WO2011001958A1 - 軟磁性材料、成形体、圧粉磁心、電磁部品、軟磁性材料の製造方法および圧粉磁心の製造方法 - Google Patents

軟磁性材料、成形体、圧粉磁心、電磁部品、軟磁性材料の製造方法および圧粉磁心の製造方法 Download PDF

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Publication number
WO2011001958A1
WO2011001958A1 PCT/JP2010/061020 JP2010061020W WO2011001958A1 WO 2011001958 A1 WO2011001958 A1 WO 2011001958A1 JP 2010061020 W JP2010061020 W JP 2010061020W WO 2011001958 A1 WO2011001958 A1 WO 2011001958A1
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Prior art keywords
magnetic material
soft magnetic
lubricant
magnetic particles
fatty acid
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Ceased
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PCT/JP2010/061020
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English (en)
French (fr)
Japanese (ja)
Inventor
麻子 渡辺
敏宏 坂本
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Sumitomo Electric Industries Ltd
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Sumitomo Electric Industries Ltd
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Application filed by Sumitomo Electric Industries Ltd filed Critical Sumitomo Electric Industries Ltd
Priority to KR1020117012279A priority Critical patent/KR101302921B1/ko
Priority to EP10794127.0A priority patent/EP2450916A4/en
Priority to CN2010800034402A priority patent/CN102227784A/zh
Priority to US13/131,746 priority patent/US20110227690A1/en
Publication of WO2011001958A1 publication Critical patent/WO2011001958A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
    • H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
    • H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
    • 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
    • B22F1/103—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing an organic binding agent comprising a mixture of, or obtained by reaction of, two or more components other than a solvent or a lubricating agent
    • 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
    • B22F3/02—Compacting only
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/255—Magnetic cores made from particles
    • 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
    • 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
    • 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
    • B22F1/08—Metallic powder characterised by particles having an amorphous microstructure
    • 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
    • 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 relates to a soft magnetic material, a molded body, a dust core, an electromagnetic component, a method for producing a soft magnetic material, and a method for producing a dust core.
  • the dust core is composed of a plurality of composite magnetic particles, and each of the plurality of composite magnetic particles has metal magnetic particles made of, for example, pure iron and an insulating film covering the surface thereof.
  • a component including a dust core and a coil configured by winding a winding around the outer periphery of the core is known.
  • the dust core is required to have a magnetic characteristic that can obtain a large magnetic flux density by applying a small magnetic field and a magnetic characteristic that can react sensitively to an external magnetic field.
  • Hysteresis loss is energy loss caused by energy required to change the magnetic flux density of the dust core, and eddy current loss is mainly in each metal magnetic particle constituting each dust core and between each metal magnetic particle. Energy loss caused by flowing eddy current. Hysteresis loss is proportional to the operating frequency, and eddy current loss is proportional to the square of the operating frequency. For this reason, hysteresis loss is predominant in the low frequency region, and eddy current loss is predominant in the high frequency region. That is, the ratio of the eddy current loss is large in the iron loss of the dust core for high frequency driving. In order to suppress eddy current loss, it is necessary to reduce the particle size of the metal magnetic particles.
  • Patent Document 1 As a material for a powder magnetic core in which the particle size of metal magnetic particles is reduced, for example, Japanese Patent Application Laid-Open No. 2004-319652 (Patent Document 1) has a particle size of 5 to 70 ⁇ m and contains iron and silicon as main components.
  • a soft magnetic powder comprising a plurality of composite magnetic particles formed of metal magnetic particles and an insulating coating formed on the surface of the metal magnetic particles and obtained by external oxidation of the metal magnetic particles is disclosed. .
  • a dust core produced by mixing a lubricant with the soft magnetic powder and applying a pressure of 16 ton / cm 2 is disclosed.
  • the soft magnetic powder disclosed in Patent Document 1 has poor fluidity because the particle size of the metal magnetic particles is small.
  • the filling property when filling the mold with this soft magnetic powder is poor. For this reason, there has been a problem that the density of a compact formed by pressure-molding this soft magnetic powder is generally low.
  • Patent Document 1 since a large pressure is applied when the dust core is molded, generally the extraction pressure when the dust core is extracted from the mold after the pressure molding is increased. For this reason, streaks, cracks, chips, and the like are generated in the dust core, and there is a problem in that molding tends to occur.
