JP2003142310A - Dust core having high electrical resistance and manufacturing method therefor - Google Patents
Dust core having high electrical resistance and manufacturing method thereforInfo
- Publication number
- JP2003142310A JP2003142310A JP2001338279A JP2001338279A JP2003142310A JP 2003142310 A JP2003142310 A JP 2003142310A JP 2001338279 A JP2001338279 A JP 2001338279A JP 2001338279 A JP2001338279 A JP 2001338279A JP 2003142310 A JP2003142310 A JP 2003142310A
- Authority
- JP
- Japan
- Prior art keywords
- powder
- soft magnetic
- core
- magnetic metal
- dust core
- 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.)
- Pending
Links
- 239000000428 dust Substances 0.000 title claims abstract description 23
- 238000004519 manufacturing process Methods 0.000 title claims description 5
- 239000000843 powder Substances 0.000 claims abstract description 61
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims abstract description 38
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims abstract description 19
- 238000000137 annealing Methods 0.000 claims abstract description 17
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 claims abstract description 17
- 239000004327 boric acid Substances 0.000 claims abstract description 16
- 229920002050 silicone resin Polymers 0.000 claims abstract description 8
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 7
- 229910052791 calcium Inorganic materials 0.000 claims abstract description 6
- 239000011248 coating agent Substances 0.000 claims abstract description 6
- 238000000576 coating method Methods 0.000 claims abstract description 6
- 238000000748 compression moulding Methods 0.000 claims abstract description 6
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 6
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 5
- 229910052700 potassium Inorganic materials 0.000 claims abstract description 5
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 5
- 229910052708 sodium Inorganic materials 0.000 claims abstract description 5
- 238000000465 moulding Methods 0.000 claims abstract 2
- 229910052751 metal Inorganic materials 0.000 claims description 27
- 239000002184 metal Substances 0.000 claims description 27
- 229910045601 alloy Inorganic materials 0.000 claims description 19
- 239000000956 alloy Substances 0.000 claims description 19
- 238000009413 insulation Methods 0.000 claims description 12
- 229910017082 Fe-Si Inorganic materials 0.000 claims description 5
- 229910017133 Fe—Si Inorganic materials 0.000 claims description 5
- 239000013067 intermediate product Substances 0.000 claims description 5
- 239000000047 product Substances 0.000 claims description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 4
- 239000012266 salt solution Substances 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 3
- 229910018598 Si-Co Inorganic materials 0.000 claims description 2
- 229910008453 Si—Co Inorganic materials 0.000 claims description 2
- 229910000838 Al alloy Inorganic materials 0.000 claims 1
- 229910019142 PO4 Inorganic materials 0.000 abstract description 12
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 abstract description 12
- 239000010452 phosphate Substances 0.000 abstract description 12
- 230000035699 permeability Effects 0.000 abstract description 6
- BTBUEUYNUDRHOZ-UHFFFAOYSA-N Borate Chemical compound [O-]B([O-])[O-] BTBUEUYNUDRHOZ-UHFFFAOYSA-N 0.000 abstract description 2
- 230000006866 deterioration Effects 0.000 abstract 1
- 239000011734 sodium Substances 0.000 abstract 1
- 230000000052 comparative effect Effects 0.000 description 17
- 239000003795 chemical substances by application Substances 0.000 description 13
- 239000011230 binding agent Substances 0.000 description 7
- 238000000034 method Methods 0.000 description 7
- 150000003839 salts Chemical class 0.000 description 7
- 230000000694 effects Effects 0.000 description 6
- 229910001004 magnetic alloy Inorganic materials 0.000 description 6
- 230000007423 decrease Effects 0.000 description 5
- 238000012360 testing method Methods 0.000 description 5
- 239000011777 magnesium Substances 0.000 description 4
- 239000011701 zinc Substances 0.000 description 4
- 239000011575 calcium Substances 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- 229910000976 Electrical steel Inorganic materials 0.000 description 2
- 238000000354 decomposition reaction Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 229920001296 polysiloxane Polymers 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229920003002 synthetic resin Polymers 0.000 description 2
- 239000000057 synthetic resin Substances 0.000 description 2
- 229910052725 zinc Inorganic materials 0.000 description 2
- 238000012935 Averaging Methods 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 229910020517 Co—Ti Inorganic materials 0.000 description 1
- 229910020516 Co—V Inorganic materials 0.000 description 1
- 229910019819 Cr—Si Inorganic materials 0.000 description 1
- 229910017061 Fe Co Inorganic materials 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910017305 Mo—Si Inorganic materials 0.000 description 1
- 229910002796 Si–Al Inorganic materials 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 150000003949 imides Chemical class 0.000 description 1
- 239000000696 magnetic material Substances 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000000682 scanning probe acoustic microscopy Methods 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
- H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
- H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、高い電気抵抗を有
する圧粉磁心と、その製造方法に関し、圧粉磁心を製造
するための中間製品をも包含する。本発明の圧粉磁心
は、とくに高周波領域で使用したとき、コアロスが少な
い磁心として有用である。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a dust core having high electric resistance and a method for producing the dust core, and also includes an intermediate product for producing the dust core. INDUSTRIAL APPLICABILITY The dust core of the present invention is useful as a core having a small core loss, especially when used in a high frequency range.
