WO2014112483A1 - 圧粉磁心の製造方法、圧粉磁心およびコイル部品 - Google Patents
圧粉磁心の製造方法、圧粉磁心およびコイル部品 Download PDFInfo
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- WO2014112483A1 WO2014112483A1 PCT/JP2014/050467 JP2014050467W WO2014112483A1 WO 2014112483 A1 WO2014112483 A1 WO 2014112483A1 JP 2014050467 W JP2014050467 W JP 2014050467W WO 2014112483 A1 WO2014112483 A1 WO 2014112483A1
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- 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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- 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
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- 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
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- 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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- B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
- B22F2302/25—Oxide
- B22F2302/253—Aluminum oxide (Al2O3)
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- C22C33/02—Making ferrous alloys by powder metallurgy
Definitions
- the present invention relates to a method of manufacturing a dust core made of soft magnetic material powder, a dust core, and a coil component formed by winding a coil around a dust core.
- the coil component includes a magnetic core (magnetic core) and a coil wound around the magnetic core.
- a magnetic core magnetic core
- ferrite having excellent magnetic properties, flexibility in shape, and cost is widely used.
- Patent Document 1 discloses an example in which an Fe—Cr—Al-based magnetic powder is used as a magnetic powder capable of self-generation of a high electrical resistance material serving as an insulating coating.
- a magnetic powder is obtained by oxidizing a magnetic powder to generate an oxide film having a high electrical resistance on the surface of the magnetic powder, and solidifying and molding the magnetic powder by discharge plasma sintering. .
- Patent Document 1 does not require the high pressure as described above, it is a manufacturing method that requires complicated equipment and a lot of time, and also pulverizes the agglomerated powder after the oxidation treatment of the magnetic powder. Therefore, the process becomes complicated. Further, since the obtained magnetic powder molded body is a sintered body sintered at high density, there is a possibility that core loss particularly in a high frequency region may be deteriorated.
- the present invention has been made in view of the above problems, and a dust core manufacturing method capable of obtaining a high-strength dust core even by a simple press molding manufacturing method, and further by simple pressure molding.
- An object of the present invention is to provide a dust core and a coil component that can obtain high strength even by a manufacturing method.
- the method for producing a dust core according to the present invention is a method for producing a dust core using soft magnetic material powder, A first step of mixing the soft magnetic material powder and the binder; A second step of pressure-molding the mixture obtained through the first step; A third step of heat-treating the molded body obtained through the second step,
- the soft magnetic material powder is an Fe—Cr—Al based alloy powder containing Fe, Cr and Al, By the heat treatment, an oxide layer having a higher ratio of Al to the sum of Fe, Cr, and Al than the inner alloy phase is formed on the surface of the soft magnetic material powder.
- a high space factor and dust core strength can be obtained even at a low molding pressure. Furthermore, since the oxide layer having a high Al ratio can be formed on the surface of the soft magnetic material powder by the heat treatment after molding, the formation of the insulating coating is also simplified. That is, according to the method for manufacturing a dust core of the present invention, a dust core having excellent strength and the like can be provided by a simple manufacturing method.
- the soft magnetic material powder may have a Cr content of 2.5 to 7.0 mass% and an Al content of 3.0 to 7.0 mass%. preferable.
- the space factor of the soft magnetic material powder in the dust core subjected to the heat treatment is in a range of 80 to 90%.
- the median diameter d50 of the soft magnetic material powder is 30 ⁇ m or less.
- the molding pressure during the pressure molding is 1.0 GPa or less, and the space factor of the soft magnetic material powder in the powder magnetic core subjected to the heat treatment is 83% or more. It is preferable.
- the dust core of the present invention is a dust core using soft magnetic material powder, and the soft magnetic material powder is Fe—Cr—Al based alloy powder containing Fe, Cr and Al, and soft magnetic material powder.
- the soft magnetic material powder preferably has a Cr content of 2.5 to 7.0 mass% and an Al content of 3.0 to 7.0 mass%.
- the average of the maximum diameter of each particle of the soft magnetic material powder in the cross-sectional observation image of the dust core is 15 ⁇ m or less.
- the coil component of the present invention is characterized by having the dust core and a coil wound around the dust core.
- high strength can be obtained even by a manufacturing method of a dust core capable of obtaining a high-strength powder magnetic core even by a manufacturing method by a simple pressure molding, and further by a manufacturing method by a simple pressure molding.
