WO2008133319A1 - 圧粉磁心とその製造方法、電動機およびリアクトル - Google Patents
圧粉磁心とその製造方法、電動機およびリアクトル Download PDFInfo
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- WO2008133319A1 WO2008133319A1 PCT/JP2008/058000 JP2008058000W WO2008133319A1 WO 2008133319 A1 WO2008133319 A1 WO 2008133319A1 JP 2008058000 W JP2008058000 W JP 2008058000W WO 2008133319 A1 WO2008133319 A1 WO 2008133319A1
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- Prior art keywords
- powder
- resin
- dust core
- magnetic
- core
- Prior art date
Links
- 239000000428 dust Substances 0.000 title claims abstract description 75
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 45
- 229920005989 resin Polymers 0.000 claims abstract description 108
- 239000011347 resin Substances 0.000 claims abstract description 108
- 239000000843 powder Substances 0.000 claims abstract description 89
- 239000006247 magnetic powder Substances 0.000 claims abstract description 38
- 230000004907 flux Effects 0.000 claims abstract description 29
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 19
- 229910052751 metal Inorganic materials 0.000 claims abstract description 19
- 239000002184 metal Substances 0.000 claims abstract description 19
- 239000000203 mixture Substances 0.000 claims abstract description 18
- 238000012643 polycondensation polymerization Methods 0.000 claims abstract description 7
- 229910052710 silicon Inorganic materials 0.000 claims description 40
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 39
- 239000010703 silicon Substances 0.000 claims description 39
- 238000000465 moulding Methods 0.000 claims description 16
- 239000011248 coating agent Substances 0.000 claims description 10
- 238000000576 coating method Methods 0.000 claims description 10
- 238000002156 mixing Methods 0.000 claims description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 abstract description 36
- 239000000377 silicon dioxide Substances 0.000 abstract description 8
- 239000011162 core material Substances 0.000 description 95
- 230000000052 comparative effect Effects 0.000 description 24
- 239000010408 film Substances 0.000 description 16
- 239000002245 particle Substances 0.000 description 16
- 238000000034 method Methods 0.000 description 14
- 230000007423 decrease Effects 0.000 description 12
- 238000009413 insulation Methods 0.000 description 11
- 229910052742 iron Inorganic materials 0.000 description 8
- 238000001879 gelation Methods 0.000 description 7
- 238000003825 pressing Methods 0.000 description 6
- 229920002050 silicone resin Polymers 0.000 description 6
- 238000010586 diagram Methods 0.000 description 5
- 238000002474 experimental method Methods 0.000 description 5
- 230000002093 peripheral effect Effects 0.000 description 5
- 239000011230 binding agent Substances 0.000 description 4
- 238000007796 conventional method Methods 0.000 description 4
- 238000006722 reduction reaction Methods 0.000 description 4
- -1 and thereafter Substances 0.000 description 3
- 238000011161 development Methods 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 229910000531 Co alloy Inorganic materials 0.000 description 2
- 229910000676 Si alloy Inorganic materials 0.000 description 2
- 238000000137 annealing Methods 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- 238000011049 filling Methods 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000006068 polycondensation reaction Methods 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 229920001296 polysiloxane Polymers 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- RSWGJHLUYNHPMX-UHFFFAOYSA-N Abietic-Saeure Natural products C12CCC(C(C)C)=CC2=CCC2C1(C)CCCC2(C)C(O)=O RSWGJHLUYNHPMX-UHFFFAOYSA-N 0.000 description 1
- 229910000521 B alloy Inorganic materials 0.000 description 1
- 229910001339 C alloy Inorganic materials 0.000 description 1
- 229910000976 Electrical steel Inorganic materials 0.000 description 1
- 229910001030 Iron–nickel alloy Inorganic materials 0.000 description 1
- 229910000576 Laminated steel Inorganic materials 0.000 description 1
- 229910001199 N alloy Inorganic materials 0.000 description 1
- 229910001096 P alloy Inorganic materials 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- KHPCPRHQVVSZAH-HUOMCSJISA-N Rosin Natural products O(C/C=C/c1ccccc1)[C@H]1[C@H](O)[C@@H](O)[C@@H](O)[C@@H](CO)O1 KHPCPRHQVVSZAH-HUOMCSJISA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- UCKMPCXJQFINFW-UHFFFAOYSA-N Sulphide Chemical compound [S-2] UCKMPCXJQFINFW-UHFFFAOYSA-N 0.000 description 1
