WO2014068928A1 - 複合磁性体およびその製造方法 - Google Patents
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- H01F41/0253—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 for manufacturing permanent magnets
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Definitions
- Example 3 Sample No. shown in Table 3 46 to Sample No. 100, an Fe—Si alloy powder having an average particle diameter of 10 ⁇ m prepared by a water atomizing method is used as the metal magnetic powder. To this metal magnetic powder, 0.3 wt% of a silane coupling agent is added together with a small amount of ethanol. Further, acrylic resin A and acrylic resin B are added by 0.5 wt% with respect to the metal magnetic powder.
- the acrylic resin A and the acrylic resin B have three or more side chains composed of the number of carbon atoms shown in (Table 3), and are composed of the number of carbon atoms shown in (Table 3). In addition to the side chain, there is no side chain composed of 12 or more carbon atoms or silicon atoms.
- the granulated powder is molded at a pressure of 12 ton / cm 2 to produce a toroidal core having an outer diameter of 14 mm, an inner diameter of 10 mm, and a thickness of about 2 mm.
- This core is heat-treated at 900 ° C. for 30 minutes.
- a thermosetting acrylic resin is impregnated and cured at 130 ° C. for 60 minutes to prepare a sample. Using this sample, the magnetic loss is measured in the same manner as in Example 1.
- the granulated powder is molded at a pressure of 12 ton / cm 2 to produce a plate-like sample having a length of 18 mm, a width of 5 mm, and a thickness of about 4 mm.
- This plate-like sample is heat-treated at 900 ° C. for 30 minutes. Thereafter, a thermosetting acrylic resin is impregnated and cured at 130 ° C. for 60 minutes to prepare a sample.
- This sample is subjected to a destructive test by a three-point bending test in the same manner as in Example 1, and the bending strength is obtained based on the formula (1).
- the silane coupling agent used in the present Example does not function as a molding aid but functions only as an insulating material.
- the gap width at which the cumulative distribution is 50% is 3 ⁇ m or less, and the gap width at which the cumulative distribution is 95% is 4 ⁇ m or more. Therefore, it shows high bending strength and low magnetic loss.
- one of the acrylic resin A and the acrylic resin B is a first polymer having 3 or more side chains having 7 to 11 carbon atoms, and the other is a side chain having 6 or less carbon atoms. Is a second polymer that has either 3 or more, or 12 or more side chains.
- Sample No. 73 to Sample No. 76, sample no. 80 to Sample No. 82, sample no. 86, sample no. 87, sample no. Even 91 has a large magnetic loss. The reason is considered to be that the gap between the metal magnetic particles is narrow over the entire sample, and that the insulating frequency is lowered and the eddy current loss is increased by increasing the contact frequency between the metal magnetic particles.
- Example 4 Sample No. shown in (Table 4). 101-Sample No. In 125, an Fe—Al—Si alloy powder having an average particle diameter of 10 ⁇ m prepared by a water atomizing method is used as the metal magnetic powder. To this metal magnetic powder, 0.2 wt% of silicon resin as an insulating material and a small amount of toluene are mixed. Silicon resin has three or more side chains composed of six carbon atoms and three or more side chains composed of one carbon atom. Then, 0.7 wt% of the resin shown in Table 4 as the first polymer and the second polymer is added to the metal magnetic powder, respectively, to prepare a mixture.
- an Fe—Al—Si alloy powder having an average particle size of 10 ⁇ m prepared by a water atomizing method is used as the metal magnetic powder.
- 0.2 wt% of silicon resin as an insulating material and a small amount of toluene are mixed.
- the silicon resin is the same as described above.
- 1.4 wt% of the first polymer or the second polymer shown in (Table 4) is added to the metal magnetic powder to produce a mixture.
- Each of the first polymers has 3 or more side chains composed of 9 carbon atoms, and has no side chain having 12 or more carbon atoms.
- the second polymer has one side chain composed of 10 carbon atoms and three or more side chains composed of 13 carbon atoms.
- the granulated powder is molded at a pressure of 12 ton / cm 2 to produce a plate-like sample having a length of 18 mm, a width of 5 mm, and a thickness of about 4 mm.
- the plate sample is heat-treated at 700 ° C. for 30 minutes.
- a thermosetting acrylic resin is impregnated and cured at 130 ° C. for 60 minutes to prepare a sample.
- This sample is subjected to a destructive test by a three-point bending test in the same manner as in Example 1, and the bending strength is obtained based on the formula (1).
- the silicon resin used in this example has both functions of an insulating material and a molding aid, and functions as an insulating material and a molding aid in this example.
- any one of a silicon resin, an epoxy resin, an acrylic resin, a phenol resin, and a butyral resin exemplified in Table 4 is used as the first polymer and the second polymer.
- the first polymer has 3 or more side chains composed of 9 carbon atoms, and has no side chain having 12 or more carbon atoms.
