JP2002289417A - Composite magnetic material, magnetic device, and its manufacturing method - Google Patents
Composite magnetic material, magnetic device, and its manufacturing methodInfo
- Publication number
- JP2002289417A JP2002289417A JP2001123837A JP2001123837A JP2002289417A JP 2002289417 A JP2002289417 A JP 2002289417A JP 2001123837 A JP2001123837 A JP 2001123837A JP 2001123837 A JP2001123837 A JP 2001123837A JP 2002289417 A JP2002289417 A JP 2002289417A
- Authority
- JP
- Japan
- Prior art keywords
- magnetic material
- alloy powder
- soft magnetic
- composite
- composite magnetic
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000000696 magnetic material Substances 0.000 title claims abstract description 38
- 239000002131 composite material Substances 0.000 title claims abstract description 34
- 238000004519 manufacturing process Methods 0.000 title claims description 6
- 239000000843 powder Substances 0.000 claims abstract description 65
- 229910001004 magnetic alloy Inorganic materials 0.000 claims abstract description 40
- 239000011572 manganese Substances 0.000 claims abstract description 25
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 21
- 239000011230 binding agent Substances 0.000 claims abstract description 17
- 239000000203 mixture Substances 0.000 claims abstract description 16
- 239000011575 calcium Substances 0.000 claims abstract description 14
- 239000010955 niobium Substances 0.000 claims abstract description 14
- 239000010936 titanium Substances 0.000 claims abstract description 14
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 13
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 11
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims abstract description 11
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 11
- 239000001301 oxygen Substances 0.000 claims abstract description 9
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 9
- 239000010703 silicon Substances 0.000 claims abstract description 9
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims abstract description 7
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 7
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims abstract description 7
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 7
- 229910052791 calcium Inorganic materials 0.000 claims abstract description 7
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 7
- 229910052758 niobium Inorganic materials 0.000 claims abstract description 7
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 claims abstract description 7
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 7
- 238000000465 moulding Methods 0.000 claims description 15
- 238000010438 heat treatment Methods 0.000 claims description 13
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 12
- 229920005989 resin Polymers 0.000 claims description 12
- 239000011347 resin Substances 0.000 claims description 12
- 239000011651 chromium Substances 0.000 claims description 10
- 239000002245 particle Substances 0.000 claims description 10
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 8
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 8
- 239000000395 magnesium oxide Substances 0.000 claims description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 5
- 229910052799 carbon Inorganic materials 0.000 claims description 5
- 229910052804 chromium Inorganic materials 0.000 claims description 5
- 229920001187 thermosetting polymer Polymers 0.000 claims description 4
- 238000002156 mixing Methods 0.000 claims description 3
- 238000003825 pressing Methods 0.000 claims description 3
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims 1
- 229910052737 gold Inorganic materials 0.000 claims 1
- 239000010931 gold Substances 0.000 claims 1
- 238000009413 insulation Methods 0.000 abstract description 3
- 239000011777 magnesium Substances 0.000 abstract 2
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 abstract 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 abstract 1
- 229910052749 magnesium Inorganic materials 0.000 abstract 1
- 230000004907 flux Effects 0.000 description 11
- 229910052751 metal Inorganic materials 0.000 description 10
- 239000002184 metal Substances 0.000 description 10
- 230000035699 permeability Effects 0.000 description 10
- 239000000428 dust Substances 0.000 description 8
- 238000005259 measurement Methods 0.000 description 7
- 239000006247 magnetic powder Substances 0.000 description 5
- 229910000859 α-Fe Inorganic materials 0.000 description 5
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 4
- 229920002050 silicone resin Polymers 0.000 description 4
- 238000009692 water atomization Methods 0.000 description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 238000000748 compression moulding Methods 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- 238000011049 filling Methods 0.000 description 3
- 238000009689 gas atomisation Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 2
- 239000002905 metal composite material Substances 0.000 description 2
- 101100219325 Phaseolus vulgaris BA13 gene Proteins 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920002037 poly(vinyl butyral) polymer Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 230000002250 progressing effect Effects 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、変圧器、電動機、
チョーク、ノイズフィルター等に用いられる高性能な金
属系複合磁性材料に関し、特に磁芯用の軟磁性材料とし
て用いられる複合磁性材料、磁性素子およびその製造方
法に関するものである。TECHNICAL FIELD The present invention relates to a transformer, an electric motor,
The present invention relates to a high-performance metal-based composite magnetic material used for a choke, a noise filter, and the like, and particularly to a composite magnetic material, a magnetic element, and a method for manufacturing the same, which are used as a soft magnetic material for a magnetic core.
【０００２】[0002]
【従来の技術】近年、電気・電子機器の小型化が進み、
小型で高効率の磁性材料が要求されており、高周波で用
いられるチョークコイルとしては、比較的保持力が小さ
いフェライト磁芯や圧粉磁芯が使用されている。これら
のうち、フェライト磁芯は飽和磁束密度が小さいという
欠点を有している。これに対して、金属磁性粉末を成形
して作製される圧粉磁芯は、軟磁性フェライトに比べて
著しく大きい飽和磁束密度を有しているため小型化に有
利である。ここで、高い飽和磁束密度、高い透磁率を得
るためには、金属磁性粉末の充填率を高くする必要があ
り、そのために高圧で圧縮成形することが行われてい
る。2. Description of the Related Art In recent years, miniaturization of electric and electronic devices has been progressing.
A small and highly efficient magnetic material is required. As a choke coil used at a high frequency, a ferrite core or a dust core having a relatively small holding force is used. Among them, the ferrite core has a disadvantage that the saturation magnetic flux density is small. On the other hand, a dust core manufactured by molding a metal magnetic powder has an extremely large saturation magnetic flux density as compared with soft magnetic ferrite, which is advantageous for miniaturization. Here, in order to obtain a high saturation magnetic flux density and a high magnetic permeability, it is necessary to increase the filling rate of the metal magnetic powder, and compression molding is performed at a high pressure.
