EP1444706B1 - Inductive component and method for producing same - Google Patents
Inductive component and method for producing same Download PDFInfo
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- EP1444706B1 EP1444706B1 EP02785387A EP02785387A EP1444706B1 EP 1444706 B1 EP1444706 B1 EP 1444706B1 EP 02785387 A EP02785387 A EP 02785387A EP 02785387 A EP02785387 A EP 02785387A EP 1444706 B1 EP1444706 B1 EP 1444706B1
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- inductive component
- casting resin
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- alloy powder
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Images
Classifications
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- 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
- H01F41/04—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 for manufacturing coils
- H01F41/041—Printed circuit coils
- H01F41/046—Printed circuit coils structurally combined with ferromagnetic material
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F17/045—Fixed inductances of the signal type with magnetic core with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
-
- 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
-
- 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
- H01F41/005—Impregnating or encapsulating
-
- 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
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
-
- 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
- H01F27/02—Casings
- H01F27/027—Casings specially adapted for combination of signal type inductors or transformers with electronic circuits, e.g. mounting on printed circuit boards
Definitions
- the invention relates to an inductive component having at least one winding and a soft magnetic core of a ferromagnetic powder composite material.
- Soft magnetic powder materials as pressed magnetic cores or as cast or injection molded magnetic cores have long been known.
- Suitable alloys for this application are iron powder, iron alloy powder, in particular FeSi or FeAlSi alloys, and various NiFe alloys.
- plastic-bonded composites of soft magnetic materials and thermoplastic or thermosetting materials which are processed as a pressed part, injection molded part or as non-pressure casting.
- shape-anisotropic magnetic particles and the production of composite parts of increased permeability from these particles with alignment of the particles by application of pressure, directed flow and external magnetic fields is also known.
- the use of magnetic powders in combination with the finest ceramic particles is known as insulating spacers.
- the use of magnetic powders of significantly different particle size (2 - 3 fractions) to optimize the packing density at atmospheric pressure Potting is the JP 11218256 refer to. From the DE 333 4827 or DE 245 2252 It is known to encase a coil with a material containing soft magnetic material.
- the EP 0 921 534 A1 and the JP 04343207 describe an inductive component with a winding and a soft magnetic core of a ferromagnetic powder composite material, wherein the ferromagnetic powder composite material contains a powder mixture of powders with formanisotropic and formisotropic powder particles.
- the DC pre-load capacity is a measure of the energy stored in the magnetic material (for the definition of DC pre-load capacity, see R. Boll: “Soft Magnetic Materials” Siemens AG, 1990 p. 114f).
- the usual manufacturing method is the pressing of cores in appropriate tools, for example, toroidal or E-core shape.
- pressures in the range of about 5 to 15 t / cm 2 are required.
- heat treatment in the temperature range above 500 ° C to restore good soft magnetic properties.
- the last variant also has narrow limits, since on the one hand the flowability of the mixture has to be ensured and on the other hand the orientation of the formanisotropic particles in the magnetic field can not be made very effective.
- the force effect that can be achieved by an external magnetic field on the particles is extremely limited, since only the shape anisotropy of the particles can be used for alignment.
- This alignment is far from being as effective as, for example, possible alignment with the permanent magnet alloys via the crystal anisotropy of the magnetic powder particles.
- This has the consequence that an alignment of formanisotropic particles by magnetic fields in high-viscosity injection molding compositions is virtually impossible and in casting compounds with relatively low-viscosity casting resins only a very moderate orientation of the powder particles can be achieved. Therefore, over the major part of the component volume, these formanisotropic particles are virtually statically distributed even after being aligned by magnetic fields. It is unavoidable that even a significant proportion of the magnetic particle with its surface normal parallel to the direction of magnetization in the device and thus virtually no longer contributes to the magnetization in the device.
- the object of the invention is therefore to provide an inductive component and a method for its production, which allows a wrapping of prefabricated coils with soft magnetic material, this material comparatively high permeabilities ( ⁇ > 40) and a high Gleichfeldvorbelastiana (B 0 > 0, 3 T).
- inductive components with universal design and high packing density at high permeability ( ⁇ > 40) and high Gleichfeldvorbelastles (B 0 > 0.3 T) can be created.
- the ferromagnetic powder composite material has an alloy powder mixture of an alloy powder with formanisotropic and an alloy powder with formisotropic powder particles and a casting resin.
- the alloy powder mixture preferably has a coercive field strength of less than 150 mA / cm, a saturation magnetostriction and a crystal anisotropy of approximately zero, a saturation induction> 0.7 T and a specific electrical resistance of greater than 0.4 ohm * mm 2 / m.
- the formanisotropic powder particles can be both flakes of amorphous or nanocrystalline alloys and elliptical Include parts of crystalline alloys with an aspect ratio greater than 1.5.
- the formanisotropic powder particles preferably have a particle diameter of 30-200 ⁇ m.
- both the formanisotropic and the formisotropic powder particles may be surface-isolated. The surface insulation can be produced for example by oxidation and / or by treatment with phosphoric acid.
- the alloy powder mixture has, in addition to the anisotropic alloy powder, two formisotropic powders of which one powder has coarse alloy particles with a particle diameter of 30-200 ⁇ m and the other powder consists of carbonyl iron particles with a particle diameter of less than 10 ⁇ m.
- the proportion of alloy powder having formanistropic particles is 5 to 65% by volume
- the alloy powder having coarse form isotropic particles is 5 to 65% by volume
- the carbonyl iron powder having fine formisotropic particles is 25 to 30% by volume of the alloy powder mixture.
- the formanisotropic powder particles may contain FeSi alloys and / or FeAlSi alloys and / or FeNi alloys and / or amorphous or nanocrystalline Fe or Co base alloys.
- the casting resin has a viscosity of less than 50 mPas in the uncured state and a continuous use temperature of more than 150 ° C in the cured state.
- casting resin for example, a resin from the group of epoxides, the epoxidized polyurethanes, the polyamides and the methacrylate ester in question.
- the proportion of the alloy powder mixture is preferably at 70 to 75 percent by volume, the proportion of the casting resin at 25 -30 volume percent.
- the powder composite material may additionally contain an addition of flow aids, for example based on silicic acid.
- the inductive component may have a housing.
- this procedure avoids that the powder particles are subjected to a mechanical load during the production process. Furthermore, especially when using a stocked with a prefabricated windings shape, which on the Winding wires applied insulation layer not damaged, since the filling of the lowest possible viscosity casting resin or casting resin powder formulation into the mold due to the gentle introduction of the formulations does not damage them. Particularly preferred are cast resin formulations having viscosities of a few millipascal seconds.
- the alloy powder mixture is mixed with the casting resin formulation before it is filled into the mold.
- the mold is then vibrated by a suitable means, such as a compressed air vibrator, which results in the casting resin powder formulation being well permeated.
- the casting resin powder formulation is degassed.
- the alloy powder mixture has a very high density in comparison to the casting resin, the alloy powder mixture in the mold settles easily, so that the casting resin excess used can be collected for example in a gate, which can be removed after curing of the powder composite.
- the mold which is filled with the alloy powder mixture and the casting resin formulation or which is already filled with a preformed casting resin powder formulation is "reused" as the housing of the inductive component. That is, in this embodiment of the present invention, the mold serves as "lost formwork".
- the component produced or the soft magnetic core made of powder composite material produced must always be removed from the mold in a complicated manner, which leads to longer production times.
- Cast resin formulations typically include polymer building blocks mixed with a polymerization initiator (initiator).
- initiator a polymerization initiator
- polymer building blocks are also conceivable, for example lactams.
- the Methacryl Acidmethylester be polymerized during curing then to polyacrylic.
- lactams are polymerized via a polyaddition reaction to polyamides.
- Suitable polymerization initiators are dibenzoyl peroxide or, for example, 2,2'-azo-isobutyric acid dinitrile.
- the powder particles are aligned during and / or after filling the mold with the alloy powder mixture by applying a magnetic field.
- a magnetic field This can be done in particular by the use of forms that are already equipped with a winding, by passing a current through the winding and the associated magnetic field.
- magnetic fields which expediently have field strengths of more than 10 A / cm, the powder particles are aligned.
- casting resin formulation takes place or casting resin powder formulation by shaking a compaction or sedimentation of the alloy powder mixture.
- the achievable permeability or the achievable DC field resilience can be controlled by the mixing ratio between the isotropic and anisotropic component to be selected.
- a formanisotropic powder particles for example, flakes of amorphous, nanocrystalline or crystalline alloys can be used and elliptical particles with aspect ratios greater than 1.5, as they can be produced for example by appropriately adapted Gasverdüsungsclar.
- the use of carbonyl iron powders is an ideal isotropic mixture component.
- These powders are preferably surface-insulated, so that in addition to the flow guidance by the fine magnetic powder particles additionally an insulating effect in the powder mixture occurs.
- These fine powder particles act as electrically insulating spacers in the mixture between the larger formanisotropic powder particles.
- ternary magnetic powder mixtures preferably a combination of on the one hand coarser formanisotropic powder particles having dimensions in the range of 30-200 ⁇ m, preferably 50-200 ⁇ m, in the lateral extent and an aspect ratio of greater than 1.5 and on the other hand a second isotropic powder component with particle diameters in the range of 30 - Used 200 microns with spherical particle shape and a third isotropic powder component with particle diameters in the range below 10 microns.
- the latter powder component preferably consists of surface-isolated carbonyl iron powder.
