WO2015079856A1 - Noyau pulvérulent, composant de bobine et procédé permettant de produire un noyau pulvérulent - Google Patents

Noyau pulvérulent, composant de bobine et procédé permettant de produire un noyau pulvérulent Download PDF

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WO2015079856A1
WO2015079856A1 PCT/JP2014/078712 JP2014078712W WO2015079856A1 WO 2015079856 A1 WO2015079856 A1 WO 2015079856A1 JP 2014078712 W JP2014078712 W JP 2014078712W WO 2015079856 A1 WO2015079856 A1 WO 2015079856A1
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soft magnetic
insulating layer
magnetic particles
dust core
powder
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PCT/JP2014/078712
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English (en)
Japanese (ja)
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朝之 伊志嶺
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住友電気工業株式会社
住友電工焼結合金株式会社
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
    • H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
    • H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/16—Metallic particles coated with a non-metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/33—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials mixtures of metallic and non-metallic particles; metallic particles having oxide skin
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/255—Magnetic cores made from particles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2201/00—Treatment under specific atmosphere
    • B22F2201/03—Oxygen
    • 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
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • 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
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
    • H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
    • H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
    • H01F1/26—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated by macromolecular organic substances

Definitions

  • the present invention relates to a dust core used for a magnetic core and the like, a coil component including the dust core, and a method for manufacturing the dust core.
  • the present invention relates to a powder core having low loss and high strength.
  • a magnetic component As a component provided in a circuit for converting energy, such as a switching power supply or a DC / DC converter, there is a magnetic component including a coil formed by winding a winding and a magnetic core in which this coil is disposed to form a closed magnetic circuit.
  • Some of the above magnetic cores utilize a powder magnetic core manufactured using a powder made of a soft magnetic material.
  • a powder magnetic core for example, Patent Document 1 and Patent Document 2 show a powder magnetic core manufactured using soft magnetic particles made of Fe—Si—Al based alloy represented by Sendust as raw material powder. ing.
  • the dust core of Patent Document 1 is made of coated particles comprising Fe—Si—Al alloy particles obtained by a gas atomization method or a water atomization method, and an insulating layer made of a silicate compound formed on the particle surface. Used for powder. And it is manufactured by pressurizing and compressing a composite material obtained by mixing a molding resin with a raw material powder, and subjecting the molded compact to a heat treatment. This heat treatment is performed in a nitrogen atmosphere when the particles are obtained by a gas atomizing method, and is performed in an air atmosphere when the particles are obtained by a water atomizing method.
  • Patent Document 2 heats Fe—Si—Al alloy particles in an oxidizing atmosphere to form an insulating layer made of an oxide derived from alloy particles (mainly Al) on the surface of the alloy particles.
  • the coated particles are used as raw material powder.
  • the compound which mixed the binder with this raw material powder is pressurized and compressed, and it heat-processes in an oxidizing atmosphere to the molded compression product, and is manufactured.
  • the dust core of Patent Document 1 can secure a certain degree of strength, and the dust core of Patent Document 2 can secure a certain amount of low loss.
  • the dust cores of Patent Document 1 and Patent Document 2 have room for further improvement in terms of both low loss and high strength.
  • This invention is made
  • Another object of the present invention is to provide a coil component having the above-described dust core.
  • Another object of the present invention is to provide a method for producing the above-described powder magnetic core.
  • the first dust core of the present invention comprises a plurality of soft magnetic particles and an insulating layer interposed between the soft magnetic particles.
  • the soft magnetic particles are made of an Fe—Si—Al-based alloy, and the maximum diameter / equivalent circle diameter in the cross section of the dust core is 1.0 or more and 1.3 or less.
  • the insulating layer is made of an oxide containing Si and O, and at least one of alkali metal and Mg.
  • the second dust core of the present invention comprises a plurality of soft magnetic particles and an insulating layer interposed between the soft magnetic particles.
  • the soft magnetic particles are made of an Fe—Si—Al alloy and have an oxygen content of 500 ppm or less.
  • the insulating layer is made of an oxide containing Si and O, and at least one of alkali metal and Mg.
  • the coil component of the present invention includes a coil formed by winding a winding and a magnetic core on which the coil is disposed. At least a part of the magnetic core is the dust core.
  • the first method for producing a dust core according to the present invention is produced using a coated soft magnetic powder comprising a plurality of coated soft magnetic particles whose outer periphery is coated with an insulating layer.
  • the manufacturing method of the powder magnetic core of the present invention includes the following raw material preparation process, composite process, molding process, and heat treatment process.
  • the soft magnetic particles are Fe—Si—Al alloy
  • the maximum diameter / equivalent circle diameter in the projected area is 1.0 or more and 1.3 or less
  • the insulating layer is made of Si and O
  • a coated soft magnetic powder made of an oxide containing at least one of alkali metal and Mg is prepared.
  • the composite process a composite material including the coated soft magnetic powder and the molding resin material is produced.
  • the composite material is pressurized to produce a molded body.