【０００３】一方、圧粉磁芯のコア損失は、通常ヒステ
リシス損失と渦電流損失よりなるが、渦電流損失は、周
波数の二乗と渦電流が流れるサイズの二乗に比例して増
大するので、金属磁性粉末表面に電気絶縁性樹脂等を覆
うことにより渦電流の発生を抑制するようにしている。
また、圧粉磁芯の成形が通常数ｔｏｎ／ｃｍ2以上の成
形圧力で行われるために、磁性体として歪みが増大する
とともに透磁率が劣化し、ヒステリシス損失が増大す
る。これを回避するために、歪みを解放することが行わ
れ、例えば特開平６−３４２７１４号公報、特開平８−
３７１０７号公報、特開平９−１２５１０８号公報に記
載されているような成形後の熱処理が行われている。On the other hand, the core loss of a dust core usually consists of hysteresis loss and eddy current loss, but eddy current loss increases in proportion to the square of the frequency and the square of the size in which the eddy current flows. The generation of eddy current is suppressed by covering the surface of the magnetic powder with an electrically insulating resin or the like.
In addition, since the molding of the dust core is usually performed at a molding pressure of several ton / cm 2 or more, the strain increases as the magnetic material, the magnetic permeability deteriorates, and the hysteresis loss increases. In order to avoid this, the distortion is released. For example, Japanese Patent Application Laid-Open Nos. Hei 6-342714 and Hei 8-
Heat treatment after molding as described in JP-A-37107 and JP-A-9-125108 is performed.
【０００４】また、コイルを金属複合磁性体の中に埋設
することにより、優れた磁気的特性を有する磁性素子が
提案されている。例えば、特開昭５４−１６３３５４号
公報、特開昭６１−１３６２１３号公報は、樹脂にフェ
ライトを分散させたものを用いている。[0004] A magnetic element having excellent magnetic properties by embedding a coil in a metal composite magnetic material has been proposed. For example, JP-A-54-163354 and JP-A-61-136213 use a resin in which ferrite is dispersed.
【０００５】[0005]
【発明が解決しようとする課題】しかしながら、上記の
とおり、軟磁性合金粉末と絶縁性結着剤からなる複合磁
性材料において、成形密度が最終的な製品密度になるた
めには、数ｔｏｎ／ｃｍ 2以上の高圧成形が通常必要と
なる。そのため、金属粉体同士が直接接触したり、金属
粉体の塑性変形により絶縁性が破れるために、渦電流損
失が増加する等の問題が発生している。また、金属複合
磁性材料中にコイルを埋設した磁性素子においても、圧
縮成形時に磁性粉末による機械的ストレスでコイルの絶
縁被膜が破壊される可能性が高いのに加え、樹脂にフェ
ライトを分散させたものにおいては、フェライトの充填
率に限界があるため、飽和磁束密度が低く、直流重畳特
性が悪いといった問題が起きている。SUMMARY OF THE INVENTION
As shown in the figure, a composite magnet consisting of a soft magnetic alloy powder and an insulating binder
Molding density becomes the final product density
For some, ton / cm TwoThe above high pressure molding is usually required
Become. Therefore, metal powders may come into direct contact
The eddy current loss occurs because the insulation is broken by plastic deformation of the powder.
Problems such as an increase in losses have occurred. Also metal composite
Even in a magnetic element with a coil embedded in a magnetic material,
The coil is cut off by mechanical stress due to magnetic powder during compression molding.
In addition to the high possibility that the edge coating will be destroyed,
Filled with ferrite for dispersed light
The saturation flux density is low,
There is a problem of poor sex.
【０００６】一方、圧縮により生じた歪みを除去する熱
処理では、その熱処理に耐え得る絶縁性結着剤あるいは
コイルを用いる必要があり、実際には、コイルを内蔵し
た磁性素子においては、熱処理が行えず、優れた磁気的
特性を得ることが困難となっている。On the other hand, in the heat treatment for removing the strain caused by the compression, it is necessary to use an insulating binder or a coil which can withstand the heat treatment. Therefore, it is difficult to obtain excellent magnetic properties.
【０００７】以上の問題点に鑑み、本発明は、従来の技
術における課題を解決し、複合磁性材料または磁性素子
の絶縁性を維持し、優れた特性を有する複合磁性材料、
磁性素子およびその製造方法を提供するものである。[0007] In view of the above problems, the present invention solves the problems in the prior art, maintains the insulating properties of a composite magnetic material or a magnetic element, and has excellent characteristics.
A magnetic element and a method for manufacturing the same are provided.
【０００８】[0008]
【課題を解決するための手段】上記課題を解決するため
に本発明の複合磁性材料は、軟磁性合金粉末と絶縁性結
着剤からなる複合磁性材料において、前記軟磁性合金粉
末の組成が、１ｗｔ％≦成分Ａ≦７ｗｔ％でかつ０．０
５ｗｔ％≦酸素（Ｏ）≦０．６ｗｔ％、０．０１ｗｔ％
≦マンガン（Ｍｎ）≦０．２ｗｔ％で残部が鉄（Ｆｅ）
であることを特徴とする複合磁性材料、あるいは、軟磁
性合金粉末と絶縁性結着剤からなる複合磁性材料におい
て、前記軟磁性合金粉末の組成が、１ｗｔ％≦成分Ａ≦
７ｗｔ％でかつ０．０５ｗｔ％≦酸素（Ｏ）≦０．６ｗ
ｔ％、０．０１ｗｔ％≦マンガン（Ｍｎ）≦０．２ｗｔ
％、０．０１ｗｔ％≦カーボン（Ｃ）≦０．２ｗｔ％で
残部が鉄（Ｆｅ）である複合磁性材料であることを特徴
とする。ここで、成分Ａは、シリコン（Ｓｉ）、アルミ
（Ａｌ）、クロム（Ｃｒ）、ニッケル（Ｎｉ）、ニオブ
（Ｎｂ）、カルシウム（Ｃａ）、チタン（Ｔｉ）、マグ
ネシア（Ｍｇ）の内、少なくとも一つを含むことを特徴
とする。また、軟磁性合金粉末の平均粒径が１μｍ以上
１００μｍ以下であることが好ましい。Means for Solving the Problems To solve the above problems, a composite magnetic material according to the present invention is a composite magnetic material comprising a soft magnetic alloy powder and an insulating binder, wherein the composition of the soft magnetic alloy powder is 1 wt% ≦ component A ≦ 7 wt% and 0.0
5 wt% ≦ Oxygen (O) ≦ 0.6 wt%, 0.01 wt%
≦ manganese (Mn) ≦ 0.2wt%, balance iron (Fe)
In a composite magnetic material or a composite magnetic material comprising a soft magnetic alloy powder and an insulating binder, the composition of the soft magnetic alloy powder is 1 wt% ≦ component A ≦
7 wt% and 0.05 wt% ≦ oxygen (O) ≦ 0.6 w
t%, 0.01wt% ≦ manganese (Mn) ≦ 0.2wt
%, 0.01 wt% ≦ carbon (C) ≦ 0.2 wt%, with the balance being iron (Fe). Here, the component A is at least one of silicon (Si), aluminum (Al), chromium (Cr), nickel (Ni), niobium (Nb), calcium (Ca), titanium (Ti), and magnesia (Mg). It is characterized by including one. The average particle size of the soft magnetic alloy powder is preferably 1 μm or more and 100 μm or less.
