WO2010073590A1 - Matériau magnétique souple composite et son procédé de production - Google Patents

Matériau magnétique souple composite et son procédé de production Download PDF

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WO2010073590A1
WO2010073590A1 PCT/JP2009/007070 JP2009007070W WO2010073590A1 WO 2010073590 A1 WO2010073590 A1 WO 2010073590A1 JP 2009007070 W JP2009007070 W JP 2009007070W WO 2010073590 A1 WO2010073590 A1 WO 2010073590A1
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powder
sendust alloy
soft magnetic
magnetic material
iron powder
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PCT/JP2009/007070
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English (en)
Japanese (ja)
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渡辺宗明
五十嵐和則
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三菱マテリアル株式会社
株式会社ダイヤメット
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Priority to JP2010543839A priority Critical patent/JPWO2010073590A1/ja
Priority to CN2009801528854A priority patent/CN102264492A/zh
Publication of WO2010073590A1 publication Critical patent/WO2010073590A1/fr

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • 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
    • B22F1/12—Metallic powder containing non-metallic particles
    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
    • 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
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/14766—Fe-Si based alloys
    • H01F1/14791—Fe-Si-Al based alloys, e.g. Sendust
    • 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

Definitions

  • the present invention relates to a composite soft magnetic material obtained by mixing and compacting an insulating iron powder and a sendust alloy powder together with a binder and firing the mixture, and a method for producing the same.
  • This application claims priority based on Japanese Patent Application No. 2008-330597 for which it applied to Japan on December 25, 2008, and uses the content here.
  • Electromagnetic components for electronic devices such as inverters, transformer cores, and choke coils are required to have stricter material properties as electronic devices become smaller and have higher performance.
  • metal magnetic materials such as Sendust alloy and silicon steel, and oxide magnetic materials such as ferrite have been used as soft magnetic materials for such parts.
  • metallic magnetic materials such as Sendust alloy have a high hardness when powdered, and there is a problem that it is difficult to increase the density by powder molding.
  • a metal soft magnetic powder having an insulating coating, and a raw material powder consisting of a lubricant powder and a binder added as needed are filled in a mold cavity. After that, a green compact having a desired shape is produced by pressure molding, and then the green compact is fired to produce a composite soft magnetic material.
  • Sendust alloy has very little plastic deformation when processed at room temperature and can be pulverized by pulverization, but cannot be formed into a plate shape. Therefore, when Sendust alloy powder is molded to produce magnetic parts such as magnetic cores, plastic deformation hardly occurs. Therefore, Sendust alloy powder is simply connected with the added binder. Even if the permeability of the sendust alloy powder itself is high, there is a problem that a high permeability cannot be obtained when a dust core is used.
  • Patent Document 1 Also known is a composite magnetic material obtained by mixing a Sendust alloy powder having an oxide film, a highly compressible soft magnetic metal powder, a soft ferrite powder, and a binder, followed by sintering and sintering.
  • the soft magnetic composite material produced by coating the metal magnetic powder such as Permalloy with an oxide magnetic material such as ferrite has a problem that the magnetic properties deteriorate because the metal and ferrite easily react at the interface between them when heat-treated. Had. Further, in the method of mixing Sendust alloy powder and other soft magnetic metal powder, since Sendust alloy powder is very hard, even if soft magnetic metal powder having good compressibility is mixed, 20 ton / cm 2. A high pressure molding technique of a certain level is required, and there is a problem that only a product having a simple shape such as a cylindrical shape such as a dust core can be obtained.
  • the present invention has been proposed in view of such conventional circumstances, and its purpose is to select iron powders to be mixed with Sendust alloy powder, the range of their addition amount, and the respective particle size ranges.
  • it is made into an optimal composition, while maintaining high saturation magnetic flux density inherent in iron powder, while high permeability, low coercivity, inherent in Sendust alloy powder,
  • the composite soft magnetic material according to the present invention comprises an insulating iron powder, a sendust alloy powder, and a binder mixed and compacted and fired, and the iron powder and the sendust alloy powder are compacted.