- the ternary mixture with coarser spherical powder particles is also characterized by a significantly improved flowability of the casting compound than the previously described binary powder mixture of flakes and fine powder.
- the movement of the powder particles in the magnetic field is greatly facilitated by the increased proportion of coarser spherical particles.
- coarser particles of both the formisotropic and the formanisotropic powder particles a very wide alloy spectrum can be used.
- the basic requirement for use in this powder mixture is an alloy with the lowest possible coercive field strength, vanishingly small saturation magnetostriction and crystal anisotropy, and the highest possible specific electrical resistance.
- FeSi alloys FeAlSi alloy powders, FeNi alloy powders and the amorphous and nanocrystalline Fe or Co base alloy powders. Furthermore, it is important that all necessary heat treatment steps can be completed before the core is made. This is also the case with the alloys mentioned.
- a homogeneous powder mixture is produced in a suitable mixer.
- silica-based flow aids to this powder mixture has proven itself.
- the pourable mixture is then prepared by mixing 70-75 volume percent magnetic powder mixture and 25-30 volume percent of a selected resin. This mixture is degassed with stirring in a vacuum and then filled into the intended casting mold. In the form by mechanical shaking, a compaction or sedimentation of the magnetic powder and at the same time by an external magnetic field or by energizing the inserted copper coil, an orientation of the formanisotropic portion of the magnetic powder. Following the alignment of the formanisotropic powder fraction, the curing of the resins takes place at elevated temperature.
- the FIG. 1 shows an inductive component 10.
- the inductive component 10 consists of a soft magnetic core 11 and a winding 12, which consists of relatively thick copper wire with few turns.
- the winding can be made of both round wire and flat wire in one or more layers.
- Especially by the use of copper flat wire can be increased by the more compact winding structure with constant component volume of the copper cross section of the wire which in turn leads to a reduction of the ohmic losses in the winding. With constant winding resistance can be inversely reduced by this measure, accordingly, the component volume.
- FIG. 1 shows the device 10 during manufacture.
- the component 10 is introduced into a mold 1a, which here consists of aluminum.
- the FIG. 2 also shows an inductive component 20, which consists of a soft magnetic core of a powder composite material 21 in which a layer winding bobbin 22 is introduced.
- the layer winding bobbin 22 is connected at its winding ends with pins 23 which protrude from the soft magnetic core 21 and serve for connection to a bottom plate, for example a printed circuit board.
- the inductive component 20 in the FIG. 2 is also like in the FIG. 1 shown during its manufacture. This means, that the inductive component 20 is shown here in the form 1b, is poured in the powder composite material.
- FIG. 3 also shows like that Figures 1 and 2 an inductive component.
- the inductive component 30 shown here consists of a soft magnetic core 31, made of a powder composite material, in turn, a layer winding bobbin 32 is introduced.
- the sheet winding bobbin 32 is connected at its winding ends with connecting pins 33, which protrude from the mold 1 c, which also serves as a housing 34.
- powder composite material As starting material for the powder composite material, one of the following powder mixtures is provided in the three exemplary embodiments:
- Comparative Example 1 Casting cores with low permeability
- the following formulation can be used: 72 g pre-annealed and surface-insulated powder of Fe 84 Al 6 Si 10 or Ni 78 Fe 18 with an average particle diameter of about 50 ⁇ m and a spherical shape 21 g phosphated carbonyl iron 9 g casting resin
- casting cores having a permeability of about 40, a Gleichfeldvorbelastiana of about 0.35 T and Ummagnetleitersleen of about 90 - 110 W / kg at 100 kHz and Mattaus horreptept of 0.1 can be produced.
- Example 1 Cores with medium permeability
- the following formulation can be used: 16 g pre-annealed and surface-insulated powder of Fe 84 Al 6 Si 10 , Ni 78 Fe 18 or Fe 73.5 Cu 1 Nb 3 Si 15.5 B 7 with an average particle size of 40-200 ⁇ m and an aspect ratio> 1.5 48 g pre-annealed and surface-insulated powder of Fe 84 Al 6 Si 10 or Ni 78 Fe 18 with an average particle diameter of about 50 ⁇ m and a spherical shape 21 g phosphated carbonyl iron 9 g casting resin
- casting cores having a permeability of about 65, a Gleichfeldvorbelastiana of about 0.30 T and re-magnetization losses of about 90 - 110 W / kg at 100 kHz and Mattausberichtmaschine of 0.1 T can be produced.
- Example 2 G clothkern with higher permeability
- casting cores having a permeability of about 85, a Gleichfeldvorbelastiana of about 0.27 T and Ummagnetleitersleen of about 90 - 110 W / kg at 100 kHz and 0.1 T alternator
- alloy powder mixtures are only exemplary in nature. There is a wide range of alloy powder mixtures other than the above listed formulations.
- the formanisotropic powder particles also called flakes by reason of their shape, were subjected to heat and surface treatment to improve their dynamic magnetic properties.
- the treatment of the formisotropic powder particles with phosphoric acid which forms electrically insulating iron phosphate on the surface thereof.
- thermoplastic methacrylate formulation had the following composition: 100 g methacrylate 2 g Methacryltrimethoxysilan 6 g Dibenzoyl peroxide and 4.5 g N, N p-toluidine
- thermoplastic methacrylate formulation was also charged, this methacrylate formulation having the following composition: 100 g methacrylate 2 g Methacryltrimethoxysilan 10 g Diglycoldimethacrylat 6 g Dibenzoyl peroxide and 4.5 g N, N p-toluidine
- the above chemical ingredients were dissolved sequentially in the methacrylic ester.
- the finished mixture was water clear in both cases and was then poured into molds 1a and 1b.
- the cast resin formulations in both cases cured at room temperature within about 60 minutes. Subsequently, a post-curing at about 150 C for an additional hour was made.
- thermosetting thermoplastic methacrylate formulation having the following composition was used: 100 g methacrylate 0.1 g 2,2'-azo-isobutyric dinitrile
- This casting resin formulation was in the form 1c, as in FIG. 3 is shown, filled and cured within 15 hours at a temperature of about 50 ° C. Since the form 1c in the FIG. 3 is used as a "lost formwork", that is, then after the manufacturing process as a housing 34 was used for the inductive component, it has proven particularly well to use a thermosetting G automatzformultechnik, as a particularly intensive and good contact between the existing plastic Form 1c and the powder composite succeeded.
- thermoplastic polyamides in particular melts of ⁇ -caprolactam and phenyl isocyanate can be used, so in further experiments, a melt of 100 g of ⁇ -caprolactam and 0.4 g of phenyl isocyanate proved to be suitable, which was mixed together at 130 ° C. This melt was then poured into a preheated to 150 ° C mold. The curing of the caprolactam to a polyamide was then carried out within about 20 minutes. A post cure at higher temperatures was usually not required in this approach.
- caprolactam instead of a caprolactam it is of course also possible to use another lactam, for example laurolactam, with a corresponding binder phase. However, when processing laurolactam, process temperatures in excess of 170 ° C are required.
- thermosetting molding materials In addition to the previously described thermoplastic binder resin formulations, of course, the use of reaction resins that provide thermosetting molding materials is conceivable. In particular, the use of two-component thermosetting epoxy resins is possible here.
- a casting resin from this group has, for example, the following composition: 100 g Cycloaliphatic epoxy resin with a molecular weight ⁇ 700 g / mol, an epoxide content of 5.7 - 6.5 equiv.
- the potting resin is prepared by mixing at room temperature.
- the mixture is heated to temperatures around 80 ⁇ 10 ° C. This reduces the viscosity of the mixture to values ⁇ 20 mPas.
- For curing, made of this mixture components is heated to temperatures of about 150 ° C for a period of about 30 minutes.
- the cast resin formulations described above were used to fabricate inductive components with soft magnetic cores made of ferromagnetic powder composites that exhibit core loss losses, such as permeable core cores made of FeAlSi or nickel-containing NiFe alloys.
- the achievable permeability of about 20 and 100 is determined by the size of the formanisotropic particles and their volume fraction in the total powder mixture. Concerning the Gleichfeldvorbelastles values are achieved by 0.3 - 0.35 T.
Description
Die Erfindung betrifft ein induktives Bauelement mit zumindest einer Wicklung und einem weichmagnetischen Kern aus einem ferromagnetischen Pulververbundwerkstoff.The invention relates to an inductive component having at least one winding and a soft magnetic core of a ferromagnetic powder composite material.
Weichmagnetische Pulverwerkstoffe als gepresste Magnetkerne oder als gegossene oder spritzgegossene Magnetkerne sind seit langem bekannt. Als für diese Anwendung geeignete Legierungen kommen Eisenpulver, Eisenlegierungspulver wie insbesondere FeSi oder FeAlSi-Legierungen sowie verschiedene NiFe-Legierungen infrage.Soft magnetic powder materials as pressed magnetic cores or as cast or injection molded magnetic cores have long been known. Suitable alloys for this application are iron powder, iron alloy powder, in particular FeSi or FeAlSi alloys, and various NiFe alloys.
Neben diesen kristallinen Legierungen werden bekannterweise auch amorphe oder nanokristalline Legierungen auf Fe- oder Co-Basis verwendet.In addition to these crystalline alloys, it is known to use Fe or Co based amorphous or nanocrystalline alloys.