  • the molded body is subjected to a heat treatment in an oxidizing atmosphere to produce a magnetic core molded body in which the insulating layer is crystallized.
  • the second method for producing a dust core according to the present invention is produced using a coated soft magnetic powder comprising a plurality of coated soft magnetic particles whose outer periphery is coated with an insulating layer.
  • the manufacturing method of the powder magnetic core of the present invention includes the following raw material preparation process, composite process, molding process, and heat treatment process.
  • the raw material preparation step is a Fe—Si—Al-based alloy having an oxygen content of 500 ppm or less, and an insulating layer made of an oxide containing Si and O, and further containing at least one of an alkali metal and Mg.
  • a composite material including the coated soft magnetic powder and the molding resin material is produced.
  • the composite material is pressurized to produce a molded body.
  • the molded body is subjected to a heat treatment in an oxidizing atmosphere to produce a magnetic core molded body in which the insulating layer is crystallized.
  • the dust core of the present invention has low loss and high strength.
  • the coil component of the present invention is excellent in soft magnetic properties and strength.
  • the dust core manufacturing method of the present invention can manufacture a dust core with low loss and high strength.
  • the gas atomization method yields particles with less unevenness on the surface, whereas the water atomization method often yields particles with more unevenness on the surface. For this reason, the particles obtained by the gas atomization method tend to reduce the meshing of irregularities between particles such as those of the water atomization method, and it is difficult to increase the strength compared to the particles of the water atomization method.
  • the insulating layer formed on the surface of the soft magnetic particles may be deformed or damaged due to the engagement of the irregularities between the particles. It is considered that the iron loss can increase when the insulating layer is damaged and soft magnetic particles come into contact with each other.
  • the present inventor has intensively studied a method for manufacturing a dust core having both low loss and high strength.
  • soft magnetic particles made of an Fe-Si-Al alloy and an insulating layer made of a specific oxide are provided, and the soft magnetic particles have a specific shape and a specific shape. It was found that a powder magnetic core having both low loss and high strength can be obtained by preparing a raw material powder satisfying at least one of the oxygen contents and performing heat treatment in a specific atmosphere.
  • the present invention is based on this finding. First, the contents of the embodiment of the present invention will be listed and described.
  • a first dust core according to the embodiment includes a plurality of soft magnetic particles and an insulating layer interposed between the soft magnetic particles.
  • the soft magnetic particles are made of a Fe—Si—Al-based alloy, and the maximum diameter / equivalent circle diameter in the cross section is 1.0 or more and 1.3 or less.
  • the insulating layer is made of an oxide containing Si and O, and at least one of alkali metal and Mg.
  • the strength is excellent and the loss can be reduced.
  • the soft magnetic particles satisfy the maximum diameter / equivalent circle diameter, the shape is close to a sphere, and the insulating layer is less likely to be deformed or damaged during pressure forming during the manufacturing process. For this reason, the insulating layer is sufficiently interposed between the soft magnetic particles in the dust core so that the soft magnetic particles can be insulated from each other and the loss can be reduced.
  • the insulating layer is made of the above oxide, the insulating layers are deformed and brought into close contact with each other at the time of pressure forming in the manufacturing process, and the insulating layer is crystallized and hardened in the subsequent heat treatment (firing) process. This is because the bond between the soft magnetic particles can be strengthened and the strength of the dust core can be increased.
  • the second dust core according to the embodiment includes a plurality of soft magnetic particles and an insulating layer interposed between the soft magnetic particles.
  • the soft magnetic particles are made of an Fe—Si—Al alloy and have an oxygen content of 500 ppm or less.
  • the insulating layer is made of an oxide containing Si and O, and at least one of alkali metal and Mg.
  • the strength is excellent and the loss can be reduced.
  • the loss tends to increase. Therefore, the loss can be reduced by satisfying the oxygen content of the soft magnetic particles. This is because the formation of fine oxide precipitates that significantly deteriorate the soft magnetic properties can be suppressed.
  • the oxygen content of a soft-magnetic particle is 500 ppm or less.
  • the strength is excellent and the loss can be further reduced.
  • the soft magnetic particles satisfy the maximum diameter / equivalent circle diameter and satisfy the oxygen content, the particle shape becomes spherical, and damage to the insulating layer during pressure molding can be suppressed.
  • the generation of fine oxide precipitates that significantly deteriorate the soft magnetic properties can be suppressed. Therefore, the insulation between the particles can be maintained in a healthy state, and iron loss can be reduced and bonding between particles can be strengthened.
  • an iron loss (W1 / 100k) is 300 kW / m ⁇ 3 > or less.
  • This iron loss is a value when measured at at least a part of the ambient temperature range of 25 ° C. or higher and 150 ° C. or lower with an excitation magnetic flux density Bm of 0.1 T and a measurement frequency of 100 kHz.
  • said iron loss (W1 / 100k) is 300 kW / m ⁇ 2 > or less, and crushing strength is 25 Mpa or more.
