WO2014034616A1 - 圧粉磁心用鉄粉および圧粉磁心の製造方法 - Google Patents
圧粉磁心用鉄粉および圧粉磁心の製造方法 Download PDFInfo
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- 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
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- 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
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
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- 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
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- 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
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- 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
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- 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
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- 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
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- 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
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- 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
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
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- 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
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
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- 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
Definitions
- Iron loss is energy loss inside the magnetic material that occurs when an alternating magnetic field is applied inside the ferromagnetic material. Since electromagnetic parts such as the inductor and the motor are often used in an alternating magnetic field, a reduction in iron loss is required for a dust core used in the electromagnetic part from the viewpoint of improving electromagnetic conversion characteristics.
- inductors, reactors, etc. are used at a high driving frequency, so it is important to reduce eddy current loss.
- the surface of iron-based particles may be covered with an insulating coating.
- an insulating coating By covering the surface of the iron-based particles with an insulating coating, the generation of eddy currents that flow across a plurality of particles is suppressed. Thereby, since an eddy current is localized in each particle, an eddy current loss can be reduced as a whole.
- an insulating inorganic film for example, a phosphoric acid-based chemical film, a water glass film, an oxide film, etc.
- a resin film for example, a silicone resin film
- soft magnetic powder having a small particle size for example, Patent Document 1.
- the magnetic flux density can also be improved by increasing the density of the compact of the dust core.
- the iron-based raw material powder used as the raw material for the powder magnetic core is often oxidized on the surface, and therefore needs to be subjected to reduction annealing.
- the reduction annealing is performed at 900 ° C. or higher and 1250 ° C. or lower in a reducing atmosphere such as hydrogen.
- reduction annealing is performed at a high temperature of 900 ° C. or higher and 1250 ° C. or lower, the sintering of the iron-based raw material powder proceeds, and adjacent iron-based raw material powders are fusion bonded.
- the mass ratio of the soft magnetic powder (second soft magnetic powder) that passes through a sieve having an opening of 600 ⁇ m is 98% by mass or more based on the total amount of the soft magnetic powder.
- the average strain is less than 0.050%.
- the soft magnetic powder is preferably iron-based particles having an insulating layer on the surface.
- a soft magnetic powder (first soft magnetic powder) that passes 95% by mass or more through a sieve having an opening of 75 ⁇ m and has an average strain of less than 0.100%. Therefore, it is possible to manufacture a dust core having an improved compact density and an improved magnetic flux density.
- a soft magnetic powder (second soft magnetic material) that passes 98% by mass or more through a sieve having an aperture of 600 ⁇ m and has an average strain of less than 0.050%.
- the iron loss can be reduced, and at the same time, the density of the compact can be improved, and a dust core having an improved magnetic flux density can be produced.
- an industrially advantageous degree of pulverization is evaluated using strain as an index. be able to.
- FIG. 1 is a graph plotting the density of the compacts of the dust cores obtained in Invention Examples 1 to 4 and Comparative Example 1 against the average strain.
- FIG. 2 is a graph plotting the density of the compacts of the powder magnetic cores obtained in Invention Examples 5 and 6 and Comparative Example 2 against the average strain.
- FIG. 3 is a graph plotting the iron loss of the dust cores obtained in Invention Examples 1 to 4 and Comparative Example 1 against the average strain.
- the strain introduced by pulverization in this way is difficult to remove even by annealing the compact, and even if the soft magnetic powder particle size is reduced and eddy current loss is reduced, the hysteresis loss further increases. As a result, the iron loss is increased.
- the soft magnetic powder into which distortion has been introduced by pulverization is cured, even if such soft magnetic powder is compression-molded, a high compact density cannot be obtained, and the magnetic flux density decreases.
- the mass ratio of the soft magnetic powder passing through the sieve having an aperture of 600 ⁇ m is 98 mass% or more with respect to the total amount of the soft magnetic powder, and the average strain is The second soft magnetic powder that is less than 0.050% is compression-molded.