- QVYYOKWPCQYKEY-UHFFFAOYSA-N [Fe].[Co] Chemical compound [Fe].[Co] QVYYOKWPCQYKEY-UHFFFAOYSA-N 0.000 description 1
- KGWWEXORQXHJJQ-UHFFFAOYSA-N [Fe].[Co].[Ni] Chemical compound [Fe].[Co].[Ni] KGWWEXORQXHJJQ-UHFFFAOYSA-N 0.000 description 1
- YYXHRUSBEPGBCD-UHFFFAOYSA-N azanylidyneiron Chemical compound [N].[Fe] YYXHRUSBEPGBCD-UHFFFAOYSA-N 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- ZDVYABSQRRRIOJ-UHFFFAOYSA-N boron;iron Chemical compound [Fe]#B ZDVYABSQRRRIOJ-UHFFFAOYSA-N 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000005261 decarburization Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- XWHPIFXRKKHEKR-UHFFFAOYSA-N iron silicon Chemical compound [Si].[Fe] XWHPIFXRKKHEKR-UHFFFAOYSA-N 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 230000005389 magnetism Effects 0.000 description 1
- QMQXDJATSGGYDR-UHFFFAOYSA-N methylidyneiron Chemical compound [C].[Fe] QMQXDJATSGGYDR-UHFFFAOYSA-N 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- DPTATFGPDCLUTF-UHFFFAOYSA-N phosphanylidyneiron Chemical compound [Fe]#P DPTATFGPDCLUTF-UHFFFAOYSA-N 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- 229920006122 polyamide resin Polymers 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000009719 polyimide resin Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 229920006259 thermoplastic polyimide Polymers 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- KHPCPRHQVVSZAH-UHFFFAOYSA-N trans-cinnamyl beta-D-glucopyranoside Natural products OC1C(O)C(O)C(CO)OC1OCC=CC1=CC=CC=C1 KHPCPRHQVVSZAH-UHFFFAOYSA-N 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
Classifications
-
- 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
- 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
- B22F2003/248—Thermal after-treatment
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C2202/00—Physical properties
- C22C2202/02—Magnetic
-
- 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
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F2017/048—Fixed inductances of the signal type with magnetic core with encapsulating core, e.g. made of resin and magnetic powder
-
- 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
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/02—Details of the magnetic circuit characterised by the magnetic material
Definitions
- the present invention relates to a dust core, a manufacturing method thereof, and an electric motor and a reactor in which a core material is formed from the dust core.
- the stator core, rotor core, and reactor constituting the electric motor are formed of a steel plate laminate formed by laminating silicon steel plates, or a pressure formed by pressure-molding a resin-coated iron-based soft magnetic powder. It is formed from a powder magnetic core.
- the magnetic properties of the core include less high-frequency iron loss than laminated steel sheets, and the ability to respond to shape variations flexibly and inexpensively because it is pressure-formed. have.
- Soft magnetic metal powder for dust cores has an insulating film formed on the surface of the metal powder to ensure the insulation of the powder, and thus the insulation of the dust core itself, thereby suppressing iron loss.
- iron powder is coated with silicon resin or epoxy resin, but resin is added to the iron powder in order to prevent film breakage during pressure molding and ensure insulation between the iron powder. Measures such as increasing the amount are taken.
- Fig. 11 shows the experimental results of the present inventors showing the relationship between the amount of resin added and specific resistance, strength, and density.
- flat iron powder with iron as the main component and containing 1 wt% Si and an aspect ratio of 6 is used.
- increasing the amount of resin added increases the specific resistance (thus improving the insulation) and also increases the dust core strength.
- the density of the dust core decreases as the ratio of resin to iron powder increases.
- this decrease in density causes a reduction in the magnetic flux density (magnetic properties) of the dust core.
- Patent Documents 1 to 3 Examples of conventional methods for producing a dust core include Patent Documents 1 to 3.
- the surface of iron powder is surface-treated with a dispersing agent, and thereafter, silicon rosin or the like is mixed and pressure-molded, followed by heat treatment.
- a polyiron sulfide (PPS) or a thermoplastic polyimide (P ⁇ ) is mixed with pure iron powder or pure iron powder having a phosphate coating. Pressure-molded and heat-treated.
