JP2018170304A - Dust core, method of producing the dust core, electrical/electronic component including the dust core, and electrical/electronic equipment including the electrical/electronic component mounted thereon - Google Patents
Dust core, method of producing the dust core, electrical/electronic component including the dust core, and electrical/electronic equipment including the electrical/electronic component mounted thereon Download PDFInfo
- Publication number
- JP2018170304A JP2018170304A JP2015171074A JP2015171074A JP2018170304A JP 2018170304 A JP2018170304 A JP 2018170304A JP 2015171074 A JP2015171074 A JP 2015171074A JP 2015171074 A JP2015171074 A JP 2015171074A JP 2018170304 A JP2018170304 A JP 2018170304A
- Authority
- JP
- Japan
- Prior art keywords
- powder
- magnetic material
- dust core
- core
- mass
- 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 89
- 238000000034 method Methods 0.000 title claims description 24
- 239000000843 powder Substances 0.000 claims abstract description 197
- 239000000696 magnetic material Substances 0.000 claims abstract description 123
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 82
- 230000005291 magnetic effect Effects 0.000 claims abstract description 34
- 239000000203 mixture Substances 0.000 claims abstract description 22
- 238000002156 mixing Methods 0.000 claims description 54
- 239000000463 material Substances 0.000 claims description 39
- 229910052742 iron Inorganic materials 0.000 claims description 33
- 239000011230 binding agent Substances 0.000 claims description 28
- 229910045601 alloy Inorganic materials 0.000 claims description 26
- 239000000956 alloy Substances 0.000 claims description 26
- 238000004519 manufacturing process Methods 0.000 claims description 22
- 238000000465 moulding Methods 0.000 claims description 22
- 230000008569 process Effects 0.000 claims description 18
- 229920005989 resin Polymers 0.000 claims description 13
- 239000011347 resin Substances 0.000 claims description 13
- 239000000758 substrate Substances 0.000 claims description 11
- 238000012545 processing Methods 0.000 claims description 7
- 229910008423 Si—B Inorganic materials 0.000 claims description 6
- 239000011810 insulating material Substances 0.000 claims description 5
- 229910001339 C alloy Inorganic materials 0.000 claims description 4
- 229910017082 Fe-Si Inorganic materials 0.000 claims description 4
- 229910017133 Fe—Si Inorganic materials 0.000 claims description 4
- 229910000838 Al alloy Inorganic materials 0.000 claims description 3
- 229910017061 Fe Co Inorganic materials 0.000 claims description 3
- 229910001030 Iron–nickel alloy Inorganic materials 0.000 claims description 3
- 229920006706 PC-C Polymers 0.000 claims description 3
- 229910008458 Si—Cr Inorganic materials 0.000 claims description 3
- 229910000756 V alloy Inorganic materials 0.000 claims description 3
- 229910002796 Si–Al Inorganic materials 0.000 claims description 2
- 238000007493 shaping process Methods 0.000 claims description 2
- 239000006247 magnetic powder Substances 0.000 abstract description 25
- 238000010438 heat treatment Methods 0.000 description 24
- 230000035699 permeability Effects 0.000 description 21
- 239000002245 particle Substances 0.000 description 13
- 238000005259 measurement Methods 0.000 description 12
- 239000007921 spray Substances 0.000 description 12
- 230000007423 decrease Effects 0.000 description 10
- 239000002002 slurry Substances 0.000 description 10
- 229910000679 solder Inorganic materials 0.000 description 8
- 239000012298 atmosphere Substances 0.000 description 7
- 238000000748 compression moulding Methods 0.000 description 7
- 238000009826 distribution Methods 0.000 description 7
- 239000000314 lubricant Substances 0.000 description 7
- 230000002829 reductive effect Effects 0.000 description 7
- 238000004804 winding Methods 0.000 description 7
- 238000009413 insulation Methods 0.000 description 6
- 230000004907 flux Effects 0.000 description 5
- 230000001603 reducing effect Effects 0.000 description 5
- 239000002904 solvent Substances 0.000 description 5
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- 239000012254 powdered material Substances 0.000 description 4
- 238000005979 thermal decomposition reaction Methods 0.000 description 4
- 238000009835 boiling Methods 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- 238000009499 grossing Methods 0.000 description 3
- 229910010272 inorganic material Inorganic materials 0.000 description 3
- 239000011147 inorganic material Substances 0.000 description 3