  • an object of the present invention is to provide a soft magnetic material, a molded body, a dust core, an electromagnetic component, a method for producing a soft magnetic material, and a method for producing a dust core that improve density and improve moldability. is there.
  • the soft magnetic material of the present invention includes a plurality of magnetic particles, a binder, and a lubricant.
  • the binder binds a plurality of magnetic particles.
  • the lubricant is included in the aggregate of the bound magnetic particles and has a melting point of 100 ° C. or lower.
  • the soft magnetic material includes a lubricant having a melting point of 100 ° C. or lower.
  • the lubricant in the magnetic particles is liquefied and extruded onto the mold surface. Since the lubricant exists at the interface between the molded body formed by pressure-molding the soft magnetic material with a mold and the mold, the extraction pressure when the molded body is extracted from the mold can be reduced. Therefore, it is possible to suppress molding defects such as streaks, cracks, and chips from occurring in the molded body, so that moldability can be improved.
  • a lubricant that liquefies during pressure molding is present inside the aggregate of the bound magnetic particles.
  • the lubricant present in the binder promotes cohesive failure of the binder and reduces the binding force.
  • the plurality of magnetic particles that have been bound can be easily separated to facilitate rearrangement of the magnetic particles.
  • the liquefied lubricant is easily discharged from the inside of the molded body to the mold surface, it can contribute to the improvement of the density of the molded body. Accordingly, it is possible to improve the density of a molded body obtained by pressure-molding a soft magnetic material.
  • the fluidity can be improved.
  • the filling property is high. For this reason, the density of a molded object can be improved.
  • the method for producing a soft magnetic material of the present invention includes the following steps. First, a binder and a lubricant having a melting point of 100 ° C. or less are mixed to form an additive. A plurality of magnetic particles are bound by the additive.
  • a plurality of magnetic particles are bound using a binder and a lubricant having a melting point of 100 ° C. or lower. For this reason, a lubricant can be included in the aggregate of bound magnetic particles. Therefore, as described above, it is possible to manufacture a soft magnetic material that can improve density and improve moldability.
  • the lubricant preferably contains a fatty acid monoamide or a fatty acid monoester.
  • a lubricant containing a fatty acid monoamide or a fatty acid monoester is used.
  • Lubricants containing fatty acid monoamides or fatty acid monoesters are liable to be liquefied during molding, so that the lubricant is easily extruded onto the mold surface. For this reason, the moldability can be further improved, and the density of the molded body formed by pressure-molding the soft magnetic material can be further improved.
  • the lubricant preferably contains an unsaturated fatty acid monoamide or an unsaturated fatty acid monoester.
  • a lubricant containing an unsaturated fatty acid monoamide or an unsaturated fatty acid monoester is used in the step of forming the additive.
  • Lubricants containing unsaturated fatty acid monoamides or unsaturated fatty acid monoesters are more liable to liquefy during molding than lubricants containing saturated fatty acid monoamides or saturated fatty acid monoesters, so that the lubricant is easily extruded onto the mold surface. It is. For this reason, the moldability can be further improved, and the density of the molded body formed by pressure-molding the soft magnetic material can be further improved.
  • the molded body of the present invention is produced by pressure molding the soft magnetic material of the present invention.
  • the soft magnetic material that can improve the moldability and the density is used. For this reason, when this soft magnetic material is pressure-molded, it is possible to realize a molded body that improves moldability and density.
  • the dust core of the present invention is produced by heat-treating the above-described molded body of the present invention. Moreover, the manufacturing method of the powder magnetic core of this invention is equipped with the following processes. First, a soft magnetic material is manufactured by the soft magnetic material manufacturing method. Then, the soft magnetic material is pressure-molded to form a molded body. And this molded object is heat-processed.
  • the soft magnetic material that can improve the formability and the density is used. For this reason, when this soft magnetic material is pressure-molded and heat-treated, a dust core having good moldability and improved density can be realized.
  • the soft magnetic material is pressure-molded by controlling the temperature of the soft magnetic material to be equal to or higher than the melting point of the lubricant.
  • the lubricant is easily extruded onto the mold surface. For this reason, the powder magnetic core which improved the moldability more and improved the density more can be manufactured.
  • the electromagnetic component of the present invention includes the dust core and a coil wound around the dust core.