【０００２】[0002]
【従来の技術】軟磁性金属の粉末、たとえばＦｅ−３％
Ｓｉで代表されるケイ素鋼の粉末を、多くの場合リング
状に圧粉成形し、そこへコイルを巻いたチョークやトラ
ンスが、広い技術分野で使用されている。たとえば、Ｄ
Ｃ−ＤＣコンバータやノイズフィルター、あるいはイン
ジェクターなどである。圧粉磁心とするのは、磁心内部
の電気抵抗を高くするためであって、渦電流による電力
のロスと回路部品の発熱を低く抑えることが望ましく、
それには、粉末相互の間が十分に絶縁されていることが
必要である。2. Description of the Related Art Soft magnetic metal powders such as Fe-3%
In many cases, a choke or a transformer in which powder of silicon steel typified by Si is compacted into a ring shape and a coil is wound around the powder is used in a wide technical field. For example, D
It is a C-DC converter, a noise filter, an injector, or the like. The powder magnetic core is used to increase the electric resistance inside the magnetic core, and it is desirable to suppress power loss due to eddy currents and heat generation of circuit components to be low.
It requires that there be sufficient insulation between the powders.
【０００３】この圧粉磁心を製造するには、軟磁性金属
を適宜の方法、たとえば溶湯の水噴霧により粉末化した
ものを、バインダーとともに金型に充填し、圧力を加え
て成形する圧縮成形を行なう。バインダーとしては、エ
ポキシ樹脂、イミド樹脂、フェノール樹脂、あるいはシ
リコーン樹脂が用いられる。In order to manufacture this dust core, a soft magnetic metal is compressed by an appropriate method, for example, a powder obtained by spraying a molten metal with water is filled in a mold together with a binder and pressure is applied. To do. An epoxy resin, an imide resin, a phenol resin, or a silicone resin is used as the binder.
【０００４】ところが、高い粉末充填密度を実現するた
めに高い圧力（１０トン／cm２以上）を加えるので、軟
磁性金属の粉末には歪みが残っていて、この歪みが磁気
特性を低くしている。具体的には、保磁力が増大し、コ
アロスの増大と透磁率の低下が起こる。そこで、成形品
に対し歪み取り焼鈍を行なってから、磁心として使用す
るのが常である。However, since a high pressure (10 tons / cm 2 or more) is applied in order to achieve a high powder packing density, distortion remains in the soft magnetic metal powder, and this distortion lowers the magnetic characteristics. There is. Specifically, coercive force increases, core loss increases and magnetic permeability decreases. Therefore, the molded product is usually used as a magnetic core after strain relief annealing.
【０００５】焼鈍は、ケイ素鋼を例にとれば、５００℃
以上、なるべくは６００℃以上の温度で実施したいが、
上記のバインダーとして有機系の合成樹脂を使用した場
合、あまり高温では樹脂が分解してバインダーとして役
立たなくなるので、高々４００℃までの焼鈍温度しか採
用できない。そのため、焼鈍に長い時間をかけたとして
も、成形品中の軟磁性金属粉末に加わった歪みは完全に
は除去されないまま、つまり、その軟磁性金属本来の性
能を十分に発揮させることができないまま、磁心として
使用しなければならない。Annealing is performed at 500 ° C. in the case of silicon steel.
As mentioned above, it is desirable to carry out at a temperature of 600 ° C or higher,
When an organic synthetic resin is used as the binder, the resin decomposes at too high a temperature and does not serve as a binder, so only an annealing temperature up to 400 ° C. can be adopted. Therefore, even if it takes a long time to anneal, the strain applied to the soft magnetic metal powder in the molded product is not completely removed, that is, the original performance of the soft magnetic metal cannot be sufficiently exhibited. , Must be used as a magnetic core.
【０００６】一方、電気抵抗を高くする意味は、圧粉磁
心を使用する周波数が高くなるにつれて大きくなる。圧
粉磁心の抵抗が高ければ、周波数が高くなっても透磁率
はほぼ一定に保たれるが、抵抗が低ければ、高い周波数
領域で透磁率が急激に低下してしまう。On the other hand, the meaning of increasing the electric resistance increases as the frequency at which the dust core is used increases. If the resistance of the dust core is high, the magnetic permeability can be kept substantially constant even if the frequency is increased, but if the resistance is low, the magnetic permeability is drastically reduced in the high frequency region.
