JP2005294458A - High-frequency composite magnetic powder material, high-frequency dust core and method for manufacturing the same - Google Patents
High-frequency composite magnetic powder material, high-frequency dust core and method for manufacturing the same Download PDFInfo
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本発明は、スイッチング電源用ＤＣ／ＤＣコンバータに用いられるインダクタ、またはＤＣインダクタなど、高い電流もしくは高周波帯域で用いられる線輪部品に使用するのに好適な、高周波用複合磁性粉末材料および高周波用圧粉磁芯ならびに高周波用圧粉磁芯の製造方法に関する。 The present invention relates to a high-frequency composite magnetic powder material and a high-frequency pressure suitable for use in high-current or high-frequency band components such as inductors used in DC / DC converters for switching power supplies or DC inductors. The present invention relates to a method for manufacturing a powder magnetic core and a high-frequency powder magnetic core.
近年の電子部品は、電気回路等に用いられる部品においても、益々、動作環境で高電流化、動作周波数の高周波化、小型化の要求によって、使用する環境などが移り変わってきている。これに伴い、センダストまたはフェライトなどの材料により高周波化の要求に対処している。 In recent years, electronic components used in electric circuits and the like are increasingly used due to demands for higher currents, higher operating frequencies, and smaller sizes in the operating environment. Along with this, the demand for higher frequency is addressed by materials such as sendust or ferrite.
１種類の粉末、あるいは粒子の大きさが粗大なものを使用した電源などに使用される従来の電気部品は、低い周波数領域では良好な磁気および電気的特性を有していたが、低い周波数領域では良好な磁気および電気的特性を有している材料も、高い周波数領域ほど特性が伸びず使用される粉末材料もほぼ特定されていた。ここで、Ｓｉ５ｗｔ％、残りＦｅのＦｅ−Ｓｉ合金粉末を使用したトロイダルコアを例にとると、周波数１００ｋＨｚ付近より透磁率が低下している。 Conventional electric parts used for power supplies using one type of powder or coarse particles have good magnetic and electrical characteristics in the low frequency range, but the low frequency range Therefore, materials having good magnetic and electrical characteristics and powder materials to be used whose characteristics do not extend in the higher frequency range have been almost specified. Here, when a toroidal core using Fe—Si alloy powder of Si 5 wt% and the remaining Fe is taken as an example, the magnetic permeability is reduced from around a frequency of 100 kHz.
図２は、本発明と、従来の高周波用圧粉磁芯の製造方法の説明図であり、図２（ａ）は、本発明の実施例による高周波用圧粉磁芯の製造工程の説明図、図２（ｂ）は、従来の高周波用圧粉磁芯の製造工程の説明図である。図２（ｂ）の従来の高周波用圧粉磁芯の製造工程は、原料粉末を、高温熱処理し、前記高温熱処理された原料粉末を秤量し、これにバインダを加えて、バインダ混合し、ついで乾燥・分級し、金型で成型し、最後にキュアを行う。 FIG. 2 is an explanatory diagram of the present invention and a conventional method for manufacturing a high-frequency dust core, and FIG. 2 (a) is an explanatory diagram of a process for manufacturing a high-frequency dust core according to an embodiment of the present invention. FIG.2 (b) is explanatory drawing of the manufacturing process of the conventional dust core for high frequency. The manufacturing process of the conventional high-frequency powder magnetic core shown in FIG. 2B is performed by subjecting the raw material powder to high-temperature heat treatment, weighing the high-temperature heat-treated raw material powder, adding a binder thereto, mixing the binder, Dry and classify, mold with mold, and finally cure.
特許文献１には、磁性粉末とバインダを混合し、熱処理工程を行って、磁気特性を得る圧粉磁芯について記載されている。 Patent Document 1 describes a dust core in which magnetic powder and a binder are mixed and a heat treatment process is performed to obtain magnetic properties.
従来の高周波用圧粉磁芯は、透磁率の周波数特性において、１ＭＨｚを超えると透磁率が低下するという問題点があった。従って、本発明の課題は、上記各問題に鑑み、実効透磁率の周波数特性が平坦であり、同時に高周波領域での実効透磁率が優れた高周波用複合磁性粉末材料および高周波用圧粉磁芯ならびに高周波用圧粉磁芯の製造方法を得ることである。 Conventional high frequency powder magnetic cores have a problem in that the magnetic permeability decreases when the frequency characteristics of the magnetic permeability exceed 1 MHz. Therefore, in view of the above-mentioned problems, the problem of the present invention is that the frequency characteristics of the effective permeability are flat, and at the same time, the high-frequency composite magnetic powder material and the high-frequency dust core that have excellent effective permeability in the high-frequency region, and It is to obtain a method for producing a high-frequency dust core.