- 230000036961 partial effect Effects 0.000 description 3
- 238000003825 pressing Methods 0.000 description 3
- 238000010298 pulverizing process Methods 0.000 description 3
- 238000003860 storage Methods 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 229920000178 Acrylic resin Polymers 0.000 description 2
- 239000004925 Acrylic resin Substances 0.000 description 2
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- 238000002441 X-ray diffraction Methods 0.000 description 2
- 229910052796 boron Inorganic materials 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 229910052804 chromium Inorganic materials 0.000 description 2
- 239000004020 conductor Substances 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 239000002612 dispersion medium Substances 0.000 description 2
- 238000001704 evaporation Methods 0.000 description 2
- 230000020169 heat generation Effects 0.000 description 2
- 230000000670 limiting effect Effects 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 239000011368 organic material Substances 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 238000012856 packing Methods 0.000 description 2
- 239000005011 phenolic resin Substances 0.000 description 2
- 238000010248 power generation Methods 0.000 description 2
- 238000001228 spectrum Methods 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- DEXFNLNNUZKHNO-UHFFFAOYSA-N 6-[3-[4-[2-(2,3-dihydro-1H-inden-2-ylamino)pyrimidin-5-yl]piperidin-1-yl]-3-oxopropyl]-3H-1,3-benzoxazol-2-one Chemical compound C1C(CC2=CC=CC=C12)NC1=NC=C(C=N1)C1CCN(CC1)C(CCC1=CC2=C(NC(O2)=O)C=C1)=O DEXFNLNNUZKHNO-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 239000004640 Melamine resin Substances 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 239000006087 Silane Coupling Agent Substances 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 230000004308 accommodation Effects 0.000 description 1
- 238000010306 acid treatment Methods 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- CEGOLXSVJUTHNZ-UHFFFAOYSA-K aluminium tristearate Chemical compound [Al+3].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CEGOLXSVJUTHNZ-UHFFFAOYSA-K 0.000 description 1
- 229940063655 aluminum stearate Drugs 0.000 description 1
- 229910000808 amorphous metal alloy Inorganic materials 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 230000001186 cumulative effect Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 230000005294 ferromagnetic effect Effects 0.000 description 1
- 239000003302 ferromagnetic material Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000006249 magnetic particle Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 238000000790 scattering method Methods 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 238000003980 solgel method Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 238000009692 water atomization Methods 0.000 description 1
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/08—Metallic powder characterised by particles having an amorphous microstructure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
-
- 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
- H01F1/147—Alloys characterised by their composition
- H01F1/153—Amorphous metallic alloys, e.g. glassy metals
-
- 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
-
- 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
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F17/06—Fixed inductances of the signal type with magnetic core with core substantially closed in itself, e.g. toroid
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Dispersion Chemistry (AREA)
- Crystallography & Structural Chemistry (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Powder Metallurgy (AREA)
- Soft Magnetic Materials (AREA)
- Coils Or Transformers For Communication (AREA)
Abstract
Description
本発明は、圧粉コア、該圧粉コアの製造方法、該圧粉コアを備える電気・電子部品、および該電気・電子部品が実装された電気・電子機器に関する。 The present invention relates to a dust core, a method for producing the dust core, an electric / electronic component including the dust core, and an electric / electronic device on which the electric / electronic component is mounted.
ハイブリッド自動車等の昇圧回路や、発電、変電設備に用いられるリアクトル、トランスやチョークコイル等に使用される圧粉コアは、多数の軟磁性粉末を圧粉成形し、得られた成形製造物を熱処理することにより得ることができる。 Powder cores used in boosters such as hybrid vehicles, reactors used in power generation and substation facilities, transformers and choke coils, etc. are compacted from a number of soft magnetic powders, and the resulting molded products are heat treated. Can be obtained.