Es sind kunststoffgebundene Verbundwerkstoffe aus weichmagnetischen Materialien und thermoplastischen bzw. duroplastischen Werkstoffen bekannt, die als Pressteil, Spritzgussteil oder als druckloser Guss verarbeitet werden. Auch die Verwendung von formanisotropen magnetischen Partikeln und das Herstellen von Verbundteilen erhöhter Permeabiltät aus diesen Partikeln unter Ausrichtung der Partikel durch Anwendung von Druck, gerichtetem Fließen sowie äußeren magnetischen Feldern ist bekannt.There are known plastic-bonded composites of soft magnetic materials and thermoplastic or thermosetting materials, which are processed as a pressed part, injection molded part or as non-pressure casting. The use of shape-anisotropic magnetic particles and the production of composite parts of increased permeability from these particles with alignment of the particles by application of pressure, directed flow and external magnetic fields is also known.
Ebenso ist die Verwendung von magnetischen Pulvern in Kombination mit feinsten keramischen Partikeln als isolierende Abstandshalter bekannt. Die Verwendung von magnetischen Pulvern deutlich unterschiedlicher Partikelgröße (2 - 3 Fraktionen) zur Optimierung der Packungsdichte bei drucklosem Verguss ist der
Die Verwendung von Legierungspulvern unterschiedlicher Duktilität zur Optimierung der Pressdichten ist ebenfalls bekannt.The use of alloy powders of different ductility to optimize the densities is also known.
Die
Für den Einsatz als Drosselwerkstoff ist es wünschenswert Magnetkerne hoher Permeabilität ( µ > 40) und Gleichstromvorbelastbarkeit ( Bo > 0,2 T) herzustellen. Die Gleichstromvorbelastbarkeit ist ein Maß für die im Magnetwerkstoff gespeicherte Energie (Zur Definition der Gleichstromvorbelastbarkeit siehe R. Boll: "Weichmagnetische Werkstoffe" Siemens AG, 1990 S. 114f).For use as a throttle material, it is desirable to produce magnetic cores of high permeability (μ> 40) and DC bias (B o > 0.2 T). The DC pre-load capacity is a measure of the energy stored in the magnetic material (for the definition of DC pre-load capacity, see R. Boll: "Soft Magnetic Materials" Siemens AG, 1990 p. 114f).
Der übliche Fertigungsweg ist das Pressen von Kernen in entsprechenden Werkzeugen zum Beispiel mit Ringkern- oder E-Kern-Form. Zum Verdichten der Magnetpulverlegierungen sind dabei Drücke im Bereich von ca. 5 - 15 t/cm2 erforderlich. Im Anschluss an die Formgebung ist bei den meisten Legierungen eine Wärmebehandlung im Temperaturbereich oberhalb 500°C zur Wiederherstellung der guten weichmagnetischen Eigenschaften erforderlich. Diese beiden Verfahrensschritte, die Formgebung unter hohem Druck und die anschließende Wärmebehandlung - machen es praktisch unmöglich, auf diesen Wege Bauelemente mit einer vom Magnetmaterial umhüllten Spule herzustellen.The usual manufacturing method is the pressing of cores in appropriate tools, for example, toroidal or E-core shape. For compacting the magnetic powder alloys, pressures in the range of about 5 to 15 t / cm 2 are required. Subsequent to molding, most alloys require heat treatment in the temperature range above 500 ° C to restore good soft magnetic properties. These two process steps, the high pressure molding and the subsequent heat treatment, make it virtually impossible to manufacture components with a coil enveloped by the magnetic material in this way.
Für die Fertigung solcher Bauelemente eignet sich praktisch ausschließlich ein Gieß- oder Spritzgießverfahren. Mit derartigen Verfahren werden jedoch nur vergleichsweise niedrige Packungsdichten im Bereich vom maximal 70 Volumenprozent Magnetmaterial erreicht. Damit verbunden sind typische Permeabilitäten des Werkstoffes im Bereich um ca. 10 - 20.
Um hier die Permeabilität zu erhöhen, ist es möglich, durch Pulvermischungen mit Pulverpartikeln unterschiedlichen Durchmessers eine Erhöhung der Packungsdichte und damit eine Verringerung des effektiven Luftspaltes zwischen den Einzelpartikeln zu erreichen. Durch diese Maßnahme lassen sich jedoch auch nur Permeabilitäten bis ca. 40 errreichen.For the production of such components is practically exclusively a casting or injection molding. With such methods, however, only comparatively low packing densities in the range of up to 70 percent by volume of magnetic material are achieved. This is associated with typical permeabilities of the material in the range of about 10 - 20.
To increase the permeability here, it is possible by powder mixtures with powder particles of different diameters, an increase in the packing density and thus a reduction in the effective air gap between the individual particles to reach. By this measure, however, only permeabilities can reach up to 40.
Eine weitere Möglichkeit ist der Einsatz von formanisotropen Partikeln und anschließender Ausrichtung im Magnetfeld hier lassen sich die effektiven Luftspalte zwischen den Einzelpartikeln durch die große Überlappung der Partikel zum Teil kompensieren.Another possibility is the use of formanisotropic particles and subsequent alignment in the magnetic field here, the effective air gaps between the individual particles can be compensated in part by the large overlap of the particles.
Der letzten Variante sind jedoch auch enge Grenzen gesetzt, da zum einen die Fließfähigkeit der Mischung sichergestellt werden muss und zum anderen die Ausrichtung der formanisotropen Partikeln im Magnetfeld nicht sehr effektiv gestaltet werden kann. Die Kraftwirkung, die durch ein äußeres magnetisches Feld an den Partikeln erzielt werden kann, ist äußerst begrenzt, da lediglich die Formanisotropie der Partikel zum Ausrichten verwendet werden kann.However, the last variant also has narrow limits, since on the one hand the flowability of the mixture has to be ensured and on the other hand the orientation of the formanisotropic particles in the magnetic field can not be made very effective. The force effect that can be achieved by an external magnetic field on the particles is extremely limited, since only the shape anisotropy of the particles can be used for alignment.
Diese Ausrichtung ist bei weitem nicht so effektiv wie die zum Beispiel bei Dauermagnetlegierungen mögliche Ausrichtung über die Kristallanisotropie der Magnetpulverpartikel. Dies hat zur Konsequenz, dass eine Ausrichtung formanisotroper Partikel durch magnetische Felder in hochviskosen Spritzgussmassen praktisch unmöglich wird und in Gießmassen mit vergleichsweise niederviskosen Gießharzen nur eine sehr mäßige Ausrichtung der Pulverpartikel erreicht werden kann. Über den größten Teil des Bauelementevolumens sind daher diese formanisotropen Partikel auch nach der Ausrichtung durch magnetische Felder quasi statisch verteilt. Es ist dabei nicht zu vermeiden, dass sich auch ein merklicher Anteil der Magnetpulverpartikel mit seiner Flächennormalen parallel zur Magnetisierungsrichtung im Bauelement stellt und somit zur Magnetisierung im Bauelement praktisch nicht mehr beiträgt.This alignment is far from being as effective as, for example, possible alignment with the permanent magnet alloys via the crystal anisotropy of the magnetic powder particles. This has the consequence that an alignment of formanisotropic particles by magnetic fields in high-viscosity injection molding compositions is virtually impossible and in casting compounds with relatively low-viscosity casting resins only a very moderate orientation of the powder particles can be achieved. Therefore, over the major part of the component volume, these formanisotropic particles are virtually statically distributed even after being aligned by magnetic fields. It is unavoidable that even a significant proportion of the magnetic particle with its surface normal parallel to the direction of magnetization in the device and thus virtually no longer contributes to the magnetization in the device.
Dieser Verlust an magnetisierbarem Material macht sich insbesondere in der erreichen Sättigungsinduktion bzw. Gleichfeldvorbelastbarkeit bei Verwendung von formanisotropen Partikeln in Magnetpulvermischungen bemerkbar. Es werden zwar vergleichsweise hohe Permeabilitäten bis in den Bereich von mehreren Hundert erreicht, die Gleichfeldvorbelastbarkeit bleibt jedoch sehr begrenzt (typischerweise < 0,2 T).This loss of magnetizable material is manifested in particular in the achievement of saturation induction or DC field resilience when using formanisotropic particles noticeable in magnetic powder mixtures. Although comparatively high permeabilities in the range of several hundred are achieved, the DC bias remains very limited (typically <0.2 T).
Aufgabe der Erfindung ist es daher, ein induktives Bauelement sowie ein Verfahren zu dessen Herstellung anzugeben, das eine Umhüllung vorgefertigter Spulen mit weichmagnetischem Material erlaubt, wobei dieses Material vergleichsweise hohe Permeabilitäten (µ > 40) bzw. eine hohe Gleichfeldvorbelastbarkeit (B0 > 0,3 T) zulässt.The object of the invention is therefore to provide an inductive component and a method for its production, which allows a wrapping of prefabricated coils with soft magnetic material, this material comparatively high permeabilities (μ> 40) and a high Gleichfeldvorbelastbarkeit (B 0 > 0, 3 T).
Die Aufgabe wird durch ein induktives Bauelement gemäß Patentanspruch 1 bzw. ein Verfahren zu dessen Herstellung gemäß Patentansprüchen 14 und 15 gelöst. Ausgestaltungen und Weiterbildungen des Erfindungsgedankens sind Gegenstand von Unteransprüchen.The object is achieved by an inductive component according to claim 1 or a method for its production according to claims 14 and 15. Embodiments and developments of the inventive concept are the subject of dependent claims.