【０００７】電気抵抗を高める一つの手段として、軟磁
性金属の粉末にリン酸塩処理を施してリン酸塩の絶縁性
被膜を形成することが考案され、実施されている。この
技術は、リン酸のマグネシウム、カルシウム、亜鉛など
の金属塩を水溶液または水分散液として用意し、場合に
よりこれにホウ酸を添加したものを、粉末の表面に適用
してリン酸塩被膜を形成するものである。絶縁性は高ま
るが、リン酸塩それ自体は粉末のバインダーとしての機
能は低いので、必要により上記のような合成樹脂バイン
ダーを添加する。As one means for increasing the electric resistance, it has been devised and practiced to subject the soft magnetic metal powder to a phosphate treatment to form a phosphate insulating coating. This technology prepares a metal salt of phosphoric acid such as magnesium, calcium, or zinc as an aqueous solution or an aqueous dispersion, and optionally adds boric acid to the surface of the powder to form a phosphate coating. To form. Although the insulating property is enhanced, the phosphate itself has a low function as a powder binder, so the above-mentioned synthetic resin binder is added if necessary.
【０００８】リン酸塩処理した軟磁性金属粉末からの成
形品に施すことのできる焼鈍温度の限界は、有機系バイ
ンダーを使用すれば、それによって決定されてしまう。
使用しなければ、有機物の分解の問題はないが、焼鈍を
５００℃以上で行なうと、電気抵抗が著しく低下するこ
とが経験された。被膜は無機物であって分解の問題はな
いが、高温では結晶化してしまい、その結果、電気抵抗
が低くなるということがわかった。結局、５００℃を超
える焼鈍はできないのが現状である。If an organic binder is used, the limit of the annealing temperature which can be applied to the molded article made of the phosphate-treated soft magnetic metal powder is determined by it.
If it is not used, there is no problem of decomposition of organic substances, but it was experienced that when the annealing was performed at 500 ° C or higher, the electric resistance was remarkably reduced. It was found that the film is an inorganic substance and has no problem of decomposition, but it is crystallized at high temperature, resulting in low electric resistance. After all, it is the current situation that annealing exceeding 500 ° C cannot be performed.
【０００９】発明者らは、リン酸またはその塩の溶液に
よる絶縁処理をより効果的に行なう技術を探求する過程
で、絶縁処理の効果が軟磁性金属の合金組成によって異
なることに着目した。研究の結果、軟磁性金属の粉末の
表面付近に、ある程度以上の濃度でＳｉが存在すると、
リン酸またはその塩の溶液を用いた処理の効果が高いこ
とを知った。さらに、この効果が、ホウ酸またはその塩
の溶液を用いて絶縁処理を行なったときにも、またシリ
コーン樹脂を用いて絶縁処理を行なったときにも、同様
に得られることを見出した。In the process of searching for a technique for more effectively performing insulation treatment with a solution of phosphoric acid or a salt thereof, the inventors have noted that the effect of insulation treatment differs depending on the alloy composition of the soft magnetic metal. As a result of the research, if Si is present near the surface of the soft magnetic metal powder at a certain concentration or more,
It was found that the treatment with the solution of phosphoric acid or its salt was highly effective. Furthermore, it has been found that this effect can be similarly obtained when the insulating treatment is performed using a solution of boric acid or a salt thereof and when the insulating treatment is performed using a silicone resin.
【００１０】[0010]
【発明が解決しようとする課題】本発明の目的は、上記
の発明者らの新しい知見を活用し、圧粉磁心において、
高い温度での焼鈍によって軟磁性金属の粉末内部の歪み
が十分に解消しており、かつ、電気抵抗が顕著に改善さ
れ、従って高い周波数領域においても透磁率の低下がほ
とんど生じないか、または僅かであるものを提供するこ
と、また、そのような圧粉磁心の製造方法を提供するこ
とにある。上記のような圧粉磁心を製造するために使用
する中間製品を提供することもまた、本発明の目的に含
まれる。SUMMARY OF THE INVENTION An object of the present invention is to make use of the above new findings of the inventors, and
Strain inside the soft magnetic metal powder is sufficiently eliminated by annealing at a high temperature, and the electric resistance is remarkably improved, so that the magnetic permeability hardly decreases even in the high frequency region, or slightly. And to provide a method for manufacturing such a dust core. It is also included in the object of the present invention to provide an intermediate product used for producing the dust core as described above.
【００１１】[0011]
【課題を解決するための手段】本発明の高い電気抵抗を
有する圧粉磁心は、粉末の表面から深さ０．２μｍまで
の部分の平均Ｓｉ含有量が少なくとも０．５重量％であ
る軟磁性金属の粉末の表面に、リン酸、ホウ酸、または
リン酸もしくはホウ酸のＮａ，Ｋ，Ｃａ，Ｍｇ，Ａｌ，
Ｓｉ，ＭｎもしくはＺｎの塩の被膜を形成したものを、
圧縮成形により磁心形状に成形し、歪み取り焼鈍を施し
てなる圧粉磁心である。The powder magnetic core having a high electric resistance according to the present invention is a soft magnetic material having an average Si content of at least 0.5% by weight from the surface of the powder to a depth of 0.2 μm. On the surface of metal powder, phosphoric acid, boric acid, or phosphoric acid or boric acid such as Na, K, Ca, Mg, Al,
The one with a coating film of a salt of Si, Mn or Zn is
The powder magnetic core is formed by compression molding into a magnetic core shape and subjected to strain relief annealing.