- the second polymer has one side chain composed of 10 carbon atoms and three or more side chains composed of 13 carbon atoms.
- a void distribution having a void width of 3 ⁇ m or less with a cumulative distribution of 50% and a void width of 4 ⁇ m or more with a cumulative distribution of 95% is satisfied. And it shows high bending strength and low magnetic loss.
- a void distribution having a gap width of 3 ⁇ m or less with a cumulative distribution of 50% and a void width of 4 ⁇ m or more with a cumulative distribution of 95% is not realized, resulting in low mechanical strength and high magnetic loss.
- sample No. using acrylic resin. 103, sample no. 108, Sample No. 111 to Sample No. 115, sample no. 118, sample no. 123 shows a particularly high mechanical strength.
- sample No. 1 in which both the first polymer and the second polymer are acrylic resins. 113 shows a particularly high mechanical strength.
- Acrylic resin is a material that has excellent decomposability and is extremely difficult to leave a residue after heat treatment. Therefore, the gap between the metal magnetic particles is hardly blocked by the residue, and the impregnated resin penetrates into the green compact more effectively. It is considered that the above result is obtained by this effect.
- Example 5 Sample No. shown in (Table 5).
- an Fe—Ni alloy powder having an average particle diameter of 10 ⁇ m prepared by a water atomizing method is used as the metal magnetic powder.
- a silane coupling agent is added to the metal magnetic powder as an insulating material according to the addition amount shown in (Table 5).
- the first epoxy resin and the second epoxy resin are added at a weight ratio of 1: 1.
- the first epoxy resin has three or more side chains composed of 11 carbon atoms, and does not have a side chain having 12 or more carbon atoms or silicon atoms.
- the second epoxy resin has three or more side chains composed of 17 carbon atoms.
- the total amount of the first epoxy resin and the second epoxy resin is the ratio shown in Table 5 with respect to the metal magnetic powder.
- the granulated powder is molded at a pressure of 8 ton / cm 2 to produce a toroidal core having an outer diameter of 14 mm, an inner diameter of 10 mm, and a thickness of about 2 mm.
- This core is heat-treated at 800 ° C. for 30 minutes.
- the sample is impregnated with an epoxy resin and cured at 150 ° C. for 60 minutes to prepare a sample. Using this sample, the magnetic loss is measured in the same manner as in Example 1.
- the relative magnetic permeability is obtained from the inductance value measured using an LCR meter under the conditions of 120 kHz and superimposed magnetic field 52 Oe.
- the granulated powder is molded at a pressure of 8 ton / cm 2 to produce a plate-like sample having a length of about 18 mm, a width of 5 mm, and a thickness of about 4 mm.
- the plate sample is heat-treated at 800 ° C. for 30 minutes. Thereafter, the sample is impregnated with an epoxy resin and cured at 150 ° C. for 60 minutes to prepare a sample.
- This sample is subjected to a destructive test by a three-point bending test in the same manner as in Example 1, and the bending strength is obtained based on the formula (1).
- the silane coupling agent used in the present Example does not function as a molding aid but functions only as an insulating material.
- sample No. added with 0.01 wt% or more of the silane coupling agent was added.
- 137 to Sample No. 142 and sample no. 144 to Sample No. 148 shows a particularly low magnetic loss. This is considered because the silane coupling agent functions effectively as an insulating material. Thus, it can be seen that the addition of an insulating material is preferable.
- Sample No. 142 and sample no. As can be seen from 148, when the total amount of the silane coupling agent and the epoxy resin added exceeds 10 wt%, the relative permeability decreases. This is presumably because the filling rate of the metal magnetic particles was lowered by the excessively added insulating material and molding aid. From the above, it is preferable that the total addition amount of the insulating material and the molding aid is 10 wt% or less.
- Example 6 Sample No. shown in (Table 6).
- Example 6 an Fe—Ni alloy powder having an average particle diameter of 12 ⁇ m prepared by a water atomization method is used as the metal magnetic powder.
- 0.3 wt% of a silane coupling agent is added as an insulating material.
- the first polymer and the second polymer the first butyral resin and the second butyral resin are added together with a small amount of ethanol at a ratio of 1 wt% with respect to the metal magnetic powder.
- the first butyral resin has three or more side chains composed of 11 carbon atoms, and the number of side chains composed of 15 carbon atoms is two.
- the second butyral resin has three or more side chains composed of 15 carbon atoms.
- the granulated powder is molded at the molding pressure shown in Table 6 to produce a toroidal core having an outer diameter of 14 mm, an inner diameter of 10 mm, and a thickness of about 2 mm.
- This core is heat-treated at 800 ° C. for 60 minutes. Then, it is impregnated with silicon resin and cured at 150 ° C. for 90 minutes to prepare a sample. Using this sample, the magnetic loss is measured in the same manner as in Example 1.