- the dust core manufactured by the second manufacturing method is preferably applied to an electromagnetic component used at a low driving frequency, for example, a rotor of a motor or a core of a stator.
- the atmosphere during the heat treatment is preferably a non-oxidizing atmosphere.
- the atmospheric gas include nitrogen or a rare gas such as helium or argon.
- the heat treatment time is not particularly limited as long as the specific resistance is not deteriorated, but is preferably 20 minutes or more, more preferably 30 minutes or more, and further preferably 1 hour or more.
- Soft magnetic powder 2-1 Soft magnetic powder 2-1-1.
- First soft magnetic powder In the first soft magnetic powder of the present invention, the mass ratio of the soft magnetic powder passing through a sieve having an opening of 75 ⁇ m is 95% by mass or more with respect to the total amount of the soft magnetic powder, and the average strain is less than 0.100%. It is characterized by being.
- the mass ratio of the soft magnetic powder that passes through a sieve having a mesh opening of 75 ⁇ m is preferably 96 mass% or more, more preferably 98 mass% or more.
- the powder magnetic core manufactured by the manufacturing method of the present invention is used at a high-frequency driving frequency. Even when used as an electromagnetic component such as an inductor, iron loss, particularly eddy current loss, is effectively reduced.
- the average strain is preferably 0.097% or less, more preferably 0.090% or less, still more preferably 0.080% or less, and particularly preferably 0.070% or less. As the average strain is smaller, the powder magnetic core produced by the first production method of the present invention has a higher molded body density and a higher magnetic flux density, so that iron loss can be reduced.
- the first soft magnetic powder of the present invention is preferably iron-based particles having a later-described insulating layer on the surface.
- the mass ratio of the soft magnetic powder that does not pass through a sieve having an opening of 45 ⁇ m is preferably 40% by mass or more.
- the mass ratio of the soft magnetic powder that does not pass through a sieve having an opening of 45 ⁇ m is preferably 42% by mass or more.
- the higher the mass ratio of the soft magnetic powder that does not pass through a sieve having a mesh opening of 45 ⁇ m the more uniform the particle size of the soft magnetic powder, and at the same time, less strain introduced during pulverization, so that the density of the compact can be increased. Since the density is increased and the iron loss is reduced, it is possible to manufacture a dust core having excellent magnetic properties.
- the mass ratio of the soft magnetic powder that passes through the sieve having an aperture of 600 ⁇ m is set to 98 mass% or more with respect to the total amount of the soft magnetic powder.
- the average strain is preferably 0.045% or less, more preferably 0.040% or less. As the average strain is smaller, the powder magnetic core produced by the second production method of the present invention has a higher compact density and a higher magnetic flux density, so that iron loss can be reduced.
- the mass ratio of the soft magnetic powder that does not pass through a sieve having an opening of 180 ⁇ m is preferably 20% by mass or more.
- the higher the mass ratio of the soft magnetic powder that does not pass through a sieve having a mesh opening of 180 ⁇ m the more uniform the particle size of the soft magnetic powder and, at the same time, less strain introduced during pulverization, the density of the compact can be increased, As a result, the magnetic flux density is increased.
- the particle size of the soft magnetic powder increases, the crystal particle size inside the particle also increases, and the hysteresis loss is reduced. Since iron loss is reduced from these, a dust core excellent in magnetic properties can be produced.
- the first and second soft magnetic powders are preferably iron-based particles having an insulating layer on the surface.
- coat are mentioned, for example. It is preferable that an insulating resin film is further formed on the surface of the insulating inorganic film.
- the total thickness of the insulating inorganic film and the insulating resin film is preferably 250 nm or less. When the film thickness exceeds 250 nm, the decrease in magnetic flux density may increase.
- Insulating inorganic film examples include a phosphoric acid-based chemical film, a chromium-based chemical film, a water glass film, and an oxide film, with a phosphoric acid-based chemical film being preferred.
- the insulating inorganic film may be formed by laminating two or more kinds of films, but it may usually be a single layer.
