WO2016035478A1 - Powder core, electric/electronic component, and electric/electronic device - Google Patents

Powder core, electric/electronic component, and electric/electronic device Download PDF

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Publication number
WO2016035478A1
WO2016035478A1 PCT/JP2015/071230 JP2015071230W WO2016035478A1 WO 2016035478 A1 WO2016035478 A1 WO 2016035478A1 JP 2015071230 W JP2015071230 W JP 2015071230W WO 2016035478 A1 WO2016035478 A1 WO 2016035478A1
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Prior art keywords
powder
atomic
soft magnetic
resin
core
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PCT/JP2015/071230
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French (fr)
Japanese (ja)
Inventor
水嶋　隆夫
山本　豊
成 花田
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アルプス・グリーンデバイス株式会社
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Priority to JP2015551910A priority Critical patent/JP6035490B2/en
Publication of WO2016035478A1 publication Critical patent/WO2016035478A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/08—Metallic powder characterised by particles having an amorphous microstructure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C45/00—Amorphous alloys
    • C22C45/02—Amorphous alloys with iron as the major constituent
    • 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
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/255—Magnetic cores made from particles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/08—Cores, Yokes, or armatures made from powder

Definitions

  • the present invention relates to a dust core using soft magnetic powder, an electric / electronic component including the dust core, and an electric / electronic device on which the electric / electronic component is mounted.
  • Patent Document 1 discloses an example of a dust core.
  • the dust core obtained by the above manufacturing method is a composite of soft magnetic powder and a resin-based material, and the soft magnetic powder in the dust core is usually up to about 300 ° C. even in the air. If present, it is thermally stable. However, when the dust core is heated to such a temperature, the thermal deterioration of the resin-based material becomes obvious, and the magnetic properties of the dust core change.
  • a heating test that is allowed to stand in an atmosphere at 250 ° C. for 1000 hours (in this specification, a “heating test”, This means the heating test.)
  • the rate of change of core loss when the powder core is performed can be mentioned.
  • the core loss Pc 0 unit: kW / m 3 of the dust core was measured before the heating test of the dust cores were measured and after the heating test core loss Pc 1 (unit kW / m 3)
  • the core loss change rate ⁇ Pc (unit:%) defined by the following formula is small is referred to as “the powder core is excellent in heat resistance”.
  • ⁇ Pc (Pc 1 ⁇ Pc 0 ) / Pc 0 ⁇ 100
  • An object of the present invention is to provide a dust core excellent in heat resistance, an electric / electronic component including the dust core, and an electric / electronic device on which the electric / electronic component is mounted.
  • a soft magnetic powder is located between two adjacent soft magnetic powders in a dust core and is involved in the fixation and insulation of these soft magnetic powders. It was found that it is possible to obtain a powder core having excellent heat resistance by optimizing the existence state between them.
  • the present invention completed based on the above knowledge, as one aspect, is a powder core comprising soft magnetic powder and an insulating resin-based material, and the resin providing the resin-based material contains an acrylic resin.
  • the gap region formed by filling the resin material into at least a part of the gap formed by the two adjacent soft magnetic powders in the powder core has a distance of the two soft magnetic powders of 30 nm or less.
  • a dust core comprising pores defined by being not partially filled with the resin-based material in a gap region having a separation distance of 30 nm or less.
  • the density of the holes is preferably 1.0 / ⁇ m or more as a value obtained by measurement based on cross-sectional observation of the gap region, and is 1.3 or more. More preferably.
  • the above-mentioned dust core contains P.
  • the dust core contains P
  • the presence density of pores in the gap region of the dust core may increase.
  • the existence density of such vacancies increases when the soft magnetic powder constituting the dust core contains P.
  • the soft magnetic powder provided in the powder core may have an amorphous part.
  • the soft magnetic powder included in the dust core is an Fe-based amorphous alloy, Ni is 0 atomic% to 10 atomic%, Sn is 0 atomic% to 3 atomic%, and Cr is 0 atomic%. 6 atom% or less, P 3.0 atom% or more and 11 atom% or less, C 1.0 atom% or more and 10 atom% or less, B 0 atom% or more and 9 atom% or less, and Si 0 atom% or more. It is preferable to contain 6 atomic% or less. When the soft magnetic powder contains P, the presence density of pores in the gap region of the dust core may increase.
  • the powder core may be obtained by pressure-molding the composition containing the soft magnetic powder and the resin to obtain a molded body, and heating the obtained molded body.
  • the heating of the molded body includes heating in an oxidizing atmosphere and subsequent heating in a non-oxidizing atmosphere.
  • the composition may contain an inorganic component, and the inorganic component preferably contains P.
  • the inorganic component contains P, the presence density of pores in the gap region of the dust core may increase.
  • Another aspect of the present invention is an electric / electronic component including the dust core, the coil, and a connection terminal connected to each end of the coil, wherein at least a part of the dust core is And an electric / electronic component arranged to be located in an induced magnetic field generated by the current when a current is passed through the coil via the connection terminal.
  • an electrical / electronic device in which the electrical / electronic component is mounted, wherein the electrical / electronic component is connected to a substrate by the connection terminal. I will provide a.
  • the dust core according to the above invention is excellent in heat resistance. Further, according to the present invention, there are provided an electric / electronic component having such a dust core and an electric / electronic device on which the electric / electronic component is mounted.
  • FIG. 5 It is a perspective view which shows a partial see-through
  • the dust core 1 according to one embodiment of the present invention shown in FIG. 1 has a ring-like appearance, and as shown in FIGS. 2 and 3, soft magnetic powder M and acrylic resin An insulating resin material R containing a component based on the above is provided.
  • the dust core 1 has a gap formed by two adjacent soft magnetic powders M ⁇ b> 1 and M ⁇ b> 2 in the dust core 1.
  • the gap region G in which at least a part is filled with the resin-based material has a gap distance between the two soft magnetic powders M1 and M2 of 30 nm or less, and the gap area G with a gap distance of 30 nm or less is empty.
  • a hole C is provided.
  • the existence density of the holes C is preferably 1.0 / ⁇ m or more as a value obtained by measurement based on cross-sectional observation of the gap region G.
  • the existence density of the holes C in the gap region G having a separation distance of 30 nm or less is defined as a value obtained as follows.
  • the powder core is cut and polished to obtain a cross section for observation.
  • the observation cross section is observed using a scanning electron microscope, arranged adjacent to each other, and the gap length is relatively large (as a specific example, the gap length is 1 ⁇ m or more).
  • Soft magnetic powders M1 and M2 are selected. Among the gaps created by the soft magnetic powders M1 and M2, the length of the gap area G, which is an area at least partially filled with a resin material, is measured, and the width of the gap area G is arbitrarily measured at 10 points.
  • the average of these measured values is defined as the distance between the soft magnetic powders M1 and M2.
  • the gap region G is observed at a magnification of 30,000, and the number of holes C defined by the resin material not being partially filled in the gap region G is counted. An observation image of 50,000 times is used to confirm the presence or absence of the hole C. Based on these measurements, the number of pores C in the gap region G per 1 ⁇ m is obtained.
  • the above measurement is performed on a plurality of dust cores manufactured under the same conditions with the same composition, and the average value of the number of pores C per 1 ⁇ m in the gap region G having a separation distance of 30 nm or less.
  • the existence density of pores C in the gap region G of the powder core (unit: piece / ⁇ m)
  • the density of holes C in the gap region G having a separation distance of 30 nm or less is assumed to be 0 / ⁇ m.
  • the density of the holes C is 0 / ⁇ m, it is assumed that the gap region G has no holes.
  • the dust core 1 according to an embodiment of the present invention having the above-described holes C and preferably having a density of holes C of 1.0 / ⁇ m or more is excellent in heat resistance. If this point is demonstrated using above-mentioned (DELTA) Pc, the powder core which concerns on one Embodiment of this invention can make (DELTA) Pc 20% or less, and, in a preferable example, (DELTA) Pc shall be 10% or less. In a more preferable example, ⁇ Pc can be 5% or less.
  • the dust core subjected to the heating test placed in an atmosphere of 250 ° C. in the atmosphere expands the volume of the soft magnetic powder. There is a possibility that a force that reduces the volume of the gap region G is generated.
  • the resin-based material may also change its mechanical characteristics or change its composition due to heating. Such changes that occur during the heating test can cause stress distortion in the soft magnetic powder in the dust core.
  • the holes C are provided, and preferably the density of the holes C is 1.0 / ⁇ m or more, the volume of the holes C There is a possibility that the stress generated in the soft magnetic powder in the dust core 1 is relaxed due to the fluctuation (for example, contraction), and as a result, the strain is difficult to accumulate in the soft magnetic powder in the dust core 1.
  • the density of the holes C is preferably 1.3 / ⁇ m or more, and more preferably 1.6 / ⁇ m or more.
  • the upper limit of the density of the holes C is not limited from the viewpoint of improving the heat resistance. When the density of the holes C is excessively high, there is a concern that the mechanical strength of the dust core 1 is reduced.
  • the dust core 1 may preferably contain P (phosphorus).
  • P (phosphorus) contained in the dust core 1 affects the physical properties and composition of the resin-based material R located in the gap region G and contributes to an increase in the density of the holes C in the gap region G.
  • the method for containing P (phosphorus) in the powder core 1 is not limited. P (phosphorus) may be included in the soft magnetic powder M, or a phosphorus-containing substance such as phosphate glass may be used in the manufacturing process of the powder core 1. In particular, it is preferable that soft magnetic powder M contains P.
  • the material which comprises the soft magnetic powder M with which the powder core 1 which concerns on one Embodiment of this invention is provided is not limited.
  • examples of such a material include a crystalline magnetic material and an amorphous magnetic material, and a material having a crystalline portion and an amorphous portion.
  • the material constituting the soft magnetic powder M may be one type or a plurality of types. When the soft magnetic powder M is composed of a plurality of types of materials, the composition and blending ratio of each constituent material are not limited.
  • the crystalline magnetic material satisfies that it is crystalline (a general X-ray diffraction measurement can obtain a diffraction spectrum having a clear peak that can identify the type of material) and a soft magnetic material.
  • crystalline magnetic materials include Fe—Si—Cr alloys, Fe—Ni alloys, Fe—Co alloys, Fe—V alloys, Fe—Al alloys, Fe—Si alloys, Fe—Si. -Al based alloys, carbonyl iron and pure iron.
  • these crystalline magnetic materials contain P.
  • the amorphous magnetic material is amorphous (a diffraction spectrum having a clear peak that can identify the type of material cannot be obtained by general X-ray diffraction measurement), and is a soft magnetic material. As long as the above is satisfied, the specific type is not limited. Specific examples of the amorphous magnetic material include Fe—P—C—B—Si alloy, Fe—Si—B alloy, Fe—PC—C alloy, and Co—Fe—Si—B alloy. . In particular, in order to increase the density of the holes C in the gap region G, it is preferable that these amorphous magnetic materials contain P.
  • amorphous magnetic material composition formula, shown in Fe 100at% -a-b-c -x-y-z-t Ni a Sn b Cr c P x C y B z Si t 0 at% ⁇ a ⁇ 10 at%, 0 at% ⁇ b ⁇ 3 at%, 0 at% ⁇ c ⁇ 6 at%, 6.8 at% ⁇ x ⁇ 10.8 at%, 2.2 at% ⁇ y ⁇ 9.8 at%,
  • Examples include Fe-based amorphous alloys in which 0 at% ⁇ z ⁇ 4.2 at% and 0 at% ⁇ t ⁇ 7 at%.
  • Ni, Sn, Cr, B, and Si are optional added elements.
  • the preferable addition amount range of each element of the Fe-based amorphous alloy is as follows.
  • the addition amount a of Ni is preferably 0 at% or more and 6 at% or less, and more preferably 0 at% or more and 4 at% or less.
  • the addition amount b of Sn is preferably 0 at% or more and 2 at% or less, and more preferably 1 at% or more and 2 at% or less.
  • the addition amount c of Cr is preferably 0 at% or more and 2 at% or less, and more preferably 1 at% or more and 2 at% or less.
  • the addition amount x of P is preferably set to 8.8 at% or more from the viewpoint of increasing the density of voids C in the powder core 1.
  • the addition amount y of C is preferably 5.8 at% or more and 8.8 at% or less.
  • the addition amount z of B is preferably 0 at% or more and 3 at% or less, and more preferably 0 at% or more and 2 at% or less.
  • the addition amount t of Si is preferably 0 at% or more and 6 at% or less, and more preferably 0 at% or more and 2 at% or less.
  • the material having a crystalline part and an amorphous part may be a mixture of a crystalline magnetic material and an amorphous magnetic material, or a material having an amorphous phase and a crystalline phase. Also good.