- a dust core and coil components can be provided.
- FIG. 1 is a process flow for explaining an embodiment of a method for producing a dust core according to the present invention.
- This manufacturing method is a manufacturing method of a powder magnetic core using soft magnetic material powder, which is a first step of mixing soft magnetic material powder and a binder, and pressurizing the mixture obtained through the first step. It has the 2nd process of shape
- the soft magnetic material powder to be used is Fe—Cr—Al alloy powder containing Fe, Cr and Al.
- the surface of the soft magnetic material powder has a mass ratio higher than that of the internal alloy phase. An oxide layer having a high ratio of Al to the sum of Fe, Cr and Al is formed.
- the Fe—Cr—Al-based alloy powder containing Cr and Al is superior in corrosion resistance to the Fe—Si-based alloy powder. Furthermore, Fe—Cr—Al based alloy powder is more easily plastically deformed than Fe—Si based or Fe—Si—Cr based alloy powder. Therefore, the Fe—Cr—Al-based alloy powder can obtain a dust core having a high space factor and strength even at a low molding pressure. Therefore, the enlargement and complexity of the molding machine can be avoided. In addition, since molding can be performed at a low pressure, damage to the mold is suppressed and productivity is improved.
- an insulating oxide can be formed on the surface of the soft magnetic material powder by heat treatment after molding, as will be described later. Therefore, it is possible to omit the step of forming the insulating oxide before molding, and the method for forming the insulating coating is simplified, so that productivity is improved in this respect.
- the composition of the Fe—Cr—Al alloy powder containing Fe, Cr, and Al as the three main elements having a high content ratio is not particularly limited as long as it can constitute a dust core.
- Cr and Al are elements that improve corrosion resistance and the like.
- the content of Cr in the soft magnetic material powder is preferably 1.0% by mass or more, more preferably 2.5% by mass or more.
- the Cr content is preferably 9.0% by mass or less, more preferably 7.0% by mass or less, and even more preferably 4.5% by mass or less. It is.
- Al is an element that improves the corrosion resistance as described above, and contributes particularly to the formation of surface oxides.
- the content of Al in the soft magnetic material powder is preferably 2.0% by mass or more, more preferably 3.0% by mass or more, and further preferably 5.0% by mass or more.
- the Al content is preferably 10.0% by mass or less, more preferably 8.0% by mass or less, and even more preferably 7.0% by mass or less. Especially preferably, it is 6.0 mass% or less.
- the total content of Cr and Al is preferably 6.0% by mass or more, and more preferably 9.0% by mass or more.
- the total content of Cr and Al is more preferably 11% by mass or more.
- Al is significantly concentrated in the surface oxide layer as compared with Cr, it is more preferable to use Fe—Cr—Al based alloy powder having a higher Al content than Cr.
- the balance other than Cr and Al is mainly composed of Fe, but may contain other elements as long as it exhibits advantages such as formability of the Fe—Cr—Al alloy powder.
- the content of such other elements is preferably 1.0% by mass or less.
- Si used in Fe—Si based alloys is an element that is disadvantageous for improving the strength of the powder magnetic core, in the present invention, impurities contained through a normal manufacturing process of Fe—Cr—Al based alloy powder. Keep it below the level.
- the Fe—Cr—Al based alloy powder is more preferably composed of Fe, Cr and Al except for inevitable impurities.
- the average particle diameter of the soft magnetic material powder (here, the median diameter d50 in the cumulative particle size distribution is used) is not particularly limited.
- a soft magnetic material powder having an average particle diameter of 1 ⁇ m or more and 100 ⁇ m or less is used. Can be used. By reducing the average particle size, the strength, core loss, and high frequency characteristics of the powder magnetic core are improved. Therefore, the median diameter d50 is more preferably 30 ⁇ m or less, and even more preferably 15 ⁇ m or less.
- the median diameter d50 is more preferably 5 ⁇ m or more. It is more preferable to remove coarse particles from the soft magnetic material powder using a sieve or the like. In this case, it is preferable to use a soft magnetic material powder that is at least under 32 ⁇ m (that is, passed through a sieve having an opening of 32 ⁇ m).
- the form of the soft magnetic material powder is not particularly limited, but it is preferable to use granular powder represented by atomized powder from the viewpoint of fluidity and the like.
- Atomization methods such as gas atomization and water atomization are suitable for producing powders of alloys that have high malleability and ductility and are difficult to grind.