【０００９】なお、前記成分Ａがシリコン（Ｓｉ）を含
む場合は、前記軟磁性合金粉末の保磁力が１２００Ａ／
ｍ以下であることが、ヒステリシス損失を低減させる上
で好ましい。When the component A contains silicon (Si), the coercive force of the soft magnetic alloy powder is 1200 A /
m or less is preferable for reducing the hysteresis loss.
【００１０】また、本発明の磁性素子は、前記複合磁性
材料を加圧成形してなることを特徴とし、好ましくは、
加圧後、熱処理を施して成形する。なお、前記複合磁性
材料の中に、コイルを埋設することもできる。[0010] The magnetic element of the present invention is characterized in that the composite magnetic material is formed by pressure molding.
After pressing, heat treatment is applied to form. Note that a coil may be embedded in the composite magnetic material.
【００１１】さらに、本発明の磁性素子の製造方法は、
前記軟磁性合金粉末に、未硬化状態の熱硬化性樹脂を混
合した後に顆粒状粉末とする工程と、この粉末を金型中
にコイルと共に入れて加圧成形する工程と、加熱によっ
てこの熱硬化性樹脂を硬化させる工程を含むことを特徴
とする。Further, the method for manufacturing a magnetic element according to the present invention comprises:
Mixing the thermosetting resin in an uncured state with the soft magnetic alloy powder to obtain a granular powder, placing the powder in a mold together with a coil and press-molding the same; A step of curing the conductive resin.
【００１２】[0012]
【発明の実施の形態】以下、本発明の実施の形態につい
て説明する。Embodiments of the present invention will be described below.
【００１３】本発明で用いる軟磁性合金粉末は、その組
成が、１ｗｔ％≦成分Ａ≦７ｗｔ％でかつ０．０５ｗｔ
％≦酸素（Ｏ）≦０．６ｗｔ％、０．０１ｗｔ％≦マン
ガン（Ｍｎ）≦０．２ｗｔ％で残部が鉄（Ｆｅ）であ
り、成分Ａとしてシリコン（Ｓｉ）、アルミ（Ａｌ）、
クロム（Ｃｒ）、ニッケル（Ｎｉ）、ニオブ（Ｎｂ）、
カルシウム（Ｃａ）、チタン（Ｔｉ）、マグネシア（Ｍ
ｇ）の内、少なくとも一つを含む。この製造方法として
は、水アトマイズ法、ガスアトマイズ法、インゴット粉
砕法等があるが、特に製造方法にはよらず、上記組成か
らなるものであればよい。また、粉末形状は、球状、偏
平状、多角形状のいずれであってもよいが、略球状であ
れば、圧縮成形において、緻密な複合磁性材料を得るこ
とができる。なお、粉末の大きさは、その平均粒径が１
μｍ以上１００μｍ以下であることが好ましい。渦電流
の低減に効果的であり、より好ましくは５０μｍ以下で
ある。平均粒径が１μｍ未満になると、成形密度が小さ
くなるため、透磁率が低下して好ましくない。The composition of the soft magnetic alloy powder used in the present invention is such that 1 wt% ≦ component A ≦ 7 wt% and 0.05 wt%
% ≦ oxygen (O) ≦ 0.6 wt%, 0.01 wt% ≦ manganese (Mn) ≦ 0.2 wt%, the balance being iron (Fe), and as component A, silicon (Si), aluminum (Al),
Chrome (Cr), nickel (Ni), niobium (Nb),
Calcium (Ca), titanium (Ti), magnesia (M
g). As the production method, there are a water atomization method, a gas atomization method, an ingot pulverization method, and the like. The shape of the powder may be any of a spherical shape, a flat shape, and a polygonal shape. If the powder shape is approximately spherical, a dense composite magnetic material can be obtained by compression molding. The average size of the powder is 1
It is preferable that it is not less than μm and not more than 100 μm. It is effective in reducing eddy currents, and more preferably 50 μm or less. If the average particle size is less than 1 μm, the molding density is reduced, and the magnetic permeability is undesirably reduced.
【００１４】また、軟磁性合金粉末の保磁力Ｈｃは、小
さければ小さいほどコア損失が低減するが、好ましくは
１２００Ａ／ｍ以下である。Further, the smaller the coercive force Hc of the soft magnetic alloy powder is, the smaller the core loss is, but it is preferably 1200 A / m or less.
【００１５】次に、この軟磁性合金粉末の結着剤とし
て、絶縁性結着剤と混合し、複合磁性材料とする。絶縁
性結着剤としては、各種樹脂等を用いることができる
が、高絶縁性を得るためには、エポキシ樹脂、フェノー
ル樹脂、ブチラール樹脂、有機シリコーン樹脂等の有機
系樹脂を用いるのが好ましい。そして、軟磁性合金粉末
と絶縁性結着剤とを混合した複合磁性材料を加圧成形す
る。加圧することにより、軟磁性合金粉末の充填率が高
くなり、高飽和磁束密度および高透磁率を得ることがで
きる。ここで、一般に加圧する圧力が高ければ高いほ
ど、軟磁性合金粉末の充填率が高くなるが、軟磁性合金
粉末には、加圧による圧縮歪みが生じる。この圧縮歪み
は、軟磁性合金粉末の磁性特性に影響を与え、その劣化
の原因となる。そこで、圧縮歪みを解放するために、加
圧成形後に熱処理を行うことで、磁気的特性が優れた複
合磁性材料を得ることができる。Next, as a binder of the soft magnetic alloy powder, an insulating binder is mixed to obtain a composite magnetic material. Various resins and the like can be used as the insulating binder, but in order to obtain high insulating properties, it is preferable to use an organic resin such as an epoxy resin, a phenol resin, a butyral resin, and an organic silicone resin. Then, a composite magnetic material in which the soft magnetic alloy powder and the insulating binder are mixed is subjected to pressure molding. By applying pressure, the filling rate of the soft magnetic alloy powder is increased, and a high saturation magnetic flux density and a high magnetic permeability can be obtained. Here, in general, the higher the pressure to be applied, the higher the filling rate of the soft magnetic alloy powder, but the soft magnetic alloy powder undergoes compression strain due to the pressurization. This compressive strain affects the magnetic properties of the soft magnetic alloy powder and causes its deterioration. Thus, a heat treatment is performed after pressure molding to release the compression strain, whereby a composite magnetic material having excellent magnetic properties can be obtained.