【００１２】この高い電気抵抗を有する圧粉磁心を製造
する本発明の方法は、Ｓｉを含有する軟磁性金属の噴霧
により、粉末の表面から深さ０．２μｍまでの部分の平
均Ｓｉ含有量が少なくとも０．５重量％である粉末を製
造し、この粉末を、リン酸、ホウ酸、またはリン酸もし
くはホウ酸のＮａ，Ｋ，Ｃａ，Ｍｇ，Ａｌ，Ｓｉ，Ｍｎ
もしくはＺｎの塩の溶液で処理して粉末表面に絶縁被膜
を形成したのち、圧縮成形して磁心形状に成形し、成形
品を５００〜１０００℃の温度で焼鈍することからな
る。According to the method of the present invention for producing the powder magnetic core having high electric resistance, the average Si content in the portion from the surface of the powder to the depth of 0.2 μm is increased by spraying the soft magnetic metal containing Si. A powder of at least 0.5% by weight is produced, which powder is treated with phosphoric acid, boric acid or phosphoric acid or boric acid Na, K, Ca, Mg, Al, Si, Mn.
Alternatively, it is formed by treating with a Zn salt solution to form an insulating coating on the powder surface, followed by compression molding to form a magnetic core, and annealing the molded product at a temperature of 500 to 1000 ° C.
【００１３】上記の高い電気抵抗を有する圧粉磁心を製
造するための本発明の中間製品は、粉末の表面から深さ
０．２μｍまでの部分の平均Ｓｉ含有量が少なくとも
０．５重量％である軟磁性金属の粉末に対し、上記した
処理を施してなるものである。The intermediate product of the present invention for producing the above-mentioned dust core having a high electric resistance has an average Si content of at least 0.5% by weight in a portion from the surface of the powder to a depth of 0.2 μm. The soft magnetic metal powder is subjected to the above-mentioned treatment.
【００１４】[0014]
【発明の実施形態】本発明においては、ある程度の量の
Ｓｉを含有する限り、任意の軟磁性金属の粉末を圧粉磁
心の材料とすることができるが、代表的なものは、下記
の合金の、とくに水噴霧粉である。
・Ｓｉ：１〜１１重量％を含有するＦｅ−Ｓｉ合金、
・Ｓｉ：１〜１１重量％およびＡｌ：７重量％以下を含
有するＦｅ−Ｓｉ−Ａｌ合金
・Ｓｉ：０．１〜５重量％およびＣｏ：１０〜６０重量
％を含有するＦｅ−Ｓｉ−Ｃｏ合金。BEST MODE FOR CARRYING OUT THE INVENTION In the present invention, powder of any soft magnetic metal can be used as the material of the dust core as long as it contains a certain amount of Si. , Especially water spray powder. -Si: Fe-Si alloy containing 1 to 11 wt% -Si: Fe-Si-Al alloy containing 1 to 11 wt% and Al: 7 wt% or less-Si: 0.1 to 5 wt% And Co: Fe-Si-Co alloy containing 10 to 60% by weight.
【００１５】後記する実施例にみるとおり、リン酸、ホ
ウ酸、それらの塩、またはシリコーン樹脂による絶縁処
理は、軟磁性金属の粉末の表面から深さ０．２μｍまで
の部分の平均Ｓｉ含有量が少なくとも０．５重量％であ
れば、効果が高い。このＳｉ含有量の条件は、軟磁性金
属が全体として０．５重量％以上のＳｉを含有していれ
ば当然に満たされるが、０．５重量％に達しないＳｉ含
有量であっても、それに近い値である場合は、表面近く
においてＳｉ濃度が高まることがしばしば認められる
（その理由は明らかでない）ので、絶縁処理の効果が高
く得られることが期待できる。この現象は、軟磁性金属
にあまり多量のＳｉを添加したくない場合に有益であ
る。As will be seen in the examples described below, the insulating treatment with phosphoric acid, boric acid, salts thereof, or silicone resin was performed so that the average Si content in the portion from the surface of the soft magnetic metal powder to a depth of 0.2 μm was measured. Is at least 0.5% by weight, the effect is high. The condition of the Si content is naturally satisfied if the soft magnetic metal contains 0.5% by weight or more of Si as a whole, but even if the Si content does not reach 0.5% by weight, When the value is close to that, it is often recognized that the Si concentration increases near the surface (the reason is not clear), and therefore, it can be expected that the effect of the insulating treatment is high. This phenomenon is useful when one does not want to add too much Si to the soft magnetic metal.