  • An example of the latter material is an Fe-based alloy in which a crystalline daughter phase is dispersed and precipitated in an amorphous matrix by containing an element that promotes crystal precipitation such as Nb, Cu, and Si. Is done.
  • the shape of the soft magnetic powder M contained in the powder core 1 is not limited.
  • the shape of the soft magnetic powder M may be spherical or non-spherical.
  • a non-spherical shape it may be a shape having a shape anisotropy such as a flat shape, a scale shape, an oval sphere, a droplet shape, a needle shape, or an indefinite shape having no special shape anisotropy. There may be.
  • the shape of the soft magnetic powder M may be the shape obtained in the stage of producing the soft magnetic powder M (the atomizing method is given as a specific example), or the produced soft magnetic powder M is subjected to secondary processing.
  • a shape obtained by performing flattening with an attritor or the like is given as a specific example.
  • Examples of the former shape include a spherical shape, an oval shape, a droplet shape, and a needle shape.
  • Examples of the latter shape include a flat shape and a scale shape.
  • the particle diameter of the soft magnetic powder M contained in the powder core 1 is not limited. If this particle size is defined by the average particle size D50 (particle size when the volume cumulative value in the volume distribution of the particle size of the soft magnetic powder M measured by the laser diffraction scattering method is 50%), it is usually from 1 ⁇ m. The range is 20 ⁇ m. From the viewpoint of enhancing the handleability and the viewpoint of increasing the packing density of the soft magnetic powder M in the dust core 1, the average particle diameter D50 of the soft magnetic powder M is preferably 2 ⁇ m or more and 15 ⁇ m or less, and 3 ⁇ m or more and 10 ⁇ m or less. More preferably, it is more preferably 4 ⁇ m or more and 7 ⁇ m or less.
  • the content of the soft magnetic powder M in the powder core 1 according to an embodiment of the present invention is not limited. Depending on the application, it is appropriately set in consideration of the composition of the resin-based material, the manufacturing process, and the like.
  • Resin-type material R with which the powder core 1 which concerns on one Embodiment of this invention is provided is insulating, Comprising: Resin which provides the said material contains acrylic resin.
  • resin-based material R is a resin and / or a resin-based component (a component in which at least a part of the resin is changed in composition, and a (part) thermal decomposition product of the resin is a specific example.
  • the resin that provides the resin-based material R includes an acrylic resin.
  • the acrylic resin only needs to contain a structural unit based on at least one of acrylic acid and its derivative, and may be a homopolymer or a copolymer.
  • acrylic acid derivatives include acrylic acid esters, methacrylic acid and esters thereof, and acrylamide.
  • the copolymer may contain a constitutional unit other than the constitutional unit based on at least one of acrylic acid and its derivative, and the type of compound that gives the constitutional unit Is not limited. Specific examples of such compounds include olefins such as ethylene and vinyl esters such as vinyl acetate.
  • the acrylic resin may have a crosslinked structure.
  • the crosslinking agent in that case is not limited, and examples thereof include polyisocyanate compounds.
  • the resin that gives the resin material may contain a resin other than the acrylic resin.
  • resins include silicone resins, epoxy resins, phenol resins, urea resins, melamine resins, and the like.
  • the resin material R is located between the adjacent soft magnetic powders M1 and M2 in the dust core 1, and fixes and insulates the soft magnetic powders M1 and M2, and compacts the dust. This contributes to maintaining the shape and insulation of the core 1.
  • the dust core 1 according to one embodiment of the present invention is As described above, since the existence density of the gap C is appropriately controlled, the magnetic characteristics are not easily lowered after the heating test.
  • the manufacturing method of the dust core 1 which concerns on one Embodiment of this invention is not limited. If an example of this manufacturing method is given, the powder core 1 can be obtained by press-molding the composition containing soft-magnetic powder and resin, and heating the obtained molded object.
  • the pressurizing condition and heating condition are appropriately set according to mechanical characteristics and magnetic characteristics required for the dust core, the composition of the composition, and the like.
  • heating conditions heating in an oxidizing atmosphere and heating in a non-oxidizing atmosphere can be given.
  • the dust core 1 according to an embodiment of the present invention includes the resin material R containing a component based on an acrylic resin
  • the composition to be pressure-molded is an acrylic resin. Containing.
  • the heating conditions preferably include heating in an oxidizing atmosphere so that a preferable resin-based material R capable of increasing the density of the voids C can be easily obtained from a composition including an acrylic resin.
  • the temperature is preferably 300 ° C. or higher and 400 ° C.
  • the powder core 1 is made of the resin material R Is preferably heated in a non-oxidizing atmosphere. Therefore, when heating in an oxidizing atmosphere and heating in a non-oxidizing atmosphere are performed, heating is performed at 300 ° C. or higher and 400 ° C. or lower in an oxidizing atmosphere, and then heating is performed at 400 ° C. or higher in a non-oxidizing atmosphere. It is preferable.
  • the above-described composition to be pressure-molded may contain components other than the soft magnetic powder and the resin.
  • examples of such components include inorganic components such as glass and lubricants such as metal soaps.
  • a component for example, phosphate glass
  • P phosphorus
  • the method for preparing the composition is not limited.
  • the material constituting the composition may be obtained simply by kneading, or the slurry containing the material constituting the composition may be dried and pulverized to form a granulated powder.
  • An electrical / electronic component includes a dust core 1 according to an embodiment of the present invention, a coil, and a connection terminal connected to each end of the coil. .
  • the dust core 1 is disposed so as to be located in an induced magnetic field generated by the current when a current is passed through the coil via the connection terminal.
  • the toroidal core 10 includes a coil 2a formed by winding a covered conductive wire 2 around a ring-shaped dust core 1.
  • the ends 2d and 2e of the coil 2a can be defined in the portion of the conductive wire located between the coil 2a formed of the wound covered conductive wire 2 and the ends 2b and 2c of the covered conductive wire 2.
  • the member constituting the coil and the member constituting the connection terminal may be composed of the same member.
  • An electric / electronic component according to an embodiment of the present invention includes a dust core having a shape different from that of the dust core 1 according to the embodiment of the present invention.
  • a specific example of such an electric / electronic component is an inductance element 20 shown in FIG.
  • FIG. 5 is a perspective view showing a part of the entire configuration of the inductance element 20 according to the embodiment of the present invention.
  • the lower surface (mounting surface) of the inductance element 20 is shown in an upward posture.
  • FIG. 6 is a partial front view showing a state in which the inductance element 20 shown in FIG. 5 is mounted on the mounting substrate 10.
  • An inductance element 20 shown in FIG. 5 includes a dust core 3, an air core coil 5 as a coil embedded in the dust core 3, and a connection terminal electrically connected to the air core coil 5 by welding. And a pair of terminal portions 4.
  • the air-core coil 5 is formed by spirally winding a conductive wire with an insulating coating.
  • the air-core coil 5 includes a winding part 5a and lead-out end parts 5b and 5b drawn from the winding part 5a.
  • the number of turns of the air-core coil 5 is appropriately set according to the required inductance.
  • an accommodation recess 30 for accommodating a part of the terminal portion 4 is formed on the mounting surface 3 a with respect to the mounting substrate.
  • the storage recesses 30 are formed on both sides of the mounting surface 3 a and are formed to be released toward the side surfaces 3 b and 3 c of the powder core 3.
  • Part of the terminal portion 4 protruding from the side surfaces 3 b and 3 c of the powder core 3 is bent toward the mounting surface 3 a and stored in the storage recess 30.
  • the terminal part 4 is formed of a thin plate-like Cu base material.
  • the terminal part 4 is exposed on the outer surface of the dust core 3 and the connection end part 40 embedded in the dust core 3 and electrically connected to the lead-out ends 5b, 5b of the air-core coil 5.
  • the powder core 3 includes a first bent portion 42a and a second bent portion 42b that are bent in order from the side surfaces 3b and 3c to the mounting surface 3a.
  • the connection end 40 is a welded portion that is welded to the air-core coil 5.
  • the first bent portion 42 a and the second bent portion 42 b are solder joint portions that are soldered to the mounting substrate 100.
  • the solder joint portion is a portion of the terminal portion 4 that is exposed from the dust core 3 and means a surface that faces at least the outside of the dust core 3.
  • connection end portion 40 of the terminal portion 4 and the extraction end portion 5b of the air-core coil 5 are joined by resistance welding.
  • the inductance element 20 is mounted on the mounting substrate 100.
  • a conductor pattern that is electrically connected to an external circuit is formed on the surface of the mounting substrate 100, and a pair of land portions 110 for mounting the inductance element 20 is formed by a part of the conductor pattern.
  • the mounting surface 3 a is directed to the mounting substrate 100 side, and the first bent portion 42 a and the second bent portion 42 b that are exposed to the outside from the dust core 3 are mounted.
  • the solder layer 120 is bonded to the land portion 110 of the substrate 100.
  • the inductance element 20 is mounted so that the second bent part 42b faces the land part 110, and the solder is applied in the heating process. Melt. As shown in FIGS. 5 and 6, the second bent portion 42 b faces the land portion 110 of the mounting substrate 100, and the first bent portion 42 a is exposed on the side surfaces 3 b and 3 c of the inductance element 20.
  • the solder layer 120 is fixed to the land portion 110 and is sufficiently spread and fixed to the surfaces of both the second bent portion 42b and the first bent portion 42a which are solder joint portions.
  • Examples of electric / electronic components other than the toroidal core 10 and the inductance element 20 described above include a reactor and a transformer.
  • An electrical / electronic device is mounted with an electrical / electronic component including the dust core according to the embodiment of the present invention.
  • Examples of such electric / electronic devices include a power supply device including a power switching circuit, a voltage raising / lowering circuit, and a smoothing circuit, a small portable communication device, and the like.
  • the electric / electronic component according to an embodiment of the present invention includes the dust core having excellent heat resistance as described above, the electric / electronic device on which the component is mounted can be easily applied to in-vehicle use. .
  • Example 1 Using a water atomization method, non-obtained obtained by weighing to a composition of Fe 74.43 at% Cr 1.96 at% P 9.04 at% C 2.16 at% B 7.54 at% Si 4.87 at% A crystalline soft magnetic powder was prepared as a soft magnetic powder.
  • the particle size distribution of the obtained soft magnetic powder was measured by volume distribution using “Microtrack particle size distribution measuring device MT3300EX” manufactured by Nikkiso Co., Ltd. As a result, the average particle diameter (D50), which is 50% in the volume distribution, was 10.6 ⁇ m.
  • the obtained slurry was dried and pulverized, and fine powder of 300 ⁇ m or less and coarse powder of 850 ⁇ m or more were removed using a sieve having an opening of 300 ⁇ m and a sieve of 850 ⁇ m to obtain granulated powder.
  • the obtained granulated powder was filled in a mold and subjected to pressure molding at a surface pressure of 1.8 GPa to obtain a molded body having a ring shape.
  • the obtained molded body was heated in the atmosphere (oxidizing atmosphere) at 360 ° C. for 10 hours, and then heat-treated in a nitrogen atmosphere (non-oxidizing atmosphere) at 450 ° C. for 1 hour to obtain an outer diameter of 20 mm ⁇
  • a dust core having a ring shape with an inner diameter of 12 mm and a thickness of 7 mm was obtained.
  • Example 1 The same operation as in Example 1 was performed except that the phosphate glass was not blended during the preparation of the slurry and the heat treatment was performed at 450 ° C. for 1 hour in a nitrogen atmosphere (non-oxidizing atmosphere). A green core was obtained.
  • Example 2 A powder core was obtained in the same manner as in Example 1 except that the kind of the soft magnetic powder was changed to Fe—Si—B—Cr amorphous (average particle diameter (D50): 50 ⁇ m). Further, this Fe—Si—B—Cr-based amorphous alloy had no addition of P.
  • Test Example 1 Measurement of the presence density of pores 15 powder cores produced in Example 1, 13 powder cores produced in Comparative Example 1, and 3 powder cores produced in Comparative Example 2 Each was cut and polished to obtain an observation cross section. This observation cross section was observed using a scanning electron microscope, and two soft magnetic powders arranged adjacent to each other and having a relatively large gap length were selected. Of the gaps created by the soft magnetic powder, the length of the gap area, which is an area at least partially filled with the resin material, was measured. Further, the width of the gap region was arbitrarily measured at 10 points, and the average of these measured values was taken as the separation distance of the soft magnetic powder.
  • the gap region was observed at a magnification of 30,000, and the number of pores defined by the resin region material not being partially filled in the gap region was counted.