本発明においては、上記課題を解決すべく、種々の検討を重ねた結果、結晶質磁性材料と、非晶質磁性材料とを均一に混合し、分散させた複合磁性材料粉末について、前記結晶質材料をＦｅ粉末とし、前記非結晶質材料をＦｅ−Ｓｉ−Ｂ合金粉末とし、前記複合磁性粉末材料に、絶縁材として、シリコーン系樹脂、フェノール系樹脂、エポキシ系樹脂等の有機高分子樹脂、または水ガラス、もしくは組み合わせたものを使用し、作製した高周波用圧粉磁芯とする。 In the present invention, as a result of various studies to solve the above-described problems, the crystalline magnetic material and the amorphous magnetic material are uniformly mixed and dispersed in the composite magnetic material powder. The material is Fe powder, the amorphous material is Fe-Si-B alloy powder, the composite magnetic powder material, the insulating material, organic polymer resin such as silicone resin, phenol resin, epoxy resin, Alternatively, water glass or a combination thereof is used to form the produced high-frequency powder magnetic core.
また、本発明の複合磁性粉末材料を使用して作製した圧粉磁芯並びに電気部品は高い周波数領域で平坦な磁気および電気的特性を有する。 Further, the dust core and electrical parts produced using the composite magnetic powder material of the present invention have flat magnetic and electrical characteristics in a high frequency range.
即ち、本発明は、結晶質磁性材料と、非晶質磁性材料とを均一に混合し、分散させた複合磁性材料粉末に、絶縁材として、シリコーン系樹脂、フェノール系樹脂、エポキシ系樹脂等の有機高分子樹脂、または水ガラス、もしくは組み合わせたものを使用し、作製された高周波用圧粉磁芯である。 That is, the present invention provides a composite magnetic material powder in which a crystalline magnetic material and an amorphous magnetic material are uniformly mixed and dispersed, and an insulating material such as a silicone resin, a phenol resin, or an epoxy resin. A high-frequency powder magnetic core produced by using an organic polymer resin, water glass, or a combination thereof.
また、本発明は、前記非晶質磁性材料のビッカース硬度は、８００以上から１４００以下の範囲であり、前記の結晶質磁性材料のビッカース硬度は、１００〜３００以下の範囲の高周波用圧粉磁芯である。 In the present invention, the amorphous magnetic material has a Vickers hardness in the range of 800 to 1400, and the crystalline magnetic material has a Vickers hardness in the range of 100 to 300 or less. The core.
また、本発明は、Ｆｅ粉末に、組成比をＳｉが５ｗｔ％〜１０ｗｔ％、Ｂが１ｗｔ％〜５ｗ％、残りＦｅとしたＦｅ−Ｓｉ−Ｂ合金粉末を均一に混合し、分散させた複合磁性材料粉末について、前記複合磁性粉末材料に、絶縁材として有機高分子樹脂、シリコーン系樹脂、フェノール系樹脂、エポキシ系樹脂、水ガラス等を絶縁材として使用し、また、これらの樹脂と無機物を組み合わせて使用して作製された高周波用圧粉磁芯である。 Further, the present invention is a composite in which Fe-Si-B alloy powder in which the composition ratio is 5 wt% to 10 wt%, B is 1 wt% to 5 w%, and the remaining Fe is uniformly mixed and dispersed in Fe powder. As for magnetic material powder, organic polymer resin, silicone resin, phenolic resin, epoxy resin, water glass, etc. are used as insulating materials in the composite magnetic powder material, and these resins and inorganic substances are used as insulating materials. It is a dust core for high frequency produced by using in combination.
また、本発明は、前記Ｆｅ−Ｓｉ−Ｂ合金粉末の、全体に対する比率は、２０ｗｔ％ 以上から８０ｗｔ％以下の範囲とする高周波用圧粉磁芯である。 Further, the present invention is the high-frequency dust core in which the ratio of the Fe—Si—B alloy powder to the whole is in the range of 20 wt% to 80 wt%.