Vorteil der Erfindung ist es, dass induktive Bauelemente mit universeller Formgebung und hoher Packungsdichte bei hoher Permeabilität (µ > 40) und hoher Gleichfeldvorbelastbarkeit (B0> 0,3 T) geschaffen werden können.Advantage of the invention is that inductive components with universal design and high packing density at high permeability (μ> 40) and high Gleichfeldvorbelastbarkeit (B 0 > 0.3 T) can be created.
Erreicht wird dies im einzelnen bei einem induktiven Bauelement der eingangs genannten Art dadurch, dass der ferromagnetische Pulververbundwerkstoff eine Legierungspulvermischung aus je einem Legierungspulver mit formanisotropen sowie einem Legierungspulver mit formisotropen Pulverpartikeln und ein Gießharz aufweist.This is achieved in detail in an inductive component of the type mentioned in the fact that the ferromagnetic powder composite material has an alloy powder mixture of an alloy powder with formanisotropic and an alloy powder with formisotropic powder particles and a casting resin.
Die Legierungspulvermischung weist dabei bevorzugt eine Koerzitivfeldstärke von kleiner 150 mA/cm, eine Sättigungsmagnetostriktion und eine Kristallanisotropie von annähernd Null, eine Sättigungsinduktion > 0,7 T sowie einen spezifischen elektrischen Widerstand von größer 0,4 Ohm*mm2/m auf. Die formanisotropen Pulverpartikel können dabei sowohl Flakes aus amorphen oder nanokristallinen Legierungen als auch elliptische Teile aus kristallinen Legierungen mit einem Aspektverhältnis größer 1,5 umfassen. Bevorzugt haben die formanisotropen Pulverpartikel dabei einen Partikeldurchmesser von 30 - 200 µm. Sowohl die formanisotropen als auch die formisotropen Pulverpartikel können darüber hinaus oberflächenisoliert sein. Die Oberflächenisolierung kann beispielsweise durch Oxidation und/oder durch Behandlung mit Phosphorsäure erzeugt werden.The alloy powder mixture preferably has a coercive field strength of less than 150 mA / cm, a saturation magnetostriction and a crystal anisotropy of approximately zero, a saturation induction> 0.7 T and a specific electrical resistance of greater than 0.4 ohm * mm 2 / m. The formanisotropic powder particles can be both flakes of amorphous or nanocrystalline alloys and elliptical Include parts of crystalline alloys with an aspect ratio greater than 1.5. The formanisotropic powder particles preferably have a particle diameter of 30-200 μm. In addition, both the formanisotropic and the formisotropic powder particles may be surface-isolated. The surface insulation can be produced for example by oxidation and / or by treatment with phosphoric acid.
Die Legierungspulvermischung weist neben dem anisotropen Legierungspulver zwei formisotrope Pulver auf, von denen ein Pulver grobe Legierungspartikel mit einem Partikel-durchmesser von 30 - 200 µm aufweist und das andere Pulver aus Carbonyleisenpartikeln mit einem Partikeldurchmesser unter 10 µm besteht. Der Anteil von Legierungspulver mit formanistropen Partikeln beträgt 5 - 65 Volumenprozent, das Legierungspulver mit groben formisotropen Partikeln beträgt 5 - 65 Volumenprozent und das Carbonyleisenpulver mit feinen formisotropen Partikeln beträgt 25 - 30 Volumenprozent der Legierungspulvermischung.The alloy powder mixture has, in addition to the anisotropic alloy powder, two formisotropic powders of which one powder has coarse alloy particles with a particle diameter of 30-200 μm and the other powder consists of carbonyl iron particles with a particle diameter of less than 10 μm. The proportion of alloy powder having formanistropic particles is 5 to 65% by volume, the alloy powder having coarse form isotropic particles is 5 to 65% by volume, and the carbonyl iron powder having fine formisotropic particles is 25 to 30% by volume of the alloy powder mixture.
Die formanisotropen Pulverpartikel können FeSi-Legierungen und/oder FeAlSi-Legierungen und/oder FeNi-Legierungen und/oder amorphe oder nanokristalline Fe- oder Co-Basis-Legierungen enthalten.The formanisotropic powder particles may contain FeSi alloys and / or FeAlSi alloys and / or FeNi alloys and / or amorphous or nanocrystalline Fe or Co base alloys.
Vorzugsweise weist das Gießharz eine Viskosität kleiner 50 mPas im unausgehärteten Zustand und eine Daueranwendungstemperatur von mehr als 150°C im ausgehärteten Zustand auf. Als Gießharz kommt beispielsweise ein Harz aus der Gruppe der Epoxide, der epoxidierten Polyurethane, der Polyamide sowie der Methacrylatester infrage.Preferably, the casting resin has a viscosity of less than 50 mPas in the uncured state and a continuous use temperature of more than 150 ° C in the cured state. As casting resin, for example, a resin from the group of epoxides, the epoxidized polyurethanes, the polyamides and the methacrylate ester in question.
Der Anteil der Legierungspulvermischung liegt vorzugsweise bei 70 - 75 Volumenprozent, der Anteil des Gießharzes bei 25 -30 Volumenprozent. Der Pulververbundwerkstoff kann zudem einen Zusatz von Fließhilfsmitteln beispielsweise auf Kieselsäurebasis enthalten.The proportion of the alloy powder mixture is preferably at 70 to 75 percent by volume, the proportion of the casting resin at 25 -30 volume percent. The powder composite material may additionally contain an addition of flow aids, for example based on silicic acid.
Schließlich kann das induktive Bauelement ein Gehäuse aufweisen.Finally, the inductive component may have a housing.
Das erfindungsgemäße Verfahren zum Herstellen eines induktiven Bauelements mit zumindest einer Wicklung und einem weichmagnetischen Kern aus einem ferromagnetischen Pulververbundwerkstoff ist in einer ersten Ausführungsform durch die folgenden Schritte gekennzeichnet:
- a) Bereitstellen einer Form, einer Legierungspulvermischung und einer Gießharzformulierung;
- b) Befüllen der Form mit der Legierungspulvermischung;
- c) Einfüllen der Gießharzformulierung in die Form; und
- d) Aushärten der Gießharzformulierung.
- a) providing a mold, an alloy powder mixture and a casting resin formulation;
- b) filling the mold with the alloy powder mixture;
- c) filling the casting resin formulation into the mold; and
- d) curing the casting resin formulation.
In einer alternativen Ausführungsform der vorliegenden Erfindung ist das Verfahren zum Herstellen eines induktiven Bauelements mit zumindest einer Wicklung und einem weichmagnetischen Kern aus einem ferromagnetischen Pulververbundwerkstoff durch folgende Schritte gekennzeichnet:
- a) Bereitstellen einer Form, einer Legierungspulvermischung und einer Gießharzformulierung;
- b) Vermischen der Legierungspulvermischung und der Gießharzformulierung zu einer Gießharzpulverformulierung;
- c) Einfüllen der Gießharzpulverformulierung in die Form; und
- d) Aushärten der Gießharzpulverformulierung.
- a) providing a mold, an alloy powder mixture and a casting resin formulation;
- b) mixing the alloy powder mixture and the casting resin formulation into a casting resin powder formulation;
- c) filling the casting resin powder formulation into the mold; and
- d) curing the casting resin powder formulation.
Durch diese Vorgehensweise wird im Unterschied zum Spritzgussverfahren vermieden, dass die Pulverpartikel einer mechanischen Belastung beim Herstellungsprozess ausgesetzt werden. Des weiteren wird auch insbesondere bei Verwendung einer mit einer vorgefertigten Wicklungen bestückten Form, die auf den Wicklungsdrähten aufgebrachte Isolationsschicht nicht beschädigt, da das Einfüllen der möglichst niedrigviskosen Gießharzformulierung bzw. Gießharzpulver-Formulierung in die Form aufgrund des sanften Einleitens der Formulierungen diese nicht beschädigt. Besonders bevorzugt sind Gießharzformulierungen mit Viskositäten von einigen wenigen Millipascalsekunden.In contrast to the injection molding process, this procedure avoids that the powder particles are subjected to a mechanical load during the production process. Furthermore, especially when using a stocked with a prefabricated windings shape, which on the Winding wires applied insulation layer not damaged, since the filling of the lowest possible viscosity casting resin or casting resin powder formulation into the mold due to the gentle introduction of the formulations does not damage them. Particularly preferred are cast resin formulations having viscosities of a few millipascal seconds.
In einer weiteren Ausgestaltung der vorliegenden Erfindung, insbesondere beim Erzielen von großen Füllhöhen in der Form, hat es sich als besonders vorteilhaft erwiesen, dass die Legierungspulvermischung bereits vor dem Einfüllen in die Form mit der Gießharzformulierung vermischt wird. Bei dieser Ausgestaltung der vorliegenden Erfindung kann mit einem kleinen Überschuss an Gießharz gearbeitet werden, der die Fließfähigkeit der dann hergestellten Gießharzpulver-Formulierung begünstigt. Beim Einfüllen in die Form wird dann die Form durch eine geeignete Einrichtung, beispielsweise einem Pressluftvibrator in Schwingungen versetzt, was dazu führt, dass die Gießharzpulverformulierung gut durchmengt wird. Gleichzeitig wird die Gießharzpulverformulierung entgast.In a further embodiment of the present invention, in particular when achieving large filling heights in the mold, it has proven to be particularly advantageous that the alloy powder mixture is mixed with the casting resin formulation before it is filled into the mold. In this embodiment of the present invention can be used with a small excess of casting resin, which favors the flowability of the cast resin powder formulation then produced. When filled into the mold, the mold is then vibrated by a suitable means, such as a compressed air vibrator, which results in the casting resin powder formulation being well permeated. At the same time, the casting resin powder formulation is degassed.