【００１６】[0016]
【実施例】［実施例１〜３および比較例１］表１に示す
Ｓｉ含有量のＦｅ−Ｓｉ合金の溶湯を水噴霧して、−１
００メッシュの粉末を用意した。それぞれの粉末の、表
面から深さ０．２μｍまでの部分の平均Ｓｉ量を測定し
て、表１に掲げた。この平均Ｓｉ量は、粉末の表面から
深さ方向へのＳｉ濃度分布をオージェ分光分析法により
測定し、平均して得た値である。各粉末を、表１に示す
処理液で処理し、乾燥後、常温で１５トン／cm２の圧力
を加え、試験片を製造した。アルゴンガス雰囲気下、７
００℃に２時間保持する熱処理によりひずみを除いた。Examples [Examples 1 to 3 and Comparative Example 1] The molten Fe-Si alloy having the Si content shown in Table 1 was sprayed with water to give -1.
A powder of 00 mesh was prepared. The average amount of Si in the portion from the surface to the depth of 0.2 μm of each powder was measured and listed in Table 1. The average Si amount is a value obtained by measuring and averaging the Si concentration distribution from the surface of the powder in the depth direction by Auger spectroscopy. Each powder was treated with the treatment liquid shown in Table 1, dried, and then subjected to a pressure of 15 ton / cm 2 at room temperature to produce a test piece. 7 in an argon gas atmosphere
The strain was removed by a heat treatment of holding at 00 ° C for 2 hours.
【００１７】これら試験片を用いて、下記の試験を行な
った。結果を、表１に併せて示す。
［電気抵抗率］
試験片：縦５mm×横５mm×長さ３０mm
直流四端子法または直流二端子法
［コアロス］
試験片：外径２８mm×内径２０mm×高さ５mm
コアロス試験機、周波数２０ＫＨｚ、磁束密度０．１ＴThe following tests were carried out using these test pieces. The results are also shown in Table 1. [Electrical resistivity] Test piece: 5 mm length x 5 mm width x 30 mm length DC four-terminal method or DC two-terminal method [core loss] Test piece: Outer diameter 28 mm x inner diameter 20 mm x height 5 mm Core loss tester, frequency 20 KHz, magnetic flux Density 0.1T
【００１８】 表 １ 合金成分 表面０．２ 絶縁処理剤 電気抵抗率 コアロス (重量％) μｍのＳｉ （濃度） ρ(μΩcm) （kW/m３） 実施例１ Si:0.5 0.80 リン酸0.2％ 2.5×10３ 8.5×10３ 実施例２ Si:3.1 4.50 リン酸(80)+ 4.5×10３ 7.9×10３ ホウ酸(20) 0.2％ 実施例３ Si:6.6 9.30 リン酸Ｚｎ0.5％ 6.5×10５ 3.3×102 比較例１ Si:0.05 0.20 リン酸0.2％ 2.5×10３ 4.9×104 Table 1 Alloy components Surface 0.2 Insulation treatment agent Electrical resistivity Core loss (% by weight) μm Si (concentration) ρ (μΩcm) (kW / m 3 ) Example 1 Si: 0.5 0.80 Phosphoric acid 0.2% 2.5 × 10 3 8.5 × 10 3 Example 2 Si: 3.1 4.50 Phosphoric acid (80) + 4.5 × 10 3 7.9 × 10 3 Boric acid (20) 0.2% Example 3 Si: 6.6 9.30 Zn phosphate 0.5% 6.5 × 10 5 3.3 × 10 2 Comparative Example 1 Si: 0.05 0.20 Phosphoric acid 0.2% 2.5 × 10 3 4.9 × 10 4
【００１９】［実施例４］軟磁性合金としてＦｅ−Ｓｉ
−Ａｌ合金を使用し、絶縁処理剤を変えて、実施例１と
同様の操作で圧粉磁心を製造した。その結果を、表２に
示す。
表 ２
合金成分 表面０．２ 絶縁処理剤 電気抵抗率 コアロス (重量％) μｍのＳｉ （濃度） ρ(μΩcm) （kW/m３）
実施例４ Si:9.6, 15.90 リン酸Ａｌ 0.5％ 7.5×10５ ２.０×10２
Al:5.4 [Example 4] Fe-Si as a soft magnetic alloy
A powder magnetic core was manufactured in the same manner as in Example 1, except that the Al treatment was used and the insulating treatment agent was changed. The results are shown in Table 2. Table 2 Alloy components Surface 0.2 Insulation treatment agent Electrical resistivity Core loss (wt%) μm Si (concentration) ρ (μΩcm) (kW / m 3 ) Example 4 Si: 9.6, 15.90 Al phosphate 0.5% 7.5 × 10 5 2.0 × 10 2 Al: 5.4
【００２０】［実施例５および比較例２］軟磁性合金と
してＦｅ−Ｎｉ−Ｍｏ−Ｓｉ合金を使用し、絶縁処理剤
を変えて実施例１と同様の操作で、圧粉磁心を製造し
た。その結果を、比較例とともに表３に示す。
表 ３
合金成分 表面０．２ 絶縁処理剤 電気抵抗率 コアロス (重量％) μｍのＳｉ （濃度） ρ(μΩcm) （kW/m３）
実施例５ Ni:80,Mo:2, 2.60 リン酸Ｍｎ0.5％ 3.3×104 1.9×10２