- the thickness of the phosphoric acid-based chemical conversion film is preferably about 1 to 250 nm. If the film thickness is thinner than 1 nm, the insulating effect may not be exhibited. On the other hand, when the film thickness exceeds 250 nm, the insulating effect is saturated, and it is not desirable from the viewpoint of increasing the density of the dust core. A more preferable film thickness is 10 to 50 nm.
- the insulating resin film examples include a silicone resin film, a phenol resin film, an epoxy resin film, a polyamide resin film, and a polyimide resin film.
- a silicone resin film is preferable.
- the insulating resin film may be formed by laminating two or more kinds of films, but it may be a single layer. In the present invention, the above-mentioned insulation means that the specific resistance of the final dust core is about 50 ⁇ ⁇ m or more when measured by the four-terminal method.
- SR2400 manufactured by Toray Dow Corning Co., Ltd., KR251, KR400, KR22OL, KR242A, KR240, KR500, KC89 manufactured by Shin-Etsu Chemical Co., Ltd.
- Etc. methyl silicone resin having no phenyl group
- the degree of strain introduced into the soft magnetic powder can be calculated using the Bragg equation expressed by the above equation (1).
- the strain introduced into the soft magnetic material can be controlled by appropriately adjusting the particle size of the iron-based raw material powder, the reduction annealing temperature in the reduction annealing step, and the pulverization yield in the pulverization step, which will be described later.
- a soft magnetic powder which is a first soft magnetic powder and has a mass ratio of 95% by mass or more passing through a sieve having an opening of 75 ⁇ m and an average strain of less than 0.100%.
- the particle size of the iron-based raw material powder used for producing the first soft magnetic powder is such that the mass ratio of the iron-based raw material powder passing through the 75 ⁇ m sieve is 90% by mass or more and a 45 ⁇ m sieve is used. It is preferable that the mass ratio of the passing iron-based material powder is 60% by mass or less with respect to the total amount of the iron-based material powder.
- the iron-based powder material is subjected to reduction annealing by heating the iron-based raw material powder in a reducing atmosphere.
- the atmosphere when the iron-based raw material powder is subjected to reduction annealing may be a reducing atmosphere.
- a hydrogen gas atmosphere and a mixed gas atmosphere of hydrogen gas and an inert gas for example, nitrogen gas, argon gas, etc.
- an inert gas for example, nitrogen gas, argon gas, etc.
- the heating temperature is preferably 1250 ° C. or less, more preferably 1200 ° C. or less.
- the pulverization yield (75 ⁇ m) is 95% by mass or more and the pulverization yield (45 ⁇ m) is obtained. Is performed by collecting the iron-based pulverized powder passing through a sieve having an opening of 75 ⁇ m as the iron-based particles of the present invention.
- pulverization yield (75 micrometers) means the mass ratio of the iron base particle
- the pulverization yield (45 ⁇ m) refers to the mass ratio of the iron powder particles that pass through the sieve having an opening of 45 ⁇ m with respect to the powder of 75 ⁇ m or less obtained by the pulverization step.
- the obtained first soft magnetic powder has a mass ratio of the soft magnetic powder passing through the aperture of 75 ⁇ m to the total amount of the soft magnetic powder. On the other hand, it is 95% by mass or more, and the average strain is 0.100% or less.
- the pulverization yield (75 ⁇ m) is preferably 96% by mass or more, and more preferably 98% by mass or more.
- the pulverization yield (45 ⁇ m) is preferably 60% by mass or less, more preferably 58% by mass or less.
- the above pulverization yield (45 ⁇ m) exceeds 60% by mass, a lot of distortion is introduced into the soft magnetic powder, which leads to an increase in iron loss of the powder magnetic core, particularly an increase in hysteresis loss, and a decrease in the density of the compact, This is not preferable because it reduces the magnetic flux density.
- the pulverization yield (75 ⁇ m) is less than 95% by mass, the pulverization yield is low, that is, the pulverization yield is low.
- the pulverization yield (600 ⁇ m) is more preferably 99% by mass or more.