Da die Legierungspulvermischung im Vergleich zum Gießharz eine sehr hohe Dichte aufweist, setzt sich die Legierungspulvermischung in der Form problemlos ab, so dass der verwendete Gießharzüberschuss beispielsweise in einem Anguss gesammelt werden kann, welcher nach dem Aushärten des Pulververbundwerkstoffs entfernt werden kann.Since the alloy powder mixture has a very high density in comparison to the casting resin, the alloy powder mixture in the mold settles easily, so that the casting resin excess used can be collected for example in a gate, which can be removed after curing of the powder composite.
Durch die Verwendung von Formen, die mit vorgefertigten Wicklungen bereits bestückt sind, können in einem Arbeitsgang induktive Bauelemente hergestellt, werden, ohne dass später das sehr arbeitsaufwendige "Bewickeln" oder Aufbringen von vorgefertigten Wicklungen auf Teilkerne und anschließendes Zusammensetzen der Teilkerne zu Gesamtkernen erforderlich wäre.By using molds that are already equipped with prefabricated windings inductive components can be produced in one operation, without later the very labor-intensive "winding" or application of prefabricated windings on split cores and subsequent assembly of the split cores to total cores would be required.
In einer bevorzugen Ausführungsform der Erfindung wird die Form, die mit der Legierungspulvermischung und der Gießharz-Formulierung befüllt wird oder die bereits mit einer vorgefertigten Gießharzpulverformulierung befüllt wird, als Gehäuse des induktiven Bauelements "weiterverwendet". Das heißt, dass in dieser Ausführungsform der vorliegenden Erfindung die Form als "verlorene Schalung" dient. Durch diese Vorgehensweise wird ein besonders effektives und kostengünstiges Verfahren bereitgestellt, das insbesondere auch im Gegensatz zu Spritzgussverfahren erhebliche Vereinfachungen bringt. Bei dem eingangs erwähnten Spritzgussverfahren ist immer eine Form, die noch dazu sehr aufwendig und teuer herzustellen ist, notwendig, die niemals als "verlorene Schalung" dienen kann.In a preferred embodiment of the invention, the mold which is filled with the alloy powder mixture and the casting resin formulation or which is already filled with a preformed casting resin powder formulation is "reused" as the housing of the inductive component. That is, in this embodiment of the present invention, the mold serves as "lost formwork". By this procedure, a particularly effective and cost-effective method is provided, which brings in particular in contrast to injection molding considerably simplifications. In the initially mentioned injection molding process is always a form that is still very complex and expensive to produce, necessary, which can never serve as a "lost formwork".
Bei den Spritzgussverfahren muss immer das hergestellte Bauelement bzw. der hergestellte weichmagnetische Kern aus Pulververbundwerkstoff aufwendig aus der Form entformt werden, was zu längeren Produktionszeiten führt.In the injection molding process, the component produced or the soft magnetic core made of powder composite material produced must always be removed from the mold in a complicated manner, which leads to longer production times.
Als Gießharzformulierungen werden typischerweise Polymerbausteine, die mit einem Polymerisationsinitiator (Starter) vermengt sind, verwendet. Insbesondere kommen als Polymerbausteine Methacrylsäuremethylester in Betracht. Es sind jedoch auch andere Polymerbausteine denkbar, beispielsweise Lactame. Die Methacrylsäuremethylester werden beim Aushärten dann zu Polyacryl polymerisiert. Analog werden die Lactame über eine Polyadditionsreaktion zu Polyamiden polymerisiert.Cast resin formulations typically include polymer building blocks mixed with a polymerization initiator (initiator). In particular, come as polymer blocks methyl methacrylate into consideration. However, other polymer building blocks are also conceivable, for example lactams. The Methacrylsäuremethylester be polymerized during curing then to polyacrylic. Similarly, the lactams are polymerized via a polyaddition reaction to polyamides.
Als Polymerisationsinitiatoren kommen Dibenzoylperoxid oder auch beispielsweise 2,2'-Azo-Isobuttersäure-dinitril in Betracht.Suitable polymerization initiators are dibenzoyl peroxide or, for example, 2,2'-azo-isobutyric acid dinitrile.
Es sind jedoch auch andere Polymerisationprozesse der bekannten Gießharze möglich, beispielsweise Polymerisationen, die über Licht- oder UV-Strahlung ausgelöst werden, das heißt also weitgehend ohne Polymerisationsinitiatoren auskommen.However, other polymerization processes of the known casting resins are possible, for example, polymerizations which are triggered by light or UV radiation, that is to say largely manage without polymerization initiators.
In einer besonders bevorzugten Ausführungsform werden die Pulverpartikel während und/oder nach dem Befüllen der Form mit der Legierungspulvermischung durch Anlegen eines Magnetfeldes ausgerichtet. Dies kann insbesondere bei der Verwendung von Formen, die bereits mit einer Wicklung bestückt sind, durch Durchleiten eines Stroms durch die Wicklung und den damit einhergehenden Magnetfeld geschehen. Durch dieses Anlegen von Magnetfelder, die zweckmäßigerweise Feldstärken von mehr als 10 A/cm aufweisen, werden die Pulverpartikel ausgerichtet.In a particularly preferred embodiment, the powder particles are aligned during and / or after filling the mold with the alloy powder mixture by applying a magnetic field. This can be done in particular by the use of forms that are already equipped with a winding, by passing a current through the winding and the associated magnetic field. By applying magnetic fields which expediently have field strengths of more than 10 A / cm, the powder particles are aligned.
Insbesondere ist es von Vorteil, die Pulverpartikel, die formanisotrop sind, entlang der Magnetfeldlinien, die im später betriebenen induktiven Bauelement vorliegen, auszurichten. Durch die Ausrichtung der Pulverpartikel mit ihrer "langen" Achse parallel zu den Magnetfeldlinien kann eine starke Absenkung der Verluste und eine Erhöhung der Permeabilität des weichmagnetischen Kerns und damit der Induktivität des induktiven Bauelementes erzielt werden.In particular, it is advantageous to align the powder particles, which are formanisotropic, along the magnetic field lines which are present in the later-operated inductive component. By aligning the powder particles with their "long" axis parallel to the magnetic field lines, a strong reduction in the losses and an increase in the permeability of the soft magnetic core and thus the inductance of the inductive component can be achieved.
Im Fall der Verwendung einer Gießharzpulverformulierung ist es zum Erzielen höherer Permeabilitäten des weichmagnetischen Kerns von Vorteil bereits beim Einfüllen der Gießharzpulver-formulierung mit der in der Form liegenden Spule ein Magnetfeld zu erzeugen, welches zu einer Orientierung der formanisotropen Pulverpartikel in Richtung des magnetischen Flusses wirkt. Nachdem die Form vollständig gefüllt ist, wird diese zunächst in Schwingungen versetzt, was wiederum beispielsweise durch den oben erwähnten Pressluftvibrator erfolgen kann und anschließend der Magnetisierungsstrom abgeschaltet. Nach der endgültigen Aushärtung der Gießharzformulierung wird dann das resultierende induktive Bauelement entformt.In the case of using a cast resin powder formulation, in order to obtain higher permeabilities of the soft magnetic core, it is advantageous to form a magnetic field already in filling the cast resin powder formulation with the in-mold coil, which acts to orient the formanisotropic powder particles in the direction of the magnetic flux. After the mold is completely filled, it is initially set in vibration, which in turn can be done for example by the above-mentioned compressed air vibrator and then turned off the magnetizing current. After the final curing of the casting resin formulation, the resulting inductive component is then removed from the mold.
Schließlich erfolgt während und/oder nach dem Befüllen der Form mit der Legierungspulvermischung, Gießharzformulierung bzw. Gießharzpulverformulierung durch Rütteln ein Verdichten bzw. eine Sedimentation der Legierungspulvermischung.Finally, during and / or after filling the mold with the alloy powder mixture, casting resin formulation takes place or casting resin powder formulation by shaking a compaction or sedimentation of the alloy powder mixture.
Obwohl bereits einzelne erfindungsgemäße Maßnahmen die Eigenschaften induktiver Bauelemente der eingangsgenannten Art deutlich verbessern, sind Kombinationen verschiedener Maßnahmen besonders vorteilhaft. So lässt sich durch das zu wählende Mischungsverhältnis zwischen dem isotropen und anisotropen Anteil die erreichbare Permeabilität bzw. die erreichbare Gleichfeldvorbelastbarkeit steuern. Als formanisotrope Pulverpartikel lassen sich beispielsweise Flakes aus amorphen, nanokristallinen oder kristallinen Legierungen einsetzen sowie elliptische Partikel mit Aspektverhältnissen größer 1,5, wie sie beispielsweise durch entsprechend angepasste Gasverdüsungsverfahren erzeugt werden können. Als isotrope Mischungskomponente bietet sich beispielsweise der Einsatz von Carbonyleisenpulvern an. Diese Pulver sind vorzugsweise oberflächenisoliert, so dass neben der Flussführung durch die feinen Magnetpulverpartikel zusätzlich ein isolierender Effekt in der Pulvermischung auftritt. Diese feinen Pulverpartikel wirken in der Mischung als elektrisch isolierende Abstandshalter zwischen den größeren formanisotropen Pulverpartikeln.Although individual measures according to the invention clearly improve the properties of inductive components of the type mentioned initially, combinations of different measures are particularly advantageous. Thus, the achievable permeability or the achievable DC field resilience can be controlled by the mixing ratio between the isotropic and anisotropic component to be selected. As a formanisotropic powder particles, for example, flakes of amorphous, nanocrystalline or crystalline alloys can be used and elliptical particles with aspect ratios greater than 1.5, as they can be produced for example by appropriately adapted Gasverdüsungsverfahren. For example, the use of carbonyl iron powders is an ideal isotropic mixture component. These powders are preferably surface-insulated, so that in addition to the flow guidance by the fine magnetic powder particles additionally an insulating effect in the powder mixture occurs. These fine powder particles act as electrically insulating spacers in the mixture between the larger formanisotropic powder particles.