  • a fired main phase and a grain boundary phase mainly composed of a binder formed around the main phase are provided, and the proportion of Sendust alloy in the main phase is 5% by mass or more and less than 20% by mass.
  • the saturation magnetic flux density is 1 T or more at a magnetic field of 10 kA / m
  • the coercive force is 260 A / m or less
  • the iron loss (at 0.1 T, 10 kHz) is 20 W / kg or less.
  • the average particle size of the iron main phase formed by compacting and firing the iron powder is 20 to 50 ⁇ m, and the average particle size of the alloy main phase formed by compacting and firing the Sendust alloy powder.
  • the thickness can be 50 to 120 ⁇ m.
  • pure iron powder having an Mg-containing oxide film can be used as the insulated iron powder.
  • the method for producing a composite soft magnetic material according to the present invention comprises a main phase formed by compacting at least mixed compacted and sintered iron powder, sendust alloy powder and binder, and then compacting the iron powder and sendust alloy powder. And a sendust alloy occupying the total mass of the insulated iron powder and sendust alloy powder in producing a composite soft magnetic material having a grain boundary phase mainly composed of a binder formed around the main phase.
  • the addition ratio of the powder is 5 mass% or more and less than 20 mass%
  • the insulated iron powder and Sendust alloy powder are mixed and compacted and fired to obtain a saturation magnetic flux density of 1 T or more at a magnetic field of 10 kA / m, a coercive force.
  • a composite soft magnetic material having 260 A / m or less and iron loss (at 0.1 T, 10 kHz) of 20 W / kg or less is obtained.
  • the addition ratio or blending ratio of Sendust alloy powder is the ratio of Sendust alloy powder to the total mass of Sendust alloy powder and the iron powder insulated with Mg-containing oxide coating or the like. It means a compounding ratio (mass%).
  • the method for producing a composite soft magnetic material according to the present invention is characterized by using an insulated iron powder having an average particle diameter of 20 to 50 ⁇ m and a sendust alloy powder having an average particle diameter of 50 to 120 ⁇ m.
  • the method for producing a composite soft magnetic material according to the present invention is characterized in that pure iron powder insulated with an Mg-containing oxide film is used as the insulated iron powder.
  • the soft magnetic characteristics such as low iron loss, low coercive force, and low eddy current loss of the proper amount of sendust alloy powder are effective.
  • the composite soft magnetic material obtained in the above can be provided.
  • a soft magnetic material can be provided.
  • pure iron powder insulated with an Mg-containing oxide coating is used as the insulated iron powder to ensure high saturation magnetic flux density, low iron loss, low coercive force, and low eddy current loss. It is possible to get to.
  • FIG. 1 is a graph showing the relationship between the blending ratio of sendust alloy powder and the specific resistance in an example of a composite soft magnetic material according to the present invention.
  • FIG. 2 is a diagram showing the relationship between the blending ratio of the sendust alloy powder and the saturation magnetic flux density in the example of the composite soft magnetic material according to the present invention.
  • FIG. 3 is a diagram showing the relationship between the saturation magnetic flux density and the loss in the example of the composite soft magnetic material according to the present invention.
  • FIG. 4 is a diagram showing the relationship between the blending ratio of the sendust alloy powder and the loss in the example of the composite soft magnetic material according to the present invention.
  • FIG. 5 is a diagram showing the relationship between the blending ratio of Sendust alloy powder and mechanical strength in the example of the composite soft magnetic material according to the present invention.
  • a powder compact having a predetermined shape can be obtained by filling the mixed powder obtained by adding and mixing a binder and a lubricant as necessary into a mold cavity of a compacting device, followed by pressure molding. Thereafter, the obtained green compact is fired in a predetermined temperature range, whereby a composite soft magnetic material having a desired shape can be obtained.
  • Insulated pure iron powder used in the present invention is, for example, an Mg-containing oxide in which a Mg—Fe—O ternary oxide deposition film containing (Mg, Fe) O is coated on the surface of pure iron particles.