- Patent Document 2
- the present invention has been made in view of the above-mentioned problems, and has a high strength and high density (high magnetic flux density) powder magnetic core, a method for producing the same, and a method for producing the powder magnetic core. It aims at providing the electric motor or reactor which has the core material which consists of.
- a method of manufacturing a dust core according to the present invention includes a magnetic powder in which an insulating film is formed in advance on the surface of a soft magnetic metal powder, a first step of preparing a resin powder, and the magnetic A second step of mixing the powder and the resin powder to form a powder mixture; and gelling the resin powder in a predetermined temperature atmosphere, and pressing the powder mixture to form a pressure that is a pressure molded body And a third process for producing a powder magnetic core.
- soft magnetic metal powder for example, pure iron, iron-silicon alloy, iron-nitrogen alloy, iron-nickel alloy, iron-carbon alloy, iron-boron alloy, iron-cobalt alloy Iron-phosphorus alloys, iron-nickel-cobalt alloys, iron-aluminum silicon alloys, and the like can be used.
- the insulating film for example, a film made of inorganic material such as silica (S i 0 2 ), nitride film (S i 3 N,), or ceramic material can be used. The material is not particularly limited as long as it has a temperature and does not gel during the warm forming.
- resin powder for example, silicon resin, epoxy resin, phenol resin, polyester resin, polyamide resin, polyimide resin and the like can be used.
- an insulating film is formed in advance on the surface of the soft magnetic metal powder, and a magnetic powder coated with the insulating film is prepared.
- a method for forming this insulating film there is a method in which Si is silicified at a high concentration by using a decarburization / reduction reaction on a soft magnetic metal powder surface such as pure iron, and thereafter an oxidation treatment is performed ( First step).
- the formed magnetic powder and the above-described resin powder are mixed to form a powder mixture, and this powder mixture is placed in a predetermined high temperature atmosphere to gel only the resin powder.
- Resin particles in which the gap between magnetic powders coated with a hard insulating coating is gelled by pressing the powder mixture in which the resin powder is in a gel form in a mold having a predetermined shape. Fulfill.
- the density of the powder magnetic core to be manufactured is increased as compared with the conventional manufacturing method in which a soft magnetic metal powder having a film formed of a relatively large amount of resin is pressure-molded.
- This increase in density leads to an improvement in the magnetic flux density of the dust core.
- the density of the dust core is increased for the following reasons. In other words, since the conventional method is intended to form an insulating layer of resin particles, many resin particles are used to ensure high insulation, and the content ratio of resin particles in the dust core is high. As a result, the density decreases.
- the resin particles to be mixed are not intended to ensure insulation, and the magnetic powders are bonded together. This is because the amount of resin required is only an amount that fills the gap between the magnetic powders.
- the strength of the produced powder magnetic core is improved by bonding the magnetic powders with a resin binder.
- the strength deteriorates due to the formation of gaps between the magnetic powders during pressure molding, but according to the manufacturing method of the present invention, the gel is gelled. Since the entire resin particles are pressed between the magnetic powders, they are pressed and molded. To join.
- the strength of the dust core can be defined by bending strength, tensile strength, crushing strength, and the like.
- the state in which the resin particles are gelled means that the viscosity of the resin particles is less than 100 0 Pa ⁇ s (pascal second), which is a viscosity that defines the flow temperature of glass. Yes, usually exhibits a viscosity state of around 5 0 0 0 Pa ⁇ s or less.
- the pressure-molded body is annealed.
- the resin added as a binder is a silica coating that ensures insulation, and the processing distortion that occurs in the powder magnetic core due to pressure molding is eliminated by annealing, so that magnetism due to pressure molding is achieved. It prevents the deterioration of the characteristics.
- the third step is to fill a mold with a powder mixture so that the resin powder does not undergo condensation polymerization.
- the resin powder does not undergo condensation polymerization.
- Warm molding is a molding method in which the powder and mold (mold) are pressure-molded in a heated atmosphere in a temperature atmosphere of approximately 100 to 150 ° C. For example, it is the temperature range in which the silicone resin does not undergo condensation polymerization.
- the resin particles exhibit a gel-like shape.
- the resin particles can be filled.
- the temperature atmosphere in the third step should be set in the range of about 120 to 145 ° C. Since such commercially available silicon resin (powder) can be purchased at a low price, a dust core can be manufactured at a lower cost.
