magnetic core having excellent bending strength even at high temperatures. The purpose.
• the soft magnetic material according to the present invention includes a plurality of composite magnetic particles including metal magnetic particles and an insulating coating, an aromatic polyetherketone resin, and a fine metal particle having an average particle size of 2.0 m or less. And an inorganic lubricant having a crystal structure of sarcophagus and Z or hexagonal system.
• the insulating coating surrounds the surface of the metal magnetic particles and contains phosphate.
• an aromatic polyetherketone resin, fine metal sarcophagus having an average particle size of 2.0 m or less, and an inorganic lubricant having a Z or hexagonal crystal structure It has been found that the deterioration of the bending strength, especially at high temperatures, is suppressed when it is provided.
• the aromatic polyether ketone melts once and re-solidifies (crystallized) when cooled, but the average particle size 2. O / zm
• the following fine inorganic lubricants are considered to have worked as nucleating agents and promoted crystallization.
• the organic fatty chain part is decomposed and desorbed in the heat treatment process, but it remains as an inorganic zinc compound such as zinc or acid zinc, which could be a nucleating agent. It is considered a thing.
• the aromatic polyetherketone resin has a dense structure due to crystallization, and exhibits improved heat resistance and mechanical properties due to increased intermolecular force. Thereby, it is considered that the heat resistance and mechanical strength of the powder magnetic core in which the aromatic polyetherketone resin functions as a binder are also improved.
• the soft magnetic material is preferably a weight average of an aromatic polyetherketone resin.
• the molecular weight is 10,000 or more and 100,000 or less. By setting it to 100,000 or less, the melt viscosity of the aromatic polyether ketone resin can be lowered. As a result, when the aromatic polyetherketone resin is melted during the heat treatment process, the aromatic polyetherketone resin tends to spread between the composite magnetic particles, and the metal silicate residue and Z or hexagonal crystal as a nucleating agent It becomes easy to incorporate an inorganic lubricant having a structure into the aromatic polyetherketone resin. As a result, the mechanical properties of the soft magnetic material can be improved. In addition, when the weight average molecular weight is 10,000 or more, the strength of the aromatic polyetherketone resin itself can be suppressed.
• the average particle diameter of the aromatic polyetherketone resin is
• the average particle size of the metal magnetic particles By setting the average particle size to 10 times or more that of metal lubricants and inorganic lubricants having a Z or hexagonal crystal structure, it is possible to suppress a decrease in fluidity of the metal magnetic particles, Can prevent the coating of the inorganic lubricant on the surface of the metal particles.
• the average particle size of the metal magnetic particles By setting the average particle size of the metal magnetic particles to 2 times or less, the dispersion of the aromatic polyetherketone resin between the composite magnetic particles can be maintained.
• the metal lubricant and the inorganic lubricant having a Z or hexagonal crystal structure are 0.001% by mass or more and 0.1% by mass with respect to a plurality of composite magnetic particles. % Or less is included.
• the content By setting the content to 0.001% by mass or more, it is possible to obtain more lubricity that suppresses damage to the insulating film from the metal sarcophagus and the inorganic lubricant having a Z or hexagonal crystal structure.
• the content to 0.1% by mass or less, it is possible to further prevent a decrease in magnetic flux density and strength in the soft magnetic material.
• a dust core according to the present invention is manufactured using any of the soft magnetic materials described above. According to the dust core configured as described above, it is possible to obtain a dust core having excellent bending strength even at high temperatures while realizing magnetic characteristics with small iron loss.
• FIG. 1 is a diagram schematically showing a soft magnetic material according to an embodiment of the present invention.
• FIG. 2 is an enlarged cross-sectional view of a dust core in the embodiment of the present invention.
• FIG. 3 is a flow chart showing a method of manufacturing a dust core in the embodiment of the present invention in the order of steps.
• metal magnetic particles 10 metal magnetic particles, 20 insulating coating, 30 composite magnetic particles, 40 aromatic polyether ketone resin, 50 metal sarcophagus and inorganic lubricant having Z or hexagonal crystal structure, 60 insulator.