  • Wet powder-coated pure iron powder, phosphate-coated pure iron powder, or a wet solution such as silica sol-gel solution (silicate) or alumina sol-gel solution is mixed and coated on the surface of pure iron powder, then dried and fired
  • the present invention is not limited to this, and it is possible to widely apply insulated pure iron powder having a structure in which pure iron powder is coated with an insulating coating layer. it can.
  • the Mg-containing oxide-coated pure iron powder coated with the Mg—Fe—O ternary oxide deposited film is obtained, for example, by the following production method (A), (B), (C) or (D). be able to.
  • A Pure iron powder is subjected to an oxidation treatment in an oxidizing atmosphere at room temperature to 500 ° C., and then mixed powder obtained by adding and mixing Mg powder to this powder is temperature: 150 to 1100 ° C., pressure When heated in an inert gas atmosphere or vacuum atmosphere of 1 ⁇ 10 ⁇ 12 to 1 ⁇ 10 ⁇ 1 MPa and further heated in an oxidizing atmosphere at a temperature of 50 to 400 ° C.
  • the surface of pure iron powder Mg-containing oxide-coated pure iron particles having an oxide insulating film containing Mg are obtained.
  • B After subjecting the pure iron powder to the oxidation treatment described above, after adding and mixing the silicon monoxide powder, or while mixing, heating in a vacuum atmosphere at a temperature of 600 to 1200 ° C., After adding and mixing Mg powder, or heating while mixing in a vacuum atmosphere at a temperature of 400 to 800 ° C., an Mg—Si containing oxide film is formed on the surface of pure iron powder. A material-coated pure iron powder is obtained.
  • the Mg—Si-containing oxide film is formed on the surface of the pure iron powder.
  • the addition amount of the silicon monoxide powder can be in the range of 0.01 to 1% by mass, and the addition amount of the Mg powder can be in the range of 0.05 to 1% by mass.
  • the vacuum atmosphere may be a vacuum atmosphere at a pressure of 1 ⁇ 10 ⁇ 12 to 1 ⁇ 10 ⁇ 1 MPa.
  • the Mg-containing oxide-coated pure iron particles obtained by these production methods have remarkably excellent coating adhesion of the Mg—Fe—O ternary oxide deposited film containing (Mg, Fe) O, Even if these particles are pressed to produce a green compact, the insulating coating is less likely to be broken and peeled off.
  • the oxide-coated pure iron powder is preferably a powder having an average particle size in the range of 20 to 50 ⁇ m. The reason is that if the average particle size is too small, the compressibility of the powder decreases and the value of the saturation magnetic flux density decreases, which is not preferable. On the other hand, if the average particle size is too large, the eddy current inside the soft magnetic powder is not preferable. This is because the magnetic permeability at a high frequency is likely to increase and decrease.
  • a sendust alloy for example, composition ratio: 10 mass% Si-6 mass% Al-residual Fe
  • a powder having a particle size range of 50 to 120 ⁇ m can be used.
  • the oxide-coated pure iron powder and Sendust alloy powder are each mixed with a binder material containing Si, such as silicone resin as a binder material, and each powder is made into a silicone resin-coated powder. .
  • the temperature is in the range of 150 to 250 ° C, more preferably 200 to 250 ° C. Can be baked and coated in the range of.
  • the temperature is in the range of 80 to 250 ° C., more preferably in the range of 100 to 200 ° C. It can be baked and coated by heating.
  • the baking temperature can be selected from a range of 150 to 250 ° C. A decrease in specific resistance, which is considered to be caused by damage to the insulation coating, is observed, and if it exceeds 250 ° C., the binder material becomes hard and the packing density during molding is decreased, which is not desirable. Even within this range, a baking temperature in the range of 200 to 250 ° C. is more preferable in order to obtain higher density and specific resistance.
  • a temperature range of 80 to 250 ° C can be selected as the baking temperature. If the temperature is outside this range, a decrease in density or variation may be observed during molding. At temperatures exceeding 250 ° C., the specific resistance is decreased, which is not desirable. Even within this range, a baking temperature in the range of 100 to 200 ° C. is more preferable in order to obtain higher density and specific resistance.