- the atomization method is also suitable for obtaining a substantially spherical soft magnetic material powder.
- the binder used in the first step When the binder is pressure-molded, the binder binds the powders together and gives the molded body the strength to withstand handling after molding.
- the kind of binder is not specifically limited, For example, various organic binders, such as polyethylene, polyvinyl alcohol, an acrylic resin, can be used.
- the organic binder is thermally decomposed by heat treatment after molding. Therefore, an inorganic binder such as a silicone resin that solidifies and remains after the heat treatment and binds the powders may be used in combination.
- the oxide layer formed in the third step has an effect of binding soft magnetic material powders, and thus the use of the above inorganic binder is omitted. Thus, it is preferable to simplify the process.
- the amount of the binder added may be an amount that can be sufficiently distributed between the powders of the soft magnetic material and can secure sufficient strength of the compact. On the other hand, if the amount is too large, the density and strength are lowered. From this point of view, the amount of binder added is preferably 0.5 to 3.0 parts by weight with respect to 100 parts by weight of the soft magnetic material powder, for example.
- the mixing method of the soft magnetic material powder and the binder in the first step is not particularly limited, and conventionally known mixing methods and mixers can be used.
- the mixed powder is an agglomerated powder having a wide particle size distribution due to its binding action.
- a granulated powder having a desired secondary particle size suitable for molding can be obtained.
- a lubricant such as stearic acid or stearate.
- the addition amount of the lubricant is preferably 0.1 to 2.0 parts by weight with respect to 100 parts by weight of the soft magnetic material powder.
- the lubricant can be applied to the mold.
- the mixture obtained in the first step is preferably granulated as described above and subjected to the second step.
- the granulated mixture is pressure-molded into a predetermined shape such as a toroidal shape or a rectangular parallelepiped shape using a molding die.
- the molding in the second step may be room temperature molding or warm molding performed by heating to such an extent that the binder does not disappear.
- molding method of a mixture are not limited above.
- the space factor (relative density) of the dust core can be increased at a low pressure, and the strength of the dust core can be improved. It is more preferable that the space factor of the soft magnetic material powder in the dust core subjected to the heat treatment be within the range of 80 to 90% by utilizing such action. The reason why such a range is preferable is that the magnetic characteristics are improved by increasing the space factor, but if the space factor is excessively increased, the equipment and cost are increased. More preferably, the space factor is 82 to 90%.
- the molding pressure during pressure molding is 1.0 GPa or less, It is more preferable that the space factor of the soft magnetic material powder in the dust core subjected to the heat treatment is 83% or more.
- the molded body that has undergone the second step is subjected to heat treatment.
- heat treatment an oxide layer having a higher ratio of Al to the sum of Fe, Cr, and Al than the inner alloy phase is formed on the surface of the soft magnetic material powder.
- This oxide layer is grown by reacting soft magnetic material powder and oxygen by heat treatment, and is formed by an oxidation reaction exceeding the natural oxidation of the soft magnetic material powder.
- Such heat treatment can be performed in an atmosphere in which oxygen exists, such as in the air or in a mixed gas of oxygen and an inert gas. Further, the heat treatment can be performed in an atmosphere in which water vapor exists, such as in a mixed gas of water vapor and inert gas. Of these, heat treatment in the air is simple and preferable.
- the soft magnetic material powder is oxidized by the heat treatment, and an oxide layer is formed on the surface.
- Al in the Fe—Cr—Al based alloy powder is concentrated in the surface layer, and the oxide layer has a higher ratio of Al to the sum of Fe, Cr and Al than the internal alloy phase.
- the ratio of Al among constituent metal elements is particularly high, and the ratio of Fe is low.
- an oxide layer having a higher Fe ratio in the center of the layer than in the vicinity of the alloy phase is formed at the grain boundary between the Fe—Cr—Al alloy powders.
- this oxide layer is formed after forming a molded object, it contributes also to the coupling
- soft magnetic material powders By combining soft magnetic material powders with each other through the oxide layer, a high-strength powder magnetic core can be obtained.
- the heat treatment in the third step may be performed at a temperature at which the oxide layer is formed. By such heat treatment, a dust core having excellent strength can be obtained. Further, the heat treatment in the third step is preferably performed at a temperature at which the soft magnetic material powder is not significantly sintered. When the soft magnetic material powder is significantly sintered, a part of the oxide layer having a high Al ratio is surrounded by the alloy phase and is isolated in an island shape. Therefore, the function as an oxide layer separating the base alloy phases of the soft magnetic material powder is lowered, and the core loss is also increased.