Si:1
比較例２ Ni:80,Mo:2, 0.20 リン酸Ｍｎ0.5％ 5.4×103 3.1×103
Si:0.1[Example 5 and Comparative Example 2] A Fe-Ni-Mo-Si alloy was used as the soft magnetic alloy, and the insulating treatment agent was changed to carry out the same operation as in Example 1 to produce a dust core. The results are shown in Table 3 together with the comparative example. Table 3 Alloy composition Surface 0.2 Insulation treatment agent Electrical resistivity Core loss (wt%) μm Si (concentration) ρ (μΩcm) (kW / m 3 ) Example 5 Ni: 80, Mo: 2, 2.60 Mn0 phosphate .5% 3.3 × 10 4 1.9 × 10 2 Si: 1 Comparative Example 2 Ni: 80, Mo: 2, 0.20 Mn phosphate 0.5% 5.4 × 10 3 3.1 × 10 3 Si: 0.1
【００２１】［実施例６および比較例３］軟磁性合金と
してＦｅ−Ｃｏ（−Ｓｉ）合金を使用し、実施例１と同
様の操作で、圧粉磁心を製造した。その結果を、比較例
とともに表４に示す。絶縁処理剤として、シリコーン樹
脂液「ＳＲ２４００」（東レ・ダウコーニング社製）を
使用した。
表 ４
合金成分 表面０．２ 絶縁処理剤 電気抵抗率 コアロス (重量％) μｍのＳｉ （濃度） ρ(μΩcm) （kW/m３）
実施例６ Co:49, Si:2 5.60 シリコーン1.0％ 1.6×104 8.6×10２
比較例３ Co:49 0 シリコーン1.0％ 2.5×102 8.5×104 [Example 6 and Comparative Example 3] A Fe-Co (-Si) alloy was used as the soft magnetic alloy, and a dust core was manufactured in the same manner as in Example 1. The results are shown in Table 4 together with the comparative example. Silicone resin liquid "SR2400" (manufactured by Toray Dow Corning) was used as an insulation treatment agent. Table 4 Alloy components Surface 0.2 Insulation treatment agent Electrical resistivity Core loss (wt%) μm Si (concentration) ρ (μΩcm) (kW / m 3 ) Example 6 Co: 49, Si: 2 5.60 Silicone 1.0% 1.6 × 10 4 8.6 × 10 2 Comparative Example 3 Co: 49 0 Silicone 1.0% 2.5 × 10 2 8.5 × 10 4
【００２２】［実施例７および比較例４］軟磁性合金と
してＦｅ−Ｃｏ−Ｖ（−Ｓｉ）合金を使用し、実施例１
と同様の操作で、圧粉磁心を製造した。その結果を、比
較例とともに表５に示す。
表 ５
合金成分 表面０．２ 絶縁処理剤 電気抵抗率 コアロス (重量％) μｍのＳｉ （濃度） ρ(μΩcm) （kW/m３）
実施例７ Co:25,V:1, 1.60 リン酸0.2％ 5.6×104 5.5×103
Si:0.5
比較例４ Co:25,V:1 0 リン酸0.2％ 8.0×101 6.9×105 [Example 7 and Comparative Example 4] An Fe-Co-V (-Si) alloy was used as the soft magnetic alloy, and Example 1 was used.
A powder magnetic core was manufactured by the same operation as. The results are shown in Table 5 together with the comparative examples. Table 5 Alloy components Surface 0.2 Insulation treatment agent Electrical resistivity Core loss (wt%) μm Si (concentration) ρ (μΩcm) (kW / m 3 ) Example 7 Co: 25, V: 1, 1.60 Phosphoric acid 0.2 % 5.6 × 10 4 5.5 × 10 3 Si: 0.5 Comparative Example 4 Co: 25, V: 1 0 Phosphoric acid 0.2% 8.0 × 10 1 6.9 × 10 5
【００２３】［実施例８および比較例５］軟磁性合金と
してＦｅ−Ｃｏ−Ｔｉ（−Ｓｉ）合金を使用し、絶縁処
理剤を変えて、実施例１と同様の操作で圧粉磁心を製造
した。その結果を、比較例とともに表６に示す。
表 ６
合金成分 表面０．２ 絶縁処理剤 電気抵抗率 コアロス (重量％) μｍのＳｉ （濃度） ρ(μΩcm) （kW/m３）
実施例８ Co:35,Ti:0.5, 2.90 リン酸Ｍｇ0.5％ 8.6×103 4.6×103
Si:1
比較例５ Co:35,Ti:0.5 0 リン酸Ｍｇ0.5％ 1.3×102 5.3×104 [Example 8 and Comparative Example 5] A powder magnetic core was manufactured in the same manner as in Example 1, except that an Fe-Co-Ti (-Si) alloy was used as the soft magnetic alloy and the insulating treatment agent was changed. did. The results are shown in Table 6 together with the comparative examples. Table 6 Alloy component Surface 0.2 Insulation treatment agent Electrical resistivity Core loss (wt%) μm Si (concentration) ρ (μΩcm) (kW / m 3 ) Example 8 Co: 35, Ti: 0.5, 2.90 MgO phosphate .5% 8.6 × 10 3 4.6 × 10 3 Si: 1 Comparative Example 5 Co: 35, Ti: 0.5 0 Mg phosphate 0.5% 1.3 × 10 2 5.3 × 10 4