  • the observation image of 50,000 times was used for confirmation of the presence or absence of pores. Based on these measurements, it was confirmed whether or not there was a hole in the gap region, and when there was a hole, the number of holes in the gap region per 1 ⁇ m was obtained. When the number of holes per 1 ⁇ m was 0, it was determined that the gap region did not have holes.
  • the measurement results are shown in Table 1.
  • the observation image of the dust core manufactured by Example 1 was shown in FIG. 3, and the observation image of the dust core manufactured by Comparative Example 1 was shown in FIG. As shown in FIG. 3, in the dust core manufactured according to Example 1, voids are easily measured in the gap region. As shown in FIG. 7, in the dust core manufactured according to Comparative Example 1, It was difficult to measure voids in the area.
  • Example Nos. 1-6 to 1-12, 1-14, and 1-15 the gap regions in the eight dust cores having a separation distance of 30 nm or less according to Example 1 were used.
  • the average value of the number of holes per 1 ⁇ m was obtained, and the obtained 1.9 / ⁇ m was defined as the existence density of the holes according to Example 1.
  • the gap regions in the five dust cores (Sample Nos. 2-2 to 2-4, 2-6, and 2-11) having a separation distance of 30 nm or less according to Comparative Example 1 were used.
  • the average value of the number of holes per 1 ⁇ m was determined, and the obtained number of holes / ⁇ m was defined as the existence density of holes according to Comparative Example 1.
  • the powder core according to Comparative Example 2 did not have a gap region with a separation distance of 30 nm or less, and thus the density of holes according to Comparative Example 2 was 0 / ⁇ m.
  • Test Example 2 Evaluation of heat resistance Copper wire winding was applied to a dust core having a ring shape produced according to Examples and Comparative Examples, and a BH analyzer (“SY-8217” manufactured by Iwasaki Tsushinki Co., Ltd.) was used.
  • the core loss Pc 0 (unit: kW / m 3 ) was measured under the conditions of a frequency of 100 kHz and a maximum magnetic flux density of 100 mT.
  • the dust core according to Example 1 having pores and a density of 1.0 / ⁇ m or more has a small core loss change rate ⁇ Pc and is excellent in heat resistance.
  • the dust cores according to Comparative Examples 1 and 2 in which the existence density of vacancies was 0 / ⁇ m and the gap region was determined not to have vacancies had a large core loss change rate ⁇ Pc, and were heat resistant.
  • the core loss itself is higher than that of Example 1.
  • the ⁇ Pc of the dust core of Example 1 is reduced because the stress generated in the soft magnetic powder in the dust core caused by heating is appropriately relieved due to the presence of pores. This is considered to be because the strain is less likely to accumulate in the soft magnetic powder. Further, although the reason is not clear, it is presumed that the generation of pores in the resin-based material was promoted by P present in the soft magnetic powder or phosphate glass during heat treatment in the atmosphere.
  • the dust core of the present invention is suitable as a power supply device including a power supply switching circuit, a voltage raising / lowering circuit, a smoothing circuit, and the like, particularly a power supply device for in-vehicle use, a small portable communication device, and the like.

Abstract

In order to provide a powder core with excellent heat resistance, an electric/electronic component equipped with this powder core, and an electric/electronic device in which this electric/electronic component is installed, this powder core (1) is equipped with a soft magnetic powder (M) and an insulating resin-based material (R), with the resin providing the resin-based material (R) containing an acrylic resin. In the powder core (1) there is an interstitial region (G) in which the resin-based material (R) fills at least a portion of the gap created between two adjacent soft magnetic powders (M1, M2), with the separation distance between the two soft magnetic powders (M1, M2) being 30 nm or less, and in the interstitial region (G) in which the separation distance is 30 nm or less, voids (C) are formed where there is incomplete filling of the resin-based material (R).

Description

圧粉コア、電気・電子部品および電気・電子機器Compact core, electrical / electronic components and electrical / electronic equipment
　本発明は、軟磁性粉末を用いた圧粉コア、当該圧粉コアを備える電気・電子部品および当該電気・電子部品が実装された電気・電子機器に関する。 The present invention relates to a dust core using soft magnetic powder, an electric / electronic component including the dust core, and an electric / electronic device on which the electric / electronic component is mounted.
　インダクタンス素子、リアクトル、トランスやチョークコイルなどの電気・電子部品の構成要素として使用される圧粉コアは、多数の軟磁性粉末を、樹脂などとともに圧粉成形し、得られた成形体を熱処理することにより得ることができる。下記の特許文献１には圧粉コアの一例が開示されている。 The dust core used as a component of electrical and electronic parts such as inductance elements, reactors, transformers and choke coils is compacted with a number of soft magnetic powders together with resin, etc., and the resulting compact is heat treated. Can be obtained. Patent Document 1 below discloses an example of a dust core.
特開２０１２－２１２８５３号公報JP 2012-212853 A
　上記の製造方法により得られた圧粉コアは軟磁性粉末と樹脂系材料との複合体であり、圧粉コア中の軟磁性粉末は、通常、大気中であっても、３００℃程度までであれば熱的に安定である。しかしながら、この程度の温度まで圧粉コアが加熱されると、樹脂系材料の熱劣化が顕在化して、圧粉コアの磁気特性が変化してしまう。 The dust core obtained by the above manufacturing method is a composite of soft magnetic powder and a resin-based material, and the soft magnetic powder in the dust core is usually up to about 300 ° C. even in the air. If present, it is thermally stable. However, when the dust core is heated to such a temperature, the thermal deterioration of the resin-based material becomes obvious, and the magnetic properties of the dust core change.
　このような圧粉コアの熱的安定性を評価する尺度の一つとして、大気中２５０℃の環境下に１０００時間放置する加熱試験（本明細書において、ことわりのない「加熱試験」とは、この加熱試験を意味する。）を圧粉コアに対して行った場合におけるコアロスの変化率を挙げることができる。本明細書において、加熱試験の前に測定された圧粉コアのコアロスＰｃ０（単位：ｋＷ／ｍ３）および加熱試験後に測定された圧粉コアのコアロスＰｃ１（単位ｋＷ／ｍ３）を用いて、下記式により定義されるコアロスの変化率ΔＰｃ（単位：％）が小さいことを、圧粉コアが「耐熱性に優れる」という。
　　ΔＰｃ＝（Ｐｃ１－Ｐｃ０）／Ｐｃ０×１００ As one of the scales for evaluating the thermal stability of such a dust core, a heating test that is allowed to stand in an atmosphere at 250 ° C. for 1000 hours (in this specification, a “heating test”, This means the heating test.) The rate of change of core loss when the powder core is performed can be mentioned. As used herein, the core loss Pc 0 (unit: kW / m 3) of the dust core was measured before the heating test of the dust cores were measured and after the heating test core loss Pc 1 (unit kW / m 3) Using the fact that the core loss change rate ΔPc (unit:%) defined by the following formula is small is referred to as “the powder core is excellent in heat resistance”.
ΔPc = (Pc 1 −Pc 0 ) / Pc 0 × 100
　本発明は、耐熱性に優れる圧粉コア、かかる圧粉コアを備える電気・電子部品およびその電気・電子部品が実装された電気・電子機器を提供することを目的とする。 An object of the present invention is to provide a dust core excellent in heat resistance, an electric / electronic component including the dust core, and an electric / electronic device on which the electric / electronic component is mounted.
　上記課題を解決するために本発明者らが検討した結果、圧粉コア中の隣接する２つの軟磁性粉末の間に位置し、これらの固着および絶縁に関与する樹脂系材料について、軟磁性粉末間の存在状態を最適化することにより、耐熱性に優れる圧粉コアを得ることが可能であるとの知見を得た。 As a result of studies by the present inventors in order to solve the above-described problems, a soft magnetic powder is located between two adjacent soft magnetic powders in a dust core and is involved in the fixation and insulation of these soft magnetic powders. It was found that it is possible to obtain a powder core having excellent heat resistance by optimizing the existence state between them.
　上記知見に基づき完成された本発明は、一態様として、軟磁性粉末と、絶縁性の樹脂系材料とを備える圧粉コアであって、前記樹脂系材料を与える樹脂はアクリル系樹脂を含有し、前記圧粉コアにおける、隣り合う２つの前記軟磁性粉末が作る間隙の少なくとも一部に前記樹脂系材料が充填されてなる間隙領域は、前記２つの軟磁性粉末の離間距離が３０ｎｍ以下であるものを有し、前記離間距離が３０ｎｍ以下の間隙領域内に、前記樹脂系材料が部分的に充填されていないことによって画成される空孔を備えることを特徴とする圧粉コアを提供する。 The present invention completed based on the above knowledge, as one aspect, is a powder core comprising soft magnetic powder and an insulating resin-based material, and the resin providing the resin-based material contains an acrylic resin. The gap region formed by filling the resin material into at least a part of the gap formed by the two adjacent soft magnetic powders in the powder core has a distance of the two soft magnetic powders of 30 nm or less. There is provided a dust core comprising pores defined by being not partially filled with the resin-based material in a gap region having a separation distance of 30 nm or less. .
　上記の圧粉コアにおいて、前記空孔の存在密度は、前記間隙領域の断面観察に基づく測定により得られた値として、１．０個／μｍ以上であることが好ましく、１．３個以上であることがより好ましい。 In the powder core, the density of the holes is preferably 1.0 / μm or more as a value obtained by measurement based on cross-sectional observation of the gap region, and is 1.3 or more. More preferably.
　上記の圧粉コアはＰを含有することが好ましい。圧粉コアがＰを含有することにより、圧粉コアの間隙領域における空孔の存在密度が高まる場合がある。特に圧粉コアを構成する軟磁性粉末がＰを含んでいることによりそのような空孔の存在密度が高まると考えられる。 It is preferable that the above-mentioned dust core contains P. When the dust core contains P, the presence density of pores in the gap region of the dust core may increase. In particular, it is considered that the existence density of such vacancies increases when the soft magnetic powder constituting the dust core contains P.
　上記の圧粉コアが備える前記軟磁性粉末は非晶質からなる部分を有していてもよい。 The soft magnetic powder provided in the powder core may have an amorphous part.
　上記の圧粉コアが備える前記軟磁性粉末は、Ｆｅ基非晶質合金であって、Ｎｉを０原子％以上１０原子％以下、Ｓｎを０原子％以上３原子％以下、Ｃｒを０原子％以上６原子％以下、Ｐを３．０原子％以上１１原子％以下、Ｃを１．０原子％以上１０原子％以下、Ｂを０原子％以上９原子％以下、およびＳｉを０原子％以上６原子％以下含有することが好ましい。軟磁性粉末がＰを含有することにより、圧粉コアの間隙領域における空孔の存在密度が高まる場合がある。 The soft magnetic powder included in the dust core is an Fe-based amorphous alloy, Ni is 0 atomic% to 10 atomic%, Sn is 0 atomic% to 3 atomic%, and Cr is 0 atomic%. 6 atom% or less, P 3.0 atom% or more and 11 atom% or less, C 1.0 atom% or more and 10 atom% or less, B 0 atom% or more and 9 atom% or less, and Si 0 atom% or more. It is preferable to contain 6 atomic% or less. When the soft magnetic powder contains P, the presence density of pores in the gap region of the dust core may increase.
　前記圧粉コアは、前記軟磁性粉末および樹脂を含有する組成物を加圧成形して成形体を得て、得られた前記成形体を加熱することにより得られたものであってもよい。 The powder core may be obtained by pressure-molding the composition containing the soft magnetic powder and the resin to obtain a molded body, and heating the obtained molded body.
　この場合において、前記成形体の加熱は、酸化性雰囲気での加熱およびその後の非酸化性雰囲気での加熱を含むことが好ましい。また、前記組成物は無機系成分を含有していてもよく、前記無機系成分はＰを含有することが好ましい。無機成分がＰを含有することにより、圧粉コアの間隙領域における空孔の存在密度が高まる場合がある。 In this case, it is preferable that the heating of the molded body includes heating in an oxidizing atmosphere and subsequent heating in a non-oxidizing atmosphere. The composition may contain an inorganic component, and the inorganic component preferably contains P. When the inorganic component contains P, the presence density of pores in the gap region of the dust core may increase.
　本発明は、別の一態様として、上記の圧粉コア、コイルおよび前記コイルのそれぞれの端部に接続された接続端子を備える電気・電子部品であって、前記圧粉コアの少なくとも一部は、前記接続端子を介して前記コイルに電流を流したときに前記電流により生じた誘導磁界内に位置するように配置されている電気・電子部品を提供する。 Another aspect of the present invention is an electric / electronic component including the dust core, the coil, and a connection terminal connected to each end of the coil, wherein at least a part of the dust core is And an electric / electronic component arranged to be located in an induced magnetic field generated by the current when a current is passed through the coil via the connection terminal.