  • the crushing strength is a value measured on the basis of “sintered bearing-crushing strength test method JIS Z 2507 (2000)”.
  • the coil component according to the embodiment includes a coil formed by winding a winding and a magnetic core on which the coil is disposed. At least a part of the magnetic core is the first or second dust core.
  • the soft magnetic characteristics are excellent, and damage is difficult.
  • the present invention can be suitably used for coil parts that are arranged at locations that are susceptible to external influences such as vibration.
  • the first dust core manufacturing method is manufactured using a coated soft magnetic powder comprising a plurality of coated soft magnetic particles whose outer periphery is coated with an insulating layer.
  • the manufacturing method of the powder magnetic core of the present invention includes the following raw material preparation process, composite process, molding process, and heat treatment process.
  • the soft magnetic particles are Fe—Si—Al alloy
  • the maximum diameter / equivalent circle diameter in the projected area is 1.0 or more and 1.3 or less
  • the insulating layer is made of Si and O
  • a coated soft magnetic powder made of an oxide containing at least one of alkali metal and Mg is prepared.
  • the composite process a composite material including the coated soft magnetic powder and the molding resin material is produced.
  • the composite material is pressurized to produce a molded body.
  • the molded body is subjected to a heat treatment in an oxidizing atmosphere to produce a magnetic core molded body in which the insulating layer is crystallized.
  • a low-loss and high-strength powder magnetic core can be manufactured. This is because the specific coated soft magnetic powder is prepared in the raw material preparation step, and the heat treatment step is performed in an oxidizing atmosphere, whereby the insulation between the soft magnetic particles can be improved.
  • the second method for producing a dust core according to the embodiment is produced using a coated soft magnetic powder comprising a plurality of coated soft magnetic particles whose outer periphery is coated with an insulating layer.
  • the manufacturing method of the powder magnetic core of the present invention includes the following raw material preparation process, composite process, molding process, and heat treatment process.
  • the raw material preparation step is a Fe—Si—Al-based alloy having an oxygen content of 500 ppm or less, and an insulating layer made of an oxide containing Si and O, and further containing at least one of an alkali metal and Mg.
  • a composite material including the coated soft magnetic powder and the molding resin material is produced.
  • the composite material is pressurized to produce a molded body.
  • the molded body is subjected to a heat treatment in an oxidizing atmosphere to produce a magnetic core molded body in which the insulating layer is crystallized.
  • a low-loss and high-strength powder magnetic core can be manufactured. This is because the specific coated soft magnetic powder is prepared in the raw material preparation step, and the heat treatment step is performed in an oxidizing atmosphere, whereby the insulation between the soft magnetic particles can be improved.
  • the oxygen content of a soft-magnetic particle is 500 ppm or less.
  • heat processing temperature makes 600 degreeC or more 900 degrees C or less and oxygen concentration 0.1 volume% or more is mentioned. .
  • the dust core according to the embodiment includes a plurality of soft magnetic particles and an insulating layer interposed between the soft magnetic particles.
  • the main features of this dust core are that the soft magnetic particles are made of Fe-Si-Al alloy, the insulating layer is made of a specific oxide, and (1) the shape of the soft magnetic particles is specified. (2) The soft magnetic particles have a low oxygen content, and have at least one of them.
  • Soft magnetic particles The kind of soft magnetic particles is Fe—Si—Al based alloy.
  • a typical example of Fe—Si—Al engagement gold includes a composition containing 7.0 mass% to 11 mass% of Si, 3 mass% to 11 mass% of Al, with the balance being Fe and inevitable impurities.
  • the Fe—Si—Al-based alloy preferably contains 7.0% by mass to 9.5% by mass of Si and 4.0% by mass to 10.0% by mass of Al. If it does so, intensity
  • the Fe—Si—Al-based alloy preferably satisfies 27 ⁇ 2.5a + b ⁇ 29 and 6 ⁇ b ⁇ 9 when the Si content is a mass% and the Al content is b mass%. . If it does so, in addition to being able to raise intensity
  • the maximum diameter / equivalent circle diameter in the cross section of the dust core is 1.0 or more and 1.3 or less. If it does so, intensity
  • the shape of the soft magnetic particles is particularly preferably a true sphere.
  • a true sphere refers to a case where the maximum diameter / equivalent circle diameter is 1.0.
  • the maximum diameter and the equivalent circle diameter of the soft magnetic particles are obtained as follows. First, the observation field of view of an arbitrary cross-section of the dust core is adjusted with a scanning electron microscope (SEM) so that the magnification is 100 to 1000 times, the number of observation fields is 2 or more, and the total observation area is 60000 ⁇ m 2 or more.
  • SEM scanning electron microscope
  • the observed image is analyzed with an image analyzer. Then, the maximum diameter, the equivalent circle diameter, and the maximum diameter / equivalent circle diameter of each soft magnetic particle are calculated, and the calculation results of the maximum diameter / equivalent circle diameter are averaged.