- the specific heat treatment temperature is preferably in the range of 600 to 900 ° C, more preferably in the range of 700 to 800 ° C, and still more preferably in the range of 750 to 800 ° C.
- the oxide layer is not substantially isolated by being surrounded by the alloy phase.
- substantially surrounded by the alloy phase and not isolated means that when the cross section of the powder magnetic core is polished and observed with a microscope, the isolated oxide layer surrounded by the alloy phase is 0.01 mm. It means 1 or less per 2 places.
- the holding time in the above temperature range is appropriately set according to the size of the dust core, the processing amount, the allowable range of characteristic variation, etc., and is set to 0.5 to 3 hours, for example.
- a preliminary step of forming an insulating film on the soft magnetic material powder by heat treatment or sol-gel method may be added before the first step.
- the oxide layer can be formed on the surface of the soft magnetic material powder by the third step, so that the preliminary step as described above is omitted. It is more preferable to simplify.
- the oxide layer itself is not easily plastically deformed. Therefore, by adopting the above-mentioned process of forming an Al-rich oxide layer after pressure forming, the high formability of the Fe—Cr—Al alloy powder is effectively obtained in the pressure forming of the second step. Can be used.
- the powder magnetic core obtained as described above exhibits an excellent effect itself.
- the soft magnetic material powder is an alloy powder containing Fe, Cr and Al, and the space factor of the soft magnetic material powder is in the range of 80 to 90%.
- the powder magnetic core having an oxide layer having a higher ratio of Al to the sum of Fe, Cr, and Al than the inner alloy phase on the surface of the soft magnetic material powder has excellent moldability and a high space factor. It is suitable for realizing the dust core strength.
- the oxide layer ensures insulation and realizes a sufficient core loss as a dust core. From the viewpoint of sufficiently exhibiting the effect of the oxide layer, it is more preferable that the oxide layer is substantially surrounded by the alloy phase and is not isolated.
- the average of the maximum diameter of each particle of the soft magnetic material powder in the cross-sectional observation image is preferably 15 ⁇ m or less, and more preferably 8 ⁇ m or less.
- the strength and high frequency characteristics are improved because the soft magnetic material powder constituting the dust core is fine.
- the number ratio of particles having a maximum diameter exceeding 40 ⁇ m in the cross-sectional observation image of the dust core is less than 1.0%.
- the average maximum particle diameter is preferably 0.5 ⁇ m or more.
- the average of the maximum diameter may be calculated by polishing the cross section of the powder magnetic core and observing under a microscope, reading the maximum diameter for 30 or more particles existing in a visual field of a certain area, and taking the number average. Although the soft magnetic material powder after molding is plastically deformed, most of the particles are exposed in the cross section of the portion other than the center in the cross section observation, so the average of the maximum diameter is smaller than the median diameter d50 evaluated in the powder state. Value.
- the number ratio of particles having a maximum diameter exceeding 40 ⁇ m is evaluated in a visual field range of at least 0.04 mm 2 or more.
- a coil component is provided using the above-described dust core and a coil wound around the dust core.
- the coil may be configured by winding a conductive wire around a powder magnetic core or may be configured by winding it around a bobbin.
- a coil component having such a dust core and a coil is used as, for example, a choke, an inductor, a reactor, a transformer, or the like.
- the powder magnetic core may be manufactured in the form of a powder magnetic core formed by pressing only the soft magnetic material powder mixed with the binder or the like as described above, or manufactured in a form in which a coil is arranged inside. Also good.
- the latter configuration is not particularly limited.
- the soft magnetic material powder and the coil can be integrally formed by pressure forming and can be manufactured in the form of a powder magnetic core having a coil enclosing structure.
- a powder magnetic core was produced as follows.
- Fe—Cr—Al based soft magnetic alloy powder was used as the soft magnetic material powder.
- Such an alloy powder was a granular atomized powder, and its composition was Fe-4.0% Cr-5.0% Al in mass percentage.
- the atomized powder was used after removing coarse particles through a sieve of 440 mesh (aperture 32 ⁇ m).
- the average particle diameter (median diameter d50) of the soft magnetic material powder measured with a laser diffraction / scattering particle size distribution analyzer (LA-920, manufactured by Horiba, Ltd.) was 18.5 ⁇ m.