また、本発明は、前記複合磁性粉末材料の透磁率が３８以上の高周波用圧粉磁芯である。 Further, the present invention is a high-frequency powder magnetic core in which the magnetic permeability of the composite magnetic powder material is 38 or more.
また、本発明は、前記高周波用圧粉磁芯は、周波数１ＭＨｚ〜５ＭＨｚにおいて平坦な周波数特性を有する高周波用圧粉磁芯である。 In the present invention, the high-frequency dust core is a high-frequency dust core having a flat frequency characteristic at a frequency of 1 MHz to 5 MHz.
また、本発明は、前記複合磁性粉末材料は、磁気特性に応じた組成比を選択し、また、粒子の形状は球状、ティアドロップ等の非球形状の粉末であり、粒径の大きさは平均粒径（Ｄ５０）で４５μｍとする高周波用圧粉磁芯である。 In the present invention, the composite magnetic powder material has a composition ratio selected according to the magnetic characteristics, and the particle shape is aspherical powder such as spherical or teardrop, and the particle size is This is a high-frequency dust core with an average particle size (D50) of 45 μm.
また、本発明は、前記Ｆｅ粉末の粒径は、１μｍ以上から１０μｍ以下の範囲であり、前記Ｆｅ−Ｓｉ−Ｂ合金粉末の粒径は、５μｍ以上から２０μｍ以下の範囲の高周波用圧粉磁芯である。 Further, in the present invention, the particle size of the Fe powder is in the range of 1 μm to 10 μm, and the particle size of the Fe—Si—B alloy powder is in the range of 5 μm to 20 μm. The core.
また、本発明は、結晶質磁性材料と、非晶質磁性材料とを均一に混合し、分散させた高周波用複合磁性粉末材料である。 Further, the present invention is a high-frequency composite magnetic powder material in which a crystalline magnetic material and an amorphous magnetic material are uniformly mixed and dispersed.
また、本発明は、前記非晶質磁性材料のビッカース硬度は、８００以上から１４００以下の範囲であり、前記の結晶質磁性材料のビッカース硬度は、１００以上から３００以下の範囲の高周波用複合磁性粉末材料である。 In the present invention, the amorphous magnetic material has a Vickers hardness in the range of 800 to 1400, and the crystalline magnetic material has a Vickers hardness in the range of 100 to 300 inclusive. It is a powder material.
また、本発明は、Ｆｅ粉末に、組成比をＳｉが５ｗｔ％〜１０ｗｔ％、Ｂが１ｗｔ％〜５ｗ％、残りＦｅとしたＦｅ−Ｓｉ−Ｂ合金粉末を均一に混合し、分散させた高周波用複合磁性粉末材料である。 In the present invention, the Fe-Si-B alloy powder in which the composition ratio is 5 wt% to 10 wt%, B is 1 wt% to 5 w%, and the remaining Fe is uniformly mixed and dispersed in the Fe powder. Composite magnetic powder material.
また、本発明は、前記Ｆｅ−Ｓｉ−Ｂ合金粉末の、全体に対する比率は、２０ｗｔ％ 以上から８０ｗｔ％以下の範囲とする高周波用複合磁性粉末材料である。 In addition, the present invention is the high-frequency composite magnetic powder material in which the ratio of the Fe—Si—B alloy powder to the whole is in the range of 20 wt% to 80 wt%.
また、本発明は、前記複合磁性粉末材料は、透磁率が３８以上の高周波用複合磁性粉末材料である。 In the present invention, the composite magnetic powder material is a high-frequency composite magnetic powder material having a magnetic permeability of 38 or more.
また、本発明は、前記複合磁性粉末材料は、磁気特性に応じた組成比を選択し、また、粒子の形状は球状、ティアドロップ等の非球形状の粉末であり、粒径の大きさは平均粒径（Ｄ５０）で４５μｍとする高周波用複合磁性粉末材料である。 In the present invention, the composite magnetic powder material has a composition ratio selected according to the magnetic characteristics, and the particle shape is aspherical powder such as spherical or teardrop, and the particle size is It is a high frequency composite magnetic powder material having an average particle size (D50) of 45 μm.
また、本発明は、前記Ｆｅ粉末の粒径は、１μｍ以上から１０μｍ以下の範囲であり、前記Ｆｅ−Ｓｉ−Ｂ合金粉末の粒径は、５μｍ以上から２０μｍ以下の範囲の高周波用複合磁性粉末材料である。 In the present invention, the Fe powder has a particle size in the range of 1 μm to 10 μm, and the Fe—Si—B alloy powder has a particle size in the range of 5 μm to 20 μm. Material.
