WO2020171178A1 - 圧粉磁心およびその製造方法 - Google Patents
圧粉磁心およびその製造方法 Download PDFInfo
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- WO2020171178A1 WO2020171178A1 PCT/JP2020/006874 JP2020006874W WO2020171178A1 WO 2020171178 A1 WO2020171178 A1 WO 2020171178A1 JP 2020006874 W JP2020006874 W JP 2020006874W WO 2020171178 A1 WO2020171178 A1 WO 2020171178A1
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- temperature
- magnetic powder
- heat treatment
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- powder
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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
- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/35—Iron
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
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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
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
Definitions
- the present invention relates to a dust core and a manufacturing method thereof.
- a silicone resin is used as an insulating binder when forming the dust core, and when molding or By performing a heat treatment at about 700° C. after molding, the silicone resin in the molded product may be converted to SiO 2 (Patent Document 1).
- the thickness of the oxygen-containing region of the magnetic powder may be preferably 30 nm or less, and more preferably 25 nm or less.
- the present invention provides, as another aspect, a method for manufacturing the above dust core.
- the manufacturing method includes a mixing step of obtaining a mixed powder body containing magnetic powder of an Fe-based Cr-containing amorphous alloy and an organic binder, a molding step of press-molding the mixed powder body to obtain a molded product, and A heat treatment step is provided that includes a strain removal heat treatment for removing strain of the molded product by setting the temperature of the atmosphere to a strain removal temperature that is the strain removal processing temperature of the molded product.
- the heat treatment step includes a first heat treatment and a second heat treatment that is performed subsequent to the first heat treatment.
- the atmosphere in the first heat treatment, it may be preferable to make the atmosphere non-oxidizing during the temperature rising process to the first temperature. Specifically, if the molded product at room temperature level is placed in a heating means such as a heating furnace, and the atmosphere is made non-oxidizing and the molded product is heated to the first temperature in the placed state, The heat treatment process can be simplified.
- the atmosphere non-oxidizing in the cooling process from the strain removal temperature. Even in the cooling process from the de-straining temperature, oxidation of the magnetic powder can occur if the atmosphere is oxidizing. Therefore, when the oxide film is properly formed in the first heat treatment, the state of the appropriately formed oxide film can be maintained by setting the cooling process in the non-oxidizing atmosphere.
- the first temperature may be a strain relief temperature.
- the strain removal heat treatment, the first heat treatment, and the simple temperature control of raising the temperature up to the first temperature (de straining temperature), maintaining the temperature for a predetermined time, and then cooling are performed.
- a second heat treatment can be performed.
- the first temperature may be different from the strain relief temperature.
- a first heat treatment for reaching a first temperature in a non-oxidizing atmosphere, and a second heat treatment for oxidizing an atmosphere in a temperature range including the first temperature are followed by an atmosphere.
- the temperature of (1) may be changed to the strain removal temperature and the atmosphere at the strain removal temperature may be made non-oxidizing to perform the strain removal heat treatment. Even if the optimum temperature is different from the viewpoint of forming a uniform thin oxide film on the surface of the magnetic powder as a passive film and the optimum temperature from the viewpoint of removing the strain of the magnetic powder, the temperature and atmosphere By controlling, the strain of the magnetic powder can be appropriately removed while forming an appropriate oxide film.
- a highly heat-resistant dust core with low loss and high initial permeability is provided.
- the present invention also provides a method for producing a dust core having such excellent magnetic properties.
- FIG. 5 is a diagram showing a profile of a heat treatment process of Example 1.
- FIG. 6 is a diagram showing a profile of a heat treatment process of Example 2.
- FIG. 8 is a diagram showing a profile of a heat treatment process of Example 3.
- 8 is a diagram showing a profile of a heat treatment process of Comparative Example 2.
- FIG. 5 is a graph showing a depth profile of Fe, C, and O (oxygen) concentrations in the magnetic powder of the dust core manufactured according to Comparative Example 1.
- 7 is a graph showing depth profiles of O/Fe ratio, C/O ratio, bulk Cr ratio, and bulk Si ratio in the magnetic powder of the dust core manufactured according to Example 3.
- 7 is a graph showing depth profiles of O/Fe ratio, C/O ratio, bulk Cr ratio, and bulk Si ratio in the magnetic powder of the dust core produced in Comparative Example 2.
- 9 is a graph showing the depth profile of the bulk C ratio in the magnetic powder of the dust core produced in Comparative Example 1.