- An emulsion acrylic resin binder (Polysol AP-604 manufactured by Showa Polymer Co., Ltd., solid content 40%) was mixed at a ratio of 2.0 parts by weight with 100 parts by weight of the alloy powder. This mixed powder was dried at 120 ° C. for 10 hours, and the dried mixed powder was passed through a sieve to obtain granulated powder. To this granulated powder, zinc stearate was added and mixed at a ratio of 0.4 parts by weight with respect to 100 parts by weight of the soft magnetic material powder to obtain a mixture for molding.
- the obtained mixed powder was press-molded at room temperature with a molding pressure of 0.91 GPa using a press machine.
- the obtained toroidal shaped molded body was heat-treated in the atmosphere at a heat treatment temperature of 800 ° C. for 1.0 hour to obtain a dust core (No. 1).
- Fe-Si soft magnetic alloy powder Fe-3.5% Si in mass percentage
- Fe-Cr-Si soft magnetic alloy powder Fe-4. 0Cr-3.5% Si
- Each molded body was heat-treated at 500 ° C. and 700 ° C. to obtain dust cores (No. 2 and No. 3).
- the heat treatment temperature of 500 ° C. was adopted as described above.
- the density of the dust core produced by the above steps was calculated from its dimensions and mass, and the space factor (relative density) was calculated by dividing the density of the dust core by the true density of the soft magnetic material powder. Further, a load was applied in the radial direction of the toroidal powder magnetic core, the maximum load P (N) at the time of fracture was measured, and the crushing strength ⁇ r (MPa) was obtained from the following equation.
- ⁇ r P (Dd) / (Id 2 ) (Here, D: outer diameter of the core (mm), d: thickness of the core (mm), I: height of the core (mm)) Furthermore, 15 turns of the winding were wound on each of the primary side and the secondary side, and the core loss Pcv was measured under the conditions of a maximum magnetic flux density of 30 mT and a frequency of 300 kHz using a BH analyzer SY-8232 manufactured by Iwatatsu Measurement Co., Ltd. The initial permeability ⁇ i was measured at a frequency of 100 kHz by winding a conducting wire 30 turns around the toroidal powder magnetic core and using 4284A manufactured by Hewlett-Packard Company.
- the No. 1 dust core produced using the Fe—Cr—Al soft magnetic alloy powder is composed of the No. 2 dust core and Fe—Cr—Si using the Fe—Si soft magnetic alloy powder.
- the space factor and the permeability were significantly increased.
- the crushing strength of the No. 1 dust core showed a high value of 100 MPa or more.
- the crushing strength of the No. 1 dust core is more than twice that of the No. 2 and 3 dust cores, and the configuration according to the above embodiment is extremely advantageous in obtaining excellent crushing strength. I found out. That is, according to the structure which concerns on the said Example, the powder magnetic core which has high intensity
- the powder magnetic core of No. 2 using Fe—Si based soft magnetic alloy powder had remarkable corrosion and insufficient corrosion resistance.
- the initial permeability at 10 MHz was maintained at 99.0% or more with respect to the initial permeability of 1 MHz. It has been clarified that the structure according to the above has excellent high frequency characteristics.
- FIGS. 2A and 3 are SEM images
- FIG. 2 is an enlarged view of FIG. It can be seen that a phase having a black color tone is formed on the surface of the soft magnetic material powder 1 having a light gray color tone. It was 8.8 micrometers when the average of the largest diameter was computed about the particle
- FIGS. 2B to 2E are mappings showing the distribution of O (oxygen), Fe (iron), Al (aluminum), and Cr (chromium), respectively. The brighter the color, the greater the number of target elements.
- the surface (grain boundaries) of the soft magnetic material powder is rich in oxygen and oxides are formed, and that the soft magnetic material powders are bonded together via this oxide.
- the Fe magnetic surface has a lower Fe concentration on the surface of the soft magnetic material powder, and Cr does not show a large concentration distribution.
- Al has a significantly high concentration on the surface of the soft magnetic material powder. From these, it was confirmed that an oxide layer having a higher ratio of Al to the sum of Fe, Cr, and Al than the internal alloy phase was formed on the surface of the soft magnetic material powder. Before the heat treatment, the concentration distribution of each constituent element as shown in FIG. 2 was not observed, and it was also found that the oxide layer was formed by the heat treatment.
- the oxide layers at each grain boundary having a high Al ratio are connected to each other.