  • the ratio of the mass of the Sendust alloy powder coated with the binder material to the total mass of the oxide-coated pure iron powder coated with these binder materials and the Sendust alloy powder coated with the binder material is 5% by mass or more and 20% by mass.
  • These powders are mixed so as to be less than the minimum, accommodated in a mold of a compacting apparatus, and warm-molded into a desired shape with a molding temperature of about 8 to 10 Ton / cm 2 at a mold temperature of 80 to 150 ° C. and consolidated. Let it be the body.
  • the molding pressure of about 8 to 10 Ton / cm 2 used here is much lower than the conventional molding pressure of about 20 Ton / cm 2 used for compacting Sendust alloy powder, and the compacting force used for general powder molding methods.
  • the Sendust alloy powder to produce an excellent composite soft magnetic material according to the present invention even at a general molding pressure.
  • the compact is fired at a temperature of 500 ° C. to 800 ° C. for about 1 hour in a vacuum atmosphere, an inert gas atmosphere (Ar, N 2 ), or in a non-oxidizing atmosphere (H 2 atmosphere) to obtain the desired composite.
  • a soft magnetic material can be obtained.
  • the pure iron powder subjected to insulation treatment is consolidated into an iron main phase
  • Sendust alloy powder is consolidated into a Sendust alloy main phase.
  • the target composite soft magnetic material can be obtained by exhibiting a structure in which a grain boundary phase formed as a result of firing the binder material so as to be present at those grain boundaries with respect to the main phase constituted by.
  • the composite soft magnetic material manufactured as described above has low loss in the high frequency range (10 to 20 kHz), excellent iron loss, hysteresis loss, coercive force, low eddy current loss, and high specific resistance. Has soft magnetic properties. This is because the composite soft magnetic material of the present invention covers pure iron powder with a film of the Mg—Fe—O ternary oxide deposited film containing (Mg, Fe) O having excellent insulation and adhesion.
  • the pure iron powder with a suitable particle size range is mixed with a suitable amount of Sendust alloy powder with a suitable particle size range, consolidated, and fired to form a composite soft magnetic material.
  • the insulation treatment of the pure iron powder is not limited to the above-described coating with the Mg—Fe—O ternary oxide deposited film containing (Mg, Fe) O, and the phosphate-coated pure iron powder, A similar composite soft magnetic material can be obtained also by a film subjected to another insulation treatment.
  • the composite soft magnetic material obtained by mixing pure iron powder and Sendust alloy powder and compacting as described above is mixed with soft pure iron powder in an appropriate blending ratio compared to Sendust alloy, compacted, and fired. Therefore, sufficient magnetic properties can be exhibited at a molding pressure of about 8 to 10 Ton / cm 2 .
  • the composite soft magnetic material of the present invention has a low loss in the high frequency range (10 to 20 kHz) inherent to the sendust alloy powder by setting the addition ratio of the sendust alloy powder in the range of 5% by mass or more and less than 20% by mass. Excellent soft magnetic properties such as low iron loss, hysteresis loss, coercive force, low eddy current loss, and high specific resistance can be obtained.
  • the send rate of the sendust alloy powder is less than the above range, these characteristics cannot be exhibited effectively.
  • the addition ratio of Sendust alloy powder is too large, the amount of pure iron powder decreases, so it becomes difficult to obtain a high saturation magnetic flux density and the pressure required during molding becomes high, and the molding pressure in the above range is good. It becomes difficult to obtain the density.
  • Examples of the electromagnetic circuit component configured using the composite soft magnetic material of the present invention include a magnetic core, a motor core, a generator core, a solenoid core, an ignition core, a reactor core, a transformer core, a choke coil core, and a magnetic sensor core. These are electromagnetic circuit components that can exhibit excellent characteristics in any case. Examples of electric devices incorporating these electromagnetic circuit components include an electric motor, a generator, a solenoid, an injector, an electromagnetically driven valve, an inverter, a converter, a transformer, a relay, or a magnetic sensor system.
  • the composite soft magnetic material of the present invention has the effect of contributing to high efficiency, high performance, small size and light weight of these electric devices.
  • MICROTRAC FRA manufactured by LEED & NORTHRUP was used.