また、本発明は、結晶質磁性材料と、非晶質磁性材料とを均一に混合し、分散させたことを特徴とする高周波用複合磁性粉末材料について、秤量を行い、前記秤量された複合磁性粉末材料に、絶縁材として各種有機高分子樹脂、シリコーン系樹脂、フェノール系樹脂、エポキシ系樹脂、水ガラス等を絶縁材として使用し、また、これらの樹脂と無機物を組み合わせて、混合し、その後、乾燥・分級し、成型し、キュアして作製する高周波用圧粉磁芯の製造方法である。 The present invention also provides a high-frequency composite magnetic powder material characterized by uniformly mixing and dispersing a crystalline magnetic material and an amorphous magnetic material, and weighing the composite magnetic powder material. Use various organic polymer resins, silicone resins, phenolic resins, epoxy resins, water glass, etc. as insulating materials in the powder material, and also combine and mix these resins and inorganic materials, and then This is a method for producing a high-frequency powder magnetic core produced by drying, classifying, molding and curing.
また、本発明は、Ｆｅ粉末に、組成比をＳｉが５ｗｔ％〜１０ｗｔ％、Ｂが１ｗｔ％〜５ｗ％、残りＦｅとしたＦｅ−Ｓｉ−Ｂ合金粉末、または、組成比をＳｉが８〜１０ｗｔ％、Ａｌが５〜８ｗｔ％、残りＦｅとしたＦｅ−Ｓｉ−Ａｌ合金粉末の中より少なくとも前記合金粉末を１種類以上均一に混合し、分散させた複合磁性材料粉末について、前記Ｆｅ−Ｓｉ−Ｂ合金粉末を、全体に対する比率を、２０ｗｔ％ 以上から８０ｗｔ％以下の範囲として秤量し、前記秤量された複合磁性粉末材料に、絶縁材として各種有機高分子樹脂、シリコーン系樹脂、フェノール系樹脂、エポキシ系樹脂、水ガラス等を絶縁材として使用し、また、これらの樹脂と無機物を組み合わせて、混合し、その後、乾燥・分級し、成型し、キュアして作製する高周波用圧粉磁芯の製造方法である。 Further, in the present invention, the Fe-Si-B alloy powder in which the composition ratio is 5 wt% to 10 wt%, B is 1 wt% to 5 w%, and the remaining Fe is the Fe powder, or the composition ratio is 8 to Si. About the composite magnetic material powder in which at least one kind of the alloy powder is uniformly mixed and dispersed from the Fe-Si-Al alloy powder in which 10 wt%, Al is 5 to 8 wt%, and the remaining Fe is used, the Fe-Si -B alloy powder is weighed in a ratio of 20 wt% to 80 wt% with respect to the whole, and various organic polymer resins, silicone resins, phenol resins are used as insulating materials in the weighed composite magnetic powder material. Epoxy resin, water glass, etc. are used as insulating materials. Also, these resins and inorganic materials are combined and mixed, then dried, classified, molded, cured, and manufactured at a high frequency. It is a manufacturing method of the dust core for waves.
本発明によれば、実効透磁率の周波数特性が平坦であり、同時に高周波領域での実効透磁率の優れた高周波用圧粉磁芯ならびに高周波用圧粉磁芯の製造方法が得られる。 ADVANTAGE OF THE INVENTION According to this invention, the frequency characteristic of an effective magnetic permeability is flat, and the manufacturing method of the dust core for high frequencies and the high frequency powder magnetic core which were excellent in the effective permeability in a high frequency area simultaneously is obtained.
この複合磁性粉末材料は、従来品には無い高周波領域における、優れた磁気および電気的特性を有する圧粉磁芯並びに電気部品を提供することができる。また、粉末製造工程においても大変短くすることができ、粉末熱処理を必要としない材料であるため特にランニングコストを削減することができ、製造コスト面でも大変有利な材料である。 This composite magnetic powder material can provide a dust core and an electrical component having excellent magnetic and electrical characteristics in a high frequency region not found in conventional products. In addition, it can be made very short in the powder manufacturing process, and since it is a material that does not require powder heat treatment, the running cost can be reduced, and it is a material that is very advantageous in terms of manufacturing cost.