- no isolated oxide layer surrounded by the alloy phase was observed. It is considered that the configuration related to the oxide layer contributes to improvement of characteristics such as loss.
- a dust core was prepared in the same manner as in the above example using Fe—Cr—Al based soft magnetic alloy powder having the same composition and the same particle size as in the above example.
- the average particle diameter (median diameter d50) of the Fe—Cr—Al based soft magnetic alloy powder used was 10.2 ⁇ m.
- the heat treatment was performed under three conditions of 700 ° C., 750 ° C., and 800 ° C., respectively.
- Table 2 The results of evaluating the characteristics in the same manner as in the above examples are shown in Table 2.
- the No. 4 to 6 dust cores made with Fe-Cr-Al soft magnetic alloy powders use the same Fe-Si soft magnetic alloy powder as the No. 1 dust cores.
- the space factor, permeability, and ring crushing strength were significantly increased.
- the No. 6 dust core using the Fe—Cr—Al soft magnetic alloy powder having a median diameter d50 of 15 ⁇ m or less is the No. 1 dust core. It can be seen that each characteristic is improved compared to the magnetic core, and in particular, the crushing strength and the core loss are greatly improved.
- an electrode was formed by applying a silver paste to the dust cores of Nos. 4 to 6, and after measuring the electric resistance by applying a DC voltage, the electric resistivity ⁇ was estimated from the electrode area and the distance between the electrodes.
- the electrical resistivity ⁇ of the Nos. 4 to 6 dust cores was 1 ⁇ 10 3 ⁇ ⁇ m, 1 ⁇ 10 4 ⁇ ⁇ m, and 1 ⁇ 10 4 ⁇ ⁇ m, respectively.
- the electric resistivity ⁇ of the used No. 2 dust core was significantly larger than 1 ⁇ 10 1 ⁇ ⁇ m.
- the electrical resistivity ⁇ of the No. 3 dust core is 1 ⁇ 10 3 ⁇ ⁇ m, and the electrical resistivity ⁇ of the No.
- FIG. 4 is a TEM photograph showing the grain boundary portion between the soft magnetic material powders observed in the cross section of the dust core.
- Table 3 shows the point analysis values of the intragranular and grain boundary phases of the soft magnetic material powder in FIG. The balance of the analysis values shown in Table 3 is impurities. Analysis point 4 is in the grain, analysis point 2 is the center of the grain boundary phase, and analysis points 1 and 3 are portions of the grain boundary phase very close to the soft magnetic material powder.
- the thickness of the grain boundary phase of the dust core shown in FIG. 4 was about 40 nm.
- Table 3 it was found that an oxide layer was formed as the grain boundary phase, and a concentration gradient of constituent elements or a plurality of phases existed.
- Cr is contained in the oxide layer, the ratio is almost the same as that in the grains of the soft magnetic material powder, and the difference between the Cr concentration in the oxide layer and the Cr concentration in the grains is within ⁇ 3%.
- the oxide layer had a higher Al content than in the grains and that Al was concentrated in the oxide layer at the grain boundary.
- the ratio of Fe is higher in the center of the layer than in the vicinity of the alloy phase in the grains, and it has also been clarified that there is more Fe than Al.
- Al was more than Fe in the portion in the very vicinity of the soft magnetic material powder. It was also found that the Al content in the center of the oxide layer at the grain boundary and in the very vicinity of the soft magnetic material powder was higher than that in Cr.
- the Al oxide has high insulation, it is presumed that the Al oxide is formed at the grain boundary of the soft magnetic material powder, thereby contributing to ensuring insulation and reducing core loss. Further, the soft magnetic material powder is bonded through the grain boundary layer as shown in FIG. 4, and it is considered that this configuration contributes to the improvement of the strength.
- a space factor of 83% or more can be obtained at 0.6 GPa or more, and a space factor of 85% or more can be obtained at 0.7 GPa or more.
- a powder magnetic core having a high space factor equivalent to or higher than that of a conventional Fe-Si based powder magnetic core can be obtained, so that the load on the molding equipment can be reduced.
- the compacting pressure was 0.73 GPa, and the heat treatment temperature was 750 ° C.
- a magnetic core was prepared. With respect to the obtained dust core, the crushing strength, the initial permeability ⁇ i, and the incremental permeability ⁇ ⁇ when a DC magnetic field of 10 kA / m was applied were evaluated. Moreover, the average of the maximum diameter was computed like the powder magnetic core of No1. The results are shown in Table 5.