  • pure Mg powder coated with Mg oxide the pure iron powder was heat-treated at 220 ° C. in the atmosphere to form an oxide film on the surface, and 0.3% by mass of Mg powder was added to the soft magnetic powder. Blending and rolling this blended powder with a granulation rolling agitation and mixing device in vacuum at 650 ° C.
  • Insulated pure iron powder As other insulation-coated pure iron powder, iron phosphate-coated iron powder S110i manufactured by Heganes Japan was prepared, and as a comparative sample, pure iron powder having a particle size equivalent to the above was prepared. .
  • the blending ratio of Sendust alloy powder (the blending ratio of Sendust alloy powder in the total mass of oxide-coated pure iron powder and Sendust alloy powder, mass%) is displayed in Table 1, and water density (g / cm 3), the specific resistance ( ⁇ m), ⁇ max, the saturation magnetic flux density when a magnetic field 10kA / m (B 10k a / m: T), the coercive force (Hc: a / m), iron loss (total Table 1 also shows the results of measuring the loss, hysteresis loss, eddy current loss) and mechanical strength (compression crushing strength: N / mm 2 ).
  • FIG. 1 is a graph plotting the relationship between the blending ratio and specific resistance of Sendust alloy powder shown in Table 1. According to the results shown in FIG. 1, the specific resistance value is remarkably low at 0% by mass in the blending ratio of Sendust alloy powder, but the specific resistance value increases rapidly in the sample to which 5% by mass of Sendust alloy powder is added. . Further, when the blending ratio is 20% by mass or more, the reduction ratio of specific resistance increases. Therefore, the blending ratio of Sendust alloy powder is preferably 5% by mass or more and less than 20% by mass.
  • FIG. 2 is a graph plotting the relationship between the blending ratio of Sendust alloy powder shown in Table 1 and the saturation magnetic flux density. According to the results shown in FIG. 2, the saturation magnetic flux density rapidly decreases when the blending ratio is 20% by mass or more. Therefore, the blending ratio of Sendust alloy powder to oxide-coated pure iron powder is preferably 5% by mass or more and less than 20% by mass in order to obtain a saturation magnetic flux density of 1T or more at a magnetic field of 10 kA / m, and a magnetic field of 10 kA / m. In order to obtain a saturation magnetic flux density of 1.1 T, 5 mass% or more and 10 mass% or less are more preferable.
  • FIG. 3 is a graph plotting the relationship between the magnetic flux density and the iron loss at the magnetic field of 10 kA / m shown in Table 1 (when the magnetic flux density is 0.1 T and the frequency is 10 kHz). According to the results shown in FIG. 3, the iron loss can be reduced without reducing the magnetic flux density by blending the sendust alloy powder.
  • FIG. 4 is a graph plotting the relationship between the blending ratio of the Sendust alloy powder shown in Table 1 and the loss. According to the result shown in FIG. 4, a blending ratio of less than 20% by mass is preferable for the loss. Moreover, when the blending ratio of Sendust alloy powder is 5 mass% or more and less than 20 mass%, an iron loss (at a magnetic flux density of 0.1 T and a frequency of 10 kHz) of 20 W / kg or less can be realized.
  • FIG. 5 is a graph plotting the relationship between the blending ratio of Sendust alloy powder shown in Table 1 and the mechanical strength. According to the results shown in FIG. 5, it is clear that the crushing strength has a mechanical strength peak between 5 and 10% by mass, but there is no problem in the practical range for the blending ratio of Sendust alloy powder. It turns out that it is.
  • a silicone resin-coated sendust in which 0.5% by mass of a silicone resin is mixed with pure iron powder and then baked at 250 ° C. is mixed with 1% by mass of silicone resin and baked at 200 ° C.
  • the alloy powder was blended so that the blending ratio of the silicone resin-coated Sendust alloy powder in the total mass of the silicone resin-coated pure iron powder and the silicone resin-coated Sendust alloy powder was 7% by mass.