  • the maximum diameter is the maximum length in the contour of each soft magnetic particle
  • the equivalent circle diameter is the diameter of a circle having the same area as the area surrounded by the contour.
  • the shape of the soft magnetic particles substantially maintains the shape of the soft magnetic particles prepared at the time of manufacture. This is because the soft magnetic particles themselves have high hardness and are not easily deformed during molding in the manufacturing process.
  • the oxygen content of the soft magnetic particles is 500 ppm or less. If it does so, intensity
  • the oxygen content of the soft magnetic particles is preferably as small as possible, and is preferably 400 ppm or less, more preferably 200 ppm or less, and particularly preferably 150 ppm or less.
  • the oxygen content of the soft magnetic particles can be determined by an electron beam microanalyzer (EPMA).
  • EPMA electron beam microanalyzer
  • the average particle diameter of the soft magnetic particles is preferably 10 ⁇ m or more and 100 ⁇ m or less. Then, iron loss can be reduced. When the average particle size of the soft magnetic particles is 10 ⁇ m or more, an increase in hysteresis loss can be suppressed. On the other hand, when the average particle diameter of the soft magnetic particles is 100 ⁇ m or less, an increase in eddy current loss can be suppressed.
  • the average particle diameter of the soft magnetic particles is the average value of equivalent circle diameters measured and calculated by the same measurement method as that for obtaining the above-described shape. The average particle diameter of the soft magnetic particles substantially maintains the average particle diameter of the soft magnetic particles prepared at the time of manufacture, similar to the shape of the soft magnetic particles described above.
  • the insulating layer is interposed between the soft magnetic particles to ensure insulation between the soft magnetic particles.
  • the insulating layer is usually formed so as to cover the outer peripheral surface of the soft magnetic particles.
  • the insulating layer is made of a silicate compound containing Si and O, and at least one of alkali metal and Mg.
  • Examples of the silicate compound containing at least one of the alkali metal and Mg include potassium silicate (K 2 SiO 3 ), sodium silicate (Na 2 SiO 3 : water glass, also called sodium silicate), lithium silicate ( Li 2 SiO 3 ), magnesium silicate (MgSiO 3 ) and the like.
  • the content of each element in the insulating layer is such that Si is 10% by mass to 35% by mass, O is 20% by mass to 70% by mass, and the total amount of alkali metal and Mg is 5% by mass to 30% by mass. A range is preferred.
  • the insulating layer may further contain Al in addition to the silicic acid compound.
  • Al to contain is not ask
  • the insulating layer contains sodium silicate and Al, the insulating property is excellent.
  • the insulating layer contains other silicate compounds such as potassium silicate, lithium silicate, magnesium silicate and Al, the heat resistance is excellent.
  • the insulating layer contains Al the content of Al is preferably in the range of more than 0% by mass and 20% by mass or less.
  • the insulating layer may contain a small amount of elements other than Si, Al, O, alkali metals, and Mg.
  • elements other than Si, Al, O, alkali metal, and Mg include Fe, Ca, and the like.
  • the content is preferably 20% by mass or less.
  • the dust core has low loss and high strength.
  • the iron loss (W1 / 100 k) is, for example, 300 kW / m 3 or less.
  • the iron loss (W1 / 100k) is a value measured at at least a part of the environmental temperature range of 25 ° C. or higher and 150 ° C. or lower with an excitation magnetic flux density Bm of 0.1T and a measurement frequency of 100 kHz.
  • the dust core has a temperature at which the iron loss (W1 / 100k) is 300 kW / m 3 or less in an environmental temperature range of 25 ° C. or more and 150 ° C. or less.
  • This iron loss (W1 / 100k) is preferably 200 kW / m 3 or less, and particularly preferably 180 kW / m 3 or less.
  • the iron loss (W1 / 100k) is low in a relatively high temperature range (for example, 100 ° C. or higher) in the environmental temperature range, it can be suitably used for a converter mounted on a hybrid vehicle that has been remarkably developed in recent years.
  • the crushing strength is, for example, 25 MPa or more.
  • the crushing strength is a value measured on the basis of “sintered bearing-crushing strength test method JIS Z 2507 (2000)”.
  • the crushing strength is preferably 35 MPa or more, and more preferably 40 MPa or more.
  • the method for producing a dust core for producing the dust core includes a raw material preparation step, a composite step, a forming step, and a heat treatment step.
  • the main feature of this method for producing a dust core is that a specific coated soft magnetic powder is prepared in the raw material preparation step and a specific heat treatment is performed in the heat treatment step. More specifically, in the raw material preparation step, a coated soft magnetic powder including a plurality of soft magnetic particles having at least one of the specific shape and the specific oxygen content described above and an insulating layer of a specific material is prepared.
  • heat treatment step heat treatment is performed in a specific atmosphere.
  • a coated soft magnetic powder including a plurality of coated soft magnetic particles including soft magnetic particles made of the above-described material and an insulating layer formed on the outer periphery thereof and made of the above-described material is prepared.