【００２４】［実施例９，１０および比較例６］軟磁性
合金としてＦｅ−Ｃｒ−Ｓｉ合金を使用し、絶縁処理剤
を変えて、実施例１と同様の操作で圧粉磁心を製造し
た。その結果を、比較例とともに表７に示す。
表 ７
合金成分 表面０．２ 絶縁処理剤 電気抵抗率 コアロス (重量％) μｍのＳｉ （濃度） ρ(μΩcm) （kW/m３）
実施例９ Cr:13,Si:1.0 1.90 ホウ酸1.0％ 3.8×103 4.3×103
実施例10 Cr:13,Si:1.0 1.90 ホウ酸Ｎａ1.0％ 2.9×103 3.9×103
比較例６ Cr:13,Si:0.05 0.15 ホウ酸1.0％ 2.5×102 6.1×104 [Examples 9 and 10 and Comparative Example 6] A Fe-Cr-Si alloy was used as the soft magnetic alloy, the insulating treatment agent was changed, and the powder magnetic core was manufactured in the same manner as in Example 1. The results are shown in Table 7 together with the comparative examples. Table 7 Alloy components Surface 0.2 Insulation treatment agent Electrical resistivity Core loss (% by weight) μm Si (concentration) ρ (μΩcm) (kW / m 3 ) Example 9 Cr: 13, Si: 1.0 1.90 Boric acid 1.0% 3.8 × 10 3 4.3 × 10 3 Example 10 Cr: 13, Si: 1.0 1.90 Na borate 1.0% 2.9 × 10 3 3.9 × 10 3 Comparative Example 6 Cr: 13, Si: 0.05 0.15 Boric acid 1.0% 2.5 × 10 2 6.1 x 10 4
【００２５】[0025]
【発明の効果】本発明の圧粉磁心は、軟磁性金属の粉末
の表面において、絶縁処理剤として適用したリン酸、ホ
ウ酸、それらの塩、またはシリコーン樹脂が、０．５重
量％以上の濃度で存在するＳｉとの作用により、強固な
絶縁被膜を形成し、その絶縁効果が高い温度で焼鈍して
も低下せず、したがって絶縁性能が低下しないため、個
の粉末から製造した圧分磁心は、高い電気抵抗を保持し
ている。焼鈍は５００℃以上、たとえば７００℃とい
う、十分な効果が得られる温度で行なうことができるか
ら、焼鈍温度に制約があって残留歪みを除去しきれない
という、従来の圧分磁心の問題が解消した。Industrial Applicability The dust core of the present invention contains 0.5% by weight or more of phosphoric acid, boric acid, a salt thereof, or a silicone resin applied as an insulating treatment agent on the surface of a soft magnetic metal powder. A strong insulating film is formed by the action of Si existing in a concentration, and its insulating effect does not decrease even when annealed at a high temperature, and therefore the insulating performance does not decrease. Holds a high electrical resistance. Since the annealing can be performed at a temperature of 500 ° C. or higher, for example 700 ° C., at which a sufficient effect can be obtained, the problem of the conventional pressure-dividing magnetic core that the residual strain cannot be removed due to the limitation of the annealing temperature is solved. did.
【００２６】焼鈍が十分に行なわれる結果、圧粉磁心の
保磁力は低く抑えられ、かつ高周波領域においても透磁
率の低下が生じない。それゆえ本発明の圧粉磁心は、種
々の電気・電子機器類がより高い周波数領域で使用され
る傾向に対して、よく対応できる。As a result of sufficient annealing, the coercive force of the dust core is kept low, and the permeability does not decrease even in the high frequency range. Therefore, the dust core of the present invention can well cope with the tendency of various electric and electronic devices to be used in a higher frequency region.
【００２７】本発明の中間製品である、表面処理した軟
磁性金属の粉末は、通常の圧縮成形により磁心形状に成
形し、適宜の温度で焼鈍することにより、高性能な圧粉
磁心を製造することができる材料である。The surface-treated soft magnetic metal powder, which is an intermediate product of the present invention, is molded into a magnetic core shape by ordinary compression molding and annealed at an appropriate temperature to produce a high-performance dust core. It is a material that can.