- 5 is a graph showing the depth profile of the bulk C ratio in the magnetic powder of the dust core manufactured according to Example 1.
- 9 is a graph showing a depth profile of the bulk C ratio in the magnetic powder of the dust core manufactured according to Example 2.
- 9 is a graph showing the depth profile of the bulk C ratio in the magnetic powder of the dust core manufactured according to Example 3.
- 9 is a graph showing the depth profile of the bulk C ratio in the magnetic powder of the dust core produced in Comparative Example 2. It is a graph which shows the relationship between the thickness of an oxide film and elapsed time. It is a graph which shows the relationship between the increase rate of iron loss Pcv and elapsed time.
- amorphous means that a general X-ray diffraction measurement cannot obtain a diffraction spectrum having a clear peak to the extent that the type of material can be specified.
- Specific examples of the amorphous alloy include Fe—Si—B alloys, Fe—PC alloys and Co—Fe—Si—B alloys.
- the amorphous magnetic material usually contains an amorphizing element that promotes amorphization in addition to the magnetic element. Examples of the amorphizing element in the Fe-based alloy include non-metal or metalloid elements such as Si, B, P and C, and metal elements such as Ti and Nb may also contribute to amorphization.
- the Fe-based Cr-containing amorphous alloy may be composed of one kind of material, or may be composed of plural kinds of materials.
- the Fe-based Cr-containing amorphous alloy is preferably one or more materials selected from the group consisting of the above-mentioned materials, and among these, Fe-PC alloys are preferably contained. Preferably, it is made of an Fe-PC alloy.
- the alloy composition will be described below by taking the case where the Fe-based Cr-containing amorphous alloy is an Fe-PC system alloy containing P and C as a specific example.
- the composition formula is represented by Fe 100 atomic% -abcxyzt Ni a Sn b Cr c P x C y B z Si t, 0 atomic% ⁇ a ⁇ 10 atomic%, 0 atomic% ⁇ b ⁇ 3 atomic%, 0 atomic% ⁇ c ⁇ 6 atomic%, 0 atomic% ⁇ x ⁇ 13 atomic%, 0 atomic% ⁇ y ⁇ 13 atomic%, 0 atomic% ⁇ z ⁇ 9 atomic%, An Fe-based amorphous alloy in which 0 atomic% ⁇ t ⁇ 7 atomic% is included.
- Ni, Sn, Cr, B and Si are optional additive elements.
- the added amount a of Ni is preferably 0 atom% or more and 6 atom% or less, and more preferably 0 atom% or more and 4 atom% or less.
- the addition amount b of Sn is preferably 0 atom% or more and 2 atom% or less, and may be added in the range of 1 atom% or more and 2 atom% or less.
- the addition amount c of Cr is preferably more than 0 atomic% and 2 atomic% or less, and more preferably 1 atomic% or more and 2 atomic% or less.
- the added amount x of P is preferably 6.8 atom% or more, and more preferably 8.8 atom% or more.
- the Fe-based Cr-containing amorphous alloy includes Co, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Mn, Re, platinum group elements, Au, Ag, Cu, Zn, It may contain an arbitrary element consisting of one or more selected from the group consisting of In, As, Sb, Bi, S, Y, N, O, and a rare earth element.
- the Fe-based Cr-containing amorphous alloy may contain inevitable impurities in addition to the above elements.
- FIG. 1 is a conceptual diagram for explaining the structure of magnetic powder contained in a dust core according to an embodiment of the present invention.
- an oxide film OC is formed on the surface of an alloy portion AP made of an Fe-based Cr-containing amorphous alloy, and at the same time, on the surface of the magnetic powder MP.
- the organic binding substance (binder BP) is attached. Since the Fe-based Cr-containing amorphous alloy forming the magnetic powder MP contains Cr, the oxide film OC formed on the surface of the magnetic powder MP is uniform, thin and stable, and becomes a passive film. It is believed that Therefore, even if the magnetic powder MPs are adjacent to each other and come into contact with each other in the dust core, the magnetic powders MPs can maintain the insulating state based on the oxide film OC.
- the first heat treatment described below is performed, whereby elements such as Cr in the amorphous alloy are concentrated on the surface and the passivation film is formed. It is formed.