- the dust core according to the present invention is a dust core in which a resin is filled and cured in a gap between magnetic powders having an insulating coating formed in advance on the surface of a soft magnetic metal powder, and the amount of the resin mixed is 0.3% by weight or less, its magnetic flux density (B 50) is 1.4 T or more, and its crushing strength is 70 MPa or more.
- the amount of resin increases if an attempt is made to improve its insulation, and the density decreases as the proportion of resin in the dust core increases.
- the decrease in the density of the magnetic core was directly linked to the decrease in the magnetic flux density.
- the magnetic flux density of the dust core is increased, the amount of resin decreases, resulting in insufficient adhesion due to the resin binder, and the strength properties such as the crushing strength of the dust core are reduced. Become. Therefore, the powder magnetic core manufactured by the conventional manufacturing method is not excellent in both strength characteristics and magnetic characteristics (magnetic flux density). According to the experiments by the present inventors, in the conventional method for manufacturing a dust core, the magnetic flux density (B
- the crushing strength is at most about 3 OMP a.
- the crushing strength obtained even when the magnetic flux density (B 5 0) is suppressed to about 1.2 T is It has been proven that it is at most about 5 OMPa.
- the dust core obtained by the production method of the present invention described above has a magnetic flux density (B 5 0) of 1.4 T or more, In addition, it has a crushing strength of 7 OMPa or more, and it is a dust core excellent in both strength and magnetic properties.
- silica (Sio 2 ) is preferably used as the insulating film forming the dust core having the above characteristics, and silicon resin is preferably used as the resin from the viewpoint of manufacturing cost and the like.
- the amount of resin added when forming a dust core having the above characteristics is adjusted to about 0.3% by weight or less. According to the experiments by the present inventors, it has been demonstrated that the crushing strength is highest when the resin addition amount is about 0.2% by weight, and the magnetic flux density gradually decreases as the resin addition amount increases. Yes. Taking this experimental result into consideration, in order to obtain a dust core having a magnetic flux density (B 50) of 1.4 T or more and a pressure ring strength of 70 MPa or more, the resin addition amount is about 0.3% by weight as described above. It may be set as follows, and is preferably set in the range of 0.1 to 0.3% by weight.
- the aspect ratio of the soft magnetic metal powder used can be set in the range of about 1 to 10, and the average particle size of the powder can be set in the range of about 150 to 200 ⁇ m. .
- this electric motor requires a driving motor excellent in both magnetic characteristics and strength characteristics.
- Hybrid vehicles are suitable for electric vehicles.
- this reactor core is also suitable for reactors mounted on hybrid vehicles and electric vehicles.
- FIG. 1 is a diagram illustrating the temperature range of solid, gel, and condensation polymerization of a silicon resin.
- FIG. 2 is an explanatory view illustrating the method of manufacturing a dust core according to the present invention in a flow.
- Fig. 3 is an enlarged view of part III in Fig. 2a.
- Figure 4 is an enlarged view of section IV in Figure 2b.
- FIG. 5 is an enlarged view of a portion V in FIG. 2d.
- Fig. 6 is a graph illustrating the gelation temperature range of silicon resin.
- FIG. 7 is a graph showing experimental results regarding the relationship between the crushing strength of the dust core (Example) of the present invention and the comparative example and the amount of resin added.
- FIG. 8 is a graph showing experimental results on the relationship between the magnetic flux density and the resin addition amount of the dust core (Example) of the present invention and the comparative example.
- FIG. 9 is a graph showing the experimental results regarding the strength characteristics and magnetic characteristics of the dust core of the present invention (Example) and the comparative example.
- FIG. 10 is a graph showing the calculation results regarding the aspect ratio of the soft magnetic metal powder, the resin mixing amount, and the average particle size.
- Figure 11 is a graph showing the relationship between the amount of resin added and the specific resistance of iron powder with an aspect ratio of 6 and Fe 1 Si component, and (b) is the amount of resin added and strength.
- (C) is a graph showing the relationship between the amount of resin added and the density.
- 1 is magnetic powder
- 1 1 is pure iron powder (soft magnetic metal powder)
- 1 is silicon force film (insulating coating)
- 2 is silicon resin powder (resin powder)
- 2 A is gel resin
- 10 indicates a pressure-molded body
- 20 indicates a dust core.
- Fig. 1 is a diagram explaining the temperature range of solid, gel, and condensation polymerization of a silicon resin
- Fig. 2 is an explanatory diagram explaining the method for producing a dust core of the present invention in flow
- Fig. 6 is a diagram illustrating the gelation temperature range of silicon resin.