　本発明は、さらに別の一態様として、上記の電気・電子部品が実装された電気・電子機器であって、前記電気・電子部品は前記接続端子にて基板に接続されている電気・電子機器を提供する。 As another aspect of the present invention, there is provided an electrical / electronic device in which the electrical / electronic component is mounted, wherein the electrical / electronic component is connected to a substrate by the connection terminal. I will provide a.
　上記の発明に係る圧粉コアは耐熱性に優れる。また、本発明によれば、かかる圧粉コアを備える電気・電子部品およびその電気・電子部品が実装された電気・電子機器が提供される。 The dust core according to the above invention is excellent in heat resistance. Further, according to the present invention, there are provided an electric / electronic component having such a dust core and an electric / electronic device on which the electric / electronic component is mounted.
本発明の一実施形態に係る圧粉コアの形状を概念的に示す斜視図である。It is a perspective view which shows notionally the shape of the powder core which concerns on one Embodiment of this invention. 本発明の一実施形態に係る圧粉コアの断面観察結果を示す図である。It is a figure which shows the cross-sectional observation result of the powder core which concerns on one Embodiment of this invention. 本発明の一実施形態に係る圧粉コアを断面観察することにより間隙領域を観察した結果を示す図である。It is a figure which shows the result of having observed the gap | interval area | region by observing a cross section of the powder core which concerns on one Embodiment of this invention. 図３ａの白破線で囲まれた領域の拡大図である。It is an enlarged view of the area | region enclosed with the white broken line of FIG. 3a. 本発明の一実施形態に係る圧粉コアを備える電気・電子部品であるトロイダルコアの形状を概念的に示す斜視図である。It is a perspective view which shows notionally the shape of the toroidal core which is an electric / electronic component provided with the powder core which concerns on one Embodiment of this invention. 本発明の別の一実施形態に係る圧粉コアを備える電気・電子部品であるインダクタンス素子の全体構成を一部透視して示す斜視図である。It is a perspective view which shows a partial see-through | perspective view and shows the whole structure of the inductance element which is an electric / electronic component provided with the powder core which concerns on another one Embodiment of this invention. 図５に示すインダクタンス素子を実装基板上に実装した状態を示す部分正面図である。It is a partial front view which shows the state which mounted the inductance element shown in FIG. 5 on the mounting board | substrate. 比較例１により製造された圧粉コアを断面観察することにより間隙領域を観察した結果を示す図である。It is a figure which shows the result of having observed the space | gap area | region by observing a cross section of the powder core manufactured by the comparative example 1. FIG.
　以下、本発明の実施形態について詳しく説明する。
１．圧粉コア
　図１に示される本発明の一実施形態に係る圧粉コア１は、その外観がリング状であって、図２，３に示されるように、軟磁性粉末Ｍと、アクリル系樹脂に基づく成分を含有する絶縁性の樹脂系材料Ｒを備える。 Hereinafter, embodiments of the present invention will be described in detail.
1. 1. The dust core 1 according to one embodiment of the present invention shown in FIG. 1 has a ring-like appearance, and as shown in FIGS. 2 and 3, soft magnetic powder M and acrylic resin An insulating resin material R containing a component based on the above is provided.
（１）空孔の存在密度
　本発明の一実施形態に係る圧粉コア１は、図３に示されるように、圧粉コア１における、隣り合う２つの軟磁性粉末Ｍ１，Ｍ２が作る間隙の少なくとも一部に樹脂系材料が充填されてなる間隙領域Ｇは、２つの軟磁性粉末Ｍ１，Ｍ２の離間距離が３０ｎｍ以下であるものを有し、この離間距離が３０ｎｍ以下の間隙領域Ｇに空孔Ｃを備える。この空孔Ｃの存在密度は、間隙領域Ｇの断面観察に基づく測定により得られた値として、１．０個／μｍ以上であることが好ましい。 (1) Density of pores As shown in FIG. 3, the dust core 1 according to an embodiment of the present invention has a gap formed by two adjacent soft magnetic powders M <b> 1 and M <b> 2 in the dust core 1. The gap region G in which at least a part is filled with the resin-based material has a gap distance between the two soft magnetic powders M1 and M2 of 30 nm or less, and the gap area G with a gap distance of 30 nm or less is empty. A hole C is provided. The existence density of the holes C is preferably 1.0 / μm or more as a value obtained by measurement based on cross-sectional observation of the gap region G.
　本明細書において、離間距離が３０ｎｍ以下の間隙領域Ｇにおける空孔Ｃの存在密度は次のようにして求めた値と定義される。まず、圧粉コアを切断・研磨して観察用断面を得る。走査型電子顕微鏡を用いてこの観察用断面を観察し、隣り合って配置され、間隙の長さが比較的大きい（具体例として、間隙の長さが１μｍ以上の場合が挙げられる。）２つの軟磁性粉末Ｍ１，Ｍ２を選択する。軟磁性粉末Ｍ１，Ｍ２が作る間隙のうち、樹脂系材料により少なくとも一部が充填された領域である間隙領域Ｇの長さを測定するとともに、間隙領域Ｇの幅を任意に１０点測定して、これらの測定値の平均を軟磁性粉末Ｍ１，Ｍ２の離間距離とする。次に、間隙領域Ｇを３０，０００倍の拡大倍率で観察し、間隙領域Ｇ内に樹脂系材料が部分的に充填されていないことによって画成される空孔Ｃの個数を数える。空孔Ｃの存否の確認には５０，０００倍の観察画像を用いる。これらの測定に基づいて、間隙領域Ｇにおける空孔Ｃの１μｍあたりの個数を求める。以上の測定を、同一組成で同一の条件で製造された複数の圧粉コアに対して行い、離間距離が３０ｎｍ以下である間隙領域Ｇの空孔Ｃの１μｍあたりの個数の平均値を、圧粉コアの間隙領域Ｇの空孔Ｃの存在密度（単位：個／μｍ）とする。なお、離間距離が３０ｎｍ以下となる間隙領域Ｇが存在しない圧粉コアについては、離間距離が３０ｎｍ以下の間隙領域Ｇにおける空孔Ｃの存在密度は０個／μｍであるとする。空孔Ｃの存在密度が０個／μｍである場合には、間隙領域Ｇは空孔を備えないとする。 In the present specification, the existence density of the holes C in the gap region G having a separation distance of 30 nm or less is defined as a value obtained as follows. First, the powder core is cut and polished to obtain a cross section for observation. The observation cross section is observed using a scanning electron microscope, arranged adjacent to each other, and the gap length is relatively large (as a specific example, the gap length is 1 μm or more). Soft magnetic powders M1 and M2 are selected. Among the gaps created by the soft magnetic powders M1 and M2, the length of the gap area G, which is an area at least partially filled with a resin material, is measured, and the width of the gap area G is arbitrarily measured at 10 points. The average of these measured values is defined as the distance between the soft magnetic powders M1 and M2. Next, the gap region G is observed at a magnification of 30,000, and the number of holes C defined by the resin material not being partially filled in the gap region G is counted. An observation image of 50,000 times is used to confirm the presence or absence of the hole C. Based on these measurements, the number of pores C in the gap region G per 1 μm is obtained. The above measurement is performed on a plurality of dust cores manufactured under the same conditions with the same composition, and the average value of the number of pores C per 1 μm in the gap region G having a separation distance of 30 nm or less The existence density of pores C in the gap region G of the powder core (unit: piece / μm) In addition, regarding the dust core in which the gap region G having a separation distance of 30 nm or less does not exist, the density of holes C in the gap region G having a separation distance of 30 nm or less is assumed to be 0 / μm. When the density of the holes C is 0 / μm, it is assumed that the gap region G has no holes.
　上記の空孔Ｃを備え、好ましくは空孔Ｃの存在密度が１．０個／μｍ以上である本発明の一実施形態に係る圧粉コア１は、耐熱性に優れる。この点を前述のΔＰｃを用いて説明すれば、本発明の一実施形態に係る圧粉コアは、ΔＰｃを２０％以下とすることが可能であり、好ましい例では、ΔＰｃを１０％以下とすることも可能であり、より好ましい例では、ΔＰｃを５％以下とすることも可能である。 The dust core 1 according to an embodiment of the present invention having the above-described holes C and preferably having a density of holes C of 1.0 / μm or more is excellent in heat resistance. If this point is demonstrated using above-mentioned (DELTA) Pc, the powder core which concerns on one Embodiment of this invention can make (DELTA) Pc 20% or less, and, in a preferable example, (DELTA) Pc shall be 10% or less. In a more preferable example, ΔPc can be 5% or less.
　圧粉コアの空孔Ｃの存在密度と耐熱性との関係は明らかでないが、大気中２５０℃の環境下に置く加熱試験に供された圧粉コアは、軟磁性粉末が体積膨張するため、間隙領域Ｇの体積を低下させるような力が生じている可能性がある。また、樹脂系材料も、加熱により機械特性が変化したり組成の変化が生じたりしている可能性がある。こうした加熱試験中に生じた変化は、圧粉コア内の軟磁性粉末に応力歪を生じさせる原因となりうる。本発明の一実施形態に係る圧粉コア１のように、空孔Ｃを備え、好ましくは空孔Ｃの存在密度が１．０個／μｍ以上である場合には、この空孔Ｃの体積変動（例えば収縮）により圧粉コア１内の軟磁性粉末に生じた応力が緩和され、結果的に、圧粉コア１内の軟磁性粉末に歪が蓄積しにくくなっている可能性がある。 Although the relationship between the density of the pores C in the dust core and the heat resistance is not clear, the dust core subjected to the heating test placed in an atmosphere of 250 ° C. in the atmosphere expands the volume of the soft magnetic powder. There is a possibility that a force that reduces the volume of the gap region G is generated. In addition, the resin-based material may also change its mechanical characteristics or change its composition due to heating. Such changes that occur during the heating test can cause stress distortion in the soft magnetic powder in the dust core. Like the dust core 1 according to one embodiment of the present invention, when the holes C are provided, and preferably the density of the holes C is 1.0 / μm or more, the volume of the holes C There is a possibility that the stress generated in the soft magnetic powder in the dust core 1 is relaxed due to the fluctuation (for example, contraction), and as a result, the strain is difficult to accumulate in the soft magnetic powder in the dust core 1.
　圧粉コア１の耐熱性をより安定的に高める観点から、空孔Ｃの存在密度は１．３個／μｍ以上であることが好ましく、１．６個／μｍ以上であることがより好ましい。空孔Ｃの存在密度の上限は、耐熱性を高める観点からは限定されない。空孔Ｃの存在密度が過度に高い場合には、圧粉コア１の力学的強度の低下などが懸念される。 From the viewpoint of improving the heat resistance of the dust core 1 more stably, the density of the holes C is preferably 1.3 / μm or more, and more preferably 1.6 / μm or more. The upper limit of the density of the holes C is not limited from the viewpoint of improving the heat resistance. When the density of the holes C is excessively high, there is a concern that the mechanical strength of the dust core 1 is reduced.
　本発明の一実施形態に係る圧粉コア１は、Ｐ（リン）を含有していることが好ましい場合がある。理由は定かでないが、圧粉コア１がＰ（リン）を含有することにより、軟磁性粉末Ｍ１，Ｍ２の離間距離が３０ｎｍ以下と狭い場合であっても、間隙領域Ｇにおける空孔Ｃの存在密度が高くなる傾向が得られやすい。圧粉コア１に含有されるＰ（リン）は、間隙領域Ｇに位置する樹脂系材料Ｒの物性や組成に影響を与えて間隙領域Ｇにおける空孔Ｃの存在密度が高まることに寄与している可能性がある。圧粉コア１にＰ（リン）を含有させる方法は限定されない。軟磁性粉末ＭにＰ（リン）を含有させてもよいし、圧粉コア１の製造過程においてリン酸ガラスなどリン含有物質を使用してもよい。特に軟磁性粉末ＭにＰを含有させることが好ましい。 The dust core 1 according to an embodiment of the present invention may preferably contain P (phosphorus). The reason is not clear, but the presence of pores C in the gap region G even when the distance between the soft magnetic powders M1 and M2 is as narrow as 30 nm or less due to the powder core 1 containing P (phosphorus). A tendency to increase the density is easily obtained. P (phosphorus) contained in the dust core 1 affects the physical properties and composition of the resin-based material R located in the gap region G and contributes to an increase in the density of the holes C in the gap region G. There is a possibility. The method for containing P (phosphorus) in the powder core 1 is not limited. P (phosphorus) may be included in the soft magnetic powder M, or a phosphorus-containing substance such as phosphate glass may be used in the manufacturing process of the powder core 1. In particular, it is preferable that soft magnetic powder M contains P.