- a second heat treatment for introducing oxygen forms a uniform oxide film as a passive film on the surface of the magnetic powder. Therefore, the iron loss Pcv of the dust core is unlikely to increase, and further, even if the dust core is placed in a high temperature environment, the increase of the iron loss Pcv can be suppressed. Further, since the organic binder is attached to the surface of the magnetic powder, the dust core, which is an aggregate of the magnetic powder, can maintain its shape.
- the amount of the organic binding substance that adheres to the surface of the magnetic powder is appropriate, the distance between adjacent magnetic powders does not become excessive. As a result, it is difficult to reduce the initial magnetic permeability of the dust core, and the increase in iron loss Pcv is also suppressed.
- the organic binder substance of the magnetic powder is preferably a component based on a polymer material, from the viewpoint of appropriately having a function of binding the magnetic powder.
- a polymer material resin
- polyvinyl alcohol (PVA) acrylic resin
- silicone resin polypropylene
- chlorinated polyethylene polyethylene
- EPDM ethylene propylene diene terpolymer
- chloroprene polyurethane
- vinyl chloride saturated
- polyester, nitrile resin, epoxy resin, phenol resin, urea resin and melamine resin When no treatment including heating is performed in the manufacturing process of the dust core, it is expected that a part of the polymer material remains as it is in the dust core and functions as an organic binder.
- the above-mentioned polymer material is denatured/decomposed by heat to become a component based on the polymer material, and the powder compact It remains in the magnetic core. At least a part of the component based on the polymer material can also function as the organic binder.
- the degree of formation of an oxide film in the magnetic powder contained in such a dust core and the degree of the organic binding substance adhering to the surface of the magnetic powder are quantitatively determined by using the depth profile, as described below. Can be evaluated.
- the depth profile means the result obtained by measuring the depth dependence of the composition from the surface side of the magnetic powder.
- Depth profile can be obtained by analyzing the composition of the surface by surface analysis equipment such as Auger electron spectrometer, photoelectron spectrometer, secondary ion mass spectrometer, etc. in combination with the removal process of the measured surface by sputtering. You can
- the depth profile of the magnetic powder of the dust core has the following features.
- An oxygen-containing region having a ratio (O/Fe ratio) of O concentration (unit: atomic%) to Fe concentration (unit: atomic%) of 0.1 or more can be defined from the surface of the magnetic powder, The oxygen-containing region has a depth from the surface of the magnetic powder of 35 nm or less.
- a carbon-containing region having a ratio of C concentration (unit: atomic %) to O concentration (C/O ratio) of 1 or more can be defined from the surface of the magnetic powder. The depth from the surface is 5 nm or less.
- the oxygen-containing region has a portion where the ratio (bulk Cr ratio) of the Cr concentration (unit: atomic %) to the Cr content (unit: atomic %) in the alloy composition of the magnetic powder exceeds 1.
- the O/Fe ratio is an index showing the degree of oxidation of the magnetic powder at that depth.
- the O concentration in the depth profile also represents the degree of oxidation of the magnetic powder.
- the O concentration value is not used for evaluation, and other O concentration values may be used.
- the magnetic powder is an Fe-based alloy, Fe is suitable as a reference element for obtaining this relative value.
- the Fe concentration decreases due to the oxidation of the magnetic powder, the O/Fe ratio is suitable as a parameter for evaluating the degree of oxidation.
- a region having an O/Fe ratio of 0.1 or more in the depth profile can be defined as an oxygen-containing region.
- this oxygen-containing region it may be considered that the magnetic powder is oxidized to form an oxide film.
- the oxide film formed on the surface of the magnetic powder can function as an insulating layer between adjacent magnetic powders that are in contact with each other. Therefore, when the oxygen-containing region can be defined from the surface of the magnetic powder, it can be said that the magnetic powder has an appropriate insulating layer on the surface. As a result, the magnetic characteristics of the dust core including the magnetic powder are improved, and the iron loss Pcv is particularly reduced.
- the depth resolution of the depth profile is determined by the measurement conditions and the sputtering conditions.
- the resolution is It becomes about 1 nm. Therefore, it can be said that the lower limit of the depth of the oxygen-containing region from the surface of the magnetic powder (may be referred to as “thickness” in this specification) is about 1 nm.
- the thickness of the oxygen-containing region of the magnetic powder exceeds 35 nm, the uniformity of the oxide film formed into a passivation film on the surface of the magnetic powder tends to decrease.
- the thickness of the oxygen-containing region of the magnetic powder may be preferably 30 nm or less, and more preferably 25 nm or less.