  • the coated soft magnetic powder can be prepared, for example, by preparing a plurality of soft magnetic particles and coating the outer periphery of the soft magnetic particles with an insulating layer.
  • the production of soft magnetic particles can be performed by a gas atomization method. Thereby, soft magnetic particles having a maximum diameter / equivalent circle diameter of 1.0 to 1.3, more preferably 1.0 to 1.1 in the projected area can be produced.
  • the atmosphere for producing the soft magnetic particles is a low oxygen atmosphere with a low oxygen concentration. Thereby, soft magnetic particles having an oxygen content of 500 ppm or less can be produced.
  • the atmosphere during the production of the soft magnetic particles is preferably an inert gas atmosphere (non-oxygen atmosphere).
  • the maximum diameter / equivalent circle diameter in the projected area is 1.0 or more and 1.3 or less, and the oxygen content is 500 ppm or less.
  • Soft magnetic particles can be produced.
  • the average particle diameter of the soft magnetic particles is preferably 10 ⁇ m or more and 100 ⁇ m or less.
  • the average particle diameter refers to a D50 (50%) particle diameter (a particle diameter corresponding to 50% of a mass-based cumulative distribution curve).
  • a natural oxide film may be formed on the surface of the soft magnetic particles.
  • This can be done by adding and mixing a solution such as a colloidal solution of magnesium silicate. It is preferable that the number of rotations of the mixer or the rotating container is 50 rpm or more and 500 rpm or less, and mixing is performed at a temperature of 30 ° C. or more and 100 ° C. or less for 10 minutes or more and 60 minutes or less.
  • the solution is preferably added by spraying the solution at the above temperature.
  • the attached solution can be quickly dried to form a dense insulating layer.
  • the coated soft magnetic powder thus produced, since some of the soft magnetic particles are bonded to each other via an insulating layer, it is preferable to perform “unraveling” to separate the bonding. This loosening operation is sufficient to lightly screen the soft magnetic powder.
  • the concentration of these solutions and the mass of the solid content in the solution with respect to the mass of the soft magnetic particles can be appropriately selected according to the desired thickness of the insulating layer. This is because the mass of the solid content can be roughly converted into the thickness of the insulating layer. Specifically, the concentration of the solution is 5% by mass or more and 50% by mass or less, and the addition amount of the solid content is 0.1% by mass or more and 3.0% by mass or less. For example, when the average particle size of soft magnetic particles is 50 ⁇ m, when the solid content is 0.1% by mass, an insulating layer having an average thickness of about 25 nm can be formed, and when the solid content is 1.0% by mass An insulating layer having an average thickness of about 750 nm can be formed.
  • the dust core When the dust core is manufactured by setting the thickness of the insulating layer to 25 nm or more, sufficient insulation between particles can be secured, and by setting the thickness of the insulating layer to 750 nm or less, soft magnetism in the dust core is achieved. A sufficient amount of particles can be secured.
  • a composite material including a raw material powder and a molding resin material is produced.
  • the molding resin material retains its shape when the raw material powder is compressed into a compact.
  • the material of the molding resin material is preferably a material that can achieve both the deformability during molding and the mechanical strength during molding.
  • An example of the material is a thermoplastic resin. Specifically, acrylic resin, polyvinyl alcohol (PVA) resin, polyvinyl butyral (PVB) resin, polyethylene (PE) resin, and the like can be given.
  • PVA polyvinyl alcohol
  • PVB polyvinyl butyral
  • PE polyethylene
  • an acrylic resin is preferable from the viewpoint of both the deformability during molding and the mechanical strength during molding. This molding resin material substantially disappears during heat treatment of the molded body.
  • the composite material can be produced by, for example, rolling the soft magnetic powder while heating it using a mixer or a dry pan granulator used when the insulating layer is coated on the soft magnetic particles, and diluting with water. This can be done by adding and mixing the molded resin material. When the same mixer as that used for coating the insulating layer is used, the insulating layer can be continuously coated and the mixed material can be produced. It is preferable that the rotational speed at the time of rolling is 50 rpm or more and 500 rpm or less, and the mixing is performed at a temperature of 30 ° C. or more and 100 ° C. or less for 10 minutes or more and 120 minutes or less.
  • the molding resin material is preferably added by spraying the molding resin material at the above temperature as described above.
  • the adhered molding resin material is quickly dried, so that the molding resin material uniform on the outer periphery of the coated soft magnetic particles is obtained.
  • the raw material powder to which the molding resin material is added is dried by heating to form a unit particle of a composite material in which a plurality of soft magnetic particles are integrated with the molding resin material.
  • the addition amount of the resin material for mold molding is 0.5% by mass or more and 3.0% by mass or less with respect to the mass of the soft magnetic powder.
  • the addition amount of the molding resin material 0.5 mass% or more, the molded body can be sufficiently retained.
  • the addition amount 3.0% or less the amount of resin in the mixture becomes an appropriate amount, and the amount of soft magnetic particles in the molded body and the molded body for magnetic core can be sufficiently secured.