- the core loss increased by 100% or more in the dust core heat-treated at 850 ° C. as compared with the dust core heat-treated at 750 ° C.
- the increase rate of core loss was 62% in the composition of No11, and 20% in the composition of No13. That is, it was found that as the Cr and Al contents are increased, the change rate of the core loss with respect to the heat treatment temperature is reduced, and there is a margin in the management range of the heat treatment temperature.
- a dust core was produced by applying discharge plasma sintering shown in Patent Document 1 as follows.
- Atomized powder having a composition of Fe-4.0% Cr-5.0% Al and an average particle diameter of 9.8 ⁇ m (median diameter d50) in a mass percentage was heat-treated at 900 ° C. for 1 hour in the air.
- the atomized powder after the heat treatment was solidified in a bulk shape, and it was necessary to add a crushing step before the discharge plasma sintering step.
- the atomized powder after heat treatment and pulverization was filled into a graphite mold without adding a binder, and then placed in a chamber, and discharge plasma sintering was performed under conditions of a pressure of 50 MPa, a heating temperature of 900 ° C., and a holding time of 5 minutes. .
- the obtained sintered body was mainly composed of oxide, and a desired magnetic core could not be obtained. This is considered to be because the atomized powder was excessively oxidized during the heat treatment of the atomized powder performed before the discharge plasma sintering, and the manufacturing method shown in Patent Document 1 only makes the manufacturing process complicated. In addition, it was confirmed that direct application was not possible when using fine atomized powder.
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Abstract
Description
軟磁性材料粉とバインダーを混合する第1の工程と、
前記第1の工程を経て得られた混合物を加圧成形する第2の工程と、
前記第2の工程を経て得られた成形体を熱処理する第3の工程とを有し、
前記軟磁性材料粉はFe、CrおよびAlを含むFe-Cr-Al系合金粉であり、
前記熱処理によって、前記軟磁性材料粉の表面に、質量比で内部の合金相よりもFe、CrおよびAlの和に対するAlの比率が高い酸化物層を形成することを特徴とする。
σr=P(D-d)/(Id2)
(ここで、D:コアの外径(mm)、d:コアの肉厚(mm)、I:コアの高さ(mm)である。)
さらに、一次側と二次側のそれぞれに巻線を15ターン巻回し、岩通計測株式会社製B-HアナライザーSY-8232により、最大磁束密度30mT、周波数300kHzの条件でコアロスPcvを測定した。また、初透磁率μiは、前記トロイダル形状の圧粉磁心に導線を30ターン巻回し、ヒューレット・パッカード社製4284Aにより、周波数100kHzで測定した。
Claims (9)
- 軟磁性材料粉を用いた圧粉磁心の製造方法であって、
軟磁性材料粉とバインダーを混合する第1の工程と、
前記第1の工程を経て得られた混合物を加圧成形する第2の工程と、
前記第2の工程を経て得られた成形体を熱処理する第3の工程とを有し、
前記軟磁性材料粉はFe、CrおよびAlを含むFe-Cr-Al系合金粉であり、
前記熱処理によって、前記軟磁性材料粉の表面に、質量比で内部の合金相よりもFe、CrおよびAlの和に対するAlの比率が高い酸化物層を形成することを特徴とする圧粉磁心の製造方法。 - 前記軟磁性材料粉のCrの含有量が2.5~7.0質量%、Alの含有量が3.0~7.0質量%であることを特徴とする請求項1に記載の圧粉磁心の製造方法。
- 前記熱処理を経た圧粉磁心における軟磁性材料粉の占積率が80~90%の範囲内であることを特徴とする請求項1または2に記載の圧粉磁心の製造方法。
- 前記第1の工程に供する前記軟磁性材料粉のメジアン径d50が30μm以下であることを特徴とする請求項1~3のいずれか一項に記載の圧粉磁心の製造方法。
- 前記加圧成形時の成形圧が1.0GPa以下であるとともに、前記熱処理を経た圧粉磁心における軟磁性材料粉の占積率が83%以上であることを特徴とする請求項1~4のいずれか一項に記載の圧粉磁心の製造方法。
- 軟磁性材料粉を用いた圧粉磁心であって、
前記軟磁性材料粉はFe、CrおよびAlを含むFe-Cr-Al系合金粉であり、