本発明の実施の形態による高周波用複合磁性粉末材料および高周波用圧粉磁芯ならびに高周波用圧粉磁芯の製造方法について、以下に説明する。 The high-frequency composite magnetic powder material, the high-frequency powder magnetic core, and the method for manufacturing the high-frequency powder magnetic core according to the embodiment of the present invention will be described below.
本発明の高周波用複合磁性粉末材料および高周波用圧粉磁芯は、結晶質磁性材料に、非晶質磁性材料とを均一に混合し、分散させた複合磁性材料粉末であって、前記複合磁性粉末材料に、絶縁材として、シリコーン系樹脂、フェノール系樹脂、エポキシ系樹脂等の有機高分子樹脂、または水ガラス、もしくは組み合わせたものを使用し、作製された高周波用圧粉磁芯である。 The high-frequency composite magnetic powder material and high-frequency powder magnetic core of the present invention are composite magnetic material powders obtained by uniformly mixing and dispersing a crystalline magnetic material and an amorphous magnetic material, A high-frequency powder magnetic core produced by using an organic polymer resin such as a silicone resin, a phenol resin, or an epoxy resin, or water glass, or a combination thereof as the insulating material for the powder material.
ここで、前記結晶質磁性材料には、例えばＦｅ粉末が用いられ、また、非晶質磁性材料には、例えばＦｅ−Ｓｉ−Ｂ合金粉末が用いられる。前記Ｆｅ−Ｓｉ−Ｂ合金粉末は、組成比をＳｉが５ｗｔ％〜１０ｗｔ％、Ｂが１ｗｔ％〜５ｗ％、残りＦｅとし、前記Ｆｅ−Ｓｉ−Ｂ合金粉末は、全体に対して、２０ｗｔ％ 以上から８０ｗｔ％以下の範囲で混合する。 Here, for example, Fe powder is used for the crystalline magnetic material, and for example, Fe—Si—B alloy powder is used for the amorphous magnetic material. The Fe—Si—B alloy powder has a composition ratio of 5 wt% to 10 wt% Si, 1 wt% to 5 w% B, and the remaining Fe, and the Fe—Si—B alloy powder is 20 wt% based on the whole. Mix in the range of 80 wt% or less.
ここで、Ｆｅ粉末のビッカース硬度は、１００以上から３００以下の範囲にあり、前記Ｆｅ−Ｓｉ−Ｂ合金粉末は、８００以上から１４００以下の範囲である。ここで、１００以下の場合は柔らかすぎ、３００以上では硬すぎ、成型が困難となる。粒径は、Ｆｅ粉末の粒径が１μｍ以上から１０μｍ以下の範囲で、Ｆｅ−Ｓｉ−Ｂ合金粉末の粒径が５μｍ以上から２０μｍ以下の範囲とすると良い。１μｍ以下ではハンドリングが悪く、２０μｍ以上では粒径に依存する渦電流損失により周波数特性が悪い。混合するので上記程度とすると、成型性が良い。更に、前記高周波用圧粉磁芯は、高温熱処理を行わず、混合、分散させるだけで透磁率が３８以上の磁気特性が得られる。 Here, the Vickers hardness of the Fe powder is in the range of 100 to 300, and the Fe—Si—B alloy powder is in the range of 800 to 1400. Here, when it is 100 or less, it is too soft, and when it is 300 or more, it is too hard, and molding becomes difficult. The particle size of the Fe powder is preferably in the range of 1 μm to 10 μm, and the particle size of the Fe—Si—B alloy powder is preferably in the range of 5 μm to 20 μm. If it is 1 μm or less, handling is bad, and if it is 20 μm or more, the frequency characteristics are bad due to eddy current loss depending on the particle size. Since it mixes, when it is the above grade, moldability is good. Furthermore, the magnetic powder core for high frequency can obtain magnetic characteristics having a magnetic permeability of 38 or more only by mixing and dispersing without high-temperature heat treatment.
図２は、本発明と、従来の高周波用圧粉磁芯の製造方法の説明図であり、図２（ａ）は、本発明の高周波用圧粉磁芯の製造工程の説明図である。図２（ａ）より、本発明の高周波用圧粉磁芯の製造工程は、原料粉末を、高温熱処理しない状態で、秤量し、これにバインダを加えて、バインダ混合し、 ついで乾燥・分級し、金型で成型し、最後にキュアを行う。このように、従来の図２（ｂ）の製造工程にあった、高温熱処理の工程が、削除される。 FIG. 2 is an explanatory view of the present invention and a conventional method for producing a high-frequency dust core, and FIG. 2 (a) is an explanatory view of the production process of the high-frequency dust core of the present invention. From FIG. 2 (a), in the manufacturing process of the high-frequency powder magnetic core of the present invention, the raw material powder is weighed without being subjected to high-temperature heat treatment, added with a binder, mixed with the binder, then dried and classified. Mold with a mold, and finally cure. In this way, the high-temperature heat treatment process that was in the conventional manufacturing process of FIG. 2B is eliminated.
