WO2016035478A1 - Noyau en poudre, composant électrique/électronique, et dispositif électrique/électronique - Google Patents

Noyau en poudre, composant électrique/électronique, et dispositif électrique/électronique 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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English (en)
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/ja
Publication of WO2016035478A1 publication Critical patent/WO2016035478A1/fr

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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.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Power Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Dispersion Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Electromagnetism (AREA)
  • Materials Engineering (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Soft Magnetic Materials (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention vise à fournir un noyau en poudre avec une excellente résistance à la chaleur, un composant électrique/électronique équipé de ce noyau en poudre, et un dispositif électrique/électronique dans lequel ce composant électrique/électronique est installé, ce noyau de poudre (1) étant équipé d'une poudre magnétique douce (M) et d'un matériau à base de résine isolante, ladite résine fournissant la matériau base de résine (R) contenant une résine acrylique. Dans le noyau de poudre (1) se situe une région interstitielle (G) dans laquelle le matériau à base de résine (R) remplit au moins une partie de l'espace créé entre deux poudres magnétiques douces (M1, M2) adjacentes, la distance de séparation entre les deux poudres magnétiques douces (M1, M2) étant inférieure ou égale à 30 nm, et dans la région interstitielle (G) dans laquelle la distance de séparation est inférieure ou égale à 30 nm, des vides (C) étant formés à l'endroit où le remplissage de la matière à base de résine (R) est incomplet.
PCT/JP2015/071230 2014-09-03 2015-07-27 Noyau en poudre, composant électrique/électronique, et dispositif électrique/électronique WO2016035478A1 (fr)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020171178A1 (fr) * 2019-02-22 2020-08-27 アルプスアルパイン株式会社 Noyau en poudre magnétique et procédé pour sa production
CN114728330A (zh) * 2019-09-26 2022-07-08 Tdk株式会社 软磁性金属粉末、软磁性金属烧成体及线圈型电子部件

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013026356A (ja) * 2011-07-19 2013-02-04 Taiyo Yuden Co Ltd 磁性材料およびそれを用いたコイル部品
JP2014033001A (ja) * 2012-08-01 2014-02-20 Alps Green Devices Co Ltd 複合磁性粉末及び前記複合磁性粉末を用いた圧粉磁心

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013026356A (ja) * 2011-07-19 2013-02-04 Taiyo Yuden Co Ltd 磁性材料およびそれを用いたコイル部品
JP2014033001A (ja) * 2012-08-01 2014-02-20 Alps Green Devices Co Ltd 複合磁性粉末及び前記複合磁性粉末を用いた圧粉磁心

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020171178A1 (fr) * 2019-02-22 2020-08-27 アルプスアルパイン株式会社 Noyau en poudre magnétique et procédé pour sa production
KR20210116611A (ko) * 2019-02-22 2021-09-27 알프스 알파인 가부시키가이샤 압분 자심 및 그 제조 방법
JPWO2020171178A1 (ja) * 2019-02-22 2021-11-18 アルプスアルパイン株式会社 圧粉磁心およびその製造方法
KR102636542B1 (ko) 2019-02-22 2024-02-15 알프스 알파인 가부시키가이샤 압분 자심 및 그 제조 방법
CN114728330A (zh) * 2019-09-26 2022-07-08 Tdk株式会社 软磁性金属粉末、软磁性金属烧成体及线圈型电子部件

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