- the pulverization yield (45 ⁇ m) is preferably 5% by mass or less, more preferably 2% by mass or less.
- the pulverization yield (45 ⁇ m) exceeds 5% by mass, a lot of distortion is introduced into the soft magnetic powder, which leads to an increase in iron loss of the powder magnetic core, particularly an increase in hysteresis loss, and a decrease in the density of the compact, This is not preferable because it reduces the magnetic flux density.
- the pulverization yield (600 ⁇ m) is less than 98% by mass, the pulverization yield is low, that is, the pulverization yield is low.
- the soft magnetic iron-based powder shown below was prepared, and a dust core was manufactured according to the procedure shown below.
- the iron-based particles of Invention Examples 1 to 6 and Comparative Examples 1 and 2 obtained by the above process were subjected to powder X-ray diffraction measurement, and the average strain was measured.
- Table 1 shows the powder X-ray diffractometer and the measurement conditions.
- the phosphoric acid-based chemical film For the formation of the phosphoric acid-based chemical film, water: 50 parts, NaHPO 4 : 30 parts, H 3 PO 4 : 10 parts, (NH 2 OH) 2 .H 2 SO 4 are used as the phosphoric acid-based chemical film treatment solution. : 10 parts, Co 3 (PO 4 ) 2 : 10 parts were mixed, and a treatment solution diluted 20 times with water was used. The thickness of the phosphoric acid-based chemical film was 10 to 100 nm.
- soft magnetic powders (hereinafter sometimes referred to as insulating coating soft magnetic powders) in which the two insulating layers (the iron-based particle side is a phosphoric acid-based chemical film and the outer side is a silicone resin film) are formed.
- a dust core was manufactured.
- the insulation-coated soft magnetic powder is put, and using a press machine, the surface pressure is 1177.5 MPa (12 ton / cm 2 ).
- the shape of the molded body was a plate shape of length 31.75 mm ⁇ width 12.7 mm ⁇ thickness 5 mm.
- FIG. 1 shows the correlation between the density and the average strain of the powder magnetic cores produced using the soft magnetic powders of Invention Examples 1 to 4 and Comparative Example 1
- FIG. 1 shows the soft magnetic properties of Invention Examples 5, 6 and Comparative Example 2.
- FIG. 2 shows the correlation between the density of the compact and the average strain of the powder magnetic core produced using the powder.
- FIG. 3 shows the correlation between the iron loss and the average strain of the dust core produced using the first soft magnetic powder.
- Inventive Examples 1 to 4 are inventive examples that satisfy the requirements defined in the present invention.
- the mass ratio of the soft magnetic powder that passes through a sieve having a mesh opening of 75 ⁇ m is 95 mass% or more, and the average strain is 0.100%. Since it was a dust core produced using the first soft magnetic powder, the core density was high and the iron loss was reduced.
- Comparative Example 1 Although the mass ratio of the soft magnetic powder passing through the sieve having an aperture of 75 ⁇ m is 95% by mass or more, a powder magnetic core is produced using the soft magnetic powder having an average strain of 0.104%. It is a thing. As a result, the density of the molded body decreased and the iron loss increased.
- Inventive Examples 1 to 4 and Comparative Example 1 are compared, and even though the particle size values are the same, by producing a dust core using soft magnetic powder with reduced strain, a pressure characteristic excellent in magnetic properties can be obtained. It turns out that a powder magnetic core is obtained.
- the dust core of the present invention is excellent in magnetic properties, particularly low in iron loss and high in density, and thus has a high magnetic flux density and is suitable for electromagnetic parts such as inductors and motors.