以下に、本発明の実施例による高周波用複合磁性粉末材料および高周波用圧粉磁芯ならびに高周波用圧粉磁芯の製造方法について説明する。 Hereinafter, a high-frequency composite magnetic powder material, a high-frequency powder magnetic core, and a method for producing a high-frequency powder magnetic core according to an embodiment of the present invention will be described.
全体としてＦｅ粉末（使用している粉末は水アトマイズ製法にて作製された粉末）、Ｆｅ−１０ｗｔ％Ｓｉ−５ｗｔ％Ｂ合金粉末（使用している粉末は水アトマイズ製法にて作製された粉末）を、それぞれ８０ｗｔ％対２０ｗｔ％、および６０ｗｔ％対４０ｗｔ％、および５０ｗｔ％対５０ｗｔ％、および４０ｗｔ％対６０ｗｔ％、および２０ｗｔ％対８０ｗｔ％となるように秤量し、秤量後の粉末全体の６.５ｗｔ％バインダを添加し、粉末混合設備によって４０分間混合し、この複合磁性粉末材料を乾燥し、加圧成型を行い、順番に、発明品１、発明品２、発明品３、発明品４、発明品５を作製した。 Fe powder as a whole (powder used is powder prepared by water atomizing method), Fe-10wt% Si-5wt% B alloy powder (powder used is powder prepared by water atomizing method) Of 80 wt% vs. 20 wt%, and 60 wt% vs. 40 wt%, and 50 wt% vs. 50 wt%, and 40 wt% vs. 60 wt%, and 20 wt% vs. 80 wt%, respectively. .5 wt% binder is added and mixed for 40 minutes with a powder mixing facility. This composite magnetic powder material is dried and pressure-molded. In order, Invention 1, Invention 2, Invention 3, and Invention 4 Inventive product 5 was produced.
この場合、使用した粉末成型用金型は、外径２４ｍｍ×内径１４ｍｍ、環状抜き型（トロイダル形状）を有するもので、５Ｔｏｎ／ｃｍ２の圧力にて成型した。この際に作製される成型品の高さ寸法が１０ｍｍとなるように、使用する複合磁性粉末材料を設定した。作製された圧粉体を使用した樹脂の推奨硬化温度条件にて適切な熱処理を行い、Ｆｅ粉末とＦｅ−１０ｗｔ％Ｓｉ−５ｗｔ％Ｂ合金粉末を用いた複合磁性粉末材料を得た。 In this case, the powder molding die used had an outer diameter of 24 mm × an inner diameter of 14 mm and an annular punching die (toroidal shape), and was molded at a pressure of 5 Ton / cm 2 . The composite magnetic powder material to be used was set so that the height of the molded product produced at this time was 10 mm. Appropriate heat treatment was performed under the recommended curing temperature condition of the resin using the produced green compact to obtain a composite magnetic powder material using Fe powder and Fe-10 wt% Si-5 wt% B alloy powder.
ここで、前記Ｆｅ粉末のビッカース硬度は、１２０であり、前記Ｆｅ−Ｓｉ−Ｂ合金粉末のビッカース硬度は、９１０であった。 Here, the Vickers hardness of the Fe powder was 120, and the Vickers hardness of the Fe—Si—B alloy powder was 910.
図２（ａ）は、本発明の高周波用圧粉磁芯の製造工程の説明図である。図２（ａ）より、本発明の高周波用圧粉磁芯の製造工程は、原料粉末を、高温熱処理しない状態で、秤量し、これにバインダを加えて、バインダ混合し、ついで乾燥・分級し、金型で成型し、最後にキュアを行う。このように、従来の製造工程にあった、高温熱処理の工程が、削除される。 Fig.2 (a) is explanatory drawing of the manufacturing process of the dust core for high frequencies of this invention. From FIG. 2 (a), in the manufacturing process of the high-frequency powder magnetic core of the present invention, the raw material powder is weighed without being subjected to high-temperature heat treatment, added with a binder, mixed with the binder, then dried and classified. Mold with a mold, and finally cure. Thus, the high-temperature heat treatment process that was in the conventional manufacturing process is eliminated.