Noch bessere Eigenschaften als beim Einsatz dieser binären Metallpulvermischungen werden durch die Verwendung ternärer Magnetpulvermischungen erreicht. Dazu wird vorzugsweise eine Kombination aus einerseits gröberen formanisotropen Pulverpartikeln mit Abmessungen im Bereich von 30 - 200 µm, vorzugsweise 50 - 200 µm, in der lateralen Ausdehnung und einem Aspektverhältnis von größer 1,5 und andererseits eine zweite isotrope Pulverkomponente mit Partikelndurchmessern im Bereich von 30 - 200 µm mit sphärischer Partikelform und einer dritten isotropen Pulverkomponente mit Partikelndurchmessern im Bereich unter 10 µm verwendet. Letztere Pulverkomponente besteht vorzugsweise aus oberflächenisoliertem Carbonyleisenpulver.Even better properties than when using these binary metal powder mixtures are achieved by the use of ternary magnetic powder mixtures. For this purpose, preferably a combination of on the one hand coarser formanisotropic powder particles having dimensions in the range of 30-200 μm, preferably 50-200 μm, in the lateral extent and an aspect ratio of greater than 1.5 and on the other hand a second isotropic powder component with particle diameters in the range of 30 - Used 200 microns with spherical particle shape and a third isotropic powder component with particle diameters in the range below 10 microns. The latter powder component preferably consists of surface-isolated carbonyl iron powder.
Die ternäre Mischung mit gröberen sphärischen Pulverpartikeln zeichnet sich darüber hinaus durch eine deutlich verbesserte Fließfähigkeit der Gießmasse als die zuvor beschriebene binäre Pulvermischung aus Flakes und Feinpulver aus. Außerdem wird die Bewegung der Pulverpartikel im magnetischen Feld durch den erhöhten Anteil gröberer sphärischer Partikel wesentlich erleichtert. Hinsichtlich der gröberen Partikel sowohl der formisotropen als auch der formanisotropen Pulverpartikel ist ein sehr weites Legierungsspektrum anwendbar. Grundvoraussetzung für die Verwendung in dieser Pulvermischung ist eine Legierung mit möglichst niedriger Koerzitivfeldstärke, verschwindend kleiner Sättigungsmagnetostriktion und Kristallanisotropie sowie ein möglichst hoher spezifischer elektrischer Widerstand. Diese Voraussetzungen werden beispielsweise von FeSi-Legierungen, FeAlSi-Legierungspulvern, FeNi-Legierungspulvern sowie den amorphen und nanokristallinen Fe- bzw. Co-Basis-Legierungspulvern erfüllt. Weiterhin ist es wichtig, dass sämtliche erforderlichen Wärmebehandlungsschritte vor der Herstellung des Gießkerns abgeschlossen werden können. Dies ist bei den genannten Legierungen ebenfalls der Fall.The ternary mixture with coarser spherical powder particles is also characterized by a significantly improved flowability of the casting compound than the previously described binary powder mixture of flakes and fine powder. In addition, the movement of the powder particles in the magnetic field is greatly facilitated by the increased proportion of coarser spherical particles. With regard to the coarser particles of both the formisotropic and the formanisotropic powder particles, a very wide alloy spectrum can be used. The basic requirement for use in this powder mixture is an alloy with the lowest possible coercive field strength, vanishingly small saturation magnetostriction and crystal anisotropy, and the highest possible specific electrical resistance. These requirements are fulfilled, for example, by FeSi alloys, FeAlSi alloy powders, FeNi alloy powders and the amorphous and nanocrystalline Fe or Co base alloy powders. Furthermore, it is important that all necessary heat treatment steps can be completed before the core is made. This is also the case with the alloys mentioned.
Zur Herstellung der erfindungsgemäßen Bauelemente lässt sich beispielsweise eine Magnetpulvermischung aus einer Kombination von 5 - 65 Volumenprozent formanisotroper Pulverpartikel mit einem Aspektverhältnis größer 1,5 und einer Partikelgröße größer 30 µm als erste Komponente sowie einer gröberen isotropen Pulverkomponente mit Partikelndurchmessern größer 30 µm und einem Anteil von 5 - 65 Volumenprozent als zweite Komponente sowie die Carbonyleisenpulver mit einem Volumenanteil von 25 - 30 Volumenprozent als dritte Komponente verwenden. Aus den genannten Einzelkomponenten wird in einem geeigneten Mischer eine homogene Pulvermischung erzeugt. Um eine Aglomeration der Feinpulveranteile zu verhindern, hat sich der Zusatz von Fließhilfsmitteln auf Kieselsäurebasis zu dieser Pulvermischung bewährt. Anschließend erfolgt beispielsweise das Vermischen der so vorbereiteten Magnetpulvermischung mit der für den Verguss vorgesehenen Harzmischung. Die Auswahl der verwendbaren Harze richtet sich dabei sowohl nach den Eigenschaften im ausgehärteten als auch im unausgehärteten Zustand. Verwendbar sind Harze mit Viskositäten kleiner 50 mPas im unausgehärteten Zustand und Dauerwendungs-temperaturen oberhalb 150 °C im ausgehärteten Zustand. Diese Eigenschaften werden beispielsweise von Harzen aus der Gruppe der Epoxide, der epoxidierten Polyurethane sowie von verschiedenen Methacrylatestern erfüllt.To produce the components of the invention, for example, a magnetic powder mixture of a combination of 5-65 volume percent formanisotropic powder particles having an aspect ratio greater than 1.5 and a particle size greater than 30 microns as the first component and a coarser isotropic powder component with particle diameters greater than 30 microns and a proportion of Use 5-65% by volume as the second component and the carbonyl iron powders with a volume fraction of 25-30% by volume as the third component. From the individual components mentioned, a homogeneous powder mixture is produced in a suitable mixer. In order to prevent aglomeration of the fine powder fractions, the addition of silica-based flow aids to this powder mixture has proven itself. Subsequently, for example Mixing the thus prepared magnetic powder mixture with the intended for the casting resin mixture. The choice of usable resins depends both on the properties in the cured and in the uncured state. Resins with viscosities of less than 50 mPas in the uncured state and continuous use temperatures above 150 ° C. in the cured state can be used. These properties are fulfilled, for example, by resins from the group of epoxides, epoxidized polyurethanes and various methacrylate esters.
Die Herstellung der gießfähigen Mischung erfolgt dann durch Vermischen von 70 - 75 Volumenprozent Magnetpulvermischung und 25 - 30 Volumenprozent eines ausgewählten Harzes. Diese Mischung wird unter Rühren im Vakuum entgast und anschließend in die vorgesehene Vergussform gefüllt. In der Form erfolgt durch mechanisches Rütteln ein Verdichten bzw. eine Sedimentation des Magnetpulvers und gleichzeitig durch ein äußeres magnetisches Feld oder aber durch Bestromen der eingelegten Kupferspule eine Ausrichtung des formanisotropen Anteiles des Magnetpulvers. Im Anschluss an das Ausrichten des formanisotropen Pulveranteils erfolgt die Aushärtung der Harze bei erhöhter Temperatur.The pourable mixture is then prepared by mixing 70-75 volume percent magnetic powder mixture and 25-30 volume percent of a selected resin. This mixture is degassed with stirring in a vacuum and then filled into the intended casting mold. In the form by mechanical shaking, a compaction or sedimentation of the magnetic powder and at the same time by an external magnetic field or by energizing the inserted copper coil, an orientation of the formanisotropic portion of the magnetic powder. Following the alignment of the formanisotropic powder fraction, the curing of the resins takes place at elevated temperature.
Mit der beschriebenen Technologie ist die Herstellung von Gießkernen im Permeabilitätsbereich zwischen ca. 20 und 100 problemlos möglich. Die erreichbare Permeabilität wird dabei durch die Größe der formanisotropen Partikel und deren Volumenanteil in der Gesamtpulvermischung bestimmt. Bezüglich der Gleichfeldvorbelastbarkeit werden Werte um 0,3 - 0,35 T erreicht. Die Ummagnetisierungsverluste so hergestellter Bauelemente bewegen sich etwa auf dem gleichen Niveau wie permeabilitätsgleiche Ringkerne aus FeAlSi bzw. hoch nickelhaltigen NiFe-Legierungen.With the described technology it is possible to produce casting cores in the permeability range between approx. 20 and 100 without problems. The achievable permeability is determined by the size of the formanisotropic particles and their volume fraction in the total powder mixture. Concerning the Gleichfeldvorbelastbarkeit values are achieved by 0.3 - 0.35 T. The re-magnetization losses of components produced in this way move approximately at the same level as permeability-equivalent toroidal cores made of FeAlSi or nickel-containing NiFe alloys.