（２）軟磁性粉末
　本発明の一実施形態に係る圧粉コア１が備える軟磁性粉末Ｍを構成する材料は限定されない。そのような材料として、結晶質磁性材料および非晶質磁性材料ならびに結晶質部分と非晶質部分とを有する材料が例示される。軟磁性粉末Ｍを構成する材料は一種類であってもよいし、複数種類であってもよい。軟磁性粉末Ｍが複数種類の材料から構成される場合には、各構成材料の組成および配合比率は限定されない。 (2) Soft magnetic powder The material which comprises the soft magnetic powder M with which the powder core 1 which concerns on one Embodiment of this invention is provided is not limited. Examples of such a material include a crystalline magnetic material and an amorphous magnetic material, and a material having a crystalline portion and an amorphous portion. The material constituting the soft magnetic powder M may be one type or a plurality of types. When the soft magnetic powder M is composed of a plurality of types of materials, the composition and blending ratio of each constituent material are not limited.
　結晶質磁性材料は、結晶質であること（一般的なＸ線回折測定により、材料種類を特定できる程度に明確なピークを有する回折スペクトルが得られること）、および軟磁性体であることを満たす限り、具体的な種類は限定されない。結晶質磁性材料の具体例として、Ｆｅ－Ｓｉ－Ｃｒ系合金、Ｆｅ－Ｎｉ系合金、Ｆｅ－Ｃｏ系合金、Ｆｅ－Ｖ系合金、Ｆｅ－Ａｌ系合金、Ｆｅ－Ｓｉ系合金、Ｆｅ－Ｓｉ－Ａｌ系合金、カルボニル鉄および純鉄が挙げられる。特に間隙領域Ｇにおける空孔Ｃの存在密度を高めるためには、これら結晶質磁性材料にＰを含んでいることが好ましい。 The crystalline magnetic material satisfies that it is crystalline (a general X-ray diffraction measurement can obtain a diffraction spectrum having a clear peak that can identify the type of material) and a soft magnetic material. As long as the specific type is not limited. Specific examples of crystalline magnetic materials include Fe—Si—Cr alloys, Fe—Ni alloys, Fe—Co alloys, Fe—V alloys, Fe—Al alloys, Fe—Si alloys, Fe—Si. -Al based alloys, carbonyl iron and pure iron. In particular, in order to increase the density of the holes C in the gap region G, it is preferable that these crystalline magnetic materials contain P.
　非晶質磁性材料は、非晶質であること（一般的なＸ線回折測定により、材料種類を特定できる程度に明確なピークを有する回折スペクトルが得られないこと）、および軟磁性体であることを満たす限り、具体的な種類は限定されない。非晶質磁性材料の具体例として、Ｆｅ－Ｐ－Ｃ－Ｂ－Ｓｉ系合金、Ｆｅ－Ｓｉ－Ｂ系合金、Ｆｅ－Ｐ－Ｃ系合金およびＣｏ－Ｆｅ－Ｓｉ－Ｂ系合金が挙げられる。特に間隙領域Ｇにおける空孔Ｃの存在密度を高めるためには、これら非晶質磁性材料にＰを含んでいることが好ましい。 The amorphous magnetic material is amorphous (a diffraction spectrum having a clear peak that can identify the type of material cannot be obtained by general X-ray diffraction measurement), and is a soft magnetic material. As long as the above is satisfied, the specific type is not limited. Specific examples of the amorphous magnetic material include Fe—P—C—B—Si alloy, Fe—Si—B alloy, Fe—PC—C alloy, and Co—Fe—Si—B alloy. . In particular, in order to increase the density of the holes C in the gap region G, it is preferable that these amorphous magnetic materials contain P.
　非晶質磁性材料のさらに具体的な例として、組成式が、Ｆｅ１００ａｔ％－ａ－ｂ－ｃ－ｘ－ｙ－ｚ－ｔＮｉａＳｎｂＣｒｃＰｘＣｙＢｚＳｉｔで示され、０ａｔ％≦ａ≦１０ａｔ％、０ａｔ％≦ｂ≦３ａｔ％、０ａｔ％≦ｃ≦６ａｔ％、６．８ａｔ％≦ｘ≦１０．８ａｔ％、２．２ａｔ％≦ｙ≦９．８ａｔ％、０ａｔ％≦ｚ≦４．２ａｔ％、０ａｔ％≦ｔ≦７ａｔ％であるＦｅ基非晶質合金が挙げられる。上記の組成式において、Ｎｉ，Ｓｎ，Ｃｒ，ＢおよびＳｉは任意添加元素である。 More specific examples of amorphous magnetic material, composition formula, shown in Fe 100at% -a-b-c -x-y-z-t Ni a Sn b Cr c P x C y B z Si t 0 at% ≦ a ≦ 10 at%, 0 at% ≦ b ≦ 3 at%, 0 at% ≦ c ≦ 6 at%, 6.8 at% ≦ x ≦ 10.8 at%, 2.2 at% ≦ y ≦ 9.8 at%, Examples include Fe-based amorphous alloys in which 0 at% ≦ z ≦ 4.2 at% and 0 at% ≦ t ≦ 7 at%. In the above composition formula, Ni, Sn, Cr, B, and Si are optional added elements.
　上記のＦｅ基非晶質合金の各元素の好ましい添加量範囲は次のとおりである。Ｎｉの添加量ａは、０ａｔ％以上６ａｔ％以下とすることが好ましく、０ａｔ％以上４ａｔ％以下とすることがより好ましい。Ｓｎの添加量ｂは、０ａｔ％以上２ａｔ％以下とすることが好ましく、１ａｔ％以上２ａｔ％以下とすることがより好ましい。Ｃｒの添加量ｃは、０ａｔ％以上２ａｔ％以下とすることが好ましく、１ａｔ％以上２ａｔ％以下とすることがより好ましい。Ｐの添加量ｘは、圧粉コア１の空隙Ｃの存在密度を高める観点から、８．８ａｔ％以上とすることが好ましい。Ｃの添加量ｙは、５．８ａｔ％以上８．８ａｔ％以下とすることが好ましい。Ｂの添加量ｚは、０ａｔ％以上３ａｔ％以下とすることが好ましく、０ａｔ％以上２ａｔ％以下とすることがより好ましい。Ｓｉの添加量ｔは、０ａｔ％以上６ａｔ％以下とすることが好ましく、０ａｔ％以上２ａｔ％以下とすることがより好ましい。 The preferable addition amount range of each element of the Fe-based amorphous alloy is as follows. The addition amount a of Ni is preferably 0 at% or more and 6 at% or less, and more preferably 0 at% or more and 4 at% or less. The addition amount b of Sn is preferably 0 at% or more and 2 at% or less, and more preferably 1 at% or more and 2 at% or less. The addition amount c of Cr is preferably 0 at% or more and 2 at% or less, and more preferably 1 at% or more and 2 at% or less. The addition amount x of P is preferably set to 8.8 at% or more from the viewpoint of increasing the density of voids C in the powder core 1. The addition amount y of C is preferably 5.8 at% or more and 8.8 at% or less. The addition amount z of B is preferably 0 at% or more and 3 at% or less, and more preferably 0 at% or more and 2 at% or less. The addition amount t of Si is preferably 0 at% or more and 6 at% or less, and more preferably 0 at% or more and 2 at% or less.
　結晶質部分と非晶質部分とを有する材料は、結晶質磁性材料と非晶質磁性材料との混合体であってもよいし、非晶質相と結晶質相とを有する材料であってもよい。後者の材料として、Ｆｅ基合金であって、Ｎｂ，Ｃｕ，Ｓｉなどの結晶析出を促進する元素を含有することにより非結晶質の母相中に結晶質の娘相が分散析出したものが例示される。 The material having a crystalline part and an amorphous part may be a mixture of a crystalline magnetic material and an amorphous magnetic material, or a material having an amorphous phase and a crystalline phase. Also good. An example of the latter material is an Fe-based alloy in which a crystalline daughter phase is dispersed and precipitated in an amorphous matrix by containing an element that promotes crystal precipitation such as Nb, Cu, and Si. Is done.
　本発明の一実施形態に係る圧粉コア１が含有する軟磁性粉末Ｍの形状は限定されない。軟磁性粉末Ｍの形状は球状であってもよいし非球状であってもよい。非球状である場合には、扁平形状、鱗片状、楕円球状、液滴状、針状といった形状異方性を有する形状であってもよいし、特段の形状異方性を有しない不定形であってもよい。 The shape of the soft magnetic powder M contained in the powder core 1 according to an embodiment of the present invention is not limited. The shape of the soft magnetic powder M may be spherical or non-spherical. In the case of a non-spherical shape, it may be a shape having a shape anisotropy such as a flat shape, a scale shape, an oval sphere, a droplet shape, a needle shape, or an indefinite shape having no special shape anisotropy. There may be.
　軟磁性粉末Ｍの形状は、軟磁性粉末Ｍを製造する段階（アトマイズ法が具体例として挙げられる。）で得られた形状であってもよいし、製造された軟磁性粉末Ｍを二次加工（アトライタなどによる扁平加工が具体例として挙げられる。）することにより得られた形状であってもよい。前者の形状としては、球状、楕円球状、液滴状、針状などが例示され、後者の形状としては、扁平形状、鱗片状が例示される。 The shape of the soft magnetic powder M may be the shape obtained in the stage of producing the soft magnetic powder M (the atomizing method is given as a specific example), or the produced soft magnetic powder M is subjected to secondary processing. A shape obtained by performing flattening with an attritor or the like is given as a specific example. Examples of the former shape include a spherical shape, an oval shape, a droplet shape, and a needle shape. Examples of the latter shape include a flat shape and a scale shape.
　本発明の一実施形態に係る圧粉コア１が含有する軟磁性粉末Ｍの粒径は限定されない。かかる粒径を、平均粒径Ｄ５０（レーザー回折散乱法により測定された軟磁性粉末Ｍの粒径の体積分布における体積累積値が５０％のときの粒径）により規定すれば、通常、１μｍから２０μｍの範囲とされる。取扱い性を高める観点、圧粉コア１における軟磁性粉末Ｍの充填密度を高める観点などから、軟磁性粉末Ｍの平均粒径Ｄ５０は、２μｍ以上１５μｍ以下とすることが好ましく、３μｍ以上１０μｍ以下とすることがより好ましく、４μｍ以上７μｍ以下とすることが特に好ましい。 The particle diameter of the soft magnetic powder M contained in the powder core 1 according to an embodiment of the present invention is not limited. If this particle size is defined by the average particle size D50 (particle size when the volume cumulative value in the volume distribution of the particle size of the soft magnetic powder M measured by the laser diffraction scattering method is 50%), it is usually from 1 μm. The range is 20 μm. From the viewpoint of enhancing the handleability and the viewpoint of increasing the packing density of the soft magnetic powder M in the dust core 1, the average particle diameter D50 of the soft magnetic powder M is preferably 2 μm or more and 15 μm or less, and 3 μm or more and 10 μm or less. More preferably, it is more preferably 4 μm or more and 7 μm or less.
　本発明の一実施形態に係る圧粉コア１における軟磁性粉末Ｍの含有量は限定されない。用途に応じて、樹脂系材料の組成、製造工程などを勘案して適宜設定される。 The content of the soft magnetic powder M in the powder core 1 according to an embodiment of the present invention is not limited. Depending on the application, it is appropriately set in consideration of the composition of the resin-based material, the manufacturing process, and the like.
（３）樹脂系材料
　本発明の一実施形態に係る圧粉コア１が備える樹脂系材料Ｒは、絶縁性であって、当該材料を与える樹脂がアクリル系樹脂を含有する。本明細書において、「樹脂系材料Ｒ」とは、樹脂および／または樹脂に基づく成分（樹脂の少なくとも一部が組成変化した成分であって、樹脂の（部分）熱分解物が一具体例として例示される。）を含有する材料を意味し、本実施形態に係る樹脂系材料Ｒは、樹脂系材料Ｒを与える樹脂がアクリル系樹脂を含む。 (3) Resin-type material The resin-type material R with which the powder core 1 which concerns on one Embodiment of this invention is provided is insulating, Comprising: Resin which provides the said material contains acrylic resin. In this specification, “resin-based material R” is a resin and / or a resin-based component (a component in which at least a part of the resin is changed in composition, and a (part) thermal decomposition product of the resin is a specific example. In the resin-based material R according to this embodiment, the resin that provides the resin-based material R includes an acrylic resin.
