Classifications

• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
  • B22F3/24—After-treatment of workpieces or articles
• • 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
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
  • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
  • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
  • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
  • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
  • H01F1/33—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials mixtures of metallic and non-metallic particles; metallic particles having oxide skin
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
  • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
  • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets

Definitions

• the present invention relates to a magnetic core and a method for manufacturing the magnetic core.
• coil components such as inductors, transformers, and chokes have been used in a wide variety of applications such as home appliances, industrial equipment, and vehicles, and the coil components are composed of coils laid on a magnetic core.
• Ferrites which have excellent magnetic characteristics, flexibility in shape, and cost, are widely used for such magnetic cores.
• a power supply device such as an electronic device has been downsized, and it has been required to be usable in various environments.
• a magnetic core using a metal-based soft magnetic material having a higher Curie temperature and a higher saturation magnetic flux density than that of a ferrite is being adopted.
• metal-based soft magnetic materials include magnetic particles such as 6 -3 1 system, 6 -1 ⁇ 11 system, 6 -3 1-8 1 system, 6- ⁇ "18 1 system alloy. ing.
• Patent Document 1 describes that a glass layer is provided on the surface of the magnetic core so as to prevent the adhesive from seeping into the minute gaps of the ferrite magnetic core.
• Patent Document 2 describes that the permeation-preventing material is filled in the pores of a dust core made of a metal-based soft magnetic material to prevent permeation of an adhesive or the like.
• Patent Document 1 Japanese Patent Laid-Open No. 201 1-01 4730
• Patent Document 2 Japanese Patent Laid-Open No. 201 3-045926 ⁇ 0 2020/175367 2 (: 17 2020/007040 Summary of invention
• Patent Document 1 and Patent Document 2 permeation of the adhesive is suppressed by performing a sealing treatment on the porous magnetic core.
• the shape of the magnetic core is complicated, and the existence amount of pores is likely to be biased due to the difference in density during molding, and the state of formation and filling of the film made of the penetration preventing material such as the glass layer are also likely to be different. Therefore, in some cases, the effect of penetration suppression could not be obtained sufficiently.
• an object of the present invention is to provide a magnetic core excellent in permeation suppression performance.
• At least a part of the surface has a coated surface coated with a siliceous coating, and the arithmetic mean curve (3 0 :I 3 0 2) of peaks on the coated surface is provided. 5 1 7 8)
• the following magnetic cores can be provided. According to this, it is possible to provide a magnetic core having an excellent permeation suppression performance.
• the magnetic core is composed of 6 _ 1 ⁇ /1 (IV! is a metal that is more easily oxidized than 6) alloy magnetic particles via an oxide derived from the magnetic particles. It preferably has a bonded structure.
• the siliceous film has a siloxane bond (3 I
• the oxide contains the IV!, and 1 ⁇ /1 contained in the oxide is at least one of eight and eight.
• an electrode formed on the coating surface it is preferable to have an electrode formed on the coating surface.
• At least a part of the magnetic core is covered with a siliceous film, and the arithmetic mean curve of the peaks (3 0: I 3 0 2 5 1 7 8)
• a step of forming a coated surface which is the following, a step of forming an electrode on the coated surface, ⁇ 0 2020/175367 3 (:171? 2020/007040
• the electrode can be formed on the coated surface having excellent permeation suppression performance, and the reliability and yield of the magnetic core can be expected to improve.
• the magnetic core is made of a 6 _ 1 ⁇ /1 (IV! is a metal that is more easily oxidized than 6) based alloy, and the magnetic particles are made of an oxide derived from the magnetic particles. It is preferable to have a structure in which they are bound via.
• the siliceous film includes a siloxane bond (one 3 I-0-3 I-bond).
• the oxide contains 1 ⁇ /1, and 1 ⁇ /1 contained in the oxide is at least one of eight and ten. ..
• the siliceous coating is preferably formed by performing the step of applying a treatment liquid for forming a siliceous coating on the surface of the magnetic core and curing it once or more.
