CN1295715C - 压粉磁心和使用该磁心的高频电抗器 - Google Patents
压粉磁心和使用该磁心的高频电抗器 Download PDFInfo
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Abstract
本发明是压缩成型磁性粉末而得到的压粉磁心。磁性粉末是1-10重量%的Si、0.1-1.0重量%的O、余量的Fe的组成的合金。在粒径为150μm以下的磁性粉末之间存在以SiO2和MgO为主成分的绝缘体。
Description
技术领域
本发明涉及在扼流圈中使用的压粉磁心,更详细地讲,涉及直流重叠特性和频率特性优异的压粉磁心。
背景技术
作为以高频使用的扼流圈,使用铁氧体磁心或压粉磁心。在它们之中,铁氧体磁心具有饱和磁通密度小的缺点。与此相比,成形金属粉末而制作的压粉磁心由于具有比软磁性铁氧体高的饱和磁通密度,因此具有直流重叠性优异的优点。
可是,对于压粉磁心,由于将金属粉末与有机粘合剂等混合并在高压下压缩成型而制作,因此具有不能保证粉末粒子间的绝缘、导磁率的频率特性降低这一缺点。另外,为了确保粉末粒子间的绝缘而大量地混合粘合剂等时,存在金属粉末的占空率降低、导磁率降低等问题。
另外,近年,从节能、二氧化碳导致的地球变暖问题的突出考虑,在普通家电和工业用机器中,节能措施迅速推进,作为其措施,要求电路高效率化等。作为其解决手段的一环,强烈希望提高压粉磁心的导磁率和改善频率特性、改善铁心损。
作为现有的提高压粉磁心导磁率的方法,主要方面在提高磁性粉末的填充率上,作为其手段,例如考虑提高成形压力等方法。可是,用该方法提高填充率的情况下,粉末粒子间的绝缘降低,招致涡流损耗增加、频率特性劣化。
因此,本发明的目的在于解决上述问题,提高直流重叠特性、频率特性优异的压粉磁心。
发明内容
本发明是为了解决上述问题而研究了使压粉磁心的磁性粒子间存在绝缘体的结果。本发明人进行了将上述方法具体化的研究,结果发现,将含有生成SiO2的化合物的粉末或溶液、和MgCO3粉末或MgO混合到压粉磁心的原材料中,通过压制、热处理可使磁性粉末粒子间介在绝缘体。
根据本发明的一个方案,得到一种压粉磁心,该磁心的特征是,在压缩成型磁性粉末而得到的压粉磁心中,磁性粉末是1-10重量%的Si、0.1-1.0重量%的O、余量的Fe的组成的合金,使粒径为150μm以下的磁性粉末之间存在以SiO2和MgO为主成分的绝缘体。
另外,根据本发明的其他方案,可以得到一种高频电抗器,该电抗器的特征是,对上述压粉磁心施行绕线。
另外,根据本发明的另一其他方案,可以得到一种权利要求1至3中任意一项所述的压粉磁心的制造方法,该方法的特征是,将混合了磁性粉末、和硅酮树脂或硅烷偶联剂的至少一方、MgCO3粉末或者MgO粉末的至少一方的混合物压缩成形,对得到的成形体施行热处理。
根据本发明,与使用了同样的磁性粉末的现有的压粉磁心相比,得到直流重叠特性、频率特性优异的压粉磁心,认为这是因为通过将生成SiO2的化合物和MgCO3粉末或MgO粉末混合并进行热处理,在磁性粒子间形成以SiO2和MgO为主成分的玻璃层,不会使填充率降低,能够确保粒子间的绝缘。
附图说明
图1是表示实施例1的压粉磁心和比较例的压粉磁心的频率特性的图。
图2是表示实施例1的压粉磁心和比较例的压粉磁心的直流重叠特性的图。
图3是表示压粉磁心的频率特性的热处理温度依赖性的图。
图4是表示压粉磁心的直流重叠特性的热处理温度依赖性的图。
图5是表示实施例1的压粉磁心和比较例的压粉磁心的频率特性的图。
图6是表示实施例5的压粉磁心的交流导磁率的图。
图7是表示实施例6的压粉磁心的铁心损的图。
具体实施方式
下面说明本发明的实施例。
在本发明中,作为磁性粉末,使用1重量%-10重量%的Si、0.1-1.0重量%的O、余量的Fe的组成的合金,只要来自熔化法的坯料的粉碎粉末、雾化粉末等组成分布均匀,则在制法上没有限制。
粉末的氧量为0.1重量%以下时,在适当的氧气氛和温度下进行热处理,对粉末表面施行氧化处理。使用150μm的筛将该粉末分级。