- the granulated powder is molded at a pressure of 10 ton / cm 2 to produce a toroidal core having an outer diameter of 14 mm, an inner diameter of 10 mm, and a thickness of about 2 mm.
- the core is subjected to heat treatment for 60 minutes at the temperature shown in (Table 7).
- a thermosetting acrylic resin is impregnated and cured at 140 ° C. for 60 minutes to prepare a sample. Using this sample, the magnetic loss is measured in the same manner as in Example 1.
- the granulated powder is molded at a pressure of 10 ton / cm 2 to produce a plate sample having a length of 18 mm, a width of 5 mm, and a thickness of about 4 mm.
- This plate-like sample is subjected to heat treatment for 60 minutes at the temperature shown in (Table 7).
- a thermosetting acrylic resin is impregnated and cured at 140 ° C. for 60 minutes to prepare a sample.
- This sample is subjected to a destructive test by a three-point bending test in the same manner as in Example 1, and the bending strength is obtained based on the formula (1).
- the silicon resin used in this example has both functions of an insulating material and a molding aid, and functions as an insulating material and a molding aid in this example.
- FIG. 3 is an enlarged schematic cross-sectional view of the composite magnetic body 20 according to Embodiment 2 of the present invention.
- the metal magnetic powder is composed of a plurality of first metal magnetic particles 12A and a plurality of second metal magnetic particles 12B.
- the mass magnetization of the first metal magnetic particles 12A is not more than the mass magnetization of the second metal magnetic particles 12B, and the average particle size of the first metal magnetic particles 12A is not less than the average particle size of the second metal magnetic particles 12B.
- the mass magnetization of the first metal magnetic particle 12A is ⁇ sL
- the average particle diameter is DL
- the mass magnetization of the second metal magnetic particle 12B is ⁇ sH
- the average particle diameter is DH
- ⁇ sL ⁇ ⁇ sH and DH ⁇ DL are satisfied.
- Japanese Patent Application Laid-Open No. 2000-188214 improves the DC superposition characteristics by containing permanent magnet powder in a dust core, applying a high magnetic field in the magnetic path direction of the core, and magnetizing the permanent magnet powder. A method has been proposed.
- factors affecting the DC superposition characteristics of the composite magnetic material include the initial permeability and saturation magnetic flux density of the composite magnetic material.
- the composite magnetic body having a higher initial permeability tends to have a lower DC superposition characteristic. Therefore, in order to improve the direct current superposition characteristics, it is effective to increase the saturation magnetic flux density while suppressing a significant increase in the initial permeability.
- the initial permeability of the magnetic material is qualitatively proportional to the square of the saturation magnetization, and in the case of powder, it depends on the particle size of the particles constituting the powder, and the smaller the particle size, the smaller the initial permeability.
- a factor affecting the direct current superposition characteristics is the uniformity of the magnetic gap, which is the distance between the metal magnetic particles. If the magnetic gap is not uniform, the magnetic flux concentrates in a portion where the magnetic gap is small, that is, a portion where metal magnetic particles are densely present, and magnetic saturation is likely to occur. As a result, the direct current superimposition characteristics deteriorate. Therefore, it is effective to improve the uniformity of the magnetic gap in the dust core for improving the DC superposition characteristics.
- the initial magnetic permeability of the composite magnetic body 20 is remarkably improved by mixing the first metal magnetic particles 12A and the second metal magnetic particles 12B having the mass magnetization of the first metal magnetic particles 12A or more.
- the direct current superimposition characteristic can be improved by suppressing. In particular, by setting the value of ⁇ sL / ⁇ sH to 0.9 or less, it is possible to suppress a rapid increase in the initial permeability of the composite magnetic body. Therefore, the direct current superimposition characteristic can be improved.
- the uniformity of the magnetic gap in the composite magnetic body 20 is improved by mixing the first metal magnetic particles 12A and the second metal magnetic particles 12B having a particle size equal to or smaller than the first metal magnetic particles 12A. Therefore, the direct current superimposition characteristic can be further improved.
- the value of DH / DL to 0.5 or less, a significant increase in the initial permeability of the composite magnetic body 20 due to the highly magnetized second metal magnetic particles 12B can be suppressed, and the magnetic gap is uniform. Therefore, magnetic saturation can be suppressed, and direct current superposition characteristics can be improved.
- the content of the second metal magnetic particles 12B with respect to the entire metal magnetic powder contained in the composite magnetic body 20 is preferably in the range of 2 wt% or more and 30 wt% or less.
- the content of the second metal magnetic particles 12B is less than 2 wt%, the effect of improving the DC superimposition characteristics by adding the second metal magnetic particles 12B having high magnetization becomes poor.
- it exceeds 30 wt% the direct current superimposition characteristic cannot be sufficiently improved due to the remarkable increase in the initial magnetic permeability of the composite magnetic body 20.