  • the amount of the resin material for molding is particularly preferably 0.5% by mass or more and 2.0% by mass or less.
  • the composite material is pressurized to produce a molded body.
  • the molded body can be manufactured by filling the composite material into a molding die capable of obtaining a predetermined shape and pressurizing the composite material in the mold. What is necessary is just to select the shape of a molded object according to the shape of the magnetic core of coil components.
  • the pressure for pressing the composite material is preferably 500 MPa or more. By setting the pressure to 500 MPa or more, a high-density molded body can be obtained.
  • the pressure is particularly preferably 800 MPa or more.
  • the upper limit of the pressure can be appropriately selected as long as the soft magnetic particles are not substantially deformed and the insulating layer is not damaged. For example, the pressure is 2500 MPa or less.
  • Heat treatment process The molded body is subjected to heat treatment to produce a molded body for a magnetic core in which the insulating layer is crystallized.
  • the heat treatment removes strain introduced into the soft magnetic particles in the molding process and crystallizes the constituent material of the insulating layer.
  • the heat treatment atmosphere is an oxidizing atmosphere. By doing so, it is possible to manufacture a magnetic core molded body having a low loss and a high strength.
  • the oxygen concentration is preferably 0.1% by volume or more, and particularly preferably 5% by volume or more. By setting the oxygen concentration to 0.1% by volume or more, the insulating property between the soft magnetic particles can be improved. Examples of the oxygen concentration include 50% by volume or less, and further 25% by volume or less.
  • the heat treatment temperature is preferably 600 ° C. or higher and 900 ° C. or lower, and particularly preferably 650 ° C. or higher and 800 ° C. or lower.
  • the holding time of this heat treatment is preferably about 0.5 hours or more and 2 hours or less, and particularly preferably 1 hour or more and 2 hours or less.
  • the oxygen content inside the soft magnetic particles in the obtained magnetic core molded body effectively maintains the oxygen content inside the soft magnetic particles in the raw material preparation step. This is because even if this heat treatment is performed at the above oxygen concentration, since the insulating layer is formed on the outer periphery of the soft magnetic particles, the oxidation of the soft magnetic particles themselves can be suppressed.
  • the above-described dust core and the dust core obtained by the above-described manufacturing method can be suitably used for the magnetic core of coil parts and its material.
  • the coil component includes a coil formed by winding a winding, and a magnetic core on which the coil is disposed.
  • An example of the winding is one having an insulating layer on the outer periphery of the conductor.
  • the conductor include a wire made of a conductive material such as copper, copper alloy, aluminum, and aluminum alloy.
  • the constituent material of the insulating layer include enamel, tetrafluoroethylene-hexafluoropropylene copolymer (FEP) resin, polytetrafluoroethylene (PTFE) resin, and silicon rubber.
  • the form of the magnetic core typically includes a columnar body and an annular body.
  • columnar magnetic cores and annular magnetic cores of various sizes can be constructed. All of the magnetic core can be formed of the powder magnetic core, or only part of the magnetic core can be formed of the powder magnetic core. In the latter case, a magnetic core member made of another material such as an electromagnetic laminated steel sheet or a molded hardened body in which soft magnetic powder is dispersed in a resin may be combined.
  • a magnetic core having a lower magnetic permeability than those dust cores and magnetic core members, in particular, a gap material made of a non-magnetic material or an air gap can be used.
  • a coil component 100 in FIG. 1 is a choke coil including an annular magnetic core 1 (magnetic core) and a coil 2 formed by winding a winding 2 w around the outer periphery of the magnetic core 1.
  • the annular magnetic core 1 is composed of the dust core.
  • examples of the coil component include a high-frequency choke coil, a high-frequency tuning coil, a bar antenna coil, a power choke coil, a power transformer, a switching power transformer, and a reactor.
  • Test Example 1 A test piece of the powder magnetic core was prepared by preparing raw material powder ⁇ preparation of composite material ⁇ preparation of molded body ⁇ heat treatment, and the soft magnetic properties and strength were measured.
  • Soft magnetic powders ⁇ to ⁇ shown in Table 1 were prepared.
  • the soft magnetic powders ⁇ to ⁇ were prepared by dissolving an Fe—Si—Al alloy raw material in an Ar atmosphere and atomizing with nitrogen gas.
  • the soft magnetic powders ⁇ to ⁇ are powders that have not been pulverized after being produced by the gas atomization method.
  • the soft magnetic powder ⁇ was prepared by dissolving a Fe—Si—Al alloy raw material in the air and atomizing with water to prepare a water atomized powder, and then pulverizing the water atomized powder in the air.
  • Table 1 summarizes the composition, shape, oxygen content, and average particle size of the soft magnetic particles ⁇ to ⁇ .
  • the spherical shape shown in Table 1 means that the maximum diameter / equivalent circle diameter in the projected area of the soft magnetic particles is 1.0 or more and 1.3 or less, and the irregular shape means the maximum diameter / circle equivalent in the projected area.