- Fig. 7 is a graph showing experimental results on the relationship between the crushing strength and the amount of resin added in the dust core of the present invention (Example) and the comparative example. It is the graph which showed the experimental result regarding the relationship between the magnetic flux density of an example) and a comparative example, and the addition amount of a resin.
- FIG. 9 is a graph showing experimental results relating to the strength and magnetic properties of the dust core of the present invention (Example) and a comparative example.
- FIG. 10 is a graph showing the calculation results regarding the resin mixing amount required to fill the voids between the magnetic powders in the aspect ratio and the average particle diameter of the soft magnetic metal powders.
- the manufacturing method of the powder magnetic core of this invention is explained in full detail.
- pure iron is used as the soft magnetic metal powder, and the insulating coating formed beforehand on the surface is made of silica (sio 2 ).
- the filling resin uses silicon resin.
- Fig. 1 is a diagram illustrating the solid state of silicon resin (A region in the figure), gel (B region in the figure), and the temperature range of condensation polymerization (. Region in the figure).
- the temperature at which the silicone resin exhibits a gel shape substantially corresponds to the temperature at the time of warm molding, and the range is ⁇ 3: approximately 120 ° C to t4: approximately 1445 ° C.
- FIG. 2 is an explanatory view illustrating a method for manufacturing a dust core in a flow.
- Fig. 2 (a) illustrates the situation in which magnetic powder 1 and silicon resin powder 2 are mixed at room temperature. Specifically, a method of stirring and mixing magnetic powder and a predetermined amount of silicon resin powder. Or, the temperature in Fig. 1: Mix with magnetic powder 1 near t 1, then volatilize the solvent near the temperature in Fig. 1: t 2, and mix silicon resin powder 2 into magnetic powder 1 homogeneously A powder mixture is formed by any of the methods.
- YR 3370 manufactured by GE Toshiba Silicone Co., Ltd.
- Fig. 3 shows an enlarged view of part III in Fig. 2a.
- the magnetic powder 1 has a silica film 12 formed on the peripheral surface of the pure iron powder 11, and the magnetic powder 1 has already been produced in the previous step. Specifically, pure iron powder 11 is decarburized. By using a reduction reaction, Si is silicified at a high concentration, and then oxidized, so that the surface of pure iron powder 11 1 is hard. A silica film having excellent insulating properties is formed.
- the powder mixture of magnetic powder 1 and silicon resin powder 2 is filled into the lower punch A 1 and the peripheral die B, and after filling the powder mixture, Fig. 2c Close with upper punch A 2 as shown, and apply upper punch A 2 with a predetermined pressing force as shown in Figure 2d.
- a pressure molded body 10 which is an intermediate molded body of the powder magnetic core is molded.
- the process of FIG. 2 b-FIG. 2 d is a warm forming process, and is performed in the temperature atmosphere shown in FIG. 1 in the range of temperature: t 3 -t 4.
- Fig. 4 shows an enlarged view of part IV in Fig. 2b.
- the temperature range of 100 to 150 ° C, especially 120 to 14 to 45 ° C only the silicon resin powder 2 in the powder mixture is gelled to form a gel-like resin 2 A Is done.
- FIG. 6 shows the results of experiments by the present inventors regarding the gelation temperature range of silicon resin. As shown in Fig. 6, when Y R 3 3 70 is used as the silicone resin, the gelation temperature range is approximately 1 2 0 to 1 4 5 ° C. In this temperature range, the viscosity of the silicone resin is
- the dotted line in the figure indicates the viscosity that defines the flow temperature of the glass, and is a value of about 1 O O O O Pa ⁇ s. Therefore, when the gelation of silicone resin is defined by its viscosity, it is at most a viscosity of lOOOP a.s, and generally has a viscosity characteristic around 5 0 00 Pa.s. Can be identified.
- Fig. 5 is an enlarged view of the V part of the molding die by pressure molding as shown in Fig. 2d with the silicone resin powder 2 in the powder mixture turned into a gel-like resin 2A.
- a pressure molded body 10 is formed by curing in a state where the gel-like resin 2A is filled in the gap between the magnetic powders 1.
- the pressure-formed body 10 is annealed in a temperature atmosphere of about 60 to 75 ° C, which corresponds to the temperature shown in Fig. 1: t5.
- a dust core 20 is obtained.