- the content of the second metal magnetic particles 12B is outside the range of 2 wt% or more and 30 wt% or less, the uniformity of the magnetic gap is lowered and the direct current superposition characteristics are not sufficiently improved.
- the mass magnetization ⁇ sL of the first metal magnetic particles 12A is preferably 70 emu / g or more.
- the mass magnetization ⁇ sL of the first metal magnetic particle 12A having low magnetization is lower than 70 emu / g, the DC superposition characteristics of the composite magnetic body 20 are degraded.
- the metal magnetic powder having a large mass magnetization ⁇ s includes 235 emu / g of Fe—Co-based powder.
- the mass magnetization of the first metal magnetic particle 12A The upper limit of ⁇ sL is about 211 emu / g.
- the average particle diameter DL of the first metal magnetic particles 12A is preferably in the range of 2 ⁇ m or more and 100 ⁇ m or less.
- the average particle size DL is preferably in the range of 2 ⁇ m or more and 100 ⁇ m or less.
- the composite magnetic body 20 can also suppress a significant increase in the initial permeability.
- the effect of improving the DC superimposition characteristics is enhanced.
- the average particle diameter of the first metal magnetic particles 12A is 2 ⁇ m or more, a significant decrease in initial permeability can be suppressed.
- the change in magnetic permeability due to the DC magnetic field in the composite magnetic body 20 becomes large.
- the average particle diameter DH of the second metal magnetic particles 12B is preferably 0.1 ⁇ m or more.
- the molding density can be improved, and the effect of improving the DC superposition characteristics is enhanced.
- the average particle diameter in a metal magnetic particle is a value calculated
- the particle diameter of a particle to be measured showing the same diffraction / scattered light pattern as a sphere having a diameter of 10 ⁇ m is measured as 10 ⁇ m regardless of its shape.
- the average particle diameter means the particle diameter when counting is started from the smallest particle diameter and the integration reaches 50% of the total.
- the constituent element of the metal magnetic powder used for the composite magnetic body 20 is preferably one containing at least Fe, for example, Fe, Fe—Si, Fe—Si—Cr, Fe—Ni, Fe—Ni—Mo. It is possible to use crystalline metal magnetic powders such as Fe-Si-Al-based and Fe-Co-based, and amorphous metal magnetic powders such as Fe-based amorphous and Co-based amorphous.
- the method for producing these metal magnetic powders is not particularly limited, and various atomization methods and various pulverized powders can be used. That is, it is the same as in the first embodiment.
- the insulating material used for the composite magnetic body 20 may be any material that is interposed between a plurality of metal magnetic particles and insulates the metal magnetic particles.
- various coupling agents, resin-based organic materials, inorganic materials, and the like can be used.
- the coupling agent include silane-based, titanium-based, chromium-based, and aluminum-based coupling agents.
- the organic material include silicone resin, epoxy resin, acrylic resin, butyral resin, and phenol resin.
- the inorganic material include aluminum oxide, titanium oxide, silicon oxide, magnesium oxide, aluminum nitride, silicon nitride, boron nitride, mica, talc, and kaolin.
- the inorganic elements contained in these organic materials such as silane, titanium, chromium or aluminum coupling agents and silicone resins remain as oxides by high-temperature heat treatment, and thus the insulating material. Those that function as are preferred.
- the insulating material in the present embodiment can be appropriately selected according to the application, as in the first embodiment.
- the order of mixing the first metal magnetic particles 12A, the second metal magnetic particles 12B, and the insulating material is not particularly limited.
- the mixing method is not particularly limited, and various ball mills such as a rotating ball mill and a planetary ball mill, a V blender, a planetary mixer, a kneader, and the like can be used.
- the pressure molding method is not particularly limited, and a normal pressure molding method is used.
- the molding pressure 6 ton / cm 2 or more, 20ton / cm 2 is preferably in a range of about.
- the filling rate of the metal magnetic particles is increased and the magnetic properties are improved. If it is higher than 20 ton / cm 2 , it is necessary to increase the size of the mold in order to ensure the strength of the mold during pressure molding, and further, the press machine will be increased in size to ensure the molding pressure. Increasing the size of the mold and press machine reduces productivity and increases costs.
- the molded body obtained as described above is heat-treated to release the processing strain introduced into the metal magnetic particles during pressure molding. It is better to perform the heat treatment at a higher temperature. However, if the temperature is too high, insulation between the metal magnetic particles is insufficient and eddy current loss increases, which is not preferable.
- the heat treatment temperature is in the range of 700 ° C. or higher and 1000 ° C. or lower. By setting the temperature to 700 ° C. or higher, the processing strain can be sufficiently released, and high magnetic characteristics can be realized. Moreover, since eddy current loss will increase when it exceeds 1000 degreeC, it is unpreferable.