• FIG. 1 is a diagram schematically showing a soft magnetic material according to an embodiment of the present invention.
• the soft magnetic material in the present embodiment includes metal magnetic particles 10, a plurality of composite magnetic particles 30 having an insulating coating 20 surrounding the surface of the metal magnetic particles 10, and aromatic polyether ketone.
• a resin 40, and an inorganic lubricant 50 having an average particle diameter of 2. O / zm or less in the form of a fine metal sarcophagus and a Z or hexagonal crystal structure.
• the insulating coating 20 contains a phosphate.
• FIG. 2 is an enlarged cross-sectional view of the dust core in the embodiment of the present invention.
• the dust core shown in FIG. 2 was manufactured by subjecting the soft magnetic material shown in FIG. 1 to pressure molding and heat treatment.
• each of the plurality of composite magnetic particles 30 is joined by an aromatic polyetherketone resin 40, or the unevenness of the composite magnetic particles 30 They are joined together.
• the insulator 60 is obtained by changing the aromatic polyether ketone resin 40, the metal sarcophagus, Z, or the inorganic lubricant 50, etc., contained in the soft magnetic material during the heat treatment.
• the metal magnetic particles 10 are, for example, iron. (Fe), iron (Fe) aluminum (Al) alloy, iron (Fe) silicon (Si) alloy, iron (Fe) -nitrogen (N) alloy, iron (Fe) -nickel (Ni) alloy, Iron (Fe) —carbon (C) alloy, iron (Fe) boron (B) alloy, iron (Fe) cobalt (Co) alloy, iron (Fe) phosphorus (P) alloy, iron (Fe) Forces such as nickel (Ni) cobalt (Co) alloy and iron (Fe) aluminum (Al) -silicon (Si) alloy are also formed.
• the metal magnetic particles 10 may be a single metal or an alloy.
• the average particle diameter of the metal magnetic particles 10 is preferably 30 ⁇ m or more and 500 ⁇ m or less! /.
• the coercive force can be reduced.
• the average particle size 500 m or less By making the average particle size 500 m or less, eddy current loss can be reduced. Moreover, it can suppress that the compressibility of mixed powder falls at the time of pressure molding. Thereby, it is possible to prevent the density of the molded body obtained by pressure molding from being lowered and difficult to handle.
• the average particle size of the metal magnetic particles 10 is the particle size of particles in which the sum of the masses of the smaller particle sizes reaches 50% of the total mass in the particle size histogram, that is, 50% particle size.
• the insulating coating 20 functions as an insulating layer between the metal magnetic particles 10.
• the insulating coating 20 By covering the metal magnetic particles 10 with the insulating coating 20, it is possible to increase the electrical resistivity P of the dust core obtained by pressure-molding this soft magnetic material. Thereby, it is possible to suppress the eddy current from flowing between the metal magnetic particles 10 and to reduce the eddy current loss of the dust core.
• the insulating coating 20 is made of phosphate.
• a metal oxide containing phosphate for the insulating coating 20, the coating layer covering the surface of the metal magnetic particles can be made thinner. This is because the magnetic flux density of the composite magnetic particle 30 can be increased and the magnetic characteristics are improved.
• iron phosphate which is an iron phosphate, manganese phosphate, zinc phosphate, calcium phosphate, aluminum phosphate, and the like can be used.
• the phosphate may be a complex metal salt of phosphoric acid such as iron phosphate doped with a small amount of aluminum.
• the oxide include acid silicon, titanium oxide, aluminum oxide, and acid zirconium.
• the insulating coating 20 may be made of an alloy of these metals. Insulating coating 20 is shown in the figure. As shown, it may be formed in one layer, or may be formed in multiple layers.
• the average thickness of the insulating coating 20 is preferably 0.005 ⁇ m or more and 20 ⁇ m or less! /. More preferably, the average film thickness of the insulating coating 20 is 0.05-11 or more and 0: m or less.