- the silicon gel resin is condensed and the magnetic powders 1,... Are strongly bonded to each other due to the mutual squeezing force and the adhesion force via the silicon resin. become.
- the inventors use pure iron powder as the soft magnetic metal powder, and forms a silica film, which is an oxide of silicon resin (YR 3 3 0), on the peripheral surface to produce magnetic powder.
- a magnetic powder and a silicon resin with an addition amount of 0.2% by weight are mixed to form a powder mixture.
- the silicon resin is gelled by the above-described method, it is pressure-molded and annealed.
- the powder magnetic core was formed by processing (Example).
- two comparative examples were obtained by molding a dust core by a conventional manufacturing method. One of them (Comparative Example 1) is simply press-molded in advance with a magnetic powder in which a silica thin film is formed on the surface of pure iron.
- Comparative Example 2 is a comparatively large amount of Si.
- Table 1 shows the measured values of density, vortex loss, strength (compression ring strength), and magnetic flux density B 50 of Examples and Comparative Examples 1 and 2.
- Fig. 7 shows the experimental results regarding the relationship between the crushing strength and the silicon resin addition amount
- Fig. 8 shows the experimental results regarding the relationship between the magnetic flux density B 50 and the silicon addition amount
- Fig. 9 shows the crushing strength and magnetic flux density B. The experimental results are shown with a single draft for both 50 and 50 respectively.
- the method of measuring the crushing strength is to manufacture a ring-shaped dust core test piece with a thickness of 5 mm, an outer diameter of 39 mm, and an inner diameter of 3 O mm, and pressurize the test piece with a compressor.
- the crushing strength is determined by the pressure applied when cracking occurs.
- Comparative Example 1 Although the magnetic flux density is similar to that of the example, the crushing strength is extremely low, about 20% of the example. The reason why the strength of Comparative Example 1 is lower than that of Comparative Example 2 is that in Comparative Example 2, the adhesion force of the resin binder was added in the bonding between the magnetic powders.
- the magnetic flux density (B 50) also exhibits a high value of 1.4 T or more, and the crushing strength also exhibits a high value of 7 OMPa or more. It can be understood that the dust core is excellent in both strength and magnetic properties.
- the crushing strength is a peak value of about 5 OMPa at most.
- high crushing strength is obtained when the amount of silicon resin added is in the range of slightly less than 0.2 to less than 0.35% by weight, particularly as strong as 90 MPa at about 0.2% by weight. Has been demonstrated to be obtained.
- Fig. 9 summarizes the results of Figs. 7 and 8 in a single graph.
- the vertical axis shows the pressure ring strength
- the horizontal axis shows the magnetic flux density.
- examples are shown:
- XI and X2 are the results of the dust core in the case of the above-mentioned preferable silicon resin addition amount, and X3 to X7 showing Comparative Example A apply the manufacturing method of the present invention. However, this is a result of the dust core in which the addition amount of the silicon resin is outside the above-described preferable addition amount range.
- Comparative Example B is the dust core of Comparative Example 2 described above.
- Fig. 10 shows the result of calculating the relationship between the resin addition amount and the average particle size of the magnetic powder while changing the aspect ratio from 1 to 18.
- the power of using a soft magnetic metal powder with an aspect ratio of about 1 to 6 When the above preferred amount and the resin addition amount range is 0.2% by weight, the average particle size of the magnetic powder is 1 It has been verified that it is about 50-200 ⁇ m.
- the above-described dust core of the present invention has excellent performance in both strength and magnetic properties, so that the applied environment changes drastically, and the motor such as a hybrid vehicle that requires high performance and downsizing is required.
- the dust core of the present invention is particularly suitable for a stator core, a rotor core, and a reactor core of a reactor device.