【００１６】また、この複合磁性材料の中に、コイルを
埋設することも可能であり、特にコアとコイル間の絶縁
耐電圧を向上することができる。この場合は、コイルを
入れた金型等に、軟磁性合金粉末および絶縁性結着剤を
入れ、加圧成形を経て熱処理を施した後、金型より取り
出し、コイル内蔵型の磁性素子を得ることができる。な
お、より詳細には、製造した軟磁性合金粉末に適量の絶
縁性結着剤を混合したものを顆粒状粉末とし、その顆粒
状粉末をコイルと共に金型等に入れる。このとき、絶縁
性結着剤として熱硬化性樹脂を用いることにより、歪み
解放の熱処理と同時に樹脂を硬化させることができる。Further, a coil can be embedded in the composite magnetic material, and in particular, the withstand voltage between the core and the coil can be improved. In this case, the soft magnetic alloy powder and the insulating binder are put into a mold or the like in which a coil is placed, and after heat treatment is performed through pressure molding, the coil is taken out of the mold to obtain a coil-embedded magnetic element. be able to. More specifically, a mixture of the produced soft magnetic alloy powder and an appropriate amount of an insulating binder is made into a granular powder, and the granular powder is put into a mold or the like together with the coil. At this time, by using a thermosetting resin as the insulating binder, the resin can be cured simultaneously with the heat treatment for releasing the strain.
【００１７】上記のとおり、本発明では、高飽和磁束密
度（１．５Ｔ以上）を有する鉄（Ｆｅ）９０ｗｔ％以上
の金属粉体に、マンガン（Ｍｎ）と酸素（Ｏ）を上記組
成で構成した場合、絶縁性特に絶縁耐電圧に優れ、かつ
磁気的特性に優れた複合磁性材料または磁性素子を見出
した。理由は、今のところ必ずしも明確とはなっていな
いが、マンガン（Ｍｎ）の酸化物が金属粉体表面から内
部に、ある程度拡散することにより、絶縁耐電圧が向上
しているものと考えられる。成分Ａとして、シリコン
（Ｓｉ）、アルミ（Ａｌ）、クロム（Ｃｒ）、ニッケル
（Ｎｉ）、ニオブ（Ｎｂ）、カルシウム（Ｃａ）、チタ
ン（Ｔｉ）、マグネシア（Ｍｇ）は７ｗｔ％以下の範囲
内であれば、磁気特性を極端に劣化させない。また、成
分Ａが１ｗｔ％以上であることにより、金属粉体自身の
比抵抗値が上昇し渦電流損失が低減するものと思われ
る。成分Ａの二つ以上の組み合わせであっても、全体と
して１ｗｔ％から７ｗｔ％の範囲内であれば、同様な効
果がある。As described above, according to the present invention, manganese (Mn) and oxygen (O) have the above composition in a metal powder of iron (Fe) having a high saturation magnetic flux density (1.5 T or more) of 90 wt% or more. In this case, a composite magnetic material or a magnetic element having excellent insulation properties, particularly excellent withstand voltage, and excellent magnetic properties was found. Although the reason is not always clear at present, it is considered that the oxide with manganese (Mn) diffuses from the surface of the metal powder to the inside to some extent, thereby improving the withstand voltage. As the component A, silicon (Si), aluminum (Al), chromium (Cr), nickel (Ni), niobium (Nb), calcium (Ca), titanium (Ti), and magnesia (Mg) are within 7 wt% or less. If this is the case, the magnetic characteristics will not be extremely deteriorated. Further, it is considered that when the component A is 1 wt% or more, the specific resistance value of the metal powder itself increases and eddy current loss is reduced. Even if two or more components A are combined, similar effects can be obtained as long as the total content is in the range of 1 wt% to 7 wt%.
【００１８】また、高飽和磁束密度（１．５Ｔ以上）で
ある鉄（Ｆｅ）９０ｗｔ％以上の金属粉体に、マンガン
（Ｍｎ）と酸素（Ｏ）、カーボン（Ｃ）を上記組成で構
成する場合、絶縁耐電圧と磁気特性が向上することも見
出した。理由は、今のところ必ずしも明確とはなってい
ないが、マンガン（Ｍｎ）の酸化物が金属粉体表面から
内部に拡散していることにより、絶縁耐電圧が向上する
と共に、熱処理時にカーボン（Ｃ）の還元性のため緻密
化が進み磁気特性が向上しているものと考えられる。In addition, manganese (Mn), oxygen (O), and carbon (C) are composed of the above composition in a metal powder of iron (Fe) having a high saturation magnetic flux density (1.5 T or more) of 90 wt% or more. In this case, the inventors have also found that the dielectric strength voltage and the magnetic properties are improved. Although the reason is not always clear at present, the oxide of manganese (Mn) diffuses from the surface of the metal powder to the inside, thereby improving the dielectric strength voltage and increasing the carbon (C) content during the heat treatment. It is considered that the densification has progressed due to the reducibility of (1) and the magnetic properties have been improved.
【００１９】なお、軟磁性合金粉末に、上記組成以外の
不純物あるいは添加剤が含まれていたとしても、その量
が少量であれば、同様な効果がある。Even if the soft magnetic alloy powder contains impurities or additives other than the above composition, a similar effect can be obtained if the amount is small.
【００２０】以下、本発明のより具体的な実施の形態と
して、実施例をあげて説明する。Hereinafter, examples will be described as more specific embodiments of the present invention.
【００２１】（実施例１）（表１）に示す軟磁性合金粉
末を、ガスアトマイズ法で作成した。平均粒径はすべて
１０〜２０μｍで、かつ保磁力Ｈｃは３００〜６００Ａ
／ｍであった。得られた粉末に、ビスフェノールＡ型樹
脂を４重量部加えて良く混合し、メッシュを通して整粒
した。次に、１ｍｍ径の被覆銅線を用いて、内径５．５
ｍｍの２段積み４．５ターンコイルを準備した。整粒粉
末を、金型にコイルと共に入れて、圧力約３．５ｔ／ｃ
ｍ2で加圧成形し、金型より取り出した後、約１２５℃
にて約１時間加熱処理して硬化させた。そして、サイズ
１２．５ｍｍ×１２．５ｍｍ×厚さ３．４〜３．６ｍｍ
のコイル内蔵磁性素子を得た。Example 1 Soft magnetic alloy powders shown in Table 1 were prepared by a gas atomizing method. The average particle size is 10 to 20 μm, and the coercive force Hc is 300 to 600 A.