另一方面,在成形压粉磁心时,往往使用粘合剂,作为一般的压粉磁心用的粘合剂,使用环氧树脂等热固性高分子。在本发明中,由于使用生成SiO2的化合物,从而可使用以用硅氧烷键构成主链的硅酮树脂为主成分的粘合剂。
另外,硅烷偶联剂由于以Si和O为构成元素,因此混合它,也能够通过热处理生成SiO2。该情况下,如果采取预先将磁性粉末用硅烷偶联剂进行表面处理这一方法,则也能够有助于提高磁性粉末的填充率。
另外,在本发明中,为了形成绝缘体而混合MgCO3粉末或MgO粉末,但由于MgO吸收空气中的CO2和水变成MgCO3水合物,因此在操作上需要注意。另一方面,MgCO3在700℃附近以上的温度释放出CO2,变化成为MgO,因此得到与使用MgO的场合相同的结果。也就是说,有必要根据制造工序的环境和热处理的条件等,适宜地灵活使用。
例如使用螺旋管形状的金属模在适当的压力、优选5-20ton/cm2的压力下压缩成形。而且,对其成形体,在适当的温度、优选500-1000℃的范围进行变形矫正热处理。接着,使用对应于额定电流的线径的磁性金属丝,按达到所要求的电感值的方式决定匝数。在此,如果叙述规定合金组成的理由,则是因为当Si量不到1重量%时,合金的磁各向异性高,而且比电阻低,因此磁心的铁心损变高,当超过10%时,合金的饱和磁化低,并且硬度高,因此成形体密度变低,直流重叠特性劣化。将O量定为0.1-1.0重量%是因为,当不到0.1%时,初始导磁率过高,直流重叠特性不能提高,当超过1.0重量%时,粉末中的磁性体的比例减少,因此饱和磁化显著降低,直流重叠特性劣化。另外,粉末粒径实质上为150μm以下,进一步细的粒径显示出也提高直流重叠特性的倾向。
另外,关于成形压力,以5ton/cm2以上的压力成形粉末时,可以得到6.0g/cm3以上的高成形体密度以及优异的直流重叠特性和铁心损特性,但在超过20ton/cm2的成形压力下,成形体的金属模寿命显著变短,因此是不现实的。
另外,关于成形体的热处理温度,在500℃以上时成形变形被去除,直流重叠特性提高,但当超过1000℃时,由于比电阻降低,因此高频特性的劣化变得显著。认为这是因为通过烧结,粉末间的电绝缘被破坏的缘故,是烧结体密度比超过95%的烧结磁心与本发明的压粉磁心的决定性差异,成形体的密度超过7.0g/cm3。
以下通过各种实施例1-6更详细地进行说明。
(实施例1)
在用水雾化法制作的、Si为5.0重量%、剩余部分为Fe的组成的合金粉末中,称量并混合需要量的硅酮树脂、硅烷系偶联剂、MgCO3粉末、MgO粉末,使用金属模在室温以15ton/cm2的压力成形,得到外径20mm、内径10mm、厚度5mm的螺旋管形状的压粉磁心。表1表示本实施例的上述成分的称量组成。在此,作为实施例制作4种压粉磁心,作为比较例制作1种压粉磁心。
表1
硅酮树脂(重量%) | 硅烷偶联剂(重量%) | MgO粉末(重量%) | MgCO3粉末(重量%) | ||
实施例 | 试样1 | 0.7 | - | 0.3 | - |
试样2 | 0.7 | - | - | 0.6 | |
试样3 | - | 0.7 | 0.3 | - | |
试样4 | - | 0.7 | - | 0.6 | |
比较例 | 1.0 | - | - | - |
然后,对该压粉磁心在800℃、2小时、氮中这一条件下施行热处理,进行硅酮树脂的热处理以及粉末成形时的变形的去除。其次,将该压粉磁心装入由绝缘体构成的外壳中,施行绕线,用ヒュ-レッドパッカ-ド公司(以下记为HP)制的4284A精密仪表测定直流重叠特性。图1示出了该结果。
另外,用HP制的4194A阻抗测定器测定了μ20kHz的频率特性。图2示出了结果。另外,表2示出了各压粉磁心的比电阻的测定结果。此外,对这些成形体施行初级15匝、次级15匝的绕线,用岩崎通信机的SY-8232交流BH描绘仪测定了20kHz、0.1T的铁心损特性,结果也示于表2。