• the average film thickness of the insulating film 20 is 0.005 / z m or more, it is possible to suppress conduction due to the tunnel effect.
• the distance By setting the distance to 0.05 m or more, power transmission due to the tunnel effect can be effectively suppressed.
• the average thickness of the insulating coating 20 to 20 / zm or less, it is possible to prevent the insulating coating 20 from being sheared and destroyed during pressure molding.
• the ratio of the insulating coating 20 to the soft magnetic material does not become too large, it is possible to prevent the magnetic flux density of the dust core obtained by pressing the soft magnetic material from being significantly reduced.
• the average film thickness of the insulating film 20 0.1 ⁇ m or less By making the average film thickness of the insulating film 20 0.1 ⁇ m or less, a decrease in magnetic flux density can be further prevented.
• the average film thickness is obtained by TEM—EDX (transmission electron microscope energy dispersive X-ray spectroscopy)! 1 ⁇ 4 Inconsistency and inductively coupled plasma mass fraction ⁇ "( ⁇ P— Ms: Inductively coupled plasma-mass spectrometry (1)
• ⁇ P— Ms Inductively coupled plasma-mass spectrometry
• aromatic polyetherketone resin 40 polyetheretherketone (PEEK), polyetherketone (PEK), polyetherketoneketone, or the like can be used.
• the aromatic polyether ketone resin 40 is preferably contained in an amount of 0.01% by mass or more and 0.1% by mass or less with respect to the plurality of composite magnetic particles 30.
• 0.01% by mass or more By containing 0.01% by mass or more, the bending strength of the soft magnetic material and the dust core can be improved.
• the content of 0.1% by mass or less restricts the proportion of the nonmagnetic layer in the soft magnetic material and the dust core, and thus prevents a decrease in the magnetic flux density.
• the metal stone cocoons include zinc stearate and stearic acid.
• Lithium, calcium stearate, lithium palmitate, calcium palmitate, lithium oleate, calcium oleate and the like can be used.
• Hexagonal system As the inorganic lubricant having the above crystal structure, boron nitride, disulfurium molybdenum, disulfur tungsten, graphite, or the like can be used.
• the fine particle metal stones having an average particle size of 2.0 ⁇ m or less and the inorganic lubricant 50 having a cocoon or hexagonal crystal structure are used for a plurality of composite magnetic particles. It is preferably contained in a proportion of not less than 0.1% by mass and not more than 0.1% by mass. By setting the content to 0.001% by mass or more, it is possible to obtain good lubricity that suppresses damage to the insulating coating from the metal lubricant and the inorganic lubricant having a Z or hexagonal crystal structure. By setting the content to 1% by mass or less, it is possible to further prevent a decrease in magnetic flux density and strength in the soft magnetic material.
• the average particle size of the metal lubricant and the inorganic lubricant 50 having a Z or hexagonal crystal structure is preferably 0.8 m or less.
• the average particle size of the metal lubricant and the inorganic lubricant 50 having a Z or hexagonal crystal structure is defined as the smaller particle size in the particle size histogram measured by the laser scattering diffraction method. This is the particle size of the particles whose sum of masses reaches 50% of the total mass, that is, 50% particle size D.
• the average particle size of the soft magnetic material is preferably 5 ⁇ m or more and 200 ⁇ m or less. This is because by setting the particle size to 5 ⁇ m or more, the powder compressibility is lowered and the magnetic flux density is lowered. On the other hand, by setting the particle size to 200 m or less, the eddy current loss in the particles can be suppressed particularly when used in the range of lkHz to 10kHz.
• FIG. 3 is a flowchart showing a method of manufacturing a dust core according to the embodiment of the present invention in the order of steps.
• the step (S 10) for producing the composite magnetic particle 30 is performed. Specifically, in this step (S10), the following is performed. Metal magnetic particles 10 are prepared. Then, the metal magnetic particles 10 are heat-treated at a temperature of 400 ° C. or higher and lower than 900 ° C., for example. Then, an insulating coating 20 is formed on each surface of the metal magnetic particles 10. The insulating coating 20 can be formed, for example, by subjecting the metal magnetic particles 10 to a phosphate formation treatment. Thereby, a plurality of composite magnetic particles 30 are obtained. [0035] The insulating coating 20 can be formed, for example, by subjecting the metal magnetic particles 10 to a phosphate-forming process.