  • the electromagnetic component of the present invention includes the above-described powder magnetic core of the present invention and a coil that is formed by winding a winding and is disposed outside the magnetic core.
  • the soft magnetic material that can improve the moldability and the density is used. For this reason, a high-density electromagnetic component can be realized.
  • the soft magnetic material, the molded body, the dust core, the electromagnetic component, the soft magnetic material manufacturing method and the dust core manufacturing method of the present invention Since the lubricant having a melting point of 100 ° C. or less is included, the density can be improved and the moldability can be improved.
  • Embodiment 1 of this invention It is a figure which shows typically the soft-magnetic material in Embodiment 1 of this invention. It is a figure which shows typically the soft-magnetic material in the modification of Embodiment 1 of this invention. It is a flowchart which shows the manufacturing method of the soft-magnetic material in Embodiment 1 of this invention. It is a figure which shows typically the soft-magnetic material in Embodiment 2 of this invention. It is a flowchart which shows the manufacturing method of the soft-magnetic material in Embodiment 2 of this invention. It is a figure which shows typically the dust core in Embodiment 3 of this invention. It is a flowchart which shows the manufacturing method of the powder magnetic core in Embodiment 3 of this invention.
  • 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 as magnetic particles, a binder 20, and a lubricant 30.
  • 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) -nickel (Ni) -cobalt (Co) alloy, iron (Fe) -aluminum (Al) -silicon (Si) alloy, iron (Fe) -aluminum ( Al) -chromium (Cr) alloy, iron (Fe) -aluminum (Al) -manganese (Mn) alloy, iron (Fe) -aluminum (Al) -nic
  • the average particle size of the metal magnetic particles 10 is preferably 1 ⁇ m or more and 70 ⁇ m or less.
  • the average particle size of the metal magnetic particles 10 is preferably 1 ⁇ m or more and 70 ⁇ m or less.
  • the average particle diameter of the metal magnetic particles 10 refers to the particle diameter of particles in which the sum of masses from the smaller particle diameter reaches 50% of the total mass in the particle diameter histogram, that is, 50% particle diameter.
  • the binder 20 binds a plurality of metal magnetic particles 10.
  • a thermoplastic resin, a thermosetting resin, or the like can be used, and it is preferable to have a general-purpose solvent that can be compatible with the lubricant 30, that is, can be dissolved together with the lubricant 30.
  • Lubricant 30 is included in the aggregate of bound metal magnetic particles 10. Further, in the soft magnetic material, the additive present inside, not the outer surface of the aggregate of the bound metal magnetic particles 10, that is, the binder 20 and the lubricant 30, is 50 mass with respect to the total amount of the additive. % Or more is preferable.
  • the lubricant 30 has a melting point of 100 ° C. or lower, preferably 75 ° C. or lower. By using a lubricant having such a low melting point, the lubricant 30 is liquefied and easily extruded onto the mold surface when pressure-molding with a mold.
  • the lubricant 30 preferably contains at least one of a fatty acid monoamide and a fatty acid monoester, and more preferably contains a fatty acid monoamide or a fatty acid monoester.
  • the lubricant 30 is more preferably composed of at least one of a fatty acid monoamide and a fatty acid monoester, and even more preferably composed of a fatty acid monoamide or a fatty acid monoester.
  • the fatty acid monoamide is represented by, for example, the following chemical formulas 1 to 3, where the alkyl group is R 1 , R 2 , or R 3 .
  • the fatty acid monoester is represented by the following chemical formula 4, for example.
  • fatty acid monoamides examples include oleic acid amide, erucic acid amide, linoleic acid amide, stearic acid amide, caprylic acid amide, lauric acid amide, myristic acid amide, palmitic acid amide, and behenic acid amide.
  • fatty acid monoester for example, oleic acid ester, erucic acid ester, linoleic acid ester, stearic acid ester, caprylic acid ester, lauric acid ester, myristic acid ester, palmitic acid ester, behenic acid ester, etc. may be used. it can.
  • the fatty acid monoamide and the fatty acid monoester are preferably unsaturated. Since unsaturated fatty acid monoamides and unsaturated fatty acid monoesters have lower melting points than saturated fatty acid monoamides and saturated fatty acid monoesters, the lubricant 30 is easily liquefied on the mold surface during pressure molding with a mold. Extruded.
  • unsaturated fatty acid amide for example, oleic acid amide, erucic acid amide, linoleic acid amide and the like can be used.