作为比较例,如表1所示,只混合1.0重量%硅酮树脂,用与上述同样的方法进行压粉磁心的制作、特性测定,将结果同样地示于图1、图2、表2中。
表2
比电阻(Ω·cm) | 铁心损(kW/m3) | |
实施例1 | 10.2 | 500 |
实施例2 | 9.6 | 550 |
实施例3 | 9.8 | 600 |
实施例4 | 9.9 | 650 |
比较例 | 0.1 | 1200 |
从图1、图2可知,本实施例的压粉磁心与比较例比,直流重叠特性、频率特性都良好。另外,由表2可知,对于本实施例的压粉磁心,比电阻和铁心损都提高。
(实施例2)
下面说明实施例2。作为试样1,以表1的试样3所示的混合比率称量原材料,与实施例1同样使用金属模,在室温以15ton/cm2的压力成形,得到外径20mm、内径10mm、厚度5mm的螺旋管形状的压粉磁心。然后,对该压粉磁心在400℃、500℃、600℃、700℃、800℃、900℃、1000℃、1100℃、在氮中施行2小时热处理,进行硅酮树脂的热处理以及粉末成形时的变形的去除。
将该压粉磁心装入由绝缘体构成的外壳中,施行绕线,用HP制的4284A精密仪表测定直流重叠特性。图3示出了结果。另外,用HP制的4194A阻抗测定器测定μ的频率特性。图4示出了结果。从图3、图4可知,热处理温度500℃以上的压粉磁心,具有直流重叠特性、频率特性都良好的特性。认为这是因为在500℃以上时,形成了SiO2和MgO的玻璃层的缘故。
另外,对于在上述温度下施行了热处理的压粉磁心测定了比电阻。此外,作为比较例,使用与实施例1相同的磁性粉末,只混合1.0重量%硅酮树脂,用与实施例1同样的方法制作压粉磁心,对于该压粉磁心,与本实施例同样,在400℃、500℃、600℃、700℃、800℃、900℃、1000℃、1100℃的温度、在氮中施行2小时热处理,进行硅酮树脂的热处理以及粉末成形时的变形的去除,制作压粉磁心。对于这些压粉磁心也同样测定了比电阻。结果示于图5。
由图5可知,对于比较例的只混合硅酮树脂的压粉磁心,伴随着热处理温度的上升,比电阻降低,在900℃的高温下绝缘被破坏。另一方面,本实施例在热处理温度增加的同时,比电阻提高,保持绝缘直到1000℃。从该结果可知,根据本发明,在高温热处理时也能够确保充分的绝缘,由此可提高磁特性。
(实施例3)
下面说明实施例3。使用在实施例1的试样1中使用的5.0重量%的Si、0.5重量%的O、其余为Fe的合金粉末,使用金属模制成外径50mm、内径25mm、高度20mm的螺旋管形的压粉磁心。然后,对该螺旋管形压粉磁心进行变形矫正热处理,与磁路成直角地***5mm间隙,将外径1.8mm的磁性金属丝绕线60匝,制作电抗器。
测定该电抗器40A直流重叠时的电感,为550μH。其次,将该电抗器与搭载了输出功率2000W级的极普通的倒相器控制用的有源滤波器的开关电源连接,测定了电路效率。在此,在输出侧连接了负载电阻。另外,电路效率使用输出电功率除以输入电功率的值。其结果示于表3。
作为比较例,使用宽20mm的Fe系非晶薄带,制成与实施例完全相同的尺寸的螺旋管形磁心。然后,按达到与实施例完全相同的电感的方式形成了间隙后,仍然绕线60匝,测定电感,为530μH。接着,用与实施例完全相同的方法与开关电源连接,测定其电路效率。其结果也一并示于表3。
表3
输入电压(W) | 输出电压(W) | 效率(%) | |
实施例 | 1980 | 1820 | 91.9 |
比较例 | 1960 | 1770 | 90.3 |
由表3可知,本实施例的电抗器与比较例比较,电路效率高。认为非晶磁心需要开大的间隙,为此发生跳动(唸り),而且在间隙附近发生的漏磁通等给效率造成不良影响。
(实施例4)
将用水雾化法制作的3.0重量%的Si、0.5重量%的O、剩余部分为Fe的合金粉末分级为150μm以下。然后,作为粘合剂,按重量比混合1.0重量%的Si系树脂、1.0重量%的MgO。接着,使用成形用金属模,以10ton/cm2的压力,模成形为外径15mm、内径10mm、高度5mm的形状。成形体密度为6.8g/cm3。其后,将该成形体在惰性气氛中保持800℃×1小时后,缓慢冷却到室温。接着,对该成形体施行初级15匝、次级15匝的绕线,用岩崎通信机的SY-8232交流BH描绘仪测定20kHz、0.1T时的导磁率、铁心损特性。