• the insulating coating 20 made of aluminum phosphate, silicon phosphate, magnesium phosphate, calcium phosphate, yttrium phosphate, zirconium phosphate, etc. is formed by the phosphate formation treatment. It is formed. In forming these phosphate insulating films, solvent spraying or sol-gel treatment using a precursor can be used. Further, an insulating film 20 made of a silicon organic compound may be formed. For the formation of this insulating film, a wet coating process using an organic solvent, a direct coating process using a mixer, or the like can be used.
• the step (S 20) of mixing the aromatic polyether ketone resin with the plurality of composite magnetic particles 30 is performed.
• the mixing method is not particularly limited, for example, mechanical-caloring method, vibration ball mill, planetary ball mill, mechanofusion, coprecipitation method, chemical vapor deposition method (CVD method), physical vapor deposition method ( Deviations such as PVD method), plating method, sputtering method, vapor deposition method or sol-gel method can also be used.
• a step (S30) of adding fine metal stone cocoons having an average particle diameter of 2.0 ⁇ m or less and an inorganic lubricant 50 having a cocoon or hexagonal crystal structure is performed.
• a metal sarcophagus and / or an inorganic lubricant 50 are added to the composite magnetic particles 30 at a predetermined ratio, and mixed using a V-type mixer, so that the soft magnetic material in the present embodiment is obtained. Complete the fee.
• the mixing method is not particularly limited.
• a step (S40) of pressure-molding the obtained soft magnetic material is performed.
• the obtained soft magnetic material is put into a mold and, for example, pressure-molded with a pressure of 700 MPa to 1500 MPa. Thereby, a soft magnetic material is compressed and a molded object is obtained.
• the atmosphere for pressure forming is preferably an inert gas atmosphere or a reduced pressure atmosphere. In this case, the composite magnetic particles 30 can be prevented from being oxidized by oxygen in the atmosphere.
• a heat treatment step (S50) is performed.
• the molded body obtained by the pressure molding is subjected to heat treatment at a temperature of 400 ° C. or higher and lower than the thermal decomposition temperature of the insulating coating 20.
• the distortion and dislocation existing in the molded body are removed.
• the heat treatment is performed at a temperature lower than the thermal decomposition temperature of the insulating coating 20, the insulating coating 20 is not deteriorated by this heat treatment.
• the aromatic polyetherketone resin 40 and the fine metal sarcophagus having an average particle size of 2.0 m or less and the inorganic lubricant 50 having a Z or hexagonal crystal structure become the insulator 60. .
• the green body shown in Fig. 2 is completed by subjecting the molded body to appropriate processing such as extrusion and cutting.
• the dust core shown in Fig. 2 produced by the above steps (S10 to S50) preferably has a filling rate of 95% or more.
• the packing ratio of the powder magnetic core is as follows: insulating coating 20, aromatic polyether ketone resin 40, fine metal sarcophagus with an average particle size of 2.0 m or less, and inorganic lubricant 50 having a Z or hexagonal crystal structure,
• the measured density of the dust core measured including the voids between the composite magnetic particles 30 and the theoretical density of the metal magnetic particles 10 is obtained by dividing the measured density of the dust core.
• the theoretical density of the magnetic metal particles 10 includes the insulating coating 20, the aromatic polyether ketone resin 40, and the fine particle metal stones with an average particle size of 2.0 m or less and the Z or hexagonal crystal structure.
• the inorganic lubricant 50 is not taken into consideration, since the ratio of these to the whole is very small, a value approximating the actual filling rate can be obtained by the above-described method.
• the metal magnetic particles 10 are made of an alloy, for example, assuming that the metal magnetic particles 10 are also formed of iron-cobalt alloy force, the theoretical density of the metal magnetic particles 10 is (the theoretical density of iron).