- the heat treatment atmosphere is preferably a non-oxidizing atmosphere in order to suppress oxidation of the metal magnetic particles.
- a magnetic element can be manufactured by applying coil winding to the composite magnetic body 20 thus manufactured and assembling it. Note that magnetic elements having various shapes such as a toroidal type and an E type can be manufactured as the magnetic element.
- the heat treatment temperature needs to be within a range in which the insulating function of the coil surface is not significantly reduced due to thermal decomposition or the like. Specifically, heat treatment at 100 ° C. to 250 ° C. is preferable.
- an insulating material is an organic material, the organic material is not thermally decomposed, and the organic material itself is interposed between the metal magnetic particles.
- the molding pressure is low and heat treatment at high temperature is not possible. Therefore, winding is performed on a composite magnetic body produced by high pressure molding and heat treatment at high temperature. Compared with the assembly structure to which is applied, the magnetic properties as a magnetic material are inferior. However, since no assembly tolerance is required, the magnetic path cross-sectional area can be increased and the magnetic path length can be shortened. As a result, the inductance value and the like exhibit good characteristics as an inductance component.
- the molding pressure at the time of manufacturing a magnetic element of the coil-buried type 2 ton / cm 2 or more, 6 ton / cm 2 is preferably in a range of about.
- the molding pressure By setting the molding pressure to 2 ton / cm 2 or more, the filling rate of the metal magnetic particles is increased and the inductance value is also increased.
- a magnetic element having a high withstand voltage can be produced by suppressing insulation failure as an inductance component without damaging the insulation coating on the surface of the coil embedded in the magnetic core core by setting it to 6 ton / cm 2 or less. Can do.
- the composite magnetic body 20 can be manufactured by a simple process in comparison with the dust core proposed in Japanese Patent Application Laid-Open No. 2000-188214, has excellent direct current superposition characteristics, and is defective. It is possible to produce a magnetic element with a small amount.
- the gap state described in the first embodiment may be applied to the second embodiment.
- the first metal magnetic particles 12A and the second metal magnetic particles 12B in the second embodiment may be mixed, and the manufacturing method described in the first embodiment may be applied using the mixture as the metal magnetic powder.
- a composite magnetic body that exhibits both the effects described in the first embodiment and the effects described in the second embodiment can be manufactured.
- Example 8 As the first metal magnetic particles, Fe—Si—Al-based metal magnetic particles having an average particle diameter of 22 ⁇ m and a mass magnetization ⁇ s of 140 emu / g, and various metal magnetic particles shown in Table 8 are used as the second metal magnetic particles.
- the average particle diameter of the first metal magnetic particles and the second metal magnetic particles is measured by a microtrack particle size distribution meter. After adding 1.2 parts by weight of the silicone resin to 100 parts by weight of the total amount of the first metal magnetic particles and the second metal magnetic particles, a small amount of toluene is added and mixed. In addition, the ratio of the 2nd metal magnetic particle in the whole metal magnetic powder is 20 wt%.
- the obtained mixture is pressure-molded at 12 ton / cm 2 and heat-treated at 850 ° C. for 1.0 h in an argon gas atmosphere. In this way, a toroidal core having an outer diameter of 14 mm, an inner diameter of 10 mm, and a thickness of about 2 mm is produced as a sample.
- the relative magnetic permeability at an applied magnetic field of 85 Oe and a frequency of 120 kHz is measured using an LCR meter. Further, the mass magnetization ⁇ s is measured using a sample vibration type magnetometer VSM with an applied magnetic field of 15 kOe. The evaluation results are shown in (Table 9).
- the relative magnetic permeability at an applied magnetic field of 80 Oe and a frequency of 120 kHz is measured using an LCR meter. Further, the mass magnetization ⁇ s is measured using a sample vibration type magnetometer VSM with an applied magnetic field of 15 kOe. The evaluation results are shown in (Table 11).
- Table 11 shows that excellent DC superposition characteristics can be realized by setting the mass magnetization ⁇ s of the first metal magnetic particles to 70 emu / g or more.
- Fe-Si-Al based metal magnetic particles having an average particle diameter of 25 ⁇ m and mass magnetization ⁇ s of 136 emu / g as the first metal magnetic particles, and Fe having an average particle diameter of 2 ⁇ m and mass magnetization ⁇ s of 186 emu / g as the second metal magnetic particles Use Si-based metal magnetic particles. And the 1st metal magnetic particle and the 2nd metal magnetic particle are mix
- 0.1 parts by weight of aluminum oxide having an average particle diameter of 0.05 ⁇ m is added to and mixed with 100 parts by weight of the total amount of the first metal magnetic particles and the second metal magnetic particles. Thereafter, 0.5 parts by weight of a silane coupling agent and 0.5 parts by weight of butyral resin are added, and then a small amount of ethanol is added and kneaded.