  • unsaturated fatty acid ester, oleic acid ester, erucic acid ester, linoleic acid ester, etc. can be used, for example.
  • FIG. 2 is a diagram schematically showing a soft magnetic material in a modification of the present embodiment.
  • the soft magnetic material includes an additive 40 in which a binder 20 and a lubricant 30 are integrated. That is, the binder 20 and the lubricant 30 may exist separately as shown in FIG. 1, or may be integrated as shown in FIG.
  • the soft magnetic material shown in FIG. 1 or 2 may further include other additives as long as the characteristics of the soft magnetic material of the present embodiment are not impaired.
  • FIG. 3 is a flowchart showing a method for manufacturing a soft magnetic material in the present embodiment.
  • metal magnetic particles 10 are prepared (step S10).
  • step S10 the metal magnetic particles 10 described above are prepared.
  • These metal magnetic particles 10 are prepared, for example, by pulverizing iron containing a predetermined component by a gas atomization method or a water atomization method.
  • the temperature of heat processing is 700 degreeC or more and less than 1400 degreeC, for example.
  • the temperature of heat processing is 700 degreeC or more and less than 1400 degreeC, for example.
  • these defects can be reduced by performing heat treatment on the metal magnetic particles 10. Note that this heat treatment step may be omitted.
  • step S20 the binder 20 and the lubricant 30 having a melting point of 100 ° C. or lower, preferably 75 ° C. or lower are mixed to form an additive (step S20).
  • the binder 20 and the lubricant 30 described above are prepared, and the lubricant 30 is dissolved in the solvent of the binder 20.
  • the lubricant to be prepared preferably contains at least one of a fatty acid monoamide and a fatty acid monoester, and more preferably contains a fatty acid monoamide or a fatty acid monoester.
  • the fatty acid monoamide or fatty acid monoester contained in the lubricant is more preferably unsaturated.
  • step S30 a plurality of metal magnetic particles 10 are bound with an additive (step S30).
  • step S30 the plurality of metal magnetic particles 10 and an additive solution or dispersion containing the binder 20 and the lubricant 30 are mixed, and the solvent or dispersion is removed by drying.
  • a plurality of metal magnetic particles 10 are bound by the binder 20, and a soft magnetic material in which the lubricant 30 is included in the aggregate of the bound metal magnetic particles 10 is obtained.
  • the soft magnetic material shown in FIG. 1 or FIG. 2 can be manufactured by performing the above steps S10 to S30.
  • FIG. 4 is a diagram schematically showing the soft magnetic material in the present embodiment.
  • the soft magnetic material in the present embodiment basically has the same configuration as the soft magnetic material in the first embodiment, but differs in that an insulating coating 70 is further provided.
  • the magnetic particles of the present embodiment include metal magnetic particles 10 and an insulating coating 70 surrounding the metal magnetic particles 10.
  • the insulating coating 70 functions as an insulating layer between the metal magnetic particles 10.
  • the average film thickness of the insulating coating 70 is preferably 10 nm or more and 1 ⁇ m or less. By setting the average film thickness of the insulating coating 70 to 10 nm or more, eddy current loss can be effectively suppressed. By setting the average film thickness of the insulating coating 70 to 1 ⁇ m or less, it is possible to prevent the insulating coating 70 from being sheared and destroyed during pressure molding. In addition, since the ratio of the insulating coating 70 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 is obtained by composition analysis (TEM-EDX: transmission electron microscope energy dispersive X-ray spectroscopy) and inductively coupled plasma mass spectrometry (ICP-MS).
  • TEM-EDX transmission electron microscope energy dispersive X-ray spectroscopy
  • ICP-MS inductively coupled plasma mass spectrometry
  • the insulating coating 70 is preferably made of at least one substance selected from the group consisting of a phosphate compound, a silicon compound, a titanium compound, a zirconium compound, and a boron compound. Since these substances are excellent in insulation, eddy currents flowing between the metal magnetic particles 10 can be effectively suppressed. Specifically, it is preferably made of silicon oxide, titanium oxide, zirconium oxide or the like. In particular, by using a metal oxide containing phosphate for the insulating coating 70, the coating layer covering the surface of the metal magnetic particles can be made thinner. This is because the magnetic flux density of the magnetic particles can be increased and the magnetic properties are improved.