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Abstract
Description
また、前記軟磁性粉末は、表面に絶縁層を有している鉄基粒子であることが好ましい。
第1の製造方法により得られる圧粉磁心は、インダクタのコアであることが好ましい。
前記軟磁性粉末は、表面に絶縁層を有している鉄基粒子であることが好ましい。
また、前記軟磁性粉末は、表面に絶縁層を有している鉄基粒子であることが好ましい。
第2の製造方法により得られる圧粉磁心は、モータの回転子または固定子のコアであることが好ましい。
前記軟磁性粉末は、表面に絶縁層を有している鉄基粒子であることが好ましい。
また、本発明の製造方法(第2の製造方法)によれば、目開き600μmの篩いを98質量%以上通過し、平均歪みが0.050%未満である軟磁性粉末(第2の軟磁性粉末)を圧縮成形するため、鉄損を低減すると同時に、成形体密度が向上し、磁束密度の向上した圧粉磁心を製造することができる。
さらに本発明によれば、鉄基原料粉末を還元焼鈍して得られた塊状や板状の鉄基還元粉末を粉砕するにあたり、工業的にも有利な粉砕の程度を、歪みを指標として評価することができる。
以下、本発明について詳しく説明する。
本発明に係る圧粉磁心の第1の製造方法は、目開き75μmの篩いを通過する軟磁性粉末の質量割合が軟磁性粉末の全量に対して95質量%以上であり、平均歪みが0.100%未満である第1の軟磁性粉末を圧縮成形することを特徴とする。第1の製造方法により製造された圧粉磁心は、高周波の駆動周波数で使用される電磁気部品、例えばインダクタ(チョークコイル、ノイズフィルタ、リアクトルなど)のコアに好ましく適用される。
また、本発明に係る圧粉磁心の第2の製造方法は、目開き600μmの篩いを通過する軟磁性粉末の質量割合が軟磁性粉末の全量に対して98質量%以上であり、平均歪みが0.050%未満である第2の軟磁性粉末を圧縮成形することを特徴とする。また、第2の製造方法により製造された圧粉磁心は、低周波の駆動周波数で使用される電磁気部品、例えばモータの回転子または固定子のコアに好ましく適用される。
2-1.軟磁性粉末
2-1-1.第1の軟磁性粉末
本発明の第1の軟磁性粉末は、目開き75μmの篩いを通過する軟磁性粉末の質量割合が、軟磁性粉末の全量に対して95質量%以上であり、平均歪みが0.100%未満であることを特徴とする。目開き75μmの篩いを通過する軟磁性粉末の質量割合は、好ましくは96質量%以上、より好ましくは98質量%以上である。目開き75μmの篩いを通過する軟磁性粉末の質量割合が多くなるほど、すなわち軟磁性粉末の粒子径が小さいほど、本発明の製造方法により製造される圧粉磁心は、高周波の駆動周波数で使用される電磁気部品、例えばインダクタとして用いた場合であっても、鉄損、特に渦電流損が効果的に低減される。また、平均歪みは好ましくは0.097%以下、より好ましくは0.090%以下、さらに好ましくは0.080%以下、特に好ましくは0.070%以下である。
平均歪みが小さいほど、本発明の第1の製造方法により製造される圧粉磁心は、成形体密度が高く磁束密度が高くなるので、鉄損を低減することができる。
本発明の第1の軟磁性粉末は、表面に後述する絶縁層を有している鉄基粒子であることが好ましい。