- the obtained mixture is pressure-molded at 12 ton / cm 2 and heat-treated at 750 ° C. for 1.5 hours in an argon gas atmosphere. In this way, a toroidal core having an outer diameter of 14 mm, an inner diameter of 10 mm, and a thickness of about 2 mm is produced as a sample.
- the relative magnetic permeability at an applied magnetic field of 85 Oe and a frequency of 120 kHz is measured using an LCR meter. Further, the mass magnetization ⁇ s is measured using a sample vibration type magnetometer VSM with an applied magnetic field of 15 kOe. The evaluation results are shown in (Table 14).
- Table 14 shows that excellent DC superposition characteristics are exhibited when the content of the second metal magnetic particles is in the range of 2 wt% to 30 wt%.
- the present embodiment is intended for a composite magnetic body in a coil-embedded magnetic element, in which the heat treatment temperature is set to 160 ° C. so that the organic material is not thermally decomposed, and between the first metal magnetic particles and the second metal magnetic particles. Organic materials are present.
- the relative magnetic permeability at an applied magnetic field of 90 Oe and a frequency of 120 kHz is measured using an LCR meter. Further, the mass magnetization ⁇ s is measured using a sample vibration type magnetometer VSM with an applied magnetic field of 15 kOe. The evaluation results are shown in (Table 16).
- Table 16 shows that the mass magnetization and the average particle diameter of the first metal magnetic particles and the second metal magnetic particles satisfy both the equations of ⁇ sL / ⁇ sH ⁇ 0.9 and DH / DL ⁇ 0.5 at the same time. It can be seen that even in a high DC magnetic field, it exhibits a high relative permeability and exhibits excellent DC superposition characteristics.
- the composite magnetic material in the present embodiment is used, it is possible to provide an inductance component that is excellent in productivity, is small and highly efficient, has a high yield in manufacturing, and has high reliability. Therefore, it is useful for various electronic devices.
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Abstract
Description
図1は本発明の実施の形態1における複合磁性体10の拡大模式断面図である。複合磁性体10は、複数の金属磁性粒子12で構成された金属磁性粉末と、複数の金属磁性粒子12の間の空隙14の少なくとも一部に含浸した絶縁物である絶縁性樹脂16とを含む。