• the soft magnetic material includes the metal magnetic particles 10 and the insulating coating 20 that surrounds the surfaces of the metal magnetic particles 10 and contains phosphate.
• the powder magnetic core in the embodiment of the present invention it is pressure-molded using a soft magnetic material. Therefore, the magnetic flux density in the case of applying a magnetic field above 12000AZm is not less 16k G or more, and is in electrical resistivity 10- 3 Omega cm or more 10 2 Omega cm or less, and the excitation magnetic flux density 2. 5 kG, measurement frequency A core with a core loss value of 1500 kWZm 3 or less when drawn in a full loop (BH curve) at 5 kHz and a bending strength at 200 ° C of lOOMPa or more is realized. be able to.
• the flexural strength (bending strength) is a value measured based on the JIS (Japanese Industrial Standard) Z2238 common test method for metal materials.
• each of the dust cores of Invention Examples 1 to 12 and Comparative Examples 1 to 5 was produced by the following method.
• Pure iron powder (trade name “ABC100.30” manufactured by Heganes Japan Co., Ltd., average particle diameter of 100 m) as metal magnetic particles was prepared. Then, the surface of the powder was bonded to form an insulating film made of iron phosphate having an average film thickness of lOOnm. Then, as an aromatic polyetherketone resin, PEEK (manufactured by Vitatrex 'Emshi Co., Ltd., average particle size 100 / ⁇ ⁇ , weight average molecular weight 43000) is 0.05% by mass with respect to a plurality of composite magnetic particles, Added.
• PEEK manufactured by Vitatrex 'Emshi Co., Ltd., average particle size 100 / ⁇ ⁇ , weight average molecular weight 43000
• zinc stearate having an average particle size of 0.8 m ( Nippon Oil & Fat Co., Ltd., with an average particle size of 0.8 m) was added in an amount of 0.005% by mass to a plurality of composite magnetic particles. Then, using a V-type mixer, these were mixed for 1 hour to prepare the soft magnetic material in Inventive Example 1. Thereafter, a pressure of 1275 MPa was applied to the soft magnetic material to produce a compact. Then, the compact was heat-treated at 420 ° C. for 1 hour in a nitrogen stream atmosphere. Thus, a dust core was produced.
• Example 2 of the present invention is an inorganic lubricant having an average particle size of 2. O / zm or less of finely divided metal sarcophagus and a Z or hexagonal crystal structure However, it differs only in that hexagonal boron nitride (hBN, manufactured by Mizushima Alloy Iron Co., Ltd., average particle size 2 m) is used.
• hBN hexagonal boron nitride
• Example 3 of the present invention is an inorganic lubricant having an average particle size of 2. O / zm or less of fine metal stalagmite and a Z or hexagonal crystal structure. Molybdenum disulfide (MoS, manufactured by Sumiko Lubricant Co., Ltd., average particle size 1 m) was used.
• Invention Example 4 is an inorganic lubricant having an average particle diameter of 2. O / zm or less in the form of fine metal stalagmites and a Z or hexagonal crystal structure. The only difference is the use of graphite (black>).
• Example 7 of the present invention uses PEEK (made by Vitatrex Emshi Co., Ltd.) having a weight average molecular weight of 109000 as an aromatic polyetherketone resin. However, it is different only.
• Example 8 of the present invention uses PEEK (manufactured by Vitatrex 'EMCHI Co., Ltd.) as an aromatic polyetherketone resin with an average particle size of 300 ⁇ m. It differs only in the points used.
• PEEK manufactured by Vitatrex 'EMCHI Co., Ltd.
• Example 9 of the present invention is different only in that PEEK having a weight average molecular weight of 10,000 is used.
• Example 10 of the present invention is different only in that PEEK having a weight average molecular weight of 100000 is used.
• Example 11 of the present invention is PEEK which is 10 times or more the average particle size of the inorganic lubricant and twice the average particle size of the metal magnetic particles. The only difference is in the use of.