• the present invention it is possible to provide a magnetic core having excellent permeation suppression performance, and it is possible to contribute to improvement in reliability and yield of the magnetic core. Further, according to the present invention, the electrode can be formed on the coated surface having an excellent permeation suppressing property, which can contribute to the improvement of the reliability and yield of the magnetic core.
• FIG. 1 A graph for explaining the relationship between the arithmetic mean curve (3: :I 3 0 2 5 1 7 8) of the peak of the coating surface coated with the siliceous film and the permeation suppression performance. is there.
• FIG. 2 This is a magnified 3M IV! image of the surface of a magnetic core not covered with a siliceous film.
• FIG. 3 This is an image of 3M IV! magnifying the coated surface of the magnetic core coated with a siliceous film.
• the magnetic core of the present embodiment is! ⁇ 1 Ceramic-based soft magnetic materials such as stainless steel ⁇ 02020/175367 4 (:171? 2020/007040
• the magnetic particles of the metal-based soft magnetic material described above are used as a porous material, and at least a part of the surface thereof is coated with a siliceous film.
• the arithmetic mean curve (3 ⁇ : 1 3025 1 78) of the peak of the coated surface is 37,000 or less, the surface of the coated surface becomes a gentle shape, and correspondingly, it is applied on the coated surface. It is possible to obtain a magnetic core in which the permeation suppression performance in which the permeation of an adhesive or the like is suppressed is improved.
• the arithmetic mean curve of mountain peaks (3: 1 3025 1 78), which three-dimensionally evaluates the surface properties of the coated surface, is specified in the International Standards Organization's ⁇ 3 025 1 78, and is measured by a measuring instrument such as a laser microscope described later. It is easily measurable.
• 1 3025 1 78 has other parameters for three-dimensional surface roughness, such as arithmetic average height 33, maximum height 32, aspect ratio 31: ", and expanded area ratio 3 ".
• the coated surface has a specific surface profile defined by the arithmetic mean curve of the peaks of the peaks, so that penetration suppression can be achieved.
• a magnetic core with excellent performance can be provided.
• the metallic soft magnetic material is preferably magnetic particles of a soft magnetic alloy containing, for example, 6 and the element IV! which is more easily oxidized than 6 .
• IV! (I and (The sum of 30 is 100 mass %, I is 3 mass% or more and 16.0 mass% or less,
• the sum of 6, IV! (eight I or ⁇ "), 3 ⁇ is 100 mass% and IV! is 1.5 mass% or more. It is preferably a soft magnetic alloy containing 8% by mass or less and 3% by more than 1% by mass and 7% by mass or less, with the balance being 6 and inevitable impurities.
• the amounts are 0 £ ⁇ .05 mass%, mass%, It is preferably 0% by mass, 3 £ ⁇ 0.02% by mass, 0 £ ⁇ 0.5% by mass, 1 ⁇ 1% £0.5% by mass, 1 ⁇ ! £0.1% by mass.
• even 3 g may be contained as unavoidable impurities in an amount of 0.5 mass% or less.
• the morphology of the magnetic particles of the soft magnetic alloy is not particularly limited, but, for example, from the viewpoint of fluidity and the like, it is easy to obtain relatively spherical particles from molten metal adjusted to have a predetermined composition. It is preferable to use magnetic particles produced by the method. Atomization methods such as gas atomization and water atomization have high malleability and ductility, and are suitable for producing magnetic particles of alloys that are difficult to grind.
• the average particle size of the magnetic particles (here, the median diameter in the cumulative particle size distribution
• Those having an average particle size of 100 or less can be used.
• dry classification such as sieving classification can be used, and it is preferable to obtain at least 32 under magnetic particles (that is, passed through a sieve having an opening of 32). Since the strength of the magnetic core, the magnetic core loss, and the high frequency characteristics are improved by reducing the average particle size, the average particle size (median diameter 50) is more preferably 15 or less. On the other hand, when the average particle size is small, the magnetic permeability is low, so the average particle size (median diameter 50) is more preferably 5 or more.