(表1)に示した試料No.1~試料No.41において、金属磁性粉末としてガスアトマイズ法にて作製した平均粒径20μmのFe-Si合金粉末を用いる。この金属磁性粉末に、絶縁材としてチタンカップリング剤を0.2wt%添加する。さらに、第1ポリマーと第2ポリマーとを(表1)に示した割合で添加する。第1ポリマーとしては、8個の炭素原子から構成される側鎖を3つ以上有しており、かつ、12個以上の炭素原子もしくはケイ素原子により構成される側鎖を有さない第1のフェノール樹脂を用いる。第2ポリマーとしては、7個以上の炭素原子もしくはケイ素原子から構成され、側鎖を有さない(側鎖は0)第2のフェノール樹脂を用いる。なお、本実施の形態において、フェノール樹脂とは樹脂の骨格における主鎖がフェノール樹脂固有のものを指し、側鎖は特に限定されるものではない。
(表2)に示した試料No.42~試料No.45において、金属磁性粉末として水アトマイズ法にて作製した平均粒径30μmのFe-Si-Cr-B-Cアモルファス合金粉末を用いる。この金属磁性粉末に、絶縁材として平均粒径1μmの酸化アルミニウム粉末を0.5wt%添加する。さらに、第1ポリマーと第2ポリマーとをそれぞれ金属磁性粉末に対して0.8wt%ずつ、少量のトルエンと共に混合する。第1ポリマーとしては、10個の炭素原子から構成される側鎖を3つ以上有しており、かつ、12個以上の炭素原子から構成される側鎖を有していない第一のエポキシ樹脂を用いる。第2ポリマーとしては、10個の炭素原子から構成される側鎖と、13個の炭素原子から構成される側鎖を、共に3つ以上有している第二のエポキシ樹脂を用いる。
(表3)に示した試料No.46~試料No.100において、金属磁性粉末として水アトマイズ法にて作製した平均粒径10μmのFe-Si合金粉末を用いる。この金属磁性粉末に、0.3wt%のシランカップリング剤を少量のエタノールと共に添加する。さらに、アクリル樹脂Aとアクリル樹脂Bとをそれぞれ金属磁性粉末に対して0.5wt%ずつ添加する。アクリル樹脂Aとアクリル樹脂Bは、(表3)に示した数の炭素原子から構成される側鎖を3つ以上有しており、かつ(表3)に示した数の炭素原子から構成される側鎖以外には、12個以上の炭素原子もしくはケイ素原子から構成される側鎖を有していない。また、アクリル樹脂Aおよびアクリル樹脂Bのうち、いずれが第1ポリマーおよび第2ポリマーに該当するか(表3)に示している。なお、本実施の形態におけるアクリル樹脂とは、樹脂の骨格における主鎖がアクリル樹脂固有のものである樹脂を指し、側鎖は特に限定されるものではない。
(表4)に示した試料No.101~試料No.125において、金属磁性粉末として水アトマイズ法にて作製した平均粒径10μmのFe-Al-Si合金粉末を用いる。この金属磁性粉末に、絶縁材としてシリコン樹脂0.2wt%と、少量のトルエンとを混合する。シリコン樹脂は6個の炭素原子から構成される側鎖と、1つの炭素原子から構成される側鎖とを、共に3つ以上有している。その後、第1ポリマーおよび第2ポリマーとして(表4)に示した樹脂を、それぞれ金属磁性粉末に対し0.7wt%添加し、混合物を作製する。
(表5)に示した試料No.136~試料No.148において、金属磁性粉末として水アトマイズ法にて作製した平均粒径10μmのFe-Ni合金粉末を用いる。この金属磁性粉末に、絶縁材としてシランカップリング剤を(表5)に示した添加量に従って添加する。さらに、第1ポリマーおよび第2ポリマーとして、第1エポキシ樹脂と第2エポキシ樹脂とを重量比で1:1となるように添加する。第1エポキシ樹脂は11個の炭素原子から構成される側鎖を3つ以上有しており、かつ、炭素原子もしくはケイ素原子の数が12個以上である側鎖を有さない。第2エポキシ樹脂は17個の炭素原子から構成される側鎖を3つ以上有している。第1エポキシ樹脂と第2エポキシ樹脂の総量は金属磁性粉末に対して(表5)に示した割合としている。
(表6)に示した試料No.149~試料No.154において、金属磁性粉末として水アトマイズ法にて作製した平均粒径12μmのFe-Ni合金粉末を用いる。この金属磁性粉末に、絶縁材としてシランカップリング剤を0.3wt%添加する。その後、さらに、第1ポリマーおよび第2ポリマーとして、第1ブチラール樹脂と第2ブチラール樹脂とをそれぞれ金属磁性粉末に対し1wt%の割合で、少量のエタノールと共に添加する。第1ブチラール樹脂は11個の炭素原子から構成される側鎖を3つ以上有しており、かつ、15個の炭素原子から構成される側鎖の数が2つである。第2ブチラール樹脂は15個の炭素原子から構成される側鎖を3つ以上有する。
(表7)に示した試料No.155~試料No.160において、金属磁性粉末としてガスアトマイズ法にて作製した平均粒径30μmのFe-Si-Cr合金粉末を用いる。この金属磁性粉末に、第1ポリマーおよび第2ポリマーとして、第1シリコン樹脂と第2シリコン樹脂とをそれぞれ金属磁性粉末に対し1.5wt%の割合で、少量のトルエンと共に添加する。第1シリコン樹脂は10個のケイ素原子から構成される側鎖を3つ以上有しており、かつ、12個以上の炭素原子もしくはケイ素原子によって構成される側鎖を有さない。第2シリコン樹脂は7個以上11個以下の炭素原子もしくはケイ素原子から構成される側鎖を有しておらず、16個のケイ素原子から構成される側鎖を3つ以上有する。
図3は本発明の実施の形態2における複合磁性体20の拡大模式断面図である。図1に示す実施の形態1における複合磁性体10と異なる点は、金属磁性粉末が複数の第1金属磁性粒子12Aと複数の第2金属磁性粒子12Bとで構成されている点である。そして、第1金属磁性粒子12Aの質量磁化は第2金属磁性粒子12Bの質量磁化以下であり、第1金属磁性粒子12Aの平均粒径は第2金属磁性粒子12Bの平均粒径以上である。