  • the insulating coating 70 is made of Fe, Al, Ca (calcium), Mn, Zn (zinc), Mg (magnesium), V (vanadium), Cr, Y (yttrium), Ba (barium), Sr (strontium) as metals. Or a metal oxide, a metal nitride, a metal oxide, a metal phosphate compound, a metal borate compound, or a metal silicate compound using a rare earth element.
  • the insulating coating 70 includes an amorphous compound of a phosphate of at least one substance selected from the group consisting of Al, Si, Mg, Y, Ca, Zr (zirconium), and Fe, and boron of the substance. It may consist of an amorphous acid salt compound.
  • the insulating coating 70 may be made of an amorphous compound of an oxide of at least one substance selected from the group consisting of Si, Mg, Y, Ca, and Zr.
  • the magnetic particles constituting the soft magnetic material are composed of a single layer of insulating coating.
  • the magnetic particles constituting the soft magnetic material may be composed of multiple layers of insulating coating. Good.
  • FIG. 5 is a flowchart showing a method for manufacturing a soft magnetic material in the present embodiment.
  • the manufacturing method of the soft magnetic material in the present embodiment basically has the same configuration as the manufacturing method of the soft magnetic material in the first embodiment, but the insulating film 70 is formed. The difference is that step S11 is further provided.
  • an insulating film 70 surrounding the surface of the metal magnetic particles 10 is formed (step S12).
  • the insulating film 70 made of the material as described above is formed.
  • the insulating coating 70 made of at least one substance selected from the group consisting of phosphorus compounds, silicon compounds, titanium compounds, zirconium compounds, boron compounds, silicone resins, thermoplastic resins, non-thermoplastic resins and higher fatty acids is formed. It is preferable.
  • the insulating coating 70 can be formed, for example, by subjecting the metal magnetic particles 10 to a phosphate chemical conversion treatment.
  • a sol-gel process using a solvent spray or a precursor can be used in addition to the phosphate chemical conversion process.
  • a wet coating process using an organic solvent, a direct coating process using a mixer, or the like can be used. Thereby, the insulating coating 70 can be formed on each surface of the metal magnetic particles 10, and a plurality of magnetic particles can be obtained.
  • the magnetic particles constituting the soft magnetic material are constituted by the single-layer insulating coating 70 .
  • the magnetic particles constituting the soft magnetic material are constituted by the multiple-layer insulating coating 70 as described above. May be.
  • one insulating coating and another insulating coating surrounding the surface of the one insulating coating are formed.
  • at least one substance selected from the group consisting of a compound, a titanium compound, a zirconium compound, and a boron compound, and the other insulating coating includes a silicone resin, a silicon compound, a thermoplastic resin, a non-thermoplastic resin, and a higher fatty acid salt. It is preferably made of at least one substance selected from the group consisting of
  • FIG. 6 is a diagram schematically showing a dust core in the present embodiment.
  • the dust core shown in FIG. 6 is manufactured using the soft magnetic material of the first embodiment.
  • the dust core in the present embodiment includes metal magnetic particles 10 and an insulator 60.
  • FIG. 7 is a flowchart showing a method of manufacturing a dust core in the present embodiment.
  • a soft magnetic material is manufactured as in the first embodiment (steps S10 to S30).
  • the soft magnetic material is pressure-molded to form a molded body (step S40).
  • the obtained soft magnetic material is put into a metal mold and press-molded at a pressure in a range from 390 MPa to 1500 MPa, for example. Thereby, the molded object formed by press-molding a soft magnetic material is formed.
  • the fluidity of the soft magnetic material is high, so the filling property is high. This is because a plurality of metal magnetic particles constituting the soft magnetic material are bound by the binder 20, and thus the apparent particle size is increased.
  • step S40 when the pressure molding is performed in step S40, the lubricant 30 is liquefied and pushed out to the mold surface of the mold, that is, the boundary surface between the molded body and the mold.
  • this step S40 it is preferable to perform pressure molding at or above the melting point of the lubricant.
  • the extraction pressure can be reduced. Therefore, it is possible to suppress molding defects such as streaks, cracks, and chips from occurring in the molded body, so that moldability can be improved.