本発明の第2の軟磁性粉末は、目開き600μmの篩いを通過する軟磁性粉末の質量割合が、軟磁性粉末の全量に対して98質量%以上であり、平均歪みが0.050%未満であることを特徴とする。目開き600μmの篩いを通過する軟磁性粉末の質量割合は、好ましくは99質量%以上である。第2の軟磁性粉末は、低周波の駆動周波数で使用される電磁気部品、例えばモータのコアに用いることを意図しているため、基本的には軟磁性粉末の粒子径が大きいことが好ましい。しかしながら、軟磁性粉末の粒子径が大きくなりすぎると金型の細部への充填がしにくくなり、得られる圧粉磁心に欠損が生じたり、密度が低下したり、密度にばらつきが生じたりする。したがって、目開き600μmの篩いを通過する軟磁性粉末の質量割合を軟磁性粉末の全量に対して98質量%以上とする。また、平均歪みは好ましくは0.045%以下、さらに好ましくは0.040%以下である。平均歪みが小さいほど、本発明の第2の製造方法により製造される圧粉磁心は、成形体密度が高く磁束密度が高くなるので、鉄損を低減することができる。
上記第1および第2の軟磁性粉末は、表面に絶縁層を有している鉄基粒子であることが好ましい。上記絶縁層を構成するものとしては、例えば、絶縁性無機皮膜や絶縁性樹脂皮膜が挙げられる。前記絶縁性無機皮膜の表面には、更に絶縁性樹脂皮膜が形成されることが好ましい。この場合、また、絶縁性無機皮膜と絶縁性樹脂皮膜との合計厚みは250nm以下とすることが好ましい。膜厚が250nmを超えると、磁束密度の低下が大きくなる場合がある。
上記絶縁性無機皮膜としては、例えば、りん酸系化成皮膜、クロム系化成皮膜、水ガラス皮膜、酸化物皮膜などが挙げられ、好ましくはりん酸系化成皮膜である。上記絶縁性無機皮膜は、2種類以上の皮膜を積層して形成してもよいが、通常は単層でよい。
上記絶縁性樹脂皮膜としては、例えば、シリコーン樹脂皮膜、フェノール樹脂皮膜、エポキシ樹脂皮膜、ポリアミド樹脂皮膜、ポリイミド樹脂皮膜などが挙げられる。好ましくはシリコーン樹脂皮膜である。上記絶縁性樹脂皮膜は、2種類以上の皮膜を積層して形成してもよいが、通常は単層でよい。なお、上記絶縁性とは、本発明では、最終的な圧粉磁心の比抵抗を4端子法で測定したときに、50μΩ・m程度以上になることを意味している。
本発明では、平均歪みは、X線回折法により測定することができる。X線で計測される歪みは、軟磁性粉末中で結晶が様々な方向を向いていることに起因して軟磁性粉末全体の歪みの平均値となるため、機械的な歪みとは完全には一致しない。しかしながら、X線回折法では、粉末材料であれば非破壊で測定することが可能であり、再現性、定量性に優れることから、X線回折法により軟磁性粉末の歪みを測定することが好ましい。
λ=2d・sinθ (1)
で与えられる関係を満たすことを利用し、原子間距離を測定するものである。物質は、物質を構成する原子の種類や結晶構造等により、夫々固有の回折面間隔を持つため、X線回折法により物質の同定を行うことができる。
3-1.鉄基原料粉末
まず、軟磁性粉末を製造する原料粉末である鉄基原料粉末とは、強磁性体の鉄基粉末であり、具体的には、純鉄粉、鉄基合金粉末(例えば、Fe-Al合金、Fe-Si合金、センダスト、パーマロイなど)、および鉄基アモルファス粉末等が挙げられる。
還元焼鈍工程では、上記鉄基原料粉末を還元性雰囲気中で加熱することによって該鉄基粉末材料を還元焼鈍する。上記鉄基原料粉末を還元焼鈍するときの雰囲気は、還元性雰囲気とすればよい。還元性雰囲気としては、例えば、水素ガス雰囲気、および水素ガスと不活性ガス(例えば、窒素ガス、アルゴンガスなど)との混合ガス雰囲気とすればよい。
この際、隣接する鉄基原料粉末同士が焼結により融着結合し、還元焼鈍により得られる鉄基還元粉末は板状や塊状の焼結体となる。
粉砕工程では、上記還元焼鈍工程で還元焼鈍した鉄基還元粉末を粉砕し、分級して所望の粒度のものを所望の割合で混合することによって鉄基粒子を得る。分級して得られた鉄基粒子は、そのままでも軟磁性粉末として用いることができ、さらに表面に絶縁層を形成した後、軟磁性粉末として用いることもできる。鉄損、特に渦電流損低減の観点から、鉄基粒子の表面に絶縁層を形成することが好ましい。