- the lower limit of the thickness of the oxygen-containing region of the magnetic powder is preferably 5 nm or more.
- the magnetic powder of the dust core according to the present embodiment is formed from an Fe-based Cr-containing amorphous alloy, and Cr contained in this alloy is concentrated in the oxide film on the surface of the magnetic powder and is in a passive state. It contributes to the formation of a uniform oxide film formed into a film.
- the oxygen-containing region has a portion where the ratio of the Cr concentration to the Cr content (bulk Cr ratio) in the alloy composition of the magnetic powder exceeds 1. If the bulk Cr ratio is more than 1 in almost all of the oxygen-containing region, it can be considered that the oxide film formed on the surface of the magnetic powder is particularly uniform. It should be noted that, on the very surface of the magnetic powder, the Cr concentration may apparently decrease due to the influence of the attached organic matter.
- the C concentration in the depth profile is affected by the amount of the organic binder that adheres to the surface of the magnetic powder, how much the organic binder adheres to the surface of the magnetic powder depending on the magnitude of the C concentration. Information can be obtained.
- C is an element having relatively low quantitativeness. Therefore, the abundance of carbon is evaluated on the basis of the abundance of oxygen constituting the oxide film located on the measurement surface, specifically, the C/O ratio is evaluated, and thus the value of the C concentration is evaluated. It becomes possible to quantitatively evaluate the amount of the organic binding substance present on the measurement surface rather than the case.
- the C/O ratio of 1 or more means that carbon equivalent to or more than oxygen forming the oxide film exists on the measurement surface.
- the powder magnetic core according to the embodiment of the present invention may be manufactured by any method as long as it has the above configuration. By adopting the manufacturing method described below, it is possible to efficiently manufacture the dust core according to the embodiment of the present invention with good reproducibility.
- the mixed powder may contain an inorganic component. Glass powder is illustrated as a specific example of the inorganic component.
- the mixed powder may further contain a lubricant, a coupling agent, an insulating filler such as silica, a flame retardant, and the like.
- the heat treatment step has a strain removal heat treatment for removing the strain of the molded product by setting the temperature of the atmosphere to the strain removal temperature which is the strain removal processing temperature of the molded product formed by the above molding process. Since the molded product is subjected to pressure in the unit of GPa from the sub-GPa in the above-mentioned molding step, strain remains inside. Since this distortion causes an increase in magnetic properties, particularly iron loss Pcv, the distortion of the molded product is taken by setting the temperature of the atmosphere of the molded product to the strain removal temperature.
- the means for setting the temperature of the atmosphere to the strain removal temperature is not limited.
- the molded product may be placed in the furnace to heat the atmosphere in the furnace, or the molded product atmosphere may be heated by directly heating the molded product by induction heating or the like.
- the atmosphere may be preferable to make the atmosphere non-oxidizing in the cooling process from the strain removal temperature. Even in the cooling process from the de-straining temperature, if the atmosphere is oxidizing, the magnetic powder may be oxidized and the organic binder may be decomposed by oxidation. Therefore, when the oxide film is properly formed in the first heat treatment, the state of the appropriately formed oxide film can be maintained by setting the cooling process in the non-oxidizing atmosphere. In addition, this cooling process may function as a part of the strain relief heat treatment.
- An electronic component according to an embodiment of the present invention is a dust core manufactured by the method for manufacturing a dust core according to the above embodiment of the present invention, a coil, and a connection connected to each end of the coil. It has a terminal.
- at least a part of the dust core is arranged so as to be located in an induction magnetic field generated by the current when a current is applied to the coil through the connection terminal.
- An electric/electronic device is an electric/electronic component mounted with 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 supply switching circuit, a voltage raising/lowering circuit, a smoothing circuit, and a small portable communication device.
- Example 2 The molded product obtained by carrying out the same mixing step and molding step as in Example 1 was subjected to a heat treatment step as shown in Table 6 and FIG. 10 in the same equipment as in Example 1.
- FIG. 10 is a diagram showing a profile of the heat treatment process of Comparative Example 2.
- the thickness (unit: nm) of the oxygen-containing region and the thickness (unit: nm) of the carbon-containing region were measured based on the depth profile shown in FIGS. 26 to 30. The results are shown in Table 7.
- the thickness of the oxygen-containing region is the thickness of the region in which the ratio (O/Fe ratio) of the O concentration (unit: atomic %) to the Fe concentration (unit: atomic %) is 0.1 or more.