  • the lubricant 30 that liquefies during pressure molding exists inside the aggregate of the metal magnetic particles 10, so when soft molding a soft magnetic material with a mold, the lubricant 30 existing inside the binder 20 promotes the cohesive failure of the binder 20 and reduces the binding force. Thereby, the plurality of metal magnetic particles 10 that have been bound can be easily separated, and rearrangement of the metal magnetic particles 10 is promoted. Accordingly, it is possible to improve the density of a molded body obtained by pressure-molding a soft magnetic material.
  • step S50 the molded body is heat-treated.
  • heat treatment is performed at a temperature of 400 ° C. or higher and 900 ° C. or lower. Since many defects are generated in the molded body that has been subjected to pressure molding, these defects can be removed by heat treatment.
  • the powder core shown in FIG. 6 is completed by subjecting the molded body to appropriate processing such as extrusion or cutting as necessary.
  • FIG. 8 is a diagram schematically showing a dust core in the present embodiment.
  • the dust core shown in FIG. 8 is manufactured using the soft magnetic material of the second embodiment.
  • the powder magnetic core in the present embodiment has basically the same configuration as the powder magnetic core in the third embodiment, but is further provided with an insulating coating 70 surrounding the surface of the metal magnetic particle 10. Different.
  • FIG. 9 is a flowchart showing a method of manufacturing a dust core in the present embodiment.
  • the method for manufacturing a powder magnetic core in the present embodiment basically has the same configuration as that of the third embodiment, but further includes step S11 for forming an insulating film, and heat treatment step S50. It differs in the heat treatment temperature.
  • a soft magnetic material is manufactured as in the second embodiment (steps S10 to S30).
  • the soft magnetic material is pressure-molded to form a molded body (step S40). Since these steps S10 to S40 are substantially the same as the method for manufacturing the soft magnetic material of the second embodiment and step S40 of the third embodiment, description thereof will not be repeated.
  • step S50 the molded body is heat-treated.
  • heat treatment is performed at a temperature not lower than 400 ° C. and not higher than the thermal decomposition temperature of the insulating coating 70, for example.
  • heat treatment is performed at a temperature lower than the thermal decomposition temperature of the insulating coating 70, deterioration of the insulating coating 70 can be suppressed by performing the heat treatment.
  • the electromagnetic component of the present invention includes the above-described dust core and coil.
  • the shape of the powder magnetic core include an E-type and an I-type core such as an annular shape and a rod shape.
  • the coil is formed by winding a winding having a conductive wire provided with an insulating coating.
  • various shapes such as a circle and a rectangle can be used. For example, a round wire is spirally wound to form a cylindrical coil, and a flat wire is spirally edgewise wound to form a rectangular tube coil.
  • This electromagnetic component may be configured by winding a winding around the outer periphery of the powder magnetic core, or may be configured by inserting an air-core coil formed in advance in a spiral shape into the outer periphery of the powder magnetic core.
  • this electromagnetic component includes a high-frequency choke coil, a high-frequency tuning coil, a bar antenna coil, a power choke coil, a power transformer, a switching power transformer, and a reactor.
  • Example 1 The dust core of Example 1 of the present invention was manufactured according to the method for manufacturing a dust core (S10 to S20) in the third embodiment of the present invention.
  • iron powder contains 99.6% by weight or more of iron by the water atomization method, and the balance is 0.3% by weight or less of O (oxygen) and 0.1%.
  • Metal magnetic particles composed of unavoidable impurities such as C, N, P, or Mn in an amount of not more than% by weight were prepared.
  • the average particle size of the metal magnetic particles was 10 ⁇ m.
  • step S20 in which the binder and the lubricant are mixed, the process was performed as follows.
  • a binding dimethyl silicone resin was prepared as a binder, and oleic acid amide having a melting point of 75 ° C. was prepared as a lubricant.
  • a binder in an amount of 1.8% by mass with respect to metal magnetic particles to be mixed later was dissolved in a xylene solvent.
  • An amount of oleic amide of 0.5% by mass with respect to metal magnetic particles to be mixed later was added to this solvent and mixed. Thereby, an additive containing a binder and a lubricant was formed.
  • step S30 for binding the metal magnetic particles the metal magnetic particles and the additive were mixed. Thereafter, the solvent was removed by drying. As a result, as shown in FIG. 1, a soft magnetic material was produced in which a lubricant having a melting point of 100 ° C. or less was contained in an assembly of magnetic particles bound together.