　アクリル系樹脂は、アクリル酸およびその誘導体の少なくとも一方に基づく構成単位を含有していればよく、単独重合体であってもよいし、共重合体であってもよい。アクリル酸の誘導体として、アクリル酸エステル、メタクリル酸およびそのエステル、アクリルアミドなどが例示される。アクリル系樹脂が共重合体である場合には、当該共重合体はアクリル酸およびその誘導体の少なくとも一方に基づく構成単位以外の構成単位を含有していてもよく、その構成単位を与える化合物の種類は限定されない。かかる化合物の具体例として、エチレン等のオレフィン、酢酸ビニル等のビニルエステルなどが挙げられる。アクリル系樹脂は、架橋構造を有していてもよい。その場合の架橋剤は限定されず、ポリイソシアネート化合物などが例示される。 The acrylic resin only needs to contain a structural unit based on at least one of acrylic acid and its derivative, and may be a homopolymer or a copolymer. Examples of acrylic acid derivatives include acrylic acid esters, methacrylic acid and esters thereof, and acrylamide. When the acrylic resin is a copolymer, the copolymer may contain a constitutional unit other than the constitutional unit based on at least one of acrylic acid and its derivative, and the type of compound that gives the constitutional unit Is not limited. Specific examples of such compounds include olefins such as ethylene and vinyl esters such as vinyl acetate. The acrylic resin may have a crosslinked structure. The crosslinking agent in that case is not limited, and examples thereof include polyisocyanate compounds.
　樹脂系材料を与える樹脂は、アクリル系樹脂以外の樹脂を含んでいてもよい。そのような樹脂として、シリコーン樹脂、エポキシ樹脂、フェノール樹脂、尿素樹脂、メラミン樹脂などが例示される。 The resin that gives the resin material may contain a resin other than the acrylic resin. Examples of such resins include silicone resins, epoxy resins, phenol resins, urea resins, melamine resins, and the like.
　図３に示されるように、樹脂系材料Ｒは、圧粉コア１内の隣り合う軟磁性粉末Ｍ１，Ｍ２の間などに位置し、軟磁性粉末Ｍ１，Ｍ２を固着させるとともに絶縁し、圧粉コア１の形状および絶縁性の維持に寄与している。一般に、圧粉コアが加熱試験に供されると、樹脂系材料の上記の固着機能および／または絶縁機能が低下することが懸念されるが、本発明の一実施形態に係る圧粉コア１は、前述のように空隙Ｃの存在密度が適切に制御されているため、加熱試験後に磁気特性が低下しにくい。 As shown in FIG. 3, the resin material R is located between the adjacent soft magnetic powders M1 and M2 in the dust core 1, and fixes and insulates the soft magnetic powders M1 and M2, and compacts the dust. This contributes to maintaining the shape and insulation of the core 1. In general, when the dust core is subjected to a heating test, there is a concern that the above-described fixing function and / or insulating function of the resin-based material may be deteriorated. However, the dust core 1 according to one embodiment of the present invention is As described above, since the existence density of the gap C is appropriately controlled, the magnetic characteristics are not easily lowered after the heating test.
（４）圧粉コアの製造方法
　本発明の一実施形態に係る圧粉コア１の製造方法は限定されない。かかる製造方法の一例を挙げれば、軟磁性粉末および樹脂を含有する組成物を加圧成形し、得られた成形体を加熱することにより、圧粉コア１を得ることができる。 (4) Manufacturing method of dust core The manufacturing method of the dust core 1 which concerns on one Embodiment of this invention is not limited. If an example of this manufacturing method is given, the powder core 1 can be obtained by press-molding the composition containing soft-magnetic powder and resin, and heating the obtained molded object.
　この製造方法において、加圧条件および加熱条件は、圧粉コアに求められる機械特性や磁気特性、組成物の組成などに応じて適宜設定される。加熱条件の一例として、酸化性雰囲気での加熱および非酸化性雰囲気での加熱を行うことが挙げられる。前述のように、本発明の一実施形態に係る圧粉コア１はアクリル系樹脂に基づく成分を含有する樹脂系材料Ｒを備えるため、上記の加圧成形の対象となる組成物はアクリル系樹脂を含有する。空隙Ｃの存在密度を高めることが可能な好ましい樹脂系材料Ｒを、アクリル系樹脂を含む組成物から得ることが容易となるように、加熱条件は酸化性雰囲気での加熱を含むことが好ましく、その温度は、３００℃以上４００℃以下とすることが好ましく、３５５℃以上４００℃以下とすることがより好ましく、３６０℃以上４００℃以下とすることが特に好ましい。また、加圧成形により軟磁性粉末Ｍに加えられた歪をより安定的に緩和させる観点から、４００℃以上の加熱を行うことが好ましく、この場合には、圧粉コア１が樹脂系材料Ｒを適切に備えることができるように、非酸化性雰囲気での加熱とすることが好ましい。したがって、酸化性雰囲気での加熱および非酸化性雰囲気での加熱を行う場合には、酸化性雰囲気において３００℃以上４００℃以下で加熱し、その後、非酸化性雰囲気において４００℃以上の加熱を行うことが好ましい。 In this manufacturing method, the pressurizing condition and heating condition are appropriately set according to mechanical characteristics and magnetic characteristics required for the dust core, the composition of the composition, and the like. As an example of the heating conditions, heating in an oxidizing atmosphere and heating in a non-oxidizing atmosphere can be given. As described above, since the dust core 1 according to an embodiment of the present invention includes the resin material R containing a component based on an acrylic resin, the composition to be pressure-molded is an acrylic resin. Containing. The heating conditions preferably include heating in an oxidizing atmosphere so that a preferable resin-based material R capable of increasing the density of the voids C can be easily obtained from a composition including an acrylic resin. The temperature is preferably 300 ° C. or higher and 400 ° C. or lower, more preferably 355 ° C. or higher and 400 ° C. or lower, and particularly preferably 360 ° C. or higher and 400 ° C. or lower. In addition, from the viewpoint of more stably relieving the strain applied to the soft magnetic powder M by pressure molding, it is preferable to perform heating at 400 ° C. or higher. In this case, the powder core 1 is made of the resin material R Is preferably heated in a non-oxidizing atmosphere. Therefore, when heating in an oxidizing atmosphere and heating in a non-oxidizing atmosphere are performed, heating is performed at 300 ° C. or higher and 400 ° C. or lower in an oxidizing atmosphere, and then heating is performed at 400 ° C. or higher in a non-oxidizing atmosphere. It is preferable.
　加圧成形される上記の組成物は、軟磁性粉末および樹脂以外の成分を含有していてもよい。そのような成分として、ガラスなどの無機系成分、金属石鹸などの潤滑剤などが例示される。組成物にＰ（リン）を含む成分（たとえばリン酸ガラス）を含有させることにより、圧粉コア１の間隙領域Ｇにおける空隙Ｃの存在密度を高めることができる場合もある。組成物の調製方法は限定されない。組成物を構成する材料を単に混練して得てもよいし、組成物を構成する材料を含有するスラリーを乾燥・粉砕して造粒粉を形成してもよい。 The above-described composition to be pressure-molded may contain components other than the soft magnetic powder and the resin. Examples of such components include inorganic components such as glass and lubricants such as metal soaps. By including a component (for example, phosphate glass) containing P (phosphorus) in the composition, the density of voids C in the gap region G of the dust core 1 may be increased. The method for preparing the composition is not limited. The material constituting the composition may be obtained simply by kneading, or the slurry containing the material constituting the composition may be dried and pulverized to form a granulated powder.
２．電気・電子部品
　本発明の一実施形態に係る電気・電子部品は、上記の本発明の一実施形態に係る圧粉コア１、コイルおよびこのコイルのそれぞれの端部に接続された接続端子を備える。ここで、圧粉コア１の少なくとも一部は、接続端子を介してコイルに電流を流したときにこの電流により生じた誘導磁界内に位置するように配置されている。 2. Electrical / Electronic Component An electrical / electronic component according to an embodiment of the present invention includes a dust core 1 according to an embodiment of the present invention, a coil, and a connection terminal connected to each end of the coil. . Here, at least a part of the dust core 1 is disposed so as to be located in an induced magnetic field generated by the current when a current is passed through the coil via the connection terminal.
　このような電気・電子部品の一例として、図４に示されるトロイダルコア１０が挙げられる。トロイダルコア１０は、リング状の圧粉コア１に、被覆導電線２を巻回することによって形成されたコイル２ａを備える。巻回された被覆導電線２からなるコイル２ａと被覆導電線２の端部２ｂ，２ｃとの間に位置する導電線の部分において、コイル２ａの端部２ｄ，２ｅを定義することができる。このように、本実施形態に係る電気・電子部品は、コイルを構成する部材と接続端子を構成する部材とが同一の部材から構成されていてもよい。 An example of such an electric / electronic component is a toroidal core 10 shown in FIG. The toroidal core 10 includes a coil 2a formed by winding a covered conductive wire 2 around a ring-shaped dust core 1. The ends 2d and 2e of the coil 2a can be defined in the portion of the conductive wire located between the coil 2a formed of the wound covered conductive wire 2 and the ends 2b and 2c of the covered conductive wire 2. As described above, in the electrical / electronic component according to the present embodiment, the member constituting the coil and the member constituting the connection terminal may be composed of the same member.
　本発明の一実施形態に係る電気・電子部品は、上記の本発明の一実施形態に係る圧粉コア１とは異なる形状を有する圧粉コアを備える。そのような電気・電子部品の具体例として、図５に示されるインダクタンス素子２０が挙げられる。図５は、本発明の一実施形態に係るインダクタンス素子２０の全体構成を一部透視して示す斜視図である。図５では、インダクタンス素子２０の下面（実装面）が上向きの姿勢で示されている。図６は、図５に示すインダクタンス素子２０を実装基板１０上に実装した状態を示す部分正面図である。 An electric / electronic component according to an embodiment of the present invention includes a dust core having a shape different from that of the dust core 1 according to the embodiment of the present invention. A specific example of such an electric / electronic component is an inductance element 20 shown in FIG. FIG. 5 is a perspective view showing a part of the entire configuration of the inductance element 20 according to the embodiment of the present invention. In FIG. 5, the lower surface (mounting surface) of the inductance element 20 is shown in an upward posture. FIG. 6 is a partial front view showing a state in which the inductance element 20 shown in FIG. 5 is mounted on the mounting substrate 10.
　図５に示すインダクタンス素子２０は、圧粉コア３と、圧粉コア３の内部に埋め込まれたコイルとしての空芯コイル５と、溶接によって空芯コイル５に電気的に接続される接続端子としての一対の端子部４とを備えて構成される。 An inductance element 20 shown in FIG. 5 includes a dust core 3, an air core coil 5 as a coil embedded in the dust core 3, and a connection terminal electrically connected to the air core coil 5 by welding. And a pair of terminal portions 4.
　空芯コイル５は、絶縁被膜された導線を螺旋状に巻回して形成されたものである。空芯コイル５は、巻回部５ａと巻回部５ａから引き出された引出端部５ｂ，５ｂとを有して構成される。空芯コイル５の巻き数は必要なインダクタンスに応じて適宜設定される。 The air-core coil 5 is formed by spirally winding a conductive wire with an insulating coating. The air-core coil 5 includes a winding part 5a and lead-out end parts 5b and 5b drawn from the winding part 5a. The number of turns of the air-core coil 5 is appropriately set according to the required inductance.
　図５に示すように、圧粉コア３において、実装基板に対する実装面３ａに、端子部４の一部を収納するための収納凹部３０が形成されている。収納凹部３０は、実装面３ａの両側に形成されており、圧粉コア３の側面３ｂ，３ｃに向けて解放されて形成されている。圧粉コア３の側面３ｂ，３ｃから突出する端子部４の一部が実装面３ａに向けて折り曲げられて、収納凹部３０の内部に収納される。 As shown in FIG. 5, in the dust core 3, an accommodation recess 30 for accommodating a part of the terminal portion 4 is formed on the mounting surface 3 a with respect to the mounting substrate. The storage recesses 30 are formed on both sides of the mounting surface 3 a and are formed to be released toward the side surfaces 3 b and 3 c of the powder core 3. Part of the terminal portion 4 protruding from the side surfaces 3 b and 3 c of the powder core 3 is bent toward the mounting surface 3 a and stored in the storage recess 30.