  • the diameter is out of the above range, that is, the maximum diameter / equivalent circle diameter in the projected area is more than 1.3.
  • the insulating layer of sodium silicate (Sample Nos. 1, 2, 5, 6, 8 to 10) was formed by adding and mixing an aqueous sodium silicate solution while stirring soft magnetic particles using a mixer.
  • the concentration of the aqueous sodium silicate solution was 20% by mass.
  • the soft magnetic particles and the aqueous solution were mixed so that the solid content of the aqueous solution was 1.2% with respect to the mass of the soft magnetic particles.
  • the mixing conditions were a rotation speed of 300 rpm, a mixing temperature of 40 ° C., and a mixing time of 20 minutes.
  • An insulating layer substantially composed of Si, O, and Na was formed on the surface of the soft magnetic particles during mixing. The thickness of the insulating layer was about 250 nm. Thereafter, the obtained coated soft magnetic powder was sieved to loosen the particles.
  • the insulating layer (sample Nos. 3 and 4) of the silicone resin was prepared by mixing soft magnetic powder and silicone resin using a mixer.
  • the blending amount of the silicone resin with respect to the soft magnetic powder was set to 1.2% by mass.
  • the mixing conditions were a rotation speed of 300 rpm, a mixing temperature of 40 ° C., and a mixing time of 20 minutes.
  • the insulating layer had a thickness of about 250 nm. Thereafter, crushing was performed to separate the particles from each other.
  • the Al 2 O 3 insulating layer (sample No. 7) was formed by subjecting soft magnetic powder to heat treatment at 850 ° C. for 1 hour in an oxidizing atmosphere with an oxygen content of 20% by volume.
  • the thickness of the insulating layer was about 200 nm.
  • a composite material including each coated soft magnetic powder and a molding resin material was produced.
  • the coated soft magnetic powder was rolled while being heated, and the molding resin material was added and mixed.
  • the molding resin material an acrylic resin diluted with water was adjusted to 1.0 mass% with respect to the coated soft magnetic powder.
  • the heating temperature was 40 ° C.
  • the rotation speed was 300 rpm
  • the mixing time was 1 hour.
  • the soft magnetic properties were measured by the following procedure. Winding was applied to the ring-shaped test piece to prepare a measurement member for measuring the soft magnetic properties of the test piece.
  • BH / ⁇ analyzer SY-8258 manufactured by Iwatsu Measurement Co., Ltd. was used for this measurement member.
  • each iron loss (W1 / 100k) when the excitation magnetic flux density Bm is 0.1 T, the measurement frequency is 100 kHz, and the environmental temperature is 25 ° C., 50 ° C., 75 ° C., 100 ° C., 125 ° C., 150 ° C. was measured.
  • the crushing strength was measured in accordance with “sintered bearing—crushing crush strength test method JIS Z 2507 (2000)”. Specifically, two plates are arranged on a ring-shaped test piece so as to face each other in the radial direction, the test piece is sandwiched between these plates, and a load is applied to one plate. And the maximum load when the said test piece broke was calculated
  • required, and this maximum load (n 3 average) was evaluated as crushing strength (MPa).
  • Sample No. 1 was prepared by preparing a coated soft magnetic powder including an insulating layer and performing heat treatment in an oxidizing atmosphere (here, the amount of oxygen is 20% by volume). Both 1, 2 and 10 had both low loss and high strength. Specifically, Sample No. 1, 2 and 10 both have an iron loss (W1 / 100k) measured at least part of the environmental temperature range of 25 ° C. or more and 150 ° C. or less satisfying 300 kW / m 3 or less, and the crushing strength is 25 MPa or more. there were.
  • W1 / 100k measured at least part of the environmental temperature range of 25 ° C. or more and 150 ° C. or less satisfying 300 kW / m 3 or less
  • Sample No. No. 1 had an iron loss (W1 / 100 k) of 300 kW / m 3 or less in the entire environmental temperature range of 25 ° C. or more and 150 ° C. or less. Further, the iron loss (W1 / 100 k) at an environmental temperature of 50 ° C. or more and 150 ° C. or less was 250 kW / m 3 or less. Furthermore, the iron loss (W1 / 100 k) at an environmental temperature of 75 ° C. to 125 ° C. is 200 kW / m 3 or less, and the iron loss (W1 / 100 k) at an environmental temperature of 100 ° C. to 125 ° C. is 180 kW. / M 3 or less. Sample No. 1 can be suitably used over the entire temperature range from a low temperature range to a high temperature range, and is particularly suitable for use in a high temperature range. On the other hand, the crushing strength was 40 MPa or more, and the strength was very high.
  • Sample No. 2 has an iron loss (W1 / 100k) in an environmental temperature range of 25 ° C. or more and 50 ° C. or less of 300 kW / m 3 or less, and an iron loss (W1 / 100k) in an environmental temperature range of 25 ° C. or more and less than 50 ° C. Was 200 kW / m 3 or less.