第1金属磁性粒子として平均粒径が22μmで質量磁化σsが140emu/gのFe-Si-Al系金属磁性粒子と、第2金属磁性粒子として(表8)に示す各種金属磁性粒子を用いる。なお、第1金属磁性粒子、第2金属磁性粒子の平均粒径はマイクロトラック粒度分布計により測定している。これら第1金属磁性粒子と第2金属磁性粒子の総量100重量部に対し、シリコーン樹脂を1.2重量部添加した後、トルエンを少量加えて混合する。なお、金属磁性粉末全体における第2金属磁性粒子の比率は20wt%としている。
第1金属磁性粒子として平均粒径が18μmで質量磁化σsが(表10)に示す各種金属磁性粒子と、第2金属磁性粒子として質量磁化σsが198emu/gで平均粒径が1.1μmのFe-Si系金属磁性粒子を用いる。なお、第1金属磁性粒子、第2金属磁性粒子の平均粒径はマイクロトラック粒度分布計により測定している。これら第1金属磁性粒子と第2金属磁性粒子を混合した後、金属磁性粉末の総量100重量部に対しチタン系カップリング材を0.7重量部とブチラール樹脂を0.7重量部添加した後、エタノールを少量加えて混合する。なお、金属磁性粉末全体における第2金属磁性粒子の比率は18wt%としている。また、DH/DL=0.06である。
第1金属磁性粒子として質量磁化σsが152emu/gで(表3)に示す平均粒径を有するFe-Ni系金属磁性粒子と、第2金属磁性粒子として質量磁化σsが190emu/gで(表12)に示す平均粒径を有するFe粒子を用いる。この場合、σsL/σsH=0.8である。なお、第1金属磁性粒子、第2金属磁性粒子の平均粒径はマイクロトラック粒度分布計により測定している。
第1金属磁性粒子として平均粒径25μmで質量磁化σsが136emu/gのFe-Si-Al系金属磁性粒子と、第2金属磁性粒子として平均粒径2μmで質量磁化σsが186emu/gのFe-Si系金属磁性粒子を用いる。そして、第1金属磁性粒子と第2金属磁性粒子とを(表4)に示す比率に配合し、混合して評価用の金属磁性粉末を調製する。この場合、σsL/σsH=0.73であり、DH/DL=0.08である。なお、第1金属磁性粒子、第2金属磁性粒子の平均粒径はマイクロトラック粒度分布計により測定している。
第1金属磁性粒子として平均粒径が12μmで質量磁化σsが170emu/gのFe-Si-Cr系金属磁性粒子と、第2金属磁性粒子として(表15)に示す各種金属磁性粒子を用いる。なお、第1金属磁性粒子、第2金属磁性粒子の平均粒径はマイクロトラック粒度分布計により測定している。
12 金属磁性粒子
12A 第1金属磁性粒子
12B 第2金属磁性粒子
14 空隙
16 絶縁性樹脂
Claims (8)
- 複数の金属磁性粒子で構成された金属磁性粉末と、
前記複数の金属磁性微粒子の間の空隙の少なくとも一部に含浸した絶縁物と、を含む複合磁性体であって、
前記金属磁性粒子間の前記空隙の幅の累積分布曲線において、
累積分布が50%となる前記空隙の幅が3μm以下であり、かつ前記累積分布が95%となる前記空隙の幅が4μm以上である、
複合磁性体。 - 前記金属磁性粉末は複数の第1金属磁性粒子と、複数の第2金属磁性粒子とを含み、
前記第1金属磁性粒子の質量磁化は前記第2金属磁性粒子の質量磁化以下であり、
前記第1金属磁性粒子の平均粒径は前記第2金属磁性粒子の平均粒径以上である、
請求項1に記載の複合磁性体。 - 前記第1金属磁性粒子の前記質量磁化を前記第2金属磁性粒子の前記質量磁化で除した値は0.9以下であり、
前記第2金属磁性粒子の前記平均粒径を前記第1金属磁性粒子の前記平均粒径で除した値は0.5以下である、
請求項2に記載の複合磁性体。 - 前記第1金属磁性粒子および前記第2の金属磁性粒子は少なくともFeを含む、
請求項2に記載の複合磁性体。 - 前記第1金属磁性粒子の前記質量磁化は70emu/g以上である、請求項2記載の複合磁性体。
- 前記第1金属磁性粒子の前記平均粒径は2μm以上、100μm以下である、
請求項2に記載の複合磁性体。 - 前記第2金属磁性粒子を2wt%以上、30wt%以下の範囲で含有する、
請求項2に記載の複合磁性体。 - 複数の金属磁性粒子で構成された金属磁性粉末と、第1ポリマーと、第2ポリマーとを混合して造粒粉を調製するステップと、
前記造粒粉を加圧成形して成形体を作製するステップと、
前記成形体を熱処理して前記第1ポリマーと前記第2ポリマーにおける有機成分を分解して前記複数の金属磁性粒子間に空隙を形成するステップと、
前記空隙の少なくとも一部に絶縁物を含浸するステップと、を備え、
前記空隙の幅の累積分布曲線において、累積分布が50%となる空隙幅が3μm以下であり、かつ前記累積分布が95%となる前記空隙の幅が4μm以上である複合磁性体の製造方法であって、
前記第1ポリマーは7個以上、11個以下の炭素原子もしくはケイ素原子から構成される側鎖を3つ以上有し、かつ12個以上の炭素原子もしくはケイ素原子から構成される側鎖を有さないか、1つ有するか、または2つ有し、
前記第2ポリマーは7個以上、11個以下の炭素原子もしくはケイ素原子から構成される側鎖を有さないか、1つ有するか、または2つ有し、かつ12個以上の炭素原子もしくはケイ素原子から構成される側鎖を3つ以上有する、
複合磁性体の製造方法。
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JP6277426B2 (ja) | 2018-02-14 |
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CN104756203B (zh) | 2017-10-20 |
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US20150287507A1 (en) | 2015-10-08 |
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