───────────────────────────────────────────────────── 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） Ｃ２２Ｃ 38/00 Ｃ２２Ｃ 38/00 ３０３Ｔ 38/06 38/06 38/10 38/10 38/18 38/18 Ｈ０１Ｆ 27/255 Ｈ０１Ｆ 41/02 Ｄ 41/02 27/24 Ｄ ─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. 7 Identification code FI theme code (reference) C22C 38/00 C22C 38/00 303T 38/06 38/06 38/10 38/10 38/18 38/18 H01F 27/255 H01F 41/02 D 41/02 27/24 D
Claims (6)
分の平均Ｓｉ含有量が少なくとも０．５重量％である軟
磁性金属の粉末を、リン酸、ホウ酸、またはリン酸もし
くはホウ酸のＮａ，Ｋ，Ｃａ，Ｍｇ，Ａｌ，Ｓｉ，Ｍｎ
もしくはＺｎの塩の溶液で絶縁処理したものを、圧縮成
形により磁心形状に成形し、歪み取り焼鈍を施してなる
高い電気抵抗を有する圧粉磁心。1. A soft magnetic metal powder having an average Si content of at least 0.5% by weight from the surface of the powder to a depth of 0.2 μm is treated with phosphoric acid, boric acid, or phosphoric acid or boric acid. Na, K, Ca, Mg, Al, Si, Mn
Alternatively, a powder magnetic core having a high electric resistance obtained by compression-molding a product obtained by performing insulation treatment with a Zn salt solution and performing strain relief annealing.
分の平均Ｓｉ含有量が少なくとも０．５重量％である軟
磁性金属の粉末の表面を、シリコーン樹脂で絶縁処理し
たものを、圧縮成形により磁心形状に成形し、歪み取り
焼鈍を施してなる高い電気抵抗を有する圧粉磁心。2. A soft magnetic metal powder having an average Si content of at least 0.5% by weight from the surface of the powder to a depth of 0.2 μm, the surface of which is insulated with a silicone resin is compressed. A dust core having a high electric resistance, which is formed by molding into a magnetic core shape and subjected to strain relief annealing.
量％を含有するＦｅ−Ｓｉ合金、またはＳｉ：１〜１１
重量％およびＡｌ：７重量％以下を含有するＦｅ−Ｓｉ
−Ａｌ合金の粉末である請求項１または２の圧粉磁心。3. A soft magnetic metal powder is a Fe—Si alloy containing Si: 1 to 11 wt%, or Si: 1 to 11.
Fe-Si containing 1 wt% and Al: 7 wt% or less
The powder magnetic core according to claim 1 or 2, which is a powder of an Al alloy.
重量％およびＣｏ：１０〜６０重量％を含有するＦｅ−
Ｓｉ−Ｃｏ合金の粉末である請求項１または２の圧粉磁
心。4. The soft magnetic metal powder contains Si: 0.1 to 5
Fe-containing wt% and Co: 10-60 wt%
The powder magnetic core according to claim 1 or 2, which is a powder of a Si-Co alloy.
り、粉末の表面から深さ０．２μｍまでの部分の平均Ｓ
ｉ含有量が少なくとも０．５重量％である粉末を製造
し、この粉末を、リン酸、ホウ酸、またはリン酸もしく
はホウ酸のＮａ，Ｋ，Ｃａ，Ｍｇ，Ａｌ，Ｓｉ，Ｍｎも
しくはＺｎの塩の溶液で処理するか、またはシリコーン
樹脂で処理して粉末表面に絶縁被膜を形成したのち、圧
縮成形して磁心形状に成形し、成形品を５００〜１００
０℃の温度で焼鈍することからなる高い電気抵抗を有す
る圧粉磁心の製造方法。5. An average S of a portion from the surface of the powder to a depth of 0.2 μm by water spraying a soft magnetic metal containing Si.
A powder having an i content of at least 0.5% by weight is produced, and the powder is mixed with phosphoric acid, boric acid, or phosphoric acid or boric acid such as Na, K, Ca, Mg, Al, Si, Mn, or Zn. After treatment with a salt solution or with a silicone resin to form an insulating coating on the surface of the powder, compression molding is performed to form a magnetic core, and the molded product is made to have a thickness of 500 to 100.
A method for producing a dust core having a high electric resistance, which comprises annealing at a temperature of 0 ° C.
分の平均Ｓｉ含有量が少なくとも０．５重量％である軟
磁性金属の粉末に対し、請求項５に記載した処理を施し
てなる、高い電気抵抗を有する圧粉磁心を製造するため
の中間製品。6. A soft magnetic metal powder having an average Si content of at least 0.5% by weight from the surface of the powder to a depth of 0.2 μm is subjected to the treatment described in claim 5. , An intermediate product for producing a dust core having high electric resistance.
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|---|---|---|---|
| JP2001338279A JP2003142310A (en) | 2001-11-02 | 2001-11-02 | Dust core having high electrical resistance and manufacturing method therefor |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001338279A JP2003142310A (en) | 2001-11-02 | 2001-11-02 | Dust core having high electrical resistance and manufacturing method therefor |
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|---|---|
| JP2003142310A true JP2003142310A (en) | 2003-05-16 |
Family
ID=19152799
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