軟磁性材料粉の占積率が80~90%の範囲内であるとともに、
前記軟磁性材料粉同士が、質量比で内部の合金相よりもFe、CrおよびAlの和に対するAlの比率が高い酸化物層を介して結合されていることを特徴とする圧粉磁心。 - 前記軟磁性材料粉のCrの含有量が2.5~7.0質量%、Alの含有量が3.0~7.0質量%であることを特徴とする請求項6に記載の圧粉磁心。
- 前記圧粉磁心の断面観察像における軟磁性材料粉の各粒子の最大径の平均が15μm以下であることを特徴とする請求項6または7に記載の圧粉磁心。
- 請求項6~8のいずれか一項に記載の圧粉磁心と、前記圧粉磁心の周囲に巻装されたコイルとを有することを特徴とするコイル部品。
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- 2014-01-14 CN CN201480004998.0A patent/CN104919551B/zh active Active
- 2014-01-14 WO PCT/JP2014/050467 patent/WO2014112483A1/ja active Application Filing
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Cited By (17)
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JP2015053491A (ja) * | 2013-01-16 | 2015-03-19 | 日立金属株式会社 | 圧粉磁心 |
WO2015108059A1 (ja) * | 2014-01-14 | 2015-07-23 | 日立金属株式会社 | 磁心およびそれを用いたコイル部品 |
JP2017168844A (ja) * | 2014-01-14 | 2017-09-21 | 日立金属株式会社 | 磁心の製造方法 |
US9805855B2 (en) | 2014-01-14 | 2017-10-31 | Hitachi Metals, Ltd. | Magnetic core and coil component using same |
US10176912B2 (en) * | 2014-03-10 | 2019-01-08 | Hitachi Metals, Ltd. | Magnetic core, coil component and magnetic core manufacturing method |
JP2015226000A (ja) * | 2014-05-29 | 2015-12-14 | 日立金属株式会社 | 磁心の製造方法、磁心およびそれを用いたコイル部品 |
JP2016009785A (ja) * | 2014-06-25 | 2016-01-18 | 日立金属株式会社 | 磁心およびそれを用いたコイル部品 |
JP2016027643A (ja) * | 2014-06-27 | 2016-02-18 | 日立金属株式会社 | コイル部品 |
US10544488B2 (en) | 2015-02-27 | 2020-01-28 | Taiyo Yuden Co., Ltd. | Magnetic body and electronic component comprising the same |
US10260132B2 (en) | 2015-03-31 | 2019-04-16 | Taiyo Yuden Co., Ltd. | Magnetic body and electronic component comprising the same |
US11192183B2 (en) * | 2015-09-16 | 2021-12-07 | Hitachi Metals, Ltd. | Method for manufacturing powder magnetic core |
US10468174B2 (en) | 2016-09-15 | 2019-11-05 | Hitachi Metals, Ltd. | Magnetic core and coil component |
US10586646B2 (en) | 2016-09-15 | 2020-03-10 | Hitachi Metals, Ltd. | Magnetic core and coil component |
JP2020155672A (ja) * | 2019-03-22 | 2020-09-24 | 日本特殊陶業株式会社 | 圧粉磁心 |
JP2020155671A (ja) * | 2019-03-22 | 2020-09-24 | 日本特殊陶業株式会社 | 圧粉磁心 |
JP7269046B2 (ja) | 2019-03-22 | 2023-05-08 | 日本特殊陶業株式会社 | 圧粉磁心 |
JP7300288B2 (ja) | 2019-03-22 | 2023-06-29 | 日本特殊陶業株式会社 | 圧粉磁心 |
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Publication number | Publication date |
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US20180268994A1 (en) | 2018-09-20 |
KR20150102084A (ko) | 2015-09-04 |
EP2947670B1 (en) | 2019-04-17 |
EP2947670B8 (en) | 2019-06-05 |
US20150332850A1 (en) | 2015-11-19 |
JP2015053491A (ja) | 2015-03-19 |
US10008324B2 (en) | 2018-06-26 |
JPWO2014112483A1 (ja) | 2017-01-19 |
EP2947670A1 (en) | 2015-11-25 |
EP2947670A4 (en) | 2016-10-05 |
CN104919551B (zh) | 2018-03-20 |
US11011305B2 (en) | 2021-05-18 |
JP6260508B2 (ja) | 2018-01-17 |
KR101792088B1 (ko) | 2017-11-01 |
JP5626672B1 (ja) | 2014-11-19 |
CN104919551A (zh) | 2015-09-16 |
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