作为比较例,由板厚0.1mm的3%硅钢板用金属模冲出完全同样的形状的磁心后,用树脂叠层制作磁心。接着,进行变形矫正热处理后,按直流磁导率μ达到与实施例大致相同的值的方式在磁心上开间隙,与实施例完全同样地进行初级、次级的绕线,测定交流的磁特性。这些结果示于表4。
表4
μ20kHz | 铁心损(kW/m3) | |
实施例 | 70 | 500 |
比较例 | 50 | 3000 |
如表4所示,本实施例制作的磁心与比较例比,高频下的磁特性良好。
(实施例5)
对于纯铁以及由Si量为1.0、3.0、5.0、7.0、9.0、11.0重量%、O量为0.5±0.1重量%、剩余部分Fe构成的合计6组的组成,采用水雾化法制作合金粉末,采用与实施例1完全同样的方法分级为150μm。
其次,作为粘合剂,添加1.0重量%的Si树脂和1.0重量%的MgO,以5-15ton/cm2的成形压力、按相对密度达到约85%以上的方式用金属模将磁心成形为外径60mm、内径35mm、高度20mm的螺旋管形状。其后,在850℃氮气氛下进行变形矫正热处理后,用磁性金属丝绕线90匝后,在频率20kHz下测定20A直流重叠时(12000A/m)的电感。由该电感值计算交流导磁率。其结果示于图6。由图6可知,Si量为1.0-10.0重量%时,μ2kHz显示出20以上。
然后,在20kHz、0.1T的条件下测定铁心损,结果,纯铁粉以外的磁心的铁心损为1000kW/m3以下。
其次,为了考察这些电抗器的安装特性,用市售的空气调节器将这些电抗器与搭载着有源滤波器的输出功率2kW的开关电源连接,测定电路效率。在此,在输出侧连接普通的电子负载装置。另外,电路效率使用输出电功率除以输入电功率的值。其结果示于表5。
表5
由表5可知,例如在1000W下得到93%以上的高效率的Si量为1.0-10.0重量%的范围,这与铁心损为1000kW/m3、并且在12000A/m下的导磁率为20以上的组成范围一致。
(实施例6)
制作Si量为4.5重量%、余量为Fe的合金组成的气雾化粉末,分级成150μm后,通过使温度恒定,并适当地调节环境,制作O量为0.05、0.1、0.25、0.5、0.75、1.0、1.25重量%的各合金粉末。
然后,用与实施例4和5完全同样的方法在该合金中混合粘合剂后,采用与实施例5完全同样的方法,以20ton/cm2的成形压力、按成形体密度92%制作同样尺寸的螺旋管形磁心,进行变形矫正热处理后,用与实施例1完全同样的方法对这些磁心绕线,在20kHz、0.1T的条件下测定铁心损。其结果示于图7。从图7可知,当O量低于0.1重量%时,铁心损急剧地劣化。
其次,用与实施例5完全同样的方法进行绕线,测定20A直流重叠时(12000A/m)的20kHz的电感,计算交流导磁率,结果O量为1.25重量%的磁心的μ20kHz是13,O量为0.05重量%的磁心的μ20kHz是19,除此以外的磁心的μ20kHz是20以上。
然后,用与实施例5完全同样的方法测定了这些电抗器的安装特性。其结果示于表6。
表6
由表6可知,例如在1000W下可以得到93%以上的高效率的O量为0.1-1.0重量%的范围,这与显示铁心损为1000kW/m3以下并且μ20kHz为20以上的特性的组成范围一致。
工业实用性
如以上那样,本发明的压粉磁心作为在高频下使用的扼流圈的磁心是有用的。
Claims (6)
1.一种压粉磁心,其特征是,在压缩成型磁性粉末而得到的压粉磁心中,磁性粉末是1-10重量%的Si、0.1-1.0重量%的O、余量的Fe的组成的合金,在粒径为150μm以下的磁性粉末之间存在含有SiO2和MgO的绝缘体。
2.根据权利要求1所述的压粉磁心,交流导磁率μ20kHz在直流外加磁场12000A/m时为20以上,并且,在20kHz、0.1T的条件下铁心损为1000kW/m3以下。