また、以下のごとく、比較品１と、比較品２とを作製した。
（比較品１）Ｆｅ粉末に、６.５ｗｔ％バインダを添加し、本発明の実施例の製造方法と同じようにトロイダル形状の圧粉磁芯を作製した。
（比較品２）Ｆｅ−１０ｗｔ％Ｓｉ−５ｗｔ％Ｂ合金粉末に、６.５ｗｔ％バインダを添加し、本発明の実施例１の製造方法と同じようにトロイダル形状の圧粉磁芯を作製した。
Moreover, the comparative product 1 and the comparative product 2 were produced as follows.
(Comparative product 1) A 6.5 wt% binder was added to the Fe powder, and a toroidal dust core was produced in the same manner as in the production method of the example of the present invention.
(Comparative product 2) To a Fe-10 wt% Si-5 wt% B alloy powder, a 6.5 wt% binder was added to produce a toroidal dust core as in the manufacturing method of Example 1 of the present invention. .
次に、上記トロイダル形状の圧粉磁芯を、ＨＰ製４２８４Ａ並びに４２８５Ａにプレジションメータによって測定し、１０ｋＨｚ〜２０ＭＨｚにおける実効透磁率を得た。また、上記トロイダル形状の圧粉磁芯について、密度を測定した。測定結果を表１に示す。 Next, the toroidal powder magnetic core was measured by HP 4284A and 4285A using a precision meter to obtain an effective magnetic permeability at 10 kHz to 20 MHz. Moreover, the density was measured about the said toroidal-shaped powder magnetic core. The measurement results are shown in Table 1.
表１より、ＦｅーＳｉ−Ｂ粉末が、２０ｗｔ％以上から８０ｗｔ％以下の範囲にて透磁率が３８以上が得られ、また密度も、４.９０ｇ/ｃｍ３以上得られている。ＦｅーＳｉ−Ｂ粉末が、５０ｗｔ％の条件にて、透磁率が５６と、最大値を示し、またこの条件の時、密度が、５.９５ｇ/ｃｍ３と、最大の密度が得られている。 From Table 1, the Fe-Si-B powder has a permeability of 38 or more and a density of 4.90 g / cm 3 or more in the range of 20 wt% to 80 wt%. The Fe—Si—B powder shows a maximum value of 56, with a magnetic permeability of 56, under the condition of 50 wt%. Under this condition, the maximum density of 5.95 g / cm 3 is obtained. Yes.
これは、前記Ｆｅ粉末のビッカース硬度が、１２０であり、また前記Ｆｅ−Ｓｉ−Ｂ合金粉末のビッカース硬度が、９１０であり、前記粉末配合率にて、最も、充填の効率が良いことを示している。また、比較品２は、Ｆｅ−Ｓｉ−Ｂ合金粉末が１００ｗｔ％であり、ビッカース硬度が高いので、磁芯とした場合、変形が困難で、密度が低いという問題点がある。 This indicates that the Vickers hardness of the Fe powder is 120, and the Vickers hardness of the Fe-Si-B alloy powder is 910, and the filling efficiency is the highest at the powder blending ratio. ing. Further, the comparative product 2 has a problem that the Fe—Si—B alloy powder is 100 wt% and the Vickers hardness is high, so that when the magnetic core is used, the deformation is difficult and the density is low.
図１は、本発明の実施例による高周波用圧粉磁芯と、従来の高周波用圧粉磁芯での透磁率対周波数対特性の比較図である。図１の中で、本発明品は、ＦｅーＳｉ−Ｂ粉末が、５０ｗｔ％の条件の最良のデータである。 FIG. 1 is a comparison diagram of magnetic permeability vs. frequency characteristics of a high frequency dust core according to an embodiment of the present invention and a conventional high frequency dust core. In FIG. 1, the product of the present invention is the best data under the condition that the Fe—Si—B powder is 50 wt%.
図１の比較図から分かる通り、本発明品は、実効透磁率は低いものの、低周波領域から高周波領域までほとんど平坦な、実効透磁率の周波数特性が実現されている。 As can be seen from the comparison diagram of FIG. 1, the product of the present invention realizes frequency characteristics of effective permeability that are almost flat from a low frequency region to a high frequency region, although the effective permeability is low.
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