特許文献１には、磁性粉末と、樹脂と、低沸点溶剤、高沸点溶剤とを混合し、スラリー状混合物を製造する混合物製造工程と；前記スラリー状混合物を加熱して、前記低沸点溶剤を蒸発させ、ペースト状混合物を製造する第１乾燥工程と；前記ペースト状混合物を、メッシュを通して解砕することによって製粒し、粒子を得る整粒工程と；前記粒子を加熱して前記高沸点溶剤を蒸発させて、磁性粒子を得る第２乾燥工程と；を備えることを特徴とする、造粒物の製造方法およびその造粒物の製造方法により製造された造粒物を使用したインダクタが開示されている。 In Patent Document 1, a magnetic powder, a resin, a low-boiling solvent, and a high-boiling solvent are mixed to produce a slurry-like mixture; and the slurry-like mixture is heated to prepare the low-boiling-point solvent. A first drying step of evaporating to produce a paste-like mixture; a granulating step of pulverizing the paste-like mixture through a mesh to obtain particles; and heating the particles to the high-boiling solvent And a second drying step of obtaining magnetic particles by evaporating the material, and a method for producing the granulated product, and an inductor using the granulated product produced by the method for producing the granulated product are disclosed. Has been.
上記の特許文献１には、粒子径が３〜５μｍのカルボニル鉄粉（Ｃａｒｂｏｎｙｌ Ｉｒｏｎ Ｐｏｗｄｅｒ、以下、「ＣＩＰ」ということがある。）からなる磁性粉末が用いられた場合が具体例として示されている。ＣＩＰを主として使用することが、透磁率が高く、直流重畳特性が向上するために好ましいとされている。 The above Patent Document 1 shows a specific example in which magnetic powder made of carbonyl iron powder (Carbonyl Iron Powder, hereinafter referred to as “CIP”) having a particle diameter of 3 to 5 μm is used. Yes. CIP is mainly used because it has high magnetic permeability and improves DC superposition characteristics.
本発明は、ＣＩＰのような結晶質磁性材料の粉末を含有する圧粉コアであって、優れた磁気特性を備える圧粉コアを提供することを目的とする。本発明は、かかる圧粉コアの製造方法を提供すること、かかる圧粉コアを備える電気・電子部品を提供すること、およびかかる電気・電子部品が実装された電気・電子機器を提供することも課題とする。 An object of the present invention is to provide a dust core containing a powder of a crystalline magnetic material such as CIP and having excellent magnetic properties. The present invention also provides a method for producing such a dust core, provides an electric / electronic component including such a dust core, and also provides an electric / electronic device mounted with such an electric / electronic component. Let it be an issue.
上記課題を解決するために本発明者らが検討した結果、圧粉コアが、ＣＩＰのような結晶質磁性材料の粉末だけでなく、所定量の非晶質磁性材料の粉末を含有することにより、磁気特性を改善させることが可能であるとの新たな知見を得た。 As a result of studies by the present inventors in order to solve the above-mentioned problems, the dust core contains not only a crystalline magnetic material powder such as CIP but also a predetermined amount of amorphous magnetic material powder. New knowledge that it is possible to improve the magnetic properties.
かかる知見に基づき完成された本発明は、一態様において、結晶質磁性材料の粉末および非晶質磁性材料の粉末を含有する圧粉コアであって、前記結晶質磁性材料の粉末の含有量と前記非晶質磁性材料の粉末の含有量との総和に対する前記結晶質磁性材料の粉末の含有量の質量比率である第一混合比率が、７５質量％以上９５質量％以下であることを特徴とする圧粉コアである。圧粉コアが、結晶質磁性材料の粉末だけでなく、所定量の非晶質磁性材料の粉末を含有することにより、鉄損Ｐｃｖが低下しやすくなる。 The present invention completed based on such knowledge is, in one aspect, a powder core containing a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, the content of the powder of the crystalline magnetic material, The first mixing ratio, which is the mass ratio of the content of the crystalline magnetic material powder to the total content of the amorphous magnetic material powder, is 75% by mass to 95% by mass. It is a compacted core. When the dust core contains not only the crystalline magnetic material powder but also a predetermined amount of the amorphous magnetic material powder, the iron loss Pcv is likely to decrease.
前記第一混合比率が８０質量％以上９０質量％以下であることが、圧粉コアの磁気特性がより安定的に改善するため、好ましい。 The first mixing ratio is preferably 80% by mass or more and 90% by mass or less because the magnetic properties of the dust core are more stably improved.