  • step S40 to form a molded body the soft magnetic material was filled in a mold, 2ton / cm 2, 4ton / cm 2, 6ton / cm 2, 8ton / cm 2, 10ton / cm 2 and 12 ton / cm
  • Six types of molded bodies were produced by applying a pressure of 2 .
  • step S50 of heat treatment the compacts were heat treated at 750 ° C. for 1 hour in a nitrogen atmosphere. Thereby, the dust core of Invention Example 1 was produced.
  • Invention Example 2 basically had the same configuration as that of Invention Example 1, except that stearic acid ester having a melting point of 60 ° C. was used as a lubricant. Incidentally, when forming the molded body, by applying a pressure of 2ton / cm 2, 4ton / cm 2, 6ton / cm 2, 8ton / cm 2, 10ton / cm 2 and 12 ton / cm 2, 6 kinds of moldings was made.
  • Comparative Example 1 The method of manufacturing the dust core of Comparative Example 2 basically had the same configuration as the method of manufacturing the dust core of Example 1 of the present invention, but the step S20 for mixing the binder and the lubricant was performed. It was different in not having.
  • step S10 for preparing metal magnetic particles was performed as in Example 1 of the present invention.
  • metal magnetic particles were bound using the same binder as in Invention Example 1.
  • a lubricant was added.
  • FIG. 10 is a diagram schematically showing the soft magnetic material of Comparative Example 1.
  • the lubricant 30 hardly contained in the aggregate of the bound metal magnetic particles 10, and the aggregate of the bound metal magnetic particles 10. Many lubricants 30 were present outside the surface.
  • step S40 for pressure forming and step S50 for heat treatment were performed. Thereby, the dust core of the comparative example 1 was manufactured.
  • Comparative Example 2 basically had the same configuration as that of Inventive Example 1, but differed only in that ethylene bisstearamide having a melting point of 140 ° C. was used as the lubricant. Incidentally, when forming the molded body, by applying a pressure of 2ton / cm 2, 4ton / cm 2, 6ton / cm 2 and 8 ton / cm 2, to prepare four types of moldings.
  • Comparative Example 3 basically had the same configuration as Comparative Example 1, but differed only in that ethylene bisstearamide was used as the lubricant. That is, as shown in FIG. 10, ethylene bisstearamide as a lubricant was hardly contained in the aggregate of bound metal magnetic particles. Incidentally, when forming the molded body, by applying a pressure of 2ton / cm 2, 4ton / cm 2, 6ton / cm 2 and 8ton / cm 2, 10ton / cm 2 and 12 ton / cm 2, 6 kinds of moldings was made.
  • Comparative Example 4 basically had the same configuration as that of Inventive Example 1, but differed only in that no lubricant was added and the amount of binder added. Specifically, in the soft magnetic material of Comparative Example 4, only 0.6% by mass of a binder was mixed with a plurality of metal magnetic particles, and no lubricant was added. Incidentally, when forming the molded body, by applying a pressure of 2ton / cm 2, 4ton / cm 2, 6ton / cm 2 and 8ton / cm 2, 10ton / cm 2 and 12 ton / cm 2, 6 kinds of moldings was made.
  • Comparative Example 5 basically had the same configuration as Comparative Example 4, but was different only in that 1.2% by mass of a binder was used. That is, in the soft magnetic material of Comparative Example 5, only 1.2% by mass of the binder was mixed with the plurality of metal magnetic particles, and no lubricant was added. Incidentally, when forming the molded body, by applying a pressure of 2ton / cm 2, 4ton / cm 2, 6ton / cm 2 and 8 ton / cm 2 and 10ton / cm 2, to prepare five kinds of molded bodies.
  • Comparative Example 6 basically had the same configuration as Example 1 of the present invention, but was different only in that no lubricant was added. Specifically, the soft magnetic material of Comparative Example 6 was A plurality of metal magnetic particles were mixed with only 1.8% by mass of a binder, and no lubricant was added. Incidentally, when forming the molded body, by applying a pressure of 2ton / cm 2, 4ton / cm 2, 6ton / cm 2 and 8 ton / cm 2 and 10ton / cm 2, to prepare five kinds of molded bodies.
  • FIG. 11 is a diagram showing the relationship between the pressure applied during pressure molding and the density of the molded body (dust core) in the examples.
  • the horizontal axis indicates the pressure (unit: ton / cm 2 ) applied during pressure molding
  • the vertical axis indicates the density of the molded body (unit: g / cm 3 ).