• the magnetic particles are preferably mixed with a binder and granulated to form granules.
• the fluidity and filling properties in the mold can be improved, and the magnetic particles are bound together during pressure molding, giving the molded body strength to withstand handling after molding. You can also do it.
• the kind of the binder is not particularly limited, for example, an organic binder such as polyethylene, polyvinyl alcohol or acrylic resin can be used. Inorganic binder that remains after heat treatment can be used together ⁇ 0 2020/175367 6 ⁇ (: 171? 2020/007040
• the addition amount of the binder may be such that the binder is sufficiently distributed between the magnetic particles and the strength of the molded body can be sufficiently secured. However, if the added amount of the binder is too large, the density of the molded body is increased. And strength tend to decrease. From this point of view, the amount of binder added is preferably 0.2 to 10 parts by weight, more preferably 0.5 to 3.0 parts by weight, based on 100 parts by weight of the magnetic particles. preferable.
• the mixing method of the magnetic particles and the binder is not particularly limited, and a conventionally known mixing method or mixer can be used.
• a conventionally known mixing method or mixer can be used.
• the granulation method for example, a wet granulation method such as rolling granulation or spray drying granulation can be adopted.
• spray-drying granulation using a spray dryer is preferable, and this allows the shape of the granules to be close to spherical and the exposure time to heated air to be short, so that a large amount of granules can be obtained.
• the obtained granules have a bulk density: ...! .5 ⁇ 2 .. Average particle size (
• 0 50 It is preferable that it is 60 to 150.
• Such granules have excellent fluidity at the time of molding, and the gaps between the magnetic particles are reduced to increase the filling property in the mold. As a result, the molded product has a high density and permeability. A high core can be obtained. Classification with a vibrating screen or the like can be used to obtain a desired granule size.
• a lubricant such as stearic acid or stearate.
• the addition amount of the lubricant is preferably 0.1 to 2.0 parts by weight with respect to 100 parts by weight of the magnetic particles.
• the lubricant can also be applied to the mold.
• the granules of magnetic particles are subjected to pressure molding.
• a press machine such as a hydraulic press or a servo press and a molding die are used to mold the mixed powder into a predetermined shape such as a toroidal shape or a rectangular parallelepiped shape.
• This pressure molding may be room temperature molding, or may be warm molding in which the granules are heated to a temperature near the glass transition temperature at which the binder softens, depending on the binder material, so that the binder does not disappear.
• the magnetic particles in the molded body obtained by the pressure molding are in point contact with each other. ⁇ 0 2020/175367 7 ⁇ (: 171? 2020 /007040
• the density of the compact is 5.6 X Is preferred.
• annealing is performed at a temperature of not less than 650° and not more than 900°. Annealing is performed in an atmosphere containing oxygen, such as in the air, in a mixed gas of oxygen and an inert gas, or in an atmosphere containing water vapor. Among them, heat treatment in the atmosphere is simple and preferable. Oxide is obtained by the reaction between magnetic particles and oxygen during heat treatment, and is generated by an oxidation reaction that exceeds the natural oxidation of magnetic particles. By generating such an oxide, a high-strength magnetic core having excellent insulating properties and corrosion resistance and firmly bonded as grain boundaries between a large number of magnetic particles can be obtained. Also, good magnetic properties can be obtained by relaxing the stress strain introduced by pressure molding.
• ⁇ O contained in the binder binds preferentially to I and 0 "in the vicinity of the surface of the magnetic particles, and is magnetic as a chemically stable I oxide or 0" oxide or a complex oxide with other non-ferrous metals. Formed on the surface of the particles By forming an oxide containing the element IV! on the surface of the magnetic particles, the corrosion resistance is excellent, and the insulating properties of the magnetic particles are enhanced to reduce eddy current loss.
• the space factor (relative density) is preferably in the range of 75 to 95%.