  • the silicone resin-coated Sendust alloy powder obtained by mixing 1% by mass of silicone resin with Sendust alloy powder and baking at 150 ° C. 0.5% by mass of silicone resin is mixed to 150 ° C., 200 ° C., 250 ° C. , And 270 ° C.
  • the blending ratio of the silicone resin-coated Sendust alloy powder occupying the total mass of the silicone resin-coated Sendust alloy powder and the silicone resin-coated Sendiron alloy powder is 7%. %.
  • the baking temperature of the silicone resin with respect to the pure iron powder can be selected in the range of 150 to 250 ° C, more preferably in the range of 200 to 250 ° C.
  • Silicone resin-coated pure iron powder obtained by mixing 0.5% by mass of a silicone resin with pure iron powder and baking at 250 ° C. and 1% by mass of silicone resin were mixed at 50 ° C., 80 ° C., 100 ° C., 150 ° C., The silicone resin-coated Sendust alloy powder occupies the total mass of the silicone resin-coated pure iron powder and the silicone resin-coated Sendust alloy powder. It mix
  • the baking temperature of the silicone resin in the Sendust alloy powder can be selected in the range of 80 to 250 ° C, more preferably in the range of 100 to 200 ° C.
  • the soft magnetic characteristics such as low iron loss, low coercive force, and low eddy current loss of the proper amount of sendust alloy powder are effective.
  • the composite soft magnetic material obtained in the above can be provided.

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Abstract

La présente invention concerne un matériau magnétique souple composite caractérisé en ce qu'il est obtenu par mélange d'une poudre de fer qui a été soumise à un traitement isolant, d'une poudre d'alliage sendust et d'un liant, puis compression et traitement thermique du mélange. Le matériau magnétique souple composite se caractérise également en ce qu'il comprend une phase principale, dans laquelle la poudre de fer et la poudre d'alliage sendust sont compactées, et une phase de limite de grains qui est formée autour de la phase principale et se compose essentiellement du liant ; et en ce qu'il présente une proportion d'alliage sendust dans la phase principale supérieure ou égale à 5 % en masse, mais inférieure à 20 % en masse, une densité de flux magnétique de saturation supérieure ou égale à 1 T dans un champ magnétique de 10 kA/m, une coercivité inférieure ou égale à 260 A/m et une perte de fer inférieure ou égale à 20 W/kg (à 0,1 T, 10 kHz). Par conséquent, le matériau magnétique souple composite possède les caractéristiques de l'alliage sendust, notamment une perméabilité magnétique élevée, une faible coercivité et une faible perte de fer, tout en conservant une densité élevée de flux magnétique de saturation intrinsèque à la poudre de fer. L'invention porte aussi sur un procédé de production du matériau magnétique souple composite.
PCT/JP2009/007070 2008-12-25 2009-12-21 Matériau magnétique souple composite et son procédé de production WO2010073590A1 (fr)

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WO2019002434A1 (fr) * 2017-06-28 2019-01-03 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Procédé pour fabriquer un matériau composite magnétique doux et matériau composite magnétique doux
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US20130298730A1 (en) * 2011-02-22 2013-11-14 Diamet Corporation Composite soft magnetic material having low magnetic strain and high magnetic flux density, method for producing same, and electromagnetic circuit component
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CN103430250A (zh) * 2011-03-24 2013-12-04 住友电气工业株式会社 复合材料、电抗器用磁芯、电抗器、转换器和功率转换器装置
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JP2017143259A (ja) * 2011-04-07 2017-08-17 ホガナス アクチボラグ （パブル） 新規な組成物及び方法
JP2015213148A (ja) * 2013-11-29 2015-11-26 株式会社神戸製鋼所 圧粉磁心用混合粉末および圧粉磁心
WO2019002434A1 (fr) * 2017-06-28 2019-01-03 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Procédé pour fabriquer un matériau composite magnétique doux et matériau composite magnétique doux
JP2023085967A (ja) * 2021-12-09 2023-06-21 株式会社タムラ製作所 軟磁性粉末及び圧粉磁心
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CN114713817A (zh) * 2022-02-17 2022-07-08 苏州创浩新材料科技有限公司 一种电磁屏蔽铁基复合材料及其制备方法

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