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- Engineering & Computer Science (AREA)
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- Manufacturing & Machinery (AREA)
- Powder Metallurgy (AREA)
- Soft Magnetic Materials (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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DE112008002226T DE112008002226T5 (de) | 2007-04-20 | 2008-04-18 | Pulverkern, Verfahren zum Herstellen desselben, Elektromotor und Reaktor |
US12/532,759 US20100079015A1 (en) | 2007-04-20 | 2008-04-18 | Dust core, method for producing the same, electric motor, and reactor |
Applications Claiming Priority (2)
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JP2007111739A JP2008270539A (ja) | 2007-04-20 | 2007-04-20 | 圧粉磁心とその製造方法、電動機およびリアクトル |
JP2007-111739 | 2007-04-20 |
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WO2008133319A1 true WO2008133319A1 (ja) | 2008-11-06 |
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PCT/JP2008/058000 WO2008133319A1 (ja) | 2007-04-20 | 2008-04-18 | 圧粉磁心とその製造方法、電動機およびリアクトル |
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US (1) | US20100079015A1 (ja) |
JP (1) | JP2008270539A (ja) |
CN (1) | CN101663716A (ja) |
DE (1) | DE112008002226T5 (ja) |
WO (1) | WO2008133319A1 (ja) |
Cited By (1)
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JP7133114B1 (ja) | 2022-03-24 | 2022-09-07 | 株式会社トーキン | 磁性体及び磁性素子 |
Families Citing this family (16)
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JP5140042B2 (ja) * | 2009-07-10 | 2013-02-06 | 株式会社豊田中央研究所 | 圧粉磁心およびその製造方法 |
CN102126530A (zh) * | 2010-01-20 | 2011-07-20 | 三洋电机株式会社 | 自行车用轮毂发电机 |
CN102263463A (zh) * | 2010-05-24 | 2011-11-30 | 上海日立电器有限公司 | 一种电机转子的制备工艺 |
JP5976284B2 (ja) | 2010-07-23 | 2016-08-23 | 株式会社豊田中央研究所 | 圧粉磁心の製造方法および磁心用粉末の製造方法 |
JP6044064B2 (ja) * | 2010-11-30 | 2016-12-14 | 住友大阪セメント株式会社 | 複合磁性体とその製造方法及びアンテナ並びに通信装置 |
JP2013026419A (ja) * | 2011-07-20 | 2013-02-04 | Sumitomo Electric Ind Ltd | リアクトル |
TW201328126A (zh) * | 2011-12-29 | 2013-07-01 | Ind Tech Res Inst | 永磁馬達與永磁馬達的轉子 |
JP5964619B2 (ja) * | 2012-03-15 | 2016-08-03 | 株式会社タムラ製作所 | リアクトル、及びリアクトルの製造方法 |
JP5978766B2 (ja) * | 2012-05-25 | 2016-08-24 | Tdk株式会社 | 軟磁性圧粉磁芯 |
JP6117504B2 (ja) | 2012-10-01 | 2017-04-19 | Ntn株式会社 | 磁性コアの製造方法 |
JP6168382B2 (ja) * | 2012-12-12 | 2017-07-26 | 日立金属株式会社 | 圧粉磁心の製造方法 |
EP3127225B1 (en) * | 2014-04-02 | 2018-08-22 | J.H. Beheer B.V. | Stator module of an electric machine comprising an permanent magnet rotor |
JP6580817B2 (ja) | 2014-09-18 | 2019-09-25 | Ntn株式会社 | 磁性コアの製造方法 |
JP6581270B2 (ja) * | 2018-09-25 | 2019-09-25 | Ntn株式会社 | 磁性コアの製造方法 |
WO2021060363A1 (ja) * | 2019-09-27 | 2021-04-01 | 東邦チタニウム株式会社 | 圧粉体の製造方法及び、焼結体の製造方法 |
CN112086257B (zh) * | 2019-10-24 | 2023-07-25 | 中国科学院宁波材料技术与工程研究所 | 高磁导率高品质因数磁粉芯及其制备方法和应用 |
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- 2008-04-18 DE DE112008002226T patent/DE112008002226T5/de not_active Withdrawn
- 2008-04-18 CN CN200880008479A patent/CN101663716A/zh active Pending
- 2008-04-18 WO PCT/JP2008/058000 patent/WO2008133319A1/ja active Application Filing
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JP2003037018A (ja) * | 2001-07-23 | 2003-02-07 | Daido Steel Co Ltd | 圧粉磁心の製造方法 |
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 |
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JP7133114B1 (ja) | 2022-03-24 | 2022-09-07 | 株式会社トーキン | 磁性体及び磁性素子 |
WO2023181902A1 (ja) * | 2022-03-24 | 2023-09-28 | 株式会社トーキン | 磁性体及び磁性素子 |
JP2023141675A (ja) * | 2022-03-24 | 2023-10-05 | 株式会社トーキン | 磁性体及び磁性素子 |
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US20100079015A1 (en) | 2010-04-01 |
CN101663716A (zh) | 2010-03-03 |
DE112008002226T5 (de) | 2010-07-01 |
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