/ M. 4 parts by weight of bisphenol A type resin was added to the obtained powder, mixed well, and sized through a mesh. Next, using a 1 mm diameter coated copper wire, the inner diameter was 5.5.
A 2.5-turn coil having a 2-mm stack length of 2.5 mm was prepared. The sized powder is put into a mold together with the coil, and the pressure is about 3.5 t / c.
After molding under pressure with m 2 and taking out from the mold, about 125 ° C
For about 1 hour to cure. And size 12.5mm x 12.5mm x thickness 3.4-3.6mm
Was obtained.
【００２２】インダクタンスＬ値を周波数５００ｋＨ
ｚ、電流値３０Ａで測定した。またコイルが埋設された
磁性素子で重要な特性であるコイルとコア間の絶対耐電
圧は、電圧１００〜５００Ｖまで１００Ｖ刻みで高くし
ながら電気抵抗を測定し、電気抵抗が急激に低下する電
圧を求め、その直前の電圧をもって絶縁耐電圧とした。
用途によって若干異なるが、インダクタンスＬ値が１．
０μＨ以上、好ましくは１．２μＨ以上、かつ絶縁耐電
圧２００Ｖ以上が必要となる。評価結果を（表１）に示
す。The inductance L value is set to a frequency of 500 kHz.
z, the current value was measured at 30A. In addition, the absolute withstand voltage between the coil and the core, which is an important characteristic of the magnetic element in which the coil is embedded, is measured in increments of 100 V from 100 to 500 V in steps of 100 V, and the electric resistance is measured. The voltage immediately before that was defined as the dielectric strength voltage.
The inductance L value is 1.
0 μH or more, preferably 1.2 μH or more, and a dielectric strength voltage of 200 V or more are required. The evaluation results are shown in (Table 1).
【００２３】[0023]
【表１】 [Table 1]
【００２４】（表１）より明らかなように、軟磁性合金
粉末と絶縁性結着剤からなる複合磁性材料において、軟
磁性合金粉末の組成が、１ｗｔ％≦Ｓｉ≦７ｗｔ％で、
かつ０．０５ｗｔ％≦Ｏ≦０．６ｗｔ％、０．０１ｗｔ
％≦Ｍｎ≦０．２ｗｔ％で残部がＦｅであるときに優れ
たＬ値、絶縁耐電圧を実現していることが分かる。As is clear from Table 1, in a composite magnetic material comprising a soft magnetic alloy powder and an insulating binder, the composition of the soft magnetic alloy powder is 1 wt% ≦ Si ≦ 7 wt%,
And 0.05 wt% ≦ O ≦ 0.6 wt%, 0.01 wt%
It can be seen that excellent L value and dielectric strength voltage are realized when% ≦ Mn ≦ 0.2 wt% and the balance is Fe.
【００２５】（実施例２）軟磁性合金粉末として、（表
２）に示す金属磁性粉末を水アトマイズ法で作成した。
平均粒径はすべて１０〜２０μｍで、保磁力Ｈｃは６０
０〜１０００Ａ／ｍであった。得られた粉末にシリコン
樹脂を３．５重量部加えて良く混合し、メッシュを通し
て整粒した。次に、１ｍｍ径の被覆銅線を用いて、内径
５．５ｍｍの２段積み４．５ターンコイルを準備した。
整粒粉末を、金型にコイルと共に入れて、圧力約５ｔ／
ｃｍ2で加圧成形し、金型より取り出した後、約１５０
℃にて約１時間加熱処理して、硬化させた。そして、サ
イズ１２．５ｍｍ×１２．５ｍｍ×厚さ３．４〜３．６
ｍｍのコイル内蔵磁性素子を得た。Example 2 As a soft magnetic alloy powder, a metal magnetic powder shown in Table 2 was prepared by a water atomizing method.
The average particle size is 10 to 20 μm, and the coercive force Hc is 60
It was 0 to 1000 A / m. 3.5 parts by weight of a silicone resin was added to the obtained powder, mixed well, and sized through a mesh. Next, using a 1 mm-diameter coated copper wire, a 4.5-turn coil with a 5.5 mm inner diameter was prepared.
The sized powder is put into a mold together with the coil, and the pressure is about 5 t /
pressurizing and pressure molded at cm 2, after taking out from the mold, about 150
C. for about 1 hour to cure. And size 12.5mm x 12.5mm x thickness 3.4-3.6
mm was obtained.
【００２６】インダクタンスＬ値を周波数５００ｋＨ
ｚ、電流値３０Ａで測定した。またコイルが埋設された
磁性素子で重要な特性であるコイルとコア間の絶対耐電
圧は、電圧１００〜５００Ｖまで１００Ｖ刻みで高くし
ながら電気抵抗を測定し、電気抵抗が急激に低下する電
圧を求め、その直前の電圧をもって絶縁耐電圧とした。
用途によって若干異なるが、インダクタンスＬ値が１．
０μＨ以上、好ましくは１．２μＨ以上、かつ絶縁耐電
圧２００Ｖ以上が必要となる。評価結果を（表２）に示
す。The inductance L value is set to a frequency of 500 kHz.
z, the current value was measured at 30A. In addition, the absolute withstand voltage between the coil and the core, which is an important characteristic of the magnetic element in which the coil is embedded, is measured while increasing the electric resistance from 100 to 500 V in steps of 100 V. The voltage immediately before that was defined as the dielectric strength voltage.
The inductance L value is 1.
0 μH or more, preferably 1.2 μH or more, and a dielectric strength voltage of 200 V or more are required. The evaluation results are shown in (Table 2).
【００２７】[0027]
【表２】 [Table 2]
【００２８】（表２）の結果から明らかなように、軟磁
性合金粉末と絶縁性結着剤からなる複合磁性材料におい
て、軟磁性合金粉末の組成が、１ｗｔ％≦Ｓｉ≦７ｗｔ
％で、かつ０．０５ｗｔ％≦Ｏ≦０．６ｗｔ％、０．０
１ｗｔ％≦Ｍｎ≦０．２ｗｔ％、０．０１ｗｔ％≦Ｃ≦
０．２ｗｔ％で残部がＦｅであるときに、優れたＬ値お
よび絶縁耐電圧を実現していることが分かる。As is clear from the results in Table 2, in the composite magnetic material composed of the soft magnetic alloy powder and the insulating binder, the composition of the soft magnetic alloy powder is 1 wt% ≦ Si ≦ 7 wt.