鉄基還元粉末は、鉄基原料粉末同士が融着結合した結果、板状や塊状の焼結体となっている。このような鉄基還元粉末を粉砕する方法は特に限定されず、公知の破砕機や粉砕機(例えば、フェザーミル、ハンマーミル、パルベライザーなど)を適宜組み合わせればよい。
上記鉄基還元粉末の粉砕は、第1の軟磁性粉末を得ようとする場合、粉砕収率(75μm)が、95質量%以上となり、かつ、粉砕収率(45μm)が60質量%以下となるように行い、この時点で、目開き75μmの篩を通過する鉄基粉砕粉末を本発明の鉄基粒子として回収することによって行う。粉砕収率(75μm)とは、粉砕工程に供した粉砕前の鉄基還元粉末の全量に対する、目開き75μmの篩を通過する粉砕後の鉄基粒子の質量割合のことをいう。また、第1の軟磁性粉末に関して、粉砕収率(45μm)とは、粉砕工程によって得られた75μm以下の粉末に対する、目開き45μmの篩を通過する鉄粉粒子の質量割合のことを言う。粉砕収率(75μm)と粉砕収率(45μm)が上記の範囲であると、得られる第1の軟磁性粉末は、目開き75μmを通過する軟磁性粉末の質量割合が軟磁性粉末の全量に対して95質量%以上であり、平均歪みが0.100%以下となる。
上記還元鉄基粉末材料の粉砕は、第2の軟磁性粉末を得ようとする場合、粉砕収率(600μm)が、98質量%以上、かつ、粉砕収率(45μm)が5質量%以下となるように行い、この時点で目開き600μmの篩を通過する鉄基粉砕粉末を本発明の鉄基粒子として回収することによって行う。粉砕収率(600μm)とは、粉砕工程に供した粉砕前の鉄基還元粉末の全量に対する、目開き600μmの篩を通過する粉砕後の鉄基粒子の質量割合のことをいう。また、第2の軟磁性粉末に関して、粉砕収率(45μm)とは、粉砕工程によって得られた600μm以下の粉末に対する、目開き45μmの篩を通過する鉄粉粒子の質量割合のことを言う。粉砕収率(600μm)が上記の範囲であると、得られる軟磁性粉末は、目開き600μmを通過する軟磁性粉末の質量割合が軟磁性粉末の全量に対して98質量%以上であり、平均歪みが0.050%以下となる。
3-4-1.りん酸系化成皮膜の形成方法
本発明で用いるりん酸系化成皮膜形成粉末は、いずれの態様で製造されてもよい。例えば、水および/または有機溶剤からなる溶媒に、Pを含む化合物を溶解させた溶液と、粗粉化した軟磁性鉄基粉末とを混合した後、必要に応じて前記溶媒を蒸発させて得ることができる。本工程で用いる溶媒としては、水や、アルコールやケトン等の親水性有機溶剤、及びこれらの混合物が挙げられる。溶媒には公知の界面活性剤を添加してもよい。上記Pを含む化合物としては、例えばオルトりん酸(H3PO4)またはその塩などが挙げられる。
上記シリコーン樹脂皮膜の形成は、例えば、シリコーン樹脂をアルコール類や、トルエン、キシレン等の石油系有機溶剤等に溶解させたシリコーン樹脂溶液と、軟磁性鉄基粉末とを混合し、次いで必要に応じて前記有機溶剤を蒸発させることによって行うことができる。軟磁性鉄基粉末としては、りん酸系化成皮膜を有する軟磁性鉄基粉末(りん酸系化成皮膜形成粉末)であることが好ましい。
発明例1~4、比較例1
鉄基原料粉末として純鉄粉を準備し、75μmの篩いを通過する純鉄粉の質量割合が95質量%以上で、かつ、45μmの篩いを通過する純鉄粉の質量割合が52質量%となるよう調整した。この鉄基原料粉末を表2に示す還元焼鈍温度で還元焼鈍した。得られた鉄基還元粉末を、表1に示す粉砕収率(45μm)となるように各種装置を用いて粉砕し、75μmの篩いを通過する鉄基粉砕粉末を回収して、鉄基粒子を得た。
鉄基原料粉末として純鉄粉を準備し、600μmの篩いを通過する純鉄粉の質量割合が99質量%で、かつ、45μmの篩いを通過する純鉄粉の質量割合が6.2質量%となるよう調整した。この鉄基原料粉末を表3に示す還元焼鈍温度で還元焼鈍した。得られた鉄基還元粉末を、表1に示す粉砕収率(45μm)となるように各種装置を用いて粉砕し、600μmの篩いを通過する鉄基粉砕粉末を回収して、鉄基粒子を得た。