• the porosity of such a magnetic core is 5% to 25%.
• the space factor (relative density) is calculated by calculating the density of the magnetic core from its size and mass and dividing the obtained density of the magnetic core by the true density of the magnetic particles.
• the true density of magnetic particles the density of an ingot prepared by melting with the same composition may be used. ⁇ 0 2020/175367 8 ⁇ (: 171? 2020 /007040
• the siliceous film has a molecular structure with a main chain in which three circles and three circles are siloxane-bonded (one hundred three hundred thirteen).
• the siliceous film only needs to have a bond represented by (1 3 _ _ _ _ 3 _), and a bond represented by (1 3 _ 0 -) is repeatedly bonded. Is also good.
• a method of forming such a siliceous film on the surface of the magnetic core a low temperature method using a sol-gel method in which a sol of an alkoxysilane oligomer is subjected to a condensation reaction by hydrolysis to form a gel is preferable.
• the siliceous film is hardened by immersing the magnetic core in the treatment liquid for forming siliceous skin film containing the alkoxysilane oligomer solution and colloidal silica, or spraying the treatment liquid for forming siliceous film on the magnetic core, and then performing the curing treatment. It is preferably formed by
• the solvent of the treatment liquid for forming a siliceous coating is preferably a hydrophilic organic solvent such as an alcohol solvent or a glycol ether solvent.
• the siliceous coating itself has excellent heat resistance and high strength, and by covering the entire surface of the magnetic core, the corrosion resistance can be improved.
• the surface of the magnetic core is covered with the oxide film by the oxide of the magnetic particles, and this film has a state in which the metal element derived from the magnetic particle is combined with ⁇ , and the metal element is And a hydroxyl group ( ⁇ 1 to 1) are associated with each other.
• a chemical bond such as covalent bond or ionic bond between the hydroxyl group or oxide on the surface of the magnetic core and the hydroxyl group in the siliceous film, it is possible to enhance the adhesive force between the magnetic particles and the siliceous film. And the siliceous film can be brought into close contact with each other.
• a siliceous film is also formed in the pores inside the magnetic core that the treatment liquid for forming a siliceous film has spread through the gaps between the magnetic particles on the surface of the magnetic core.
• the siliceous film fills the pores inside the magnetic core, and the surface of the magnetic core (covering surface) forms a gentle shape due to the formation of the siliceous skin film.
• the arithmetic mean curve (3 0: ⁇ 3 0 2 5 1 7 8) of the peaks on the coated surface is 3 7 0 0 0 01 01 or less, a magnetic core with excellent permeation suppression performance can be obtained.
• the magnetic core is treated to form a siliceous film. ⁇ 0 2020/175367 9 ⁇ (: 171? 2020 /007040
• the method of applying the treatment liquid for forming the siliceous film onto the magnetic core may be any known method such as a dip spin coating method, a dip coating method, or a spray coating method, and is not particularly limited.
• the temperature may be adjusted to 100 to 200°° before coating.
• the curing treatment may be carried out at room temperature, for example, but may be accelerated at a temperature of about 40 to 200 ° C.
• the thickness of the siliceous film formed on the surface of the magnetic core is preferably about 0.5 to 10 ⁇ .
• the thickness of the siliceous film can be adjusted by repeatedly applying and curing the treatment liquid for forming the siliceous film on the surface of the magnetic core.
• the film thickness increases, cracks tend to occur on the surface side of the film due to residual stress in the film. Although the occurrence of cracks can be suppressed by slowing the curing speed, the film thickness is preferably 5 or less, more preferably 3 or less in view of productivity.
• An electrode can be formed on the coating layer of the magnetic core to form a magnetic core including the electrode. It is covered with a siliceous film and the arithmetic mean of the peaks (3: :I 3 0 2 5 1 7 8)
• the following coating layers have excellent permeation suppression performance and can stably form electrodes.
• the electrode material eight 9, can be used ⁇ Li, conductive material eight I like (including its alloy).