% And 0.05 wt% ≦ O ≦ 0.6 wt%, 0.0
1 wt% ≦ Mn ≦ 0.2 wt%, 0.01 wt% ≦ C ≦
It can be seen that when the balance is 0.2 wt% and the balance is Fe, excellent L value and dielectric strength voltage are realized.
【００２９】（実施例３）（表３）に示す軟磁性合金粉
末を、水アトマイズ法で作成した。平均粒径はすべて８
〜２０μｍであった。得られた粉末に、ビスフェノール
Ａ型樹脂を３重量部加えて良く混合し、メッシュを通し
て整粒した。次に、０．８ｍｍ径の被覆銅線を用いて、
内径４ｍｍの２段積み３．５ターンコイルを準備した。
整粒粉末を、金型にコイルと共に入れて、圧力約３ｔ／
ｃｍ2で加圧成形し、金型より取り出した後、約１２０
℃にて約１時間加熱処理して硬化させた。そして、サイ
ズ１０ｍｍ×１０ｍｍ×厚さ３．４〜３．６ｍｍのコイ
ル内蔵磁性素子を得た。インダクタンスＬ値を周波数５
００ｋＨｚ、電流値３０Ａで測定した。またコイルが埋
設された磁性素子で重要な特性であるコイルとコア間の
絶対耐電圧は、電圧１００〜５００Ｖまで１００Ｖ刻み
で高くしながら電気抵抗を測定し、電気抵抗が急激に低
下する電圧を求め、その直前の電圧をもって絶縁耐電圧
とした。用途によって若干異なるが、インダクタンスＬ
値０．８μＨ以上、好ましくは１．０μＨ以上、かつ絶
縁耐電圧２００Ｖ以上が必要となる。評価結果を（表
３）に示す。Example 3 Soft magnetic alloy powders shown in Table 3 were prepared by a water atomizing method. Average particle size is 8
２０20 μm. To the obtained powder, 3 parts by weight of a bisphenol A type resin was added, mixed well, and sized through a mesh. Next, using a covered copper wire of 0.8 mm diameter,
A two-stage 3.5-turn coil having an inner diameter of 4 mm was prepared.
The sized powder is put into a mold together with the coil, and a pressure of about 3 t /
and pressed at cm 2, after taking out from the mold, about 120
The composition was cured by heating at about 1 hour. Then, a coil-embedded magnetic element having a size of 10 mm × 10 mm × thickness of 3.4 to 3.6 mm was obtained. Inductance L value at frequency 5
The measurement was performed at 00 kHz and a current value of 30 A. In addition, the absolute withstand voltage between the coil and the core, which is an important characteristic of the magnetic element in which the coil is embedded, is measured while increasing the electric resistance from 100 to 500 V in steps of 100 V. The voltage immediately before that was determined as the dielectric withstand voltage. Depending on the application, the inductance L
A value of 0.8 μH or more, preferably 1.0 μH or more, and a dielectric strength voltage of 200 V or more is required. The evaluation results are shown in (Table 3).
【００３０】[0030]
【表３】 [Table 3]
【００３１】（表３）の結果から明らかなように、軟磁
性合金粉末と絶縁性結着剤からなり、熱処理を施した複
合磁性材料において、軟磁性合金粉末の組成が、１ｗｔ
％≦成分Ａ≦７ｗｔ％で、かつ０．０５ｗｔ％≦酸素
（Ｏ）≦０．６ｗｔ％、０．０１ｗｔ％≦マンガン（Ｍ
ｎ）≦０．２ｗｔ％で残部が鉄（Ｆｅ）であり、成分Ａ
としてシリコン（Ｓｉ）、アルミ（Ａｌ）、クロム（Ｃ
ｒ）、ニッケル（Ｎｉ）、ニオブ（Ｎｂ）、カルシウム
（Ｃａ）、チタン（Ｔｉ）、マグネシア（Ｍｇ）である
とき、優れたＬ値、絶縁耐電圧を実現していることが分
かる。また、好ましくは、０．０１ｗｔ％≦カーボン
（Ｃ）≦０．２ｗｔ％のときである。As is clear from the results shown in Table 3, in the composite magnetic material comprising the soft magnetic alloy powder and the insulating binder and subjected to the heat treatment, the composition of the soft magnetic alloy powder was 1 wt.
% ≦ component A ≦ 7 wt%, and 0.05 wt% ≦ oxygen (O) ≦ 0.6 wt%, 0.01 wt% ≦ manganese (M
n) ≦ 0.2 wt%, the balance being iron (Fe), component A
As silicon (Si), aluminum (Al), chromium (C
r), nickel (Ni), niobium (Nb), calcium (Ca), titanium (Ti), and magnesia (Mg), it can be seen that excellent L value and dielectric strength were realized. Also, preferably, 0.01 wt% ≦ carbon (C) ≦ 0.2 wt%.
【００３２】（実施例４）組成が、Ｓｉ＝３．５ｗｔ
％、Ｏ＝０．３ｗｔ％、Ｍｎ＝０．１ｗｔ％で残部がＦ
ｅであり、（表４）に示すように粒径が異なる軟磁性合
金粉末を水アトマイズ法で作成した。これらの粉末に、
シリコン樹脂を１．５重量部加えて良く混合し、メッシ
ュを通して整粒した。この整粒を、金型中にて、約８ｔ
／ｃｍ2の圧力で加圧成形し、金型より取り出した後、
約８５０℃にてＮ2中、約１時間加熱処理して、トロイ
ダルコア形状の圧粉磁芯を得た。この圧粉磁芯につい
て、透磁率、コア損失、直流重畳を測定した。透磁率
は、ＬＣＲメーターで周波数１００ｋＨｚで測定し、コ
ア損失は、交流Ｂ−Ｈカーブ測定器を用いて、測定周波
数１００ｋＨｚ、測定磁束密度０．１Ｔで測定した。Example 4 When the composition is Si = 3.5 wt.
%, O = 0.3 wt%, Mn = 0.1 wt%, and the balance is F
e, soft magnetic alloy powders having different particle sizes as shown in Table 4 were prepared by a water atomizing method. To these powders,
1.5 parts by weight of a silicone resin was added, mixed well, and sized through a mesh. This sized product is placed in a mold for about 8 tons.