- the thickness of the containing region was measured by defining the thickness of the region where the ratio of the C concentration (unit: atomic %) to the O concentration (C/O ratio) was 1 or more.
- the oxygen-containing region in the depth profile of the magnetic powder according to the example including the first heat treatment and the second heat treatment in the heat treatment step, the oxygen-containing region can be defined, and the thickness thereof is 35 nm or less. Met. Specifically, the thickness of the oxygen-containing region can be defined as 31 nm or less, 23 nm or less, or 12 nm or less from Examples 1 to 3. On the other hand, in the depth profile according to the example, the carbon-containing region can be defined, and the thickness was 5 nm or less. Specifically, from Example 1 to Example 3, it was 2 nm or less, and sometimes 1 nm or less.
- Table 7 shows the measurement results of the carbon concentration region.
- the carbon enriched region could be defined, but in Comparative Example 1, the thickness of the carbon enriched region was large and exceeded 50 nm. In all other cases, the thickness of the carbon-rich region was 2 nm or less or 1 nm or less.
- Test Example 3 Measurement of iron loss A toroidal coil obtained by winding a coated copper wire around the dust core manufactured in the example 40 times on the primary side and 10 times on the secondary side, respectively, was measured by a BH analyzer (Iwasaki Tsushinkisha Co., Ltd.). Manufactured by "SY-8218"), the iron loss (unit: kW/m 3 ) was measured at a measurement frequency of 100 kHz under the condition that the effective maximum magnetic flux density Bm was 100 mT. The results are shown in Table 7. As shown in Table 7, the iron loss Pcv of the toroidal coils according to Examples 1 to 3 was lower than the iron loss Pcv of the toroidal coils according to Comparative Example 1 and Comparative Example 2.
- the thickness of the oxide film does not particularly increase even if the elapsed time increases, but in the dust core according to Comparative Example 1, the thickness of the oxide film is large. It was confirmed that there was a tendency to increase with increasing elapsed time. In the dust core according to Example 1 in which the thickness of the oxide film does not substantially change, it is expected that the magnetic characteristics are unlikely to change even when placed in a high temperature environment.