• Example 12 of the present invention is different only in that an inorganic lubricant contained in an amount of 0.1% by mass is used for a plurality of composite magnetic particles.
• Comparative Example 1 differs only in that polyphenylene sulfide (PPS, manufactured by Idemitsu Petrochemical Co., Ltd.) was used instead of the aromatic polyetherketone resin. .
• PPS polyphenylene sulfide
• Comparative Example 2 is a polyetherimide (PEI, manufactured by GE Plastics Co., Ltd.), which is an amorphous resin instead of an aromatic polyetherketone resin. The only difference is the use of.
• PEI polyetherimide
• Comparative Example 3 is an inorganic lubricant having an average particle size of 2. O / zm or less of finely divided metal sarcophagus and a Z or hexagonal crystal structure. The only difference is that zinc stearate (made by NOF Corporation) with an average particle size of 7.5 ⁇ m was used instead.
• Comparative Example 4 is an inorganic lubricant having an average particle size of 2. O / zm or less of finely divided metal stalagmite and a Z or hexagonal crystal structure. The only difference is that ethylene bis-stearic acid amide (manufactured by NOF Corporation) was used instead.
• Comparative Example 5 is an inorganic lubricant having an average particle diameter of 2. O / zm or less of finely divided metal stalagmite and a Z or hexagonal crystal structure. The only difference is that no is added.
• a 300-mm primary and 20-second secondary wire is applied to a ring-shaped molded body (heat-treated) with an outer diameter of 34 mm, an inner diameter of 20 mm, and a thickness of 5 mm. It was.
• the measurement result is a core loss value per unit volume (WZm 3 ), and Table 3 shows the measurement result.
• a test piece for a three-point bending strength test having a size of 10 mm X 10 mm X 55 mm was manufactured.
• a test piece for the three-point bending strength test was carried out using a universal material testing machine, Autodaraf (trade name “TG-25” manufactured by Shimadzu Corporation).
• the point bending flexural strength test was performed with the test piece supported at a span of 40 mm at room temperature and 200 ° C. Table 3 shows the measurement results.
• the dust cores of Examples 1 to 12 of the present invention maintained a low core loss and exhibited a high bending strength.
• the weight average molecular weight of the aromatic polyether ketone resin is 10,000 to 100,000
• the average particle diameter of the aromatic polyether ketone resin is More than 10 times the average particle size of inorganic lubricants having a Z or hexagonal crystal structure and less than 2 times the average particle size of metal magnetic particles.
• An inorganic lubricant having a hexagonal crystal structure is used for a plurality of composite magnetic particles.
• L 1 is at a high temperature of 200 ° C. Shows very good bending strength at
• Inventive Example 12 showed very low core loss.
• the powder magnetic core in Comparative Example 2 using I had a force that could prevent the core loss from being deteriorated, and the bending strength at room temperature and 200 ° C was low.
• the metal stone instead of the fine metal stone cocoons having an average particle size of 2.0 ⁇ m or less and the inorganic lubricant having a cocoon or hexagonal crystal structure, the metal stone having an average particle size of 7.5 m
• the dust core in Comparative Example 3 using a kite (manufactured by Nippon Oil & Fats Co., Ltd.) had poor core loss and low bending strength at room temperature and 200 ° C.
• Comparative Example 4 in which ethylenebisstearic acid amide was used in place of fine metal stone cocoons having an average particle size of 2.0 ⁇ m or less and inorganic lubricants having a cocoon or hexagonal crystal structure
• the powder magnetic cores at 2 were extremely low in bending strength at room temperature and 200 ° C.
• Example 1 As described above, according to Example 1, the aromatic polyetherketone resin, the fine metal sarcophagus having an average particle size of 2.0 m or less, and the inorganic lubricant having a hexagonal crystal structure It was found that the bending strength was improved without increasing the core loss by providing at least one of the agents.
• the soft magnetic material and the dust core of the present study are used, for example, for automobile engine peripheral devices, motor cores, solenoid valves, rear tuttles, or electromagnetic parts in general.

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