/ Cm 2 , and after taking out from the mold,
Heat treatment was performed in N 2 at about 850 ° C. for about 1 hour to obtain a dust core having a toroidal core shape. The magnetic permeability, core loss, and direct current superposition of this dust core were measured. The magnetic permeability was measured at a frequency of 100 kHz with an LCR meter, and the core loss was measured at a measurement frequency of 100 kHz and a measured magnetic flux density of 0.1 T using an AC BH curve measuring instrument.
【００３３】用途によって若干異なるが、チョークコイ
ルでは、測定周波数１００ｋＨｚ、測定磁束密度０．１
Ｔでコア損失２０００ｋＷ／ｍ3以下、初透磁率は６０
以上必要とされるが、より好ましくはコア損失１５００
ｋＷ／ｍ3以下である。The choke coil has a measurement frequency of 100 kHz and a measurement magnetic flux density of 0.1
At T, core loss is less than 2000 kW / m 3 and initial permeability is 60
Although the above is required, core loss 1500 is more preferable.
kW / m 3 or less.
【００３４】[0034]
【表４】 [Table 4]
【００３５】（表４）の結果から明らかなように、平均
粒径が１μｍ以上１００μｍ以下のとき、好ましくは、
１μｍ以上５０μｍ以下のとき、低損失を実現している
ことがわかる。また、軟磁性合金粉末の保磁力が１２０
０Ａ／ｍ以下のとき、低損失を実現していることがわか
る。As is evident from the results in Table 4, when the average particle size is 1 μm or more and 100 μm or less, preferably,
It can be seen that low loss is realized when the thickness is 1 μm or more and 50 μm or less. Further, the coercive force of the soft magnetic alloy powder is 120
When it is 0 A / m or less, it is understood that low loss is realized.
【００３６】（実施例５）組成が、Ａｌ＝３．０ｗｔ
％、Ｏ＝０．２ｗｔ％、Ｍｎ＝０．２ｗｔ％で残部がＦ
ｅであり、（表５）に示すように粒径が異なる軟磁性合
金粉末をガスアトマイズ法で作成した。これらの粉末
に、シリコン樹脂を１．５重量部加えて良く混合し、メ
ッシュを通して整粒した。この整粒粉末を金型中にて、
約８ｔ／ｃｍ2の圧力で加圧成形し、金型より取り出し
た後、約８２０℃にてＮ2中、約１時間加熱処理してト
ロイダルコア形状の圧粉磁芯を得た。このようにして得
られた圧粉磁芯について透磁率、コア損失、直流重畳を
測定した。透磁率は、ＬＣＲメーターで周波数２００ｋ
Ｈｚで測定し、コア損失は交流Ｂ−Ｈカーブ測定器を用
いて測定周波数２００ｋＨｚ、測定磁束密度０．１Ｔで
測定した。Example 5 When the composition was Al = 3.0 wt.
%, O = 0.2 wt%, Mn = 0.2 wt%, and the balance is F
e, and soft magnetic alloy powders having different particle diameters as shown in Table 5 were prepared by a gas atomizing method. 1.5 parts by weight of a silicone resin was added to these powders, mixed well, and sized through a mesh. In the mold, this sized powder
After being molded under pressure at a pressure of about 8 t / cm 2 and taken out of the mold, it was heated at about 820 ° C. in N 2 for about 1 hour to obtain a dust core having a toroidal core shape. The magnetic permeability, core loss, and DC superposition of the thus obtained dust core were measured. Permeability is LCR meter frequency 200k
Hz, and the core loss was measured at a measurement frequency of 200 kHz and a measured magnetic flux density of 0.1 T using an AC BH curve measuring instrument.
【００３７】用途によって若干異なるがチョークコイル
では、測定周波数２００ｋＨｚ、測定磁束密度０．１Ｔ
でコア損失６０００ｋＷ／ｍ3以下、初透磁率は６０以
上必要とされるが、より好ましくはコア損失４０００ｋ
Ｗ／ｍ3以下である。The choke coil has a measurement frequency of 200 kHz and a measurement magnetic flux density of 0.1 T
6000 kW / m 3 or less and an initial magnetic permeability of 60 or more are required. More preferably, the core loss is 4,000 kW / m 3.
W / m 3 or less.
【００３８】[0038]
【表５】 [Table 5]
【００３９】（表５）の結果から明らかなように、平均
粒径が１μｍ以上１００μｍ以下のとき、好ましくは１
μｍ以上５０μｍ以下のとき、低損失を実現しているこ
とが分かる。As is clear from the results shown in Table 5, when the average particle size is 1 μm or more and 100 μm or less, preferably 1 μm or less.
It can be seen that low loss is realized when the thickness is not less than μm and not more than 50 μm.
【００４０】[0040]
【発明の効果】以上説明したように本発明によれば、絶
縁性および磁気特性を有した複合磁性材料を提供するこ
とができる。この複合磁性材料は、トランスやチョーク
コイル等の小型化あるいは高周波領域での使用に十分適
応できる。As described above, according to the present invention, a composite magnetic material having insulating properties and magnetic properties can be provided. This composite magnetic material can be sufficiently adapted to miniaturization of a transformer, a choke coil, and the like, or use in a high-frequency region.
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.7 識別記号 ＦＩ テーマコート゛(参考） Ｈ０１Ｆ 1/22 Ｈ０１Ｆ 1/14 Ｚ (72)発明者 井上 修 大阪府門真市大字門真1006番地 松下電器 産業株式会社内 (72)発明者 加藤 純一 大阪府門真市大字門真1006番地 松下電器 産業株式会社内 Ｆターム(参考） 4K018 AA24 BA13 BD01 FA08 GA04 KA44 5E041 AA11 AC05 CA01 HB11 ──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. 7 Identification symbol FI Theme coat ゛ (Reference) H01F 1/22 H01F 1/14 Z (72) Inventor Osamu 1006 Kazuma Kazuma, Kadoma City, Osaka Matsushita Electric Industrial Inside (72) Inventor Junichi Kato 1006 Kadoma, Kazuma, Osaka Prefecture Matsushita Electric Industrial Co., Ltd.F-term (reference) 4K018 AA24 BA13 BD01 FA08 GA04 KA44 5E041 AA11 AC05 CA01 HB11
Claims (8)
り、複合磁性材料において、前記軟磁性合金粉末の組成
が、１ｗｔ％≦成分Ａ≦７ｗｔ％でかつ０．０５ｗｔ％
≦酸素（Ｏ）≦０．６ｗｔ％、０．０１ｗｔ％≦マンガ
ン（Ｍｎ）≦０．２ｗｔ％で残部が鉄（Ｆｅ）であり、
前記成分Ａがシリコン（Ｓｉ）、アルミ（Ａｌ）、クロ
ム（Ｃｒ）、ニッケル（Ｎｉ）、ニオブ（Ｎｂ）、カル
シウム（Ｃａ）、チタン（Ｔｉ）、マグネシア（Ｍｇ）
の内、少なくとも一つを含むことを特徴とする複合磁性
材料。1. A composite magnetic material comprising a soft magnetic alloy powder and an insulating binder, wherein the composition of the soft magnetic alloy powder is 1 wt% ≦ component A ≦ 7 wt% and 0.05 wt%
≦ Oxygen (O) ≦ 0.6 wt%, 0.01 wt% ≦ Manganese (Mn) ≦ 0.2 wt%, the balance being iron (Fe),
The component A is silicon (Si), aluminum (Al), chromium (Cr), nickel (Ni), niobium (Nb), calcium (Ca), titanium (Ti), magnesia (Mg)
A composite magnetic material comprising at least one of the following.