  • FIG. 12 is a diagram showing the relationship between the pressure applied during pressure molding and the extraction pressure in the examples.
  • the horizontal axis indicates the pressure (unit: ton / cm 2 ) applied during pressure molding
  • the vertical axis indicates the extraction pressure (unit: MPa).
  • Example 1 of the present invention produced using a soft magnetic material having an oleic amide contained in an aggregate of bound metal magnetic particles, and the bound metal magnetic particles
  • the dust core of Example 2 of the present invention produced by using a soft magnetic material containing a stearate ester contained in the aggregate was the dust of Comparative Examples 1 to 3 that had the same pressure applied during pressure molding. It was higher than the density of the magnetic core and had a high density of 4.8 g / cm 3 to 5.6 g / cm 3 . In other words, it was found that Examples 1 and 2 of the present invention can improve the density even when the pressure during pressure molding is low.
  • the dust cores of the inventive examples 1 and 2 can realize an extraction pressure that is lower than the extraction pressure of the same comparative examples 1 to 6 when the pressure applied during the pressure molding is the same.
  • the body was free from streaks, cracks and chips, and had good moldability. In other words, it was found that Examples 1 and 2 of the present invention can maintain good moldability even when the pressure applied during pressure molding is increased.
  • the pressure of Comparative Example 1 in which a large amount of the lubricant 30 was present outside the aggregate of the plurality of bound metal magnetic particles 10 was hardly included in the aggregate of the bound metal magnetic particles 10.
  • the density of the powder magnetic core was lower than that of Invention Example 1 when the pressure at the time of pressure molding was the same as that of Invention Example 1.
  • the extraction pressure was higher than Example 1 of the present invention, but when the pressure applied during pressure molding was 12 ton / cm 2 , the extraction pressure remained at 17 MPa, and good moldability could be maintained.
  • Comparative Example 2 using ethylene bisstearamide having a melting point exceeding 100 ° C. as a lubricant
  • Comparative Example 3 using ethylene bisstearamide as a lubricant which is hardly included in the metal magnetic particles
  • the pressure at the time of pressure forming was the same as in Invention Examples 1 and 2
  • the density was lower and the extraction pressure was higher than in Invention Examples 1 and 2.
  • extraction pressure is 20MPa As a result, streaks, cracks and chips occurred in the molded product.
  • the moldability is improved by reducing the extraction pressure.
  • the density can be improved.
  • the dust core made of the soft magnetic material of the present invention is used for, for example, a high-frequency choke coil, a high-frequency tuning coil, a bar antenna coil, a power choke coil, a power transformer, a switching power transformer, a reactor, etc. Can do.

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PCT/JP2010/061020 2009-06-30 2010-06-29 軟磁性材料、成形体、圧粉磁心、電磁部品、軟磁性材料の製造方法および圧粉磁心の製造方法 Ceased WO2011001958A1 (ja)

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KR1020117012279A KR101302921B1 (ko) 2009-06-30 2010-06-29 연자성 재료, 성형체, 압분자심, 전자 부품, 연자성 재료의 제조 방법 및 압분자심의 제조 방법
EP10794127.0A EP2450916A4 (en) 2009-06-30 2010-06-29 SOFT MAGNETIC MATERIAL, FORM BODY, MAGNETIC PRESSURE PULVERARY CORE, ELECTROMAGNETIC COMPONENT, METHOD FOR PRODUCING SOFT MAGNETIC MATERIAL AND FOR PRODUCING THE MAGNETIC PRESS POWDER CORE
CN2010800034402A CN102227784A (zh) 2009-06-30 2010-06-29 软磁性材料、压粉体、压粉磁心、电磁元件、制造软磁性材料的方法以及制造压粉磁心的方法
US13/131,746 US20110227690A1 (en) 2009-06-30 2010-06-29 Soft magnetic material, compact, dust core, electromagnetic component, method of producing soft magnetic material, and method of producing dust core

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KR101302921B1 (ko) 2013-09-06
TW201117240A (en) 2011-05-16
US20110227690A1 (en) 2011-09-22
CN102227784A (zh) 2011-10-26
EP2450916A4 (en) 2016-11-16
JP5650928B2 (ja) 2015-01-07
KR20110090979A (ko) 2011-08-10
JP2011029605A (ja) 2011-02-10

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