  • Sample No. 2 is particularly suitable for use in a low temperature range.
  • the crushing strength was 40 MPa or more, and the strength was very high.
  • Sample No. No. 10 had an iron loss (W1 / 100 k) of 300 kW / m 3 or less, more preferably 250 kW / m 3 in an environmental temperature range of 50 ° C. or more and 150 ° C. or less. Moreover, the iron loss (W1 / 100k) in the environmental temperature of 100 degreeC or more and 125 degrees C or less was 200 kW / m ⁇ 3 > or less. Sample No. No. 10 can be suitably used over the entire temperature range from a low temperature range to a high temperature range, and is particularly suitable for use in a high temperature range. On the other hand, the crushing strength was 40 MPa or more, and the strength was very high.
  • sample No. 7 had a temperature at which the iron loss (W1 / 100 k) measured in any of the environmental temperature ranges from 25 ° C. to 150 ° C. was 300 kW / m 3 or less, but the crushing strength was as extremely low as 9 MPa. This is considered to be because the insulating layer is derived from soft magnetic particles, the insulating layer is hard, and the connection between the insulating layers is weak as described above with respect to the knowledge of the present inventors. Sample No. Although No.
  • the iron loss (W1 / 100 k) was extremely large in the entire environmental temperature range of 25 ° C. or more and 150 ° C. or less. Also, as described above with respect to the inventor's knowledge, the unevenness between the particles meshed with each other, so that the strength could be improved. However, the insulating layer was deformed or damaged, so that sufficient insulation between the particles could not be secured. It is thought that it was because of the reason.
  • the dust core of the present invention can be used as a magnetic core of various coil parts (for example, a reactor, a transformer, a motor, a choke coil, an antenna, a fuel injector, an ignition coil, etc.) and its material.
  • the method for producing a dust core of the present invention can be suitably used for producing the dust core.
  • the coil component of the present invention can be used for a reactor, a transformer, a motor, a choke coil, an antenna, a fuel injector, an ignition coil, and the like.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Soft Magnetic Materials (AREA)

Abstract

L'invention concerne un noyau pulvérulent qui comprend une pluralité de particules magnétiques douces et une couche isolante intercalée entre les particules magnétiques douces, les particules magnétiques douces comprenant un alliage à base de fer (Fe), de silicium (Si) et d'aluminium (Al) et présentant le plus grand diamètre/un diamètre de cercle équivalent dans une coupe transversale du noyau pulvérulent variant entre 1,0 et 1,3 inclus, et la couche isolante comprenant un oxyde qui contient du silicium (Si) et de l'oxygène (O) et, en outre, au moins un élément parmi les éléments alcalins et le magnésium (Mg). En variante, le noyau pulvérulent comprend une pluralité de particules magnétiques douces et une couche isolante intercalée entre les particules magnétiques douces, les particules magnétiques douces comprenant un alliage à base de fer (Fe), de silicium (Si) et d'aluminium (Al) et présentant une teneur en oxygène inférieure ou égale à 500 ppm et couche isolante comprenant un oxyde qui contient du silicium (Si) et de l'oxygène (O) et, en outre, au moins un élément parmi les éléments alcalins et le magnésium (Mg).
PCT/JP2014/078712 2013-11-26 2014-10-29 Noyau pulvérulent, composant de bobine et procédé permettant de produire un noyau pulvérulent WO2015079856A1 (fr)

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CN112420308A (zh) * 2019-08-21 2021-02-26 Tdk株式会社 复合颗粒和压粉磁芯
JP2021086990A (ja) * 2019-11-29 2021-06-03 株式会社タムラ製作所 リアクトル
WO2022186222A1 (fr) * 2021-03-05 2022-09-09 パナソニックＩｐマネジメント株式会社 Matériau magnétique, noyau de poussière, inducteur et procédé de production de noyau de poussière

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JP6243298B2 (ja) 2014-06-13 2017-12-06 株式会社豊田中央研究所 圧粉磁心およびリアクトル
JP2017092225A (ja) * 2015-11-10 2017-05-25 住友電気工業株式会社 圧粉成形体、電磁部品、及び圧粉成形体の製造方法
JP6940674B2 (ja) * 2015-11-10 2021-09-29 住友電気工業株式会社 圧粉成形体の製造方法
CN107871594B (zh) * 2017-05-31 2019-07-02 洪豪立 太极式石墨烯滤波扼流圈及其制作方法
JP6909181B2 (ja) * 2018-06-04 2021-07-28 デンカ株式会社 絶縁被覆金属粒子

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CN112420308B (zh) * 2019-08-21 2024-03-19 Tdk株式会社 复合颗粒和压粉磁芯
JP2021086990A (ja) * 2019-11-29 2021-06-03 株式会社タムラ製作所 リアクトル
WO2022186222A1 (fr) * 2021-03-05 2022-09-09 パナソニックＩｐマネジメント株式会社 Matériau magnétique, noyau de poussière, inducteur et procédé de production de noyau de poussière

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