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Abstract
Description
照射イオン:Bi3+
加速電圧:25keV
照射電流:0.3pA
照射モード:バンチングモード
(1)O濃度(単位:原子%)のFe濃度(単位:原子%)に対する比(本明細書において「O/Fe比」ともいう。)が0.1以上である酸素含有領域を磁性粉末の表面から定義可能であって、酸素含有領域は、磁性粉末の表面からの深さが35nm以下である。
(2)C濃度(単位:原子%)のO濃度に対する比(本明細書において「C/O比」ともいう。)が1以上である炭素含有領域を磁性粉末の表面から定義可能であって、炭素含有領域は、磁性粉末の表面からの深さが5nm以下である。
(3)酸素含有領域は、磁性粉末の合金組成におけるCr含有量(単位:原子%)に対するCr濃度(単位:原子%)の比(本明細書において「バルクCr比」ともいう。)が1を超える部分(本明細書において「Cr濃化部」ともいう。)を有する。
(1)O濃度(単位:原子%)のFe濃度(単位:原子%)に対する比(O/Fe比)が0.1以上である酸素含有領域を磁性粉末の表面から定義可能であって、酸素含有領域は、磁性粉末の表面からの深さが35nm以下である。
(2)C濃度(単位:原子%)のO濃度に対する比(C/O比)が1以上である炭素含有領域を磁性粉末の表面から定義可能であって、炭素含有領域は、磁性粉末の表面からの深さが5nm以下である。
(3)酸素含有領域は、磁性粉末の合金組成におけるCr含有量(単位:原子%)に対するCr濃度(単位:原子%)の比(バルクCr比)が1を超える部分を有する。
次の組成のFe基合金組成物を溶製し、ガスアトマイズ法により粉体からなる軟磁性材料(磁性粉末)を得た。
Fe:77.9原子%
Cr:1原子%
P:7.3原子%
C:2.2原子%
B:7.7原子%
Si:3.9原子%
その他不可避的不純物
上記の磁性粉末および下記表1に示される他の成分を混合してスラリーを得た。なお、アクリル樹脂の熱分解温度は360℃程度であった。
得られた混合粉末体を金型キャビティ内に入れ、成形圧力を1.8GPaとする圧粉成形を行った。こうして、図2に示されるような外観を有するトロイダルコア(外径:20mm、内径:12.75mm、厚さ:6.8mm)の形状を有する成形製造物を得た。
得られた成形製造物をイナートガスオーブンに投入し、炉内に供給する窒素中に大気を混合させることによって炉内雰囲気の酸素濃度を調整可能として、表2および図6に示されるように雰囲気の温度および酸素濃度を制御した。図6は、比較例1の熱処理工程のプロファイルを示す図である。まず、酸素濃度が0体積%の状態を維持して、炉内温度を20℃から第1の温度である360℃まで85分間かけて昇温する第1の熱処理を行った。その後、酸素濃度が0体積%の状態のまま、炉内温度を360℃で3時間保持した。続いて、酸素濃度が0体積%の状態のまま、20分間かけて炉内温度を除歪温度である440℃まで上昇させた。酸素濃度が0体積%の状態のまま、炉内温度を440℃として1時間保持し、その後、酸素濃度が0体積%の状態のまま、炉内温度を25℃まで3時間かけて冷却した。こうして、トロイダルコアの形状を有する圧粉磁心を得た。
比較例1と同じ混合工程および成形工程を実施して得られた成形製造物について、比較例1の場合と同じ設備で、表3および図7に示されるように熱処理工程を行った。図7は、実施例1の熱処理工程のプロファイルを示す図である。
実施例1と同じ混合工程および成形工程を実施して得られた成形製造物について、実施例1の場合と同じ設備で、表4および図8に示されるように熱処理工程を行った。図8は、実施例2の熱処理工程のプロファイルを示す図である。
実施例1と同じ混合工程および成形工程を実施して得られた成形製造物について、実施例1の場合と同じ設備で、表5および図9に示されるように熱処理工程を行った。図9は、実施例3の熱処理工程のプロファイルを示す図である。
実施例1と同じ混合工程および成形工程を実施して得られた成形製造物について、実施例1の場合と同じ設備で、表6および図10に示されるように熱処理工程を行った。図10は、比較例2の熱処理工程のプロファイルを示す図である。
実施例および比較例において作製した圧粉磁心の磁性粉末について、オージェ電子分光装置(日本電子株式会社製「JAMP-7830F」)を用いて、測定面をアルゴンによりスパッタリングしながら表面分析を行うことにより、深さプロファイルを測定した。測定領域は、直径1μmの円形であった。測定結果を図11から図25に示す。
A:酸素含有領域のほぼ全域がCr濃化部であった。
B:酸素含有領域のごく表面部以外にもCr濃化部を定義できない部分があった。
A:酸素含有領域のほぼ全域をSi濃化部と定義することができた。
B:酸素含有領域の一部をSi濃化部と定義することができた。
C:酸素含有領域のほぼ全域についてSi濃化部を定義できなかった。