3.一种高频电抗器,其特征是,对权利要求1-2中的任1项所述的压粉磁心施行绕线。
4.权利要求1-2中的任1项所述的压粉磁心的制造方法,其特征是,将混合了磁性粉末、和硅酮树脂或硅烷偶联剂的至少一方、MgCO3粉末或者MgO粉末的至少一方的混合物压缩成形,对得到的成形体施行热处理。
5.根据权利要求4所述的压粉磁心的制造方法,其中,以5-20ton/cm2的成形压力将上述混合物成形,在500-1000℃的温度区域进行上述热处理,据此使上述成形体的密度为6.0-7.0g/cm3。
6.根据权利要求4或5所述的压粉磁心的制造方法,其中,上述硅烷偶联剂的混合通过采用硅烷偶联剂对磁性粉末粒子实施表面处理来进行。
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US20070261231A1 (en) * | 2006-05-09 | 2007-11-15 | Spang & Company | Methods of manufacturing and assembling electromagnetic assemblies and core segments that form the same |
KR20090006826A (ko) * | 2006-05-09 | 2009-01-15 | 스팽 & 컴퍼니 | 전자기 어셈블리, 이를 형성하기 위한 코어 세그먼트, 및 그 제조 방법 |
US20070262839A1 (en) * | 2006-05-09 | 2007-11-15 | Spang & Company | Electromagnetic assemblies, core segments that form the same, and their methods of manufacture |
JP4970899B2 (ja) * | 2006-10-27 | 2012-07-11 | 株式会社日立製作所 | 高抵抗圧粉磁心の製造方法 |
JP4465635B2 (ja) * | 2008-03-17 | 2010-05-19 | トヨタ自動車株式会社 | リアクトル装置 |
TWI407462B (zh) | 2009-05-15 | 2013-09-01 | Cyntec Co Ltd | 電感器及其製作方法 |
JP5501970B2 (ja) * | 2009-12-25 | 2014-05-28 | 株式会社タムラ製作所 | 圧粉磁心及びその製造方法 |
WO2011118774A1 (ja) * | 2010-03-26 | 2011-09-29 | 日立粉末冶金株式会社 | 圧粉磁心及びその製造方法 |
JP5976284B2 (ja) * | 2010-07-23 | 2016-08-23 | 株式会社豊田中央研究所 | 圧粉磁心の製造方法および磁心用粉末の製造方法 |
JP6265210B2 (ja) * | 2013-03-27 | 2018-01-24 | 日立化成株式会社 | リアクトル用圧粉磁心 |
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JPH02290002A (ja) * | 1989-01-18 | 1990-11-29 | Nippon Steel Corp | Fe―Si系合金圧粉磁心およびその製造方法 |
JPH09180924A (ja) * | 1995-12-27 | 1997-07-11 | Kobe Steel Ltd | 圧粉磁心及びその製造方法 |
CN1267894A (zh) * | 1999-03-23 | 2000-09-27 | Tdk株式会社 | 压粉磁心及其制造方法 |
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