Die Erfindung wird nachfolgend anhand der in den Figuren der Zeichnung dargestellten Ausführungsformen näher erläutert. Es zeigen:
- Figur 1
- ein induktives Bauelement gemäß einer ersten Ausführungsform der vorliegenden Erfindung im Querschnitt;
- Figur 2
- ein induktives Bauelement gemäß einer zweiten Ausführungsform im Querschnitt; und
- Figur 3
- ein induktives Bauelement gemäß einer dritten Ausführungsform der vorliegenden Erfindung im Querschnitt.
- FIG. 1
- an inductive component according to a first embodiment of the present invention in cross section;
- FIG. 2
- an inductive component according to a second embodiment in cross section; and
- FIG. 3
- an inductive component according to a third embodiment of the present invention in cross section.
Die
Die
Die
Als Ausgangsmaterial für den Pulververbundwerkstoff ist in den drei Ausführungsbeispielen eine der folgenden Pulvermischungen vorgesehen:As starting material for the powder composite material, one of the following powder mixtures is provided in the three exemplary embodiments:
Zur Herstellung eines Gießkernes im Permeabilitätsbereich um ca. 35 - 40 und einem Bauelementgewicht um 100 g läßt sich z.B. folgende Formulierung verwenden:
Aus obiger Mischung lassen sich Gießkerne mit einer Permeabilität um ca. 40, einer Gleichfeldvorbelastbarkeit von ca. 0,35 T und Ummagnetisierungsverlusten von ca. 90 - 110 W/kg bei 100 kHz und Wechselaussteuerungen von 0,1 herstellen.From the above mixture, casting cores having a permeability of about 40, a Gleichfeldvorbelastbarkeit of about 0.35 T and Ummagnetisierungsverlusten of about 90 - 110 W / kg at 100 kHz and Wechselaussteuerungen of 0.1 can be produced.
Zur Herstellung eines Gießkernes im Permeabilitätsbereich um ca. 60 und einem Bauelementgewicht um 100 g lässt sich z.B. folgende Formulierung verwenden:
Aus obiger Mischung lassen sich Gießkerne mit einer Permeabilität um ca. 65, einer Gleichfeldvorbelastbarkeit von ca. 0,30 T und Ummagnetisierungsverlusten von ca. 90 - 110 W/kg bei 100 kHz und Wechselaussteuerungen von 0,1 T herstellen.From the above mixture, casting cores having a permeability of about 65, a Gleichfeldvorbelastbarkeit of about 0.30 T and re-magnetization losses of about 90 - 110 W / kg at 100 kHz and Wechselaussteuerungen of 0.1 T can be produced.
Aus obiger Mischung lassen sich Gießkerne mit einer Permeabilität um ca. 85, einer Gleichfeldvorbelastbarkeit von ca. 0,27 T und Ummagnetisierungsverlusten von ca. 90 - 110 W/kg bei 100 kHz und Wechselaussteuerungen von 0,1 T herstellenFrom the above mixture, casting cores having a permeability of about 85, a Gleichfeldvorbelastbarkeit of about 0.27 T and Ummagnetisierungsverlusten of about 90 - 110 W / kg at 100 kHz and 0.1 T alternator
Es wird angemerkt, dass die vorstehenden Legierungspulvermischungen nur beispielhaften Charakter haben. Es sind eine große Fülle von anderen Legierungspulvermischungen als die oben aufgeführten Formulierungen möglich ist.It is noted that the above alloy powder mixtures are only exemplary in nature. There is a wide range of alloy powder mixtures other than the above listed formulations.
Wie zu ersehen ist, wurden die formanisotropen Pulverpartikel, aufgrund ihrer Form auch Flakes genannt, zur Verbesserung ihrer dynamischen magnetischen Eigenschaften einer Wärme- und Oberflächenbehandlung unterzogen. Außerdem erfolgte zum Zwecke der Isolation die Behandlung der formisotropen Pulverpartikel mit Phosphorsäure, wodurch sich an deren Oberfläche elektrisch isolierendes Eisenphosphat bildet.As can be seen, the formanisotropic powder particles, also called flakes by reason of their shape, were subjected to heat and surface treatment to improve their dynamic magnetic properties. In addition, for the purpose of isolation, the treatment of the formisotropic powder particles with phosphoric acid, which forms electrically insulating iron phosphate on the surface thereof.
Die so vorbereiteten gemischten Legierungspulvermischungen wurden dann bei den in den
Anschließend wurden bei den in den
Bei der in der
Bei dem in
In beiden Ausführungsformen wurden die vorstehenden chemischen Bestandteile nacheinander im Methacrylester gelöst. Die fertige Mischung war in beiden Fällen wasserklar und wurde dann in die Formen 1a und 1b gegossen. Die Gießharzformulierungen härteten in beiden Fällen bei Raumtemperatur innerhalb von ca. 60 min aus. Anschließend wurde eine Nachhärtung bei ca. 150 C für eine weitere Stunde vorgenommen.In both embodiments, the above chemical ingredients were dissolved sequentially in the methacrylic ester. The finished mixture was water clear in both cases and was then poured into
Beim Befüllen der Formen 1a bzw. 1b mit der Legierungspulvermischung hat es sich als zweckmäßig erwiesen, die Formen 1a bzw. 1b während des Befüllens in Schwingungen zu versetzen, um damit die Legierungspulvermischung zu verdichten. Mit diesem Vorgehen konnten in beiden Fällen problemlos Volumenanteile von bis zu 70 Volumenprozent Legierungspulvermischung in dem Pulververbundwerkstoff erzielt werden.When filling the
Bei dem in der
Diese Gießharzformulierung wurde in die Form 1c, wie in der
Anschließend wurde auch diese die Gießharzformulierung bei einer Temperatur von ungefähr 150 °C für ca. eine Stunde nachgehärtet.Subsequently, this, too, was postcured in the cast resin formulation at a temperature of about 150 ° C for about one hour.
Es wird angemerkt, dass die vorstehenden Gießharzformulierungen nur beispielhaften Charakter haben. Es sind eine große Fülle von anderen Gießharzformulierungen möglich, die auch chemisch anders vernetzt werden, als es in den oben aufgeführten Formulierungen der Fall war.It is noted that the above cast resin formulations are only exemplary in nature. There is a wide range of other cast resin formulations possible, which are chemically crosslinked differently than was the case in the formulations listed above.
Der Vollständigkeit halber wird angemerkt, dass die oben genannten Formulierungen polymerisiert wurden und als Startersubstanzen Dibenzoylperoxid bzw. 2,2'-Azo-Isobuttersäure-Dinitril verwendet wurden. Es ist jedoch insbesondere auch möglich, ohne eine spezielle Startersubstanz auszukommen und Monomerbaussteine, das heißt chemische Agentien wie hier den Methacrylsäuremethylester, mit UV-Licht zu polymerisieren. Durch die Beimengungen von Methacrylmethoxisilan bzw. Diglycoldimethacrylat und anderen chemischen Substanzen kann die Zähigkeit bzw. die Schlagfestigkeit des entstehenden Pulververbundwerkstoffes eingestellt, insbesondere erhöht werden.For completeness, it is noted that the above-mentioned formulations were polymerized and were used as starter substances dibenzoyl peroxide or 2,2'-azo-isobutyric acid dinitrile. However, it is also possible in particular to manage without a special starter substance and to polymerize monomer building blocks, that is to say chemical agents such as here the methyl methacrylate, with UV light. By the admixtures of Methacrylmethoxisilan or Diglycoldimethacrylat and other chemical substances, the toughness or the impact resistance of the resulting powder composite material can be adjusted, in particular increased.
Bei der Verwendung von thermoplastischen Polyamiden können insbesondere Schmelzen aus ε-Caprolactam und Phenylisocyanat verwendet werden, so hat sich in weiteren Versuchen eine Schmelze aus 100 g ε-Caprolactam und 0,4 g Phenylisocyanat als geeignet erwiesen, welche bei 130 °C miteinander vermischt wurde. Diese Schmelze wurde dann in eine auf 150 °C vorgewärmte Form eingefüllt. Die Aushärtung des Caprolactams zu einem Polyamid erfolgte dann innerhalb von ungefähr 20 min. Eine Nachhärtung bei höheren Temperaturen war bei dieser Vorgehensweise in der Regel nicht erforderlich.When using thermoplastic polyamides in particular melts of ε-caprolactam and phenyl isocyanate can be used, so in further experiments, a melt of 100 g of ε-caprolactam and 0.4 g of phenyl isocyanate proved to be suitable, which was mixed together at 130 ° C. This melt was then poured into a preheated to 150 ° C mold. The curing of the caprolactam to a polyamide was then carried out within about 20 minutes. A post cure at higher temperatures was usually not required in this approach.
Statt eines Caprolactams kann selbstverständlich auch ein anderes Lactam, beispielsweise Laurinlactam mit einer entsprechenden Binderphase verwendet werden. Bei der Verarbeitung von Laurinlactam sind jedoch Prozesstemperaturen von über 170 °C erforderlich.Instead of a caprolactam it is of course also possible to use another lactam, for example laurolactam, with a corresponding binder phase. However, when processing laurolactam, process temperatures in excess of 170 ° C are required.