• a method of forming the electrode for example, Form a film by a method of adhering and fixing metal terminals such as copper alloy, ⁇ alloy, and stainless steel, or by a method such as a sputtering method, an ion plating method, a printing method using a conductive paste, a transfer method, or a dip method. You may form an electrode.
• a ⁇ C "Atomized powder (average particle size 0 50 1 0) was prepared. 8 as a binder (Kuraray Co., Ltd. Poval 8 _ 2 0 5) Aqueous solution, dissolution ⁇ 0 2020/175367 10 ⁇ (: 171? 2020 /007040
• Ion-exchanged water was used as a medium, and they were put into a stirrer and mixed by stirring to obtain a slurry.
• the mixing ratio of the binder and the ion-exchanged water was adjusted so that eight solids were 0.75 parts by weight and the slurry concentration was 80% with respect to 100 parts by weight of the atomized powder.
• the slurry was spray dried with a spray dryer device. The slurry was sprayed inside the spray dryer device, and the slurry was instantaneously dried with hot air of 240 ° C to recover granular granules from the lower part of the device.
• the granules were passed through a 100-mesh sieve, and the average particle size of the granules after sieving was set within the range of 60 to 80.
• Zinc stearate was added to the granules obtained by each of the above granulation methods at a ratio of 0.4 parts by weight to 100 parts by weight of granules and mixed by a mixer to obtain granules for molding. It was
• the obtained molded body was heat-treated in the atmosphere at 750° for 1 hour to obtain a magnetic core of Sample 8, Sample No. Then, the density was calculated from the size and weight of the magnetic core.
• the columnar magnetic core was placed in a stainless steel mesh basket and immersed in the siliceous film forming treatment liquid for 1 minute.
• the liquid temperature was 23 ° .
• As the treatment liquid for forming the siliceous film " ⁇ 1 0 6 0 1 0" 3 series sealing agent manufactured by Okuno Chemical Industries Co., Ltd. was used.
• the magnetic core was put into a centrifugal dehydrator, the excess sealing agent adhering at a peripheral speed of 8.401/3 was removed, and the magnetic core was dried and hardened with hot air at 70 ° C. Repeat the coating process from 1 to 3 times from 1 to 3.
• the condensation reaction proceeds even in hot air drying at 70 °C to form a siliceous film, but unreacted parts remain, so after the coating process, After hardening again under the condition of 120 ⁇ X20 minutes, the entire surface of the magnetic core was covered with a siliceous film.
• the surface roughness of the obtained magnetic core was measured.
• the surface roughness was measured using a laser microscope manufactured by Keyence Corporation [ ⁇ -X120. Magnification is 100 times, ⁇ 0 2020/175367 1 1 ⁇ (: 171? 2020 /007040
• the valency region is set to 1 4 5 10 9 region, leveling of cross-section curve (slope adjustment) and smoothing processing are performed, and the arithmetic mean curve of the average peaks in five evaluation regions with different fields of view (3: 1 3 0 2 5 1 7 8) was obtained. Moreover, the arithmetic mean curve of the peaks (30: I 3 0 2 5 1 7 8) was similarly obtained for the magnetic core on which the siliceous film was not formed.
• Figure 2 is an image of the surface of a sample that has not been subjected to coating treatment at 100 times magnification
• Figure 3 shows the surface of the sample 8 that has been subjected to two coating treatments at 100 times magnification. It is an image of 3 Mi IV!
• test ink was applied to the surface of the magnetic core, and the progress was recorded as a movie.
• the test ink and other areas were binarized with a computer in a still image 2 seconds after the application, and the sealing property was judged from the ratio of the ink absorbed on the observation surface. When the ink absorption was within 30%, it was judged as good, and when it was over 30%, it was judged as bad.

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• 2020
  • 2020-02-21 JP JP2021502187A patent/JP7626063B2/ja active Active
  • 2020-02-21 WO PCT/JP2020/007040 patent/WO2020175367A1/ja not_active Ceased

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