前記結晶質磁性材料の粉末は絶縁処理が施された材料からなることが好ましい場合がある。 In some cases, the crystalline magnetic material powder is preferably made of an insulating material.
前記結晶質磁性材料は、Ｆｅ−Ｓｉ−Ｃｒ系合金、Ｆｅ−Ｎｉ系合金、Ｆｅ−Ｃｏ系合金、Ｆｅ−Ｖ系合金、Ｆｅ−Ａｌ系合金、Ｆｅ−Ｓｉ系合金、Ｆｅ−Ｓｉ−Ａｌ系合金、カルボニル鉄（ＣＩＰ）および純鉄からなる群から選ばれた１種または２種以上の材料を含んでいてもよい。これらの中でも、前記結晶質磁性材料はカルボニル鉄（ＣＩＰ）からなることが好ましい場合がある。 The crystalline magnetic material is Fe-Si-Cr alloy, Fe-Ni alloy, Fe-Co alloy, Fe-V alloy, Fe-Al alloy, Fe-Si alloy, Fe-Si-Al. One or two or more materials selected from the group consisting of a system alloy, carbonyl iron (CIP) and pure iron may be included. Among these, the crystalline magnetic material may be preferably made of carbonyl iron (CIP).
前記非晶質磁性材料は、Ｆｅ−Ｓｉ−Ｂ系合金、Ｆｅ−Ｐ−Ｃ系合金およびＣｏ−Ｆｅ−Ｓｉ−Ｂ系合金からなる群から選ばれた１種または２種以上の材料を含んでいてもよい。これらの中でも、前記非晶質磁性材料はＦｅ−Ｐ−Ｃ系合金からなることが好ましい場合がある。 The amorphous magnetic material includes one or more materials selected from the group consisting of Fe-Si-B alloys, Fe-PC-C alloys, and Co-Fe-Si-B alloys. You may go out. Among these, it may be preferable that the amorphous magnetic material is made of a Fe—PC alloy.
前記非晶質磁性材料の粉末のメジアン径Ｄ５０は２０μｍ以下であることが好ましい場合がある。 In some cases, the median diameter D50 of the powder of the amorphous magnetic material is preferably 20 μm or less.
前記結晶質磁性材料の粉末および前記非晶質磁性材料の粉末を、前記圧粉コアに含有される他の材料に対して結着させる結着成分を含有してもよい。この場合において、前記結着成分は、樹脂材料に基づく成分を含むことが好ましい。 The crystalline magnetic material powder and the amorphous magnetic material powder may contain a binding component that binds to another material contained in the powder core. In this case, the binding component preferably includes a component based on a resin material.
本発明は、他の一態様において、上記の本発明に係る圧粉コアの製造方法であって、前記結晶質磁性材料の粉末および前記非晶質磁性材料の粉末ならびに前記樹脂材料からなるバインダー成分を含む混合物の加圧成形を含む成形処理により成形製造物を得る成形工程を備えることを特徴とする圧粉コアの製造方法である。 In another aspect, the present invention provides a method for producing a powder core according to the present invention, wherein the binder component comprises the crystalline magnetic material powder, the amorphous magnetic material powder, and the resin material. A method for producing a dust core, comprising a molding step of obtaining a molded product by a molding process including pressure molding of a mixture including
前記成形工程により得られた前記成形製造物が前記圧粉コアであってもよい。あるいは、前記成形工程により得られた前記成形製造物を加熱する熱処理により前記圧粉コアを得る熱処理工程を備えてもよい。 The compacted core obtained by the molding step may be the powder core. Or you may provide the heat processing process of obtaining the said powder core by the heat processing which heats the said molded product obtained by the said shaping | molding process.
本発明は、別の一態様において、上記の本発明に係る圧粉コア、コイルおよび前記コイルのそれぞれの端部に接続された接続端子を備える電気・電子部品であって、前記圧粉コアの少なくとも一部は、前記接続端子を介して前記コイルに電流を流したときに前記電流により生じた誘導磁界内に位置するように配置されている電気・電子部品である。かかる電気・電子部品は、上記の圧粉コアの優れた特性に基づいて、鉄損を低減させることが可能である。 In another aspect, the present invention is an electric / electronic component comprising the dust core according to the present invention, a coil, and a connection terminal connected to each end of the coil, At least a part is an electric / electronic component arranged to be located in an induced magnetic field generated by the current when a current is passed through the coil via the connection terminal. Such an electric / electronic component can reduce iron loss based on the excellent characteristics of the powder core.