実施例において作製した圧粉磁心に被覆銅線を34回巻いて得られたトロイダルコイルについて、インピーダンスアナライザー(HP社製「42841A」)を用いて、100kHzの条件で、初透磁率μ'を測定した。結果を表7に示した。表7に示されるように、実施例1の初透磁率μ'は比較例1および比較例2の初透磁率μ'よりも高くなっていることがわかる。一方、実施例2および実施例3の初透磁率μ'は比較例1と比較してやや低いが同等レベルであった。また、実施例2および実施例3の初透磁率μ'は、比較例2の初透磁率μ'よりも高くなった。
実施例において作製した圧粉磁心に被覆銅線をそれぞれ1次側40回、2次側10回巻いて得られたトロイダルコイルについて、BHアナライザー(岩崎通信機社製「SY-8218」)を用いて、実効最大磁束密度Bmを100mTとする条件で、測定周波数100kHzで鉄損(単位:kW/m3)を測定した。その結果を表7に示した。表7に示されるように、実施例1から実施例3に係るトロイダルコイルの鉄損Pcvは、比較例1および比較例2に係るトロイダルコイルの鉄損Pcvよりも低くなった。
実施例1に係る圧粉磁心および比較例1に係る圧粉磁心を、250℃の高温環境(大気中)に放置する耐熱試験を行った。高温環境に置いてからの経過時間を複数設定して、それぞれの試験後の圧粉磁心について、酸素濃度の深さプロファイルを測定した。深さプロファイルにおいて、酸素のピーク濃度の50%となる濃度の深さを、酸化被膜の厚さとした。酸化被膜の厚さと経過時間との関係を図36に示す。図36に示されるように、実施例1に係る圧粉磁心では、酸化被膜の厚さは経過時間が増えても特に増加しないが、比較例1に係る圧粉磁心では、酸化被膜の厚さについて、経過時間の増加とともに増加する傾向が確認された。酸化被膜の厚さがほぼ変化しない実施例1に係る圧粉磁心では、高温環境に置かれても磁気特性が変化しにくいと期待される。
表8に示されるFe基合金組成物を溶製し、ガスアトマイズ法により粉体からなる軟磁性材料(磁性粉末)を得た。
10…トロイダルコイル
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…EEコア
30…インダクタンス素子
20CL,21CL,22CL…中脚部
20OL,21OL,22OL…外脚部
21,22 :Eコア
21B,22B :底部
30 :インダクタンス素子
40 :コイル
MP :磁性粉末
AP :合金部分
OC :酸化被膜
BP :バインダー
Claims (9)
- Fe基Cr含有非晶質合金の磁性粉末および有機結着物質を含有する圧粉磁心であって、
前記圧粉磁心中の前記磁性粉末の表面側から組成の深さプロファイルを求めたときに、
O濃度(単位:原子%)のFe濃度(単位:原子%)に対する比が0.1以上である酸素含有領域を前記磁性粉末の表面から定義可能であって、前記酸素含有領域は、前記磁性粉末の表面からの深さが35nm以下であり、
C濃度(単位:原子%)の前記O濃度に対する比が1以上である炭素含有領域を前記磁性粉末の表面から定義可能であって、前記炭素含有領域は、前記磁性粉末の表面からの深さが5nm以下であり、
前記酸素含有領域は、前記磁性粉末の合金組成におけるCr含有量(単位:原子%)に対するCr濃度(単位:原子%)の比が1を超える部分を有することを特徴とする圧粉磁心。 - 前記酸素含有領域は、前記磁性粉末の合金組成におけるSi含有量(単位:原子%)に対するSi濃度(単位:原子%)の比が1を超える部分を有する、請求項1に記載の圧粉磁心。
- 前記深さプロファイルにおいて、
前記磁性粉末の合金組成におけるC含有量(単位:原子%)に対する前記C濃度の比が1を超える炭素濃化領域を前記磁性粉末の表面から定義可能であって、前記炭素濃化領域は、前記磁性粉末の表面からの深さが2nm以下である、請求項1または請求項2に記載の圧粉磁心。 - 前記Fe基Cr含有非晶質合金は、PおよびCを含有する、請求項1から請求項3のいずれか一項に記載の圧粉磁心。
- 請求項1から請求項4のいずれか一項に記載される圧粉磁心の製造方法であって、
Fe基Cr含有非晶質合金の磁性粉末と有機結着材とを含む混合粉末体を得る混合工程、
前記混合粉末体を加圧成形して成形製造物を得る成形工程、および
前記成形製造物の歪取り処理温度である除歪温度に雰囲気の温度を設定して前記成形製造物の歪みを取る除歪熱処理を有する熱処理工程を備え、
前記熱処理工程は、第1の熱処理と、当該第1の熱処理に引き続いて行われる第2の熱処理とを有し、
前記第1の熱処理では、前記有機結着材の熱分解温度以上前記除歪温度以下の第1の温度に到達するまで、前記雰囲気を非酸化性とし、
前記第2の熱処理では、前記第1の温度を含む温度域にある前記雰囲気を酸化性とすること
を特徴とする圧粉磁心の製造方法。 - 前記第1の熱処理では、前記第1の温度への昇温過程において、前記雰囲気を非酸化性とする、請求項5に記載の圧粉磁心の製造方法。
- 前記除歪温度からの冷却過程において、前記雰囲気を非酸化性とする、請求項5または請求項6に記載の圧粉磁心の製造方法。
- 前記第1の温度は、前記除歪温度である、請求項5から請求項7のいずれか一項に記載の圧粉磁心の製造方法。
- 前記第1の温度は前記除歪温度と異なる温度であって、前記第2の熱処理に続いて、前記雰囲気の温度を前記除歪温度に変更し、前記除歪温度にある前記雰囲気を非酸化性として前記除歪熱処理を行う、請求項5から請求項7のいずれか一項に記載の圧粉磁心の製造方法。
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