次に、得られた発明例1~6、比較例1、2鉄基粒子の表面に、絶縁層として絶縁性無機皮膜、絶縁性樹脂皮膜をこの順(鉄基粒子側が絶縁性無機皮膜、外側が絶縁性有機皮膜)で形成した。絶縁性無機皮膜としてはりん酸系化成皮膜を形成し、絶縁性樹脂皮膜としてはシリコーン樹脂皮膜を形成した。
シリコーン樹脂皮膜の厚みは100~150nmであった。
圧粉磁心の成形体密度を表2、3に示す。また、発明例1~4及び比較例1の軟磁性粉末を用いて作製した圧粉磁心の成形体密度と平均歪みとの相関を図1に、発明例5、6及び比較例2の軟磁性粉末を用いて作製した圧粉磁心の成形体密度と平均歪みとの相関を図2に示す。
これらの測定結果をまとめて表2、3に示す。また、第1の軟磁性粉末を用いて作製した圧粉磁心の鉄損と平均歪みとの相関を図3に示す。
本出願は、2012年8月31日出願の日本特許出願(特願2012-192146)に基づくものであり、その内容はここに参照として取り込まれる。
Claims (10)
- 目開き75μmの篩いを通過する軟磁性粉末の質量割合が、軟磁性粉末の全量に対して95質量%以上であり、平均歪みが0.100%未満である軟磁性粉末を圧縮成形することを特徴とする圧粉磁心の製造方法。
- 軟磁性粉末は、表面に絶縁層を有している鉄基粒子である請求項1に記載の圧粉磁心の製造方法。
- 前記圧粉磁心がインダクタのコアである請求項1または2に記載の圧粉磁心の製造方法。
- 目開き75μmの篩いを通過する軟磁性粉末の質量割合が、軟磁性粉末の全量に対して95質量%以上であり、平均歪みが0.100%未満であることを特徴とする圧粉磁心用軟磁性粉末。
- 軟磁性粉末は、表面に絶縁層を有している鉄基粒子である請求項4に記載の圧粉磁心用軟磁性粉末。
- 目開き600μmの篩いを通過する軟磁性粉末の質量割合が、軟磁性粉末の全量に対して98質量%以上であり、平均歪みが0.050%未満である軟磁性粉末を圧縮成形することを特徴とする圧粉磁心の製造方法。
- 軟磁性粉末は、表面に絶縁層を有している鉄基粒子である請求項6に記載の圧粉磁心の製造方法。
- 前記圧粉磁心がモータの回転子または固定子のコアである請求項6または7に記載の圧粉磁心の製造方法。
- 目開き600μmの篩いを通過する軟磁性粉末の質量割合が、軟磁性粉末の全量に対して98質量%以上であり、平均歪みが0.050%未満であることを特徴とする圧粉磁心用軟磁性粉末。
- 軟磁性粉末は、表面に絶縁層を有している鉄基粒子である請求項9に記載の圧粉磁心用軟磁性粉末。
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CN104584150A (zh) | 2015-04-29 |
KR101639960B1 (ko) | 2016-07-14 |
KR20150038299A (ko) | 2015-04-08 |
CA2880249A1 (en) | 2014-03-06 |
CA2880249C (en) | 2018-07-31 |
SE540119C2 (en) | 2018-04-03 |
JP2014049643A (ja) | 2014-03-17 |
US9583261B2 (en) | 2017-02-28 |
US20150187493A1 (en) | 2015-07-02 |
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CN104584150B (zh) | 2017-09-22 |
JP5919144B2 (ja) | 2016-05-18 |
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