　端子部４は、薄板状のＣｕ基材で形成されている。端子部４は圧粉コア３の内部に埋設されて空芯コイル５の引出端部５ｂ，５ｂに電気的に接続される接続端部４０と、圧粉コア３の外面に露出し、前記圧粉コア３の側面３ｂ，３ｃから実装面３ａにかけて順に折り曲げ形成される第１曲折部４２ａおよび第２曲折部４２ｂとを有して構成される。接続端部４０は、空芯コイル５に溶接される溶接部である。第１曲折部４２ａと第２曲折部４２ｂは、実装基板１００に対して半田接合される半田接合部である。半田接合部は、端子部４のうちの圧粉コア３から露出している部分であって、少なくとも圧粉コア３の外側に向けられる表面を意味している。 The terminal part 4 is formed of a thin plate-like Cu base material. The terminal part 4 is exposed on the outer surface of the dust core 3 and the connection end part 40 embedded in the dust core 3 and electrically connected to the lead-out ends 5b, 5b of the air-core coil 5. The powder core 3 includes a first bent portion 42a and a second bent portion 42b that are bent in order from the side surfaces 3b and 3c to the mounting surface 3a. The connection end 40 is a welded portion that is welded to the air-core coil 5. The first bent portion 42 a and the second bent portion 42 b are solder joint portions that are soldered to the mounting substrate 100. The solder joint portion is a portion of the terminal portion 4 that is exposed from the dust core 3 and means a surface that faces at least the outside of the dust core 3.
　端子部４の接続端部４０と空芯コイル５の引出端部５ｂとは、抵抗溶接によって接合されている。 The connection end portion 40 of the terminal portion 4 and the extraction end portion 5b of the air-core coil 5 are joined by resistance welding.
　図６に示すように、インダクタンス素子２０は、実装基板１００上に実装される。
　実装基板１００の表面には外部回路と導通する導体パターンが形成され、この導体パターンの一部によって、インダクタンス素子２０を実装するための一対のランド部１１０が形成されている。 As shown in FIG. 6, the inductance element 20 is mounted on the mounting substrate 100.
A conductor pattern that is electrically connected to an external circuit is formed on the surface of the mounting substrate 100, and a pair of land portions 110 for mounting the inductance element 20 is formed by a part of the conductor pattern.
　図６に示すように、インダクタンス素子２０においては、実装面３ａが実装基板１００側に向けられて、圧粉コア３から外部に露出している第１曲折部４２ａと第２曲折部４２ｂが実装基板１００のランド部１１０との間で半田層１２０にて接合される。 As shown in FIG. 6, in the inductance element 20, the mounting surface 3 a is directed to the mounting substrate 100 side, and the first bent portion 42 a and the second bent portion 42 b that are exposed to the outside from the dust core 3 are mounted. The solder layer 120 is bonded to the land portion 110 of the substrate 100.
　半田付け工程は、ランド部１１０にペースト状の半田が印刷工程で塗布された後に、ランド部１１０に第２の曲折部４２ｂが対面するようにしてインダクタンス素子２０が実装され、加熱工程で半田が溶融する。図５と図６に示すように、第２曲折部４２ｂは実装基板１００のランド部１１０に対向し、第１曲折部４２ａはインダクタンス素子２０の側面３ｂ、３ｃに露出しているため、フィレット状の半田層１２０は、ランド部１１０に固着するとともに、半田接合部である第２曲折部４２ｂと第１曲折部４２ａの双方の表面に十分に広がって固着される。 In the soldering process, after the paste-like solder is applied to the land part 110 in the printing process, the inductance element 20 is mounted so that the second bent part 42b faces the land part 110, and the solder is applied in the heating process. Melt. As shown in FIGS. 5 and 6, the second bent portion 42 b faces the land portion 110 of the mounting substrate 100, and the first bent portion 42 a is exposed on the side surfaces 3 b and 3 c of the inductance element 20. The solder layer 120 is fixed to the land portion 110 and is sufficiently spread and fixed to the surfaces of both the second bent portion 42b and the first bent portion 42a which are solder joint portions.
　以上説明したトロイダルコア１０、インダクタンス素子２０以外の電気・電子部品の例として、リアクトルやトランスが挙げられる。 Examples of electric / electronic components other than the toroidal core 10 and the inductance element 20 described above include a reactor and a transformer.
３．電気・電子機器
　本発明の一実施形態に係る電気・電子機器は、上記の本発明の一実施形態に係る圧粉コアを備える電気・電子部品が実装されたものである。そのような電気・電子機器として、電源スイッチング回路、電圧昇降回路、平滑回路等を備えた電源装置や小型携帯通信機器等が例示される。 3. Electrical / Electronic Device An electrical / electronic device according to an embodiment of the present invention is mounted with an electrical / electronic component including the dust core according to the embodiment of the present invention. Examples of such electric / electronic devices include a power supply device including a power switching circuit, a voltage raising / lowering circuit, and a smoothing circuit, a small portable communication device, and the like.
　こうした電気・電子機器が車載用途である場合には、高温の環境下に長期間置かれても動作安定性に優れていることが、強く求められる。こうした要求に応えるためには、電気・電子機器に組み込まれた電気・電子部品のそれぞれについて、高温の環境下に長期間置かれても動作安定性に優れていることが必要とされる。本発明の一実施形態に係る電気・電子部品は、上記のように、耐熱性に優れる圧粉コアを備えるため、当該部品が実装された電気・電子機器は車載用途への適用が容易である。 When such electric / electronic devices are used in vehicles, it is strongly required that they have excellent operational stability even when placed in a high temperature environment for a long period of time. In order to meet these demands, it is necessary that each of the electric and electronic components incorporated in the electric and electronic equipment has excellent operational stability even when placed in a high temperature environment for a long period of time. Since the electric / electronic component according to an embodiment of the present invention includes the dust core having excellent heat resistance as described above, the electric / electronic device on which the component is mounted can be easily applied to in-vehicle use. .
　以上説明した実施形態は、本発明の理解を容易にするために記載されたものであって、本発明を限定するために記載されたものではない。したがって、上記実施形態に開示された各要素は、本発明の技術的範囲に属する全ての設計変更や均等物をも含む趣旨である。 The embodiment described above is described for facilitating understanding of the present invention, and is not described for limiting the present invention. Therefore, each element disclosed in the above embodiment is intended to include all design changes and equivalents belonging to the technical scope of the present invention.
　以下、実施例等により本発明をさらに具体的に説明するが、本発明の範囲はこれらの実施例等に限定されるものではない。 Hereinafter, the present invention will be described more specifically with reference to examples and the like, but the scope of the present invention is not limited to these examples and the like.
（実施例１）
　水アトマイズ法を用いて、Ｆｅ７４．４３ａｔ％Ｃｒ１．９６ａｔ％Ｐ９．０４ａｔ％Ｃ２．１６ａｔ％Ｂ７．５４ａｔ％Ｓｉ４．８７ａｔ％なる組成になるように秤量して得られた非晶質軟磁性粉末を軟磁性粉末として作製した。得られた軟磁性粉末の粒度分布は、日機装社製「マイクロトラック粒度分布測定装置　ＭＴ３３００ＥＸ」を用いて体積分布で測定した。その結果、体積分布において５０％となる粒径である平均粒径（Ｄ５０）は１０．６μｍであった。 (Example 1)
Using a water atomization method, non-obtained obtained by weighing to a composition of Fe 74.43 at% Cr 1.96 at% P 9.04 at% C 2.16 at% B 7.54 at% Si 4.87 at% A crystalline soft magnetic powder was prepared as a soft magnetic powder. The particle size distribution of the obtained soft magnetic powder was measured by volume distribution using “Microtrack particle size distribution measuring device MT3300EX” manufactured by Nikkiso Co., Ltd. As a result, the average particle diameter (D50), which is 50% in the volume distribution, was 10.6 μm.
　上記の軟磁性粉末を１００質量部、アクリル系樹脂を１．７質量部、リン酸ガラスからなる無機系成分を０．６質量部およびステアリン酸亜鉛からなる潤滑剤を０．３質量部混合してスラリーを得た。 100 parts by mass of the above soft magnetic powder, 1.7 parts by mass of an acrylic resin, 0.6 parts by mass of an inorganic component made of phosphate glass, and 0.3 parts by mass of a lubricant made of zinc stearate are mixed. To obtain a slurry.
　得られたスラリーを乾燥後に粉砕し、目開き３００μｍのふるいおよび８５０μｍのふるいを用いて、３００μｍ以下の微細な粉末および８５０μｍ以上の粗大な粉末を除去して、造粒粉を得た。 The obtained slurry was dried and pulverized, and fine powder of 300 μm or less and coarse powder of 850 μm or more were removed using a sieve having an opening of 300 μm and a sieve of 850 μm to obtain granulated powder.
　得られた造粒粉を金型に充填し、面圧１．８ＧＰａで加圧成形して、リング形状を有する成形体を得た。得られた成形体を、大気（酸化性雰囲気）中３６０℃で１０時間加熱し、その後、窒素雰囲気（非酸化性雰囲気）において４５０℃で１時間加熱する条件で熱処理して、外径２０ｍｍ×内径１２ｍｍ×厚さ７ｍｍのリング形状を有する圧粉コアを得た。 The obtained granulated powder was filled in a mold and subjected to pressure molding at a surface pressure of 1.8 GPa to obtain a molded body having a ring shape. The obtained molded body was heated in the atmosphere (oxidizing atmosphere) at 360 ° C. for 10 hours, and then heat-treated in a nitrogen atmosphere (non-oxidizing atmosphere) at 450 ° C. for 1 hour to obtain an outer diameter of 20 mm × A dust core having a ring shape with an inner diameter of 12 mm and a thickness of 7 mm was obtained.
（比較例１）
　スラリーの調製の際にリン酸ガラスを配合しなかったことおよび熱処理の条件を窒素雰囲気（非酸化性雰囲気）において４５０℃で１時間加熱としたこと以外は、実施例１と同様の操作を行い、圧粉コアを得た。 (Comparative Example 1)
The same operation as in Example 1 was performed except that the phosphate glass was not blended during the preparation of the slurry and the heat treatment was performed at 450 ° C. for 1 hour in a nitrogen atmosphere (non-oxidizing atmosphere). A green core was obtained.
（比較例２）
　軟磁性粉末の種類をＦｅ－Ｓｉ－Ｂ－Ｃｒ系アモルファス（平均粒径（Ｄ５０）：５０μｍ）に変更したこと以外は、実施例１と同様の操作を行い、圧粉コアを得た。また、このＦｅ－Ｓｉ－Ｂ－Ｃｒ系アモルファス合金は、Ｐの添加が無いものであった。 (Comparative Example 2)
A powder core was obtained in the same manner as in Example 1 except that the kind of the soft magnetic powder was changed to Fe—Si—B—Cr amorphous (average particle diameter (D50): 50 μm). Further, this Fe—Si—B—Cr-based amorphous alloy had no addition of P.
（試験例１）　空孔の存在密度の測定
　実施例１により作製した１５個の圧粉コア、比較例１により作製した１３個の圧粉コアおよび比較例２により作製した３個の圧粉コアのそれぞれについて、切断・研磨して観察断面を得た。走査電子顕微鏡を用いてこの観察断面を観察し、隣り合って配置され、間隙の長さが比較的大きい２つの軟磁性粉末を選択した。軟磁性粉末が作る間隙のうち、樹脂系材料により少なくとも一部が充填された領域である間隙領域の長さを測定した。また、間隙領域の幅を任意に１０点測定して、これらの測定値の平均を軟磁性粉末の離間距離とした。続いて、間隙領域を３０，０００倍の拡大倍率で観察し、間隙領域内に樹脂系材料が部分的に充填されていないことによって画成される空孔の個数を数えた。空孔の存否の確認には５０，０００倍の観察画像を用いた。これらの測定に基づいて、間隙領域に空孔が存在するか否かを確認するとともに、空孔が存在する場合には間隙領域における空孔の１μｍあたりの個数を求めた。空孔の１μｍあたりの個数が０個である場合には、間隙領域は空孔を備えないと判定した。測定結果を表１に示す。また、実施例１により製造された圧粉コアの観察画像を図３に示し、比較例１により製造された圧粉コアの観察画像を図７に示した。図３に示したように、実施例１により製造された圧粉コアでは、間隙領域に空隙が測定されやすく、図７に示したように、比較例１により製造された圧粉コアでは、間隙領域に空隙が測定されにくかった。 (Test Example 1) Measurement of the presence density of pores 15 powder cores produced in Example 1, 13 powder cores produced in Comparative Example 1, and 3 powder cores produced in Comparative Example 2 Each was cut and polished to obtain an observation cross section. This observation cross section was observed using a scanning electron microscope, and two soft magnetic powders arranged adjacent to each other and having a relatively large gap length were selected. Of the gaps created by the soft magnetic powder, the length of the gap area, which is an area at least partially filled with the resin material, was measured. Further, the width of the gap region was arbitrarily measured at 10 points, and the average of these measured values was taken as the separation distance of the soft magnetic powder. Subsequently, the gap region was observed at a magnification of 30,000, and the number of pores defined by the resin region material not being partially filled in the gap region was counted. The observation image of 50,000 times was used for confirmation of the presence or absence of pores. Based on these measurements, it was confirmed whether or not there was a hole in the gap region, and when there was a hole, the number of holes in the gap region per 1 μm was obtained. When the number of holes per 1 μm was 0, it was determined that the gap region did not have holes. The measurement results are shown in Table 1. Moreover, the observation image of the dust core manufactured by Example 1 was shown in FIG. 3, and the observation image of the dust core manufactured by Comparative Example 1 was shown in FIG. As shown in FIG. 3, in the dust core manufactured according to Example 1, voids are easily measured in the gap region. As shown in FIG. 7, in the dust core manufactured according to Comparative Example 1, It was difficult to measure voids in the area.