複合磁性材料において、前記軟磁性合金粉末の組成が、
１ｗｔ％≦成分Ａ≦７ｗｔ％でかつ０．０５ｗｔ％≦酸
素（Ｏ）≦０．６ｗｔ％、０．０１ｗｔ％≦マンガン
（Ｍｎ）≦０．２ｗｔ％、０．０１ｗｔ％≦カーボン
（Ｃ）≦０．２ｗｔ％で残部が鉄（Ｆｅ）であり、前記
成分Ａがシリコン（Ｓｉ）、アルミ（Ａｌ）、クロム
（Ｃｒ）、ニッケル（Ｎｉ）、ニオブ（Ｎｂ）、カルシ
ウム（Ｃａ）、チタン（Ｔｉ）、マグネシア（Ｍｇ）の
内、少なくとも一つを含むことを特徴とする複合磁性材
料。2. A composite magnetic material comprising a soft magnetic alloy powder and an insulating binder, wherein the composition of the soft magnetic alloy powder is
1 wt% ≦ component A ≦ 7 wt% and 0.05 wt% ≦ oxygen (O) ≦ 0.6 wt%, 0.01 wt% ≦ manganese (Mn) ≦ 0.2 wt%, 0.01 wt% ≦ carbon (C) ≦ 0.2 wt%, the balance being iron (Fe), and the component A is silicon (Si), aluminum (Al), chromium (Cr), nickel (Ni), niobium (Nb), calcium (Ca), titanium ( A composite magnetic material comprising at least one of Ti) and magnesia (Mg).
１００μｍ以下で構成されていることを特徴とする請求
項１または２記載の複合磁性材料。3. The composite magnetic material according to claim 1, wherein the soft magnetic alloy powder has an average particle diameter of 1 μm or more and 100 μm or less.
前記軟磁性合金粉末の保磁力が１２００Ａ／ｍ以下であ
ることを特徴とする請求項１、２または３記載の複合磁
性材料。4. The component A comprises silicon (Si),
4. The composite magnetic material according to claim 1, wherein the soft magnetic alloy powder has a coercive force of 1200 A / m or less.
複合磁性材料を、加圧して成形したことを特徴とする磁
性素子。5. A magnetic element obtained by molding the composite magnetic material according to claim 1 by applying pressure.
してなることを特徴とする請求項５記載の磁性素子。6. The magnetic element according to claim 5, wherein the composite magnetic material is subjected to a heat treatment after being pressurized.
中に、コイルが埋設されていることを特徴とする請求項
５または６記載の磁性素子。7. A magnetic element according to claim 5, wherein a coil is embedded in the composite magnetic material according to claim 1.
軟磁性合金粉末に未硬化状態の熱硬化性樹脂を混合した
後に、顆粒状粉末とする工程と、この顆粒状粉末を金型
中にコイルと共に入れて加圧成形する工程と、加熱によ
ってこの熱硬化性樹脂を硬化させる工程を含むことを特
徴とする磁性素子の製造方法。8. A step of mixing an uncured thermosetting resin with the soft magnetic alloy powder according to any one of claims 1 to 4 to obtain a granular powder, and the step of mixing the granular powder with gold. A method for manufacturing a magnetic element, comprising: a step of press-molding together with a coil in a mold; and a step of curing the thermosetting resin by heating.
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| JP2007092162A (en) * | 2005-02-03 | 2007-04-12 | Jfe Steel Kk | Highly compressive iron powder, iron powder for dust core using the same and dust core |
| JP2017092482A (en) * | 2015-05-14 | 2017-05-25 | Tdk株式会社 | Soft magnetic metal powder and soft magnetic metal powder core |
| JP2019077952A (en) * | 2017-09-04 | 2019-05-23 | Ｄｏｗａエレクトロニクス株式会社 | Soft magnetic powder, soft magnetic material, manufacturing method of powder magnetic core |
| WO2020188940A1 (en) * | 2019-03-19 | 2020-09-24 | Ｄｏｗａエレクトロニクス株式会社 | Soft magnetic powder, soft magnetic powder heat processing method, soft magnetic material, pressed powder magnetic core, and pressed powder magnetic core production method |
| JP2021061408A (en) * | 2020-12-04 | 2021-04-15 | Tdk株式会社 | Soft magnetic metal powder and powder-compact magnetic core |
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| KR102428560B1 (en) | 2017-09-04 | 2022-08-02 | 도와 일렉트로닉스 가부시키가이샤 | Method for producing soft magnetic powder, Fe powder or alloy powder containing Fe, soft magnetic material, and method for producing powder core |
| JP2020152947A (en) * | 2019-03-19 | 2020-09-24 | Ｄｏｗａエレクトロニクス株式会社 | Soft-magnetic powder, heat-treatment method for soft-magnetic powder, soft-magnetic material, powder magnetic core, and manufacturing method for powder magnetic core |
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| CN113518674B (en) * | 2019-03-19 | 2023-09-08 | 同和电子科技有限公司 | Soft magnetic powder, heat treatment method for soft magnetic powder, soft magnetic material, dust core, and method for producing dust core |
| JP2021061408A (en) * | 2020-12-04 | 2021-04-15 | Tdk株式会社 | Soft magnetic metal powder and powder-compact magnetic core |
| CN113223804A (en) * | 2021-03-31 | 2021-08-06 | 宁波中科毕普拉斯新材料科技有限公司 | Composite soft magnetic powder material, preparation method and magnetic component |
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