Neben den bisher beschriebenen thermoplastischen Binderharzformulierungen ist natürlich auch der Einsatz von Reaktionsharzen, die duroplastische Formstoffe liefern denkbar. Insbesondere ist hier der Einsatz von zweikomponentigen heißhärtenden Epoxydharzen möglich. Ein Gießharz aus dieser Gruppe hat beispielsweise folgende Zusammensetzung:
Aus den vorstehend genannten Einzelkomponenten wird das Vergußharz durch Vermischen bei Raumtemperatur hergestellt. Zur Verarbeitung wird die Mischung auf Temperaturen um 80 ± 10 °C erwärmt. Dadurch verringert sich die Viskosität der Mischung auf Werte < 20 mPas. Zur Aushärtung von, aus dieser Mischung hergestellten Bauelementen erfolgt eine Erwärmung auf Temperaturen von ca. 150 °C für eine Zeitdauer von ca. 30 Minuten.From the above-mentioned individual components, the potting resin is prepared by mixing at room temperature. For processing, the mixture is heated to temperatures around 80 ± 10 ° C. This reduces the viscosity of the mixture to values <20 mPas. For curing, made of this mixture components is heated to temperatures of about 150 ° C for a period of about 30 minutes.
Mit den vorstehend beschriebenen Gießharzformulierungen wurden induktive Bauelemente mit weichmagnetischen Kernen aus ferromagnetischen Pulververbundwerkstoffen hergestellt, die Ummagnetisierungsverluste zeigen, wie permeabilitätsgleiche Ringkerne aus FeAlSi bzw. hoch nickelhaltigen NiFe-Legierungen. Die erreichbare Permeabilität von ca. 20 und 100 wird dabei durch die Größe der formanisotropen Partikel und deren Volumenanteil in der Gesamtpulvermischung bestimmt. Bezüglich der Gleichfeldvorbelastbarkeit werden Werte um 0,3 - 0,35 T erreicht.The cast resin formulations described above were used to fabricate inductive components with soft magnetic cores made of ferromagnetic powder composites that exhibit core loss losses, such as permeable core cores made of FeAlSi or nickel-containing NiFe alloys. The achievable permeability of about 20 and 100 is determined by the size of the formanisotropic particles and their volume fraction in the total powder mixture. Concerning the Gleichfeldvorbelastbarkeit values are achieved by 0.3 - 0.35 T.
Claims (25)
- An inductive component (10; 20; 30) with at least one winding (12; 22; 32) and a soft magnetic core (11; 21; 31) of a ferromagnetic powder composite material, wherein the ferromagnetic powder composite material includes an alloy powder mixture of powders with shape anisotropic and shape isotropic powder particles and a casting resin, characterised in that in addition to an anisotropic alloy powder, the alloy powder mixture includes two shape isotropic powders, of which one powder has large alloy particles with a particle diameter of 30 to 200µm and the other powder consists of carbonyl iron particles with a particle diameter less than 10µm.
- An inductive component as claimed in Claim 1, characterised in that the alloy powder mixture has a coercivity field strength of less than 150 mA/cm, a saturation magnetostriction and a crystal anisotropy of approaching 0, a saturation induction 0.7T and specific electrical resistance of greater than 0.4 Ohm*mm2/m.
- An inductive component as claimed in Claims 1 or 2, characterised in that shape isotropic powder particles include amorphous, nanocrystalline or crystalline alloys.
- An inductive component as claimed in Claim 1 or 2, characterised in that shape anisotropic powder particles have an elliptical shape with an aspect ratio greater than 1.5.
- An inductive component as claimed in one of Claims 1 to 4, characterised in that shape anisotropic powder particles have a particle diameter of 30 to 200µm.
- An inductive component as claimed in one of Claims 1 to 5, characterised in that shape isotropic powder particles are surface insulated.
- An inductive component as claimed in one of Claims 1 to 6, characterised in that the proportion of alloy powder with shape anisotropic particles is 5 to 65 volume percent of alloy powder with coarse shape isotropic particles is 5 to 65 volume percent and of carbonyl iron powder with fine shape isotropic particles is 25 to 30 volume percent of the alloy powder mixture.
- An inductive component as claimed in Claims 1 to 7, characterised in that shape anisotropic powder particles include FeSi alloys and/or FeAlSi alloys and/or FeNi alloys and/or amorphous or nanocrystalline alloys based on Fe or Co.
- An inductive component as claimed in one of Claims 1 to 8, characterised in that the casting resin has a viscosity smaller than 50 mPas in the uncured form and a long term usage temperature of more than 150°C in the cured state.
- An inductive component as claimed in Claim 9, characterised in that at least one resin from the group of epoxides, epoxidated polyurethanes and methylacrylate esters is provided as the casting resin.
- An inductive component as claimed in one of Claims 1 to 10, characterised in that the proportion of the alloy powder mixture is 70 to 75 volume percent and the proportion of the casting resin is 25 to 30 volume percent in the powder composite material.
- An inductive component as claimed in one of Claims 1 to 11, characterised in that the powder composite material includes an addition of flow promoting agents.
- An inductive component as claimed in one of Claims 1 to 12, characterised in that the inductive component (30) has a housing (34).
- A method of producing an inductive component as claimed in one of Claims 1 to 3, characterised by the following steps:(a) providing a mould (1a; 1b; 1c), an alloy powder mixture and a casting resin formulation;(b) filling the mould (1a; 1b; 1c), with the alloy powder mixture;(c) introducing the casting resin formulation into the mould (1a; 1b; 1c); and(d) curing the casting resin formulation.
- A method of producing an inductive component as claimed in one of Claims 1 to 13, characterised by the following steps:(a) providing a mould (1a; 1b; 1c), an alloy powder mixture and a casting resin formulation;(b) mixing the alloy powder mixture and the casting resin formulation to form a casting resin powder formulation;(c) introducing the casting resin formulation into the mould (1a; 1b; 1c); and(d) curing the casting resin formulation.
- A method as claimed in Claim 14 or 15, characterised in that a mould (1a; 1b; 1c) is provided equipped with at least one winding (12; 22; 32), provided with an insulating layer, of round or profiled wire.
- A method as claimed in one of Claims 14 to 16, characterised in that the mould (1c) is used as a housing (34) of the inductive component (30).
- A method as claimed in one of Claims 14 to 17, characterised in that a casting resin formulation consisting of polymer units and a polymerisation initiator is used.
- A method as claimed in Claim 18, characterised in that methacrylic acid methyl ester is used as the polymer unit.
- A method as claimed in Claim 19, characterised in that dibenzoylperoxide is used as the polymerisation initiator.
- A method as claimed in Claim 19, characterised in that 2,2' - azoisobutyric dinitrile is used as the polymerisation initiator.
- A method as claimed in Claims 14 to 21, characterised in that the powder particles are aligned during and/or after the filling of the mould with the alloy powder mixture by the application of a magnetic field.
- A method as claimed in Clam 22, characterised in that the magnetic field is applied by energising the winding (12; 22; 32).
- A method as claimed in Claim 22 or 23, characterised in that a magnetic field is applied with a field strength greater than 10 A/cm.
- A method as claimed in one of Claims 14 to 24, characterised in that after filling the mould with alloy powder mixture, casting resin formulation or casting resin powder formulation, compression or sedimentation of the alloy powder mixture is effected by vibration.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE10155898 | 2001-11-14 | ||
DE10155898A DE10155898A1 (en) | 2001-11-14 | 2001-11-14 | Inductive component and method for its production |
PCT/EP2002/012708 WO2003043033A1 (en) | 2001-11-14 | 2002-11-13 | Inductive component and method for producing same |
Publications (2)
Publication Number | Publication Date |
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EP1444706A1 EP1444706A1 (en) | 2004-08-11 |
EP1444706B1 true EP1444706B1 (en) | 2009-01-14 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP02785387A Expired - Lifetime EP1444706B1 (en) | 2001-11-14 | 2002-11-13 | Inductive component and method for producing same |
Country Status (5)
Country | Link |
---|---|
US (1) | US7230514B2 (en) |
EP (1) | EP1444706B1 (en) |
JP (1) | JP2005510049A (en) |
DE (2) | DE10155898A1 (en) |
WO (1) | WO2003043033A1 (en) |
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JP4023138B2 (en) * | 2001-02-07 | 2007-12-19 | 日立金属株式会社 | Compound containing iron-based rare earth alloy powder and iron-based rare earth alloy powder, and permanent magnet using the same |
DE10128004A1 (en) * | 2001-06-08 | 2002-12-19 | Vacuumschmelze Gmbh | Wound inductive device has soft magnetic core of ferromagnetic powder composite of amorphous or nanocrystalline ferromagnetic alloy powder, ferromagnetic dielectric powder and polymer |
-
2001
- 2001-11-14 DE DE10155898A patent/DE10155898A1/en not_active Withdrawn
-
2002
- 2002-11-13 DE DE50213224T patent/DE50213224D1/en not_active Expired - Lifetime
- 2002-11-13 US US10/250,733 patent/US7230514B2/en not_active Expired - Fee Related
- 2002-11-13 JP JP2003544772A patent/JP2005510049A/en active Pending
- 2002-11-13 EP EP02785387A patent/EP1444706B1/en not_active Expired - Lifetime
- 2002-11-13 WO PCT/EP2002/012708 patent/WO2003043033A1/en active Application Filing
Also Published As
Publication number | Publication date |
---|---|
JP2005510049A (en) | 2005-04-14 |
EP1444706A1 (en) | 2004-08-11 |
DE10155898A1 (en) | 2003-05-28 |
US20040074564A1 (en) | 2004-04-22 |
US7230514B2 (en) | 2007-06-12 |
DE50213224D1 (en) | 2009-03-05 |
WO2003043033A1 (en) | 2003-05-22 |
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