　表１に示されるように、実施例１に係る離間距離が３０ｎｍ以下であった８つの圧粉コア（試料番号１－６から１－１２、１－１４および１－１５）における間隙領域の空孔の１μｍあたりの個数の平均値を求め、得られた１．９個／μｍを、実施例１に係る空孔の存在密度とした。 As shown in Table 1, the gap regions in the eight dust cores (Sample Nos. 1-6 to 1-12, 1-14, and 1-15) having a separation distance of 30 nm or less according to Example 1 were used. The average value of the number of holes per 1 μm was obtained, and the obtained 1.9 / μm was defined as the existence density of the holes according to Example 1.
　表１に示されるように、比較例１に係る離間距離が３０ｎｍ以下であった５つの圧粉コア（試料番号２－２から２－４、２－６および２－１１）における間隙領域の空孔の１μｍあたりの個数の平均値を求め、得られた０個／μｍを、比較例１に係る空孔の存在密度とした。 As shown in Table 1, the gap regions in the five dust cores (Sample Nos. 2-2 to 2-4, 2-6, and 2-11) having a separation distance of 30 nm or less according to Comparative Example 1 were used. The average value of the number of holes per 1 μm was determined, and the obtained number of holes / μm was defined as the existence density of holes according to Comparative Example 1.
　比較例２に係る圧粉コアは、離間距離が３０ｎｍ以下となる間隙領域が存在しなかったため、比較例２に係る空孔の存在密度は０個／μｍとした。 The powder core according to Comparative Example 2 did not have a gap region with a separation distance of 30 nm or less, and thus the density of holes according to Comparative Example 2 was 0 / μm.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
（試験例２）　耐熱性の評価
　実施例および比較例により作製したリング状の形状を有する圧粉コアに銅線の巻線を施し、ＢＨアナライザー（岩崎通信機社製「ＳＹ－８２１７」）を用いて周波数１００ｋＨｚ，最大磁束密度１００ｍＴの条件でコアロスＰｃ０（単位：ｋＷ／ｍ３）を測定した。 (Test Example 2) Evaluation of heat resistance Copper wire winding was applied to a dust core having a ring shape produced according to Examples and Comparative Examples, and a BH analyzer (“SY-8217” manufactured by Iwasaki Tsushinki Co., Ltd.) was used. The core loss Pc 0 (unit: kW / m 3 ) was measured under the conditions of a frequency of 100 kHz and a maximum magnetic flux density of 100 mT.
　銅線が巻かれた圧粉コアに対して、大気中２５０℃の環境下に１０００時間放置する加熱試験を行った。加熱試験後に、上記の条件でコアロスＰｃ１（単位：ｋＷ／ｍ３）を測定した。下記式に基づいてコアロスの変化率ΔＰｃ（単位：％）を算出した。
　　ΔＰｃ＝（Ｐｃ１－Ｐｃ０）／Ｐｃ０×１００ A heating test was performed on the dust core around which the copper wire was wound, which was left in an atmosphere of 250 ° C. for 1000 hours. After the heating test, the core loss Pc 1 (unit: kW / m 3 ) was measured under the above conditions. Based on the following formula, the core loss change rate ΔPc (unit:%) was calculated.
ΔPc = (Pc 1 −Pc 0 ) / Pc 0 × 100
　コアロスの測定結果およびコアロスの変化率を、空孔の存在密度とともに、表２に示す。 The measurement results of core loss and the rate of change of core loss are shown in Table 2 together with the density of holes.
Figure JPOXMLDOC01-appb-T000002
Figure JPOXMLDOC01-appb-T000002
　表２に示されるように、空孔が存在し、その存在密度が１．０個／μｍ以上である実施例１に係る圧粉コアは、コアロスの変化率ΔＰｃが小さく、耐熱性に優れる。これに対し、空孔の存在密度が０個／μｍであって間隙領域が空孔を備えないと判定された比較例１、２に係る圧粉コアは、コアロスの変化率ΔＰｃが大きく、耐熱性に劣り、コアロス自体も実施例１に比較して高い値となっている。 As shown in Table 2, the dust core according to Example 1 having pores and a density of 1.0 / μm or more has a small core loss change rate ΔPc and is excellent in heat resistance. On the other hand, the dust cores according to Comparative Examples 1 and 2 in which the existence density of vacancies was 0 / μm and the gap region was determined not to have vacancies had a large core loss change rate ΔPc, and were heat resistant. The core loss itself is higher than that of Example 1.
　このように、実施例１の圧粉コアのΔＰｃが小さくなっているのは、空孔の存在により、加熱に伴って生じた圧粉コア内の軟磁性粉末に生じた応力が適切に緩和され、軟磁性粉末に歪が蓄積しにくくなったことが原因と考えられる。また、理由は定かではないが、軟磁性粉末やリン酸ガラスに存在するＰによって、大気中の熱処理時に樹脂系材料における空孔の生成が助長されたものと推察される。 As described above, the ΔPc of the dust core of Example 1 is reduced because the stress generated in the soft magnetic powder in the dust core caused by heating is appropriately relieved due to the presence of pores. This is considered to be because the strain is less likely to accumulate in the soft magnetic powder. Further, although the reason is not clear, it is presumed that the generation of pores in the resin-based material was promoted by P present in the soft magnetic powder or phosphate glass during heat treatment in the atmosphere.
　本発明の圧粉コアは、電源スイッチング回路、電圧昇降回路、平滑回路等を備えた電源装置、特に車載用途の電源装置や、小型携帯通信機器等として好適である。 The dust core of the present invention is suitable as a power supply device including a power supply switching circuit, a voltage raising / lowering circuit, a smoothing circuit, and the like, particularly a power supply device for in-vehicle use, a small portable communication device, and the like.
１…圧粉コア
Ｍ，Ｍ１，Ｍ２…軟磁性粉末
Ｒ…樹脂系材料
Ｇ…間隙領域
Ｃ…空孔
１０…トロイダルコア
２…被覆導電線
２ａ…コイル
２ｂ，２ｃ…被覆導電線２の端部
２ｄ，２ｅ…コイル２ａの端部
２０…インダクタンス素子
３…圧粉コア
３ａ…圧粉コア３の実装面
３ｂ，３ｃ…圧粉コア３の側面
４…端子部
５…空芯コイル
５ａ…空芯コイル５の巻回部
５ｂ…空芯コイル５の引出端部
３０…収納凹部
４０…接続端部
４２ａ…第１曲折部
４２ｂ…第２曲折部
１００…実装基板
１１０…ランド部
１２０…半田層 DESCRIPTION OF SYMBOLS 1 ... Powder core M, M1, M2 ... Soft-magnetic powder R ... Resin-type material G ... Gap area | region C ... Hole 10 ... Toroidal core 2 ... Coated conductive wire 2a ... Coil 2b, 2c ... End of coated conductive wire 2 2d, 2e ... end 20 of coil 2a ... inductance element 3 ... dust core 3a ... mounting surface 3b, 3c ... side of dust core 3 ... terminal part 5 ... air core coil 5a ... air core Winding portion 5b of coil 5 ... Drawing end portion 30 of air-core coil 5 ... Storage recess 40 ... Connection end portion 42a ... First bent portion 42b ... Second bent portion 100 ... Mounting substrate 110 ... Land portion 120 ... Solder layer

Claims (12)

  1. 　軟磁性粉末と、絶縁性の樹脂系材料とを備える圧粉コアであって、
    　前記樹脂系材料を与える樹脂はアクリル系樹脂を含有し、
    　前記圧粉コアにおける、隣り合う２つの前記軟磁性粉末が作る間隙の少なくとも一部に前記樹脂系材料が充填されてなる間隙領域は、前記２つの軟磁性粉末の離間距離が３０ｎｍ以下であるものを有し、
    　前記離間距離が３０ｎｍ以下の間隙領域内に、前記樹脂系材料が部分的に充填されていないことによって画成される空孔を備えること
    を特徴とする圧粉コア。     A dust core comprising soft magnetic powder and an insulating resin material,
    The resin that gives the resin material contains an acrylic resin,
    In the powder core, a gap region in which at least a part of a gap formed by two adjacent soft magnetic powders is filled with the resin-based material has a distance between the two soft magnetic powders of 30 nm or less. Have
    A dust core comprising pores defined by not being partially filled with the resin-based material in a gap region having a separation distance of 30 nm or less.
  2. 　前記空孔の存在密度は、前記間隙領域の断面観察に基づく測定により得られた値として、１．０個／μｍ以上である、請求項１に記載の圧粉コア。 2. The dust core according to claim 1, wherein the existence density of the pores is 1.0 piece / μm or more as a value obtained by measurement based on cross-sectional observation of the gap region.
  3. 　Ｐを含有する、請求項１または２に記載の圧粉コア。 The powder core according to claim 1 or 2, containing P.
  4. 　前記軟磁性粉末はＰを含有する、請求項１から３のいずれか一項に記載の圧粉コア。 The powder core according to any one of claims 1 to 3, wherein the soft magnetic powder contains P.
  5. 　前記軟磁性粉末は非晶質からなる部分を有する、請求項１から４のいずれか一項に記載の圧粉コア。 The powder core according to any one of claims 1 to 4, wherein the soft magnetic powder has an amorphous part.
  6. 　前記軟磁性粉末は、Ｆｅ基非晶質合金であって、Ｎｉを０原子％以上１０原子％以下、Ｓｎを０原子％以上３原子％以下、Ｃｒを０原子％以上６原子％以下、Ｐを３．０原子％以上１１原子％以下、Ｃを１．０原子％以上１０原子％以下、Ｂを０原子％以上９原子％以下、およびＳｉを０原子％以上６原子％以下含有する、請求項１から５のいずれか一項に記載の圧粉コア。 The soft magnetic powder is an Fe-based amorphous alloy, Ni is 0 atomic% to 10 atomic%, Sn is 0 atomic% to 3 atomic%, Cr is 0 atomic% to 6 atomic%, P 3.0 atomic% to 11 atomic%, C 1.0 atomic% to 10 atomic%, B 0 atomic% to 9 atomic%, and Si 0 atomic% to 6 atomic%, The powder core according to any one of claims 1 to 5.
  7. 　前記圧粉コアは、前記軟磁性粉末および樹脂を含有する組成物を加圧成形して成形体を得て、得られた前記成形体を加熱することにより得られたものである、請求項１から６のいずれか一項に記載の圧粉コア。 The said powder core is obtained by press-molding the composition containing the said soft-magnetic powder and resin, obtaining a molded object, and heating the obtained said molded object. To the powder core according to any one of 6 to 6.
  8. 　前記成形体の加熱は、酸化性雰囲気での加熱およびその後の非酸化性雰囲気での加熱を含む、請求項７に記載の圧粉コア。 The powder core according to claim 7, wherein the heating of the compact includes heating in an oxidizing atmosphere and subsequent heating in a non-oxidizing atmosphere.
  9. 　前記組成物は無機系成分を含有する、請求項７または８に記載の圧粉コア。 The powder core according to claim 7 or 8, wherein the composition contains an inorganic component.
  10. 　前記無機系成分はＰを含有する、請求項９に記載の圧粉コア。 The powder core according to claim 9, wherein the inorganic component contains P.
  11. 　請求項１から１０のいずれかに記載される圧粉コア、コイルおよび前記コイルのそれぞれの端部に接続された接続端子を備える電気・電子部品であって、前記圧粉コアの少なくとも一部は、前記接続端子を介して前記コイルに電流を流したときに前記電流により生じた誘導磁界内に位置するように配置されている電気・電子部品。 An electric / electronic component comprising a dust core, a coil, and a connection terminal connected to each end of the coil according to any one of claims 1 to 10, wherein at least a part of the dust core is An electric / electronic component arranged so as to be located in an induced magnetic field generated by the current when a current is passed through the coil via the connection terminal.
  12. 　請求項１１に記載される電気・電子部品が実装された電気・電子機器であって、前記電気・電子部品は前記接続端子にて基板に接続されている電気・電子機器。 12. An electric / electronic device in which the electric / electronic component according to claim 11 is mounted, wherein the electric / electronic component is connected to a substrate by the connection terminal.
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