本発明は、また別の一態様において、上記の本発明に係る電気・電子部品が実装された電気・電子機器であって、前記電気・電子部品は前記接続端子にて基板に接続されている電気・電子機器である。かかる電気・電子機器として、電源スイッチング回路、電圧昇降回路、平滑回路等を備えた電源装置や小型携帯通信機器等が例示される。本発明に係る電気・電子機器は、上記の本発明に係る電気・電子部品を備えるため、大電流化・高速化に対応しやすい。 According to another aspect of the present invention, there is provided an electrical / electronic device on which the electrical / electronic component according to the present invention is mounted, wherein the electrical / electronic component is connected to a substrate by the connection terminal. Electric / electronic equipment. Examples of such electrical / electronic devices include a power supply device including a power supply switching circuit, a voltage raising / lowering circuit, and a smoothing circuit, and a small portable communication device. Since the electrical / electronic device according to the present invention includes the electrical / electronic component according to the present invention, it is easy to cope with a large current and high speed.
上記の発明に係る圧粉コアは、結晶質磁性材料の粉末からなる磁性粉末を備える圧粉コアに比べて優れた磁気特性を有することができる。また、本発明によれば、上記の圧粉コアの製造方法、上記の圧粉コアを備える電気・電子部品、およびこの電気・電子部品が実装された電気・電子機器が提供される。 The dust core according to the above-described invention can have magnetic properties superior to those of a dust core including magnetic powder made of crystalline magnetic material powder. Moreover, according to this invention, the manufacturing method of said powder core, the electric / electronic component provided with said powder core, and the electric / electronic device by which this electric / electronic component was mounted are provided.
以下、本発明の実施形態について詳しく説明する。
１．圧粉コア
図１に示す本発明の一実施形態に係る圧粉コア１は、その外観がリング状であって、結晶質磁性材料の粉末および非晶質磁性材料の粉末を含有する。本実施形態に係る圧粉コア１は、これらの粉末を含む混合物の加圧成形を含む成形処理を備える製造方法により製造されたものである。限定されない一例として、本実施形態に係る圧粉コア１は、結晶質磁性材料の粉末および非晶質磁性材料の粉末を、圧粉コア１に含有される他の材料（同種の材料である場合もあれば、異種の材料である場合もある。）に対して結着させる結着成分を含有する。以下、これらの成分について説明する。
Hereinafter, embodiments of the present invention will be described in detail.
1. 1. The dust core 1 according to one embodiment of the present invention shown in FIG. 1 is ring-shaped in appearance, and contains a powder of a crystalline magnetic material and a powder of an amorphous magnetic material. The powder core 1 according to the present embodiment is manufactured by a manufacturing method including a molding process including pressure molding of a mixture containing these powders. As a non-limiting example, the dust core 1 according to the present embodiment includes a crystalline magnetic material powder and an amorphous magnetic material powder as other materials (same type of material) contained in the dust core 1. Or it may be a dissimilar material). Hereinafter, these components will be described.
（１）結晶質磁性材料の粉末
本発明の一実施形態に係る圧粉コア１が含有する結晶質磁性材料の粉末を与える結晶質磁性材料は、結晶質であること（一般的なＸ線回折測定により、材料種類を特定できる程度に明確なピークを有する回折スペクトルが得られること）、および強磁性体であることを満たす限り、具体的な種類は限定されない。結晶質磁性材料の具体例として、Ｆｅ−Ｓｉ−Ｃｒ系合金、Ｆｅ−Ｎｉ系合金、Ｆｅ−Ｃｏ系合金、Ｆｅ−Ｖ系合金、Ｆｅ−Ａｌ系合金、Ｆｅ−Ｓｉ系合金、Ｆｅ−Ｓｉ−Ａｌ系合金、カルボニル鉄（ＣＩＰ）および純鉄が挙げられる。上記の結晶質磁性材料は１種類の材料から構成されていてもよいし複数種類の材料から構成されていてもよい。結晶質磁性材料の粉末を与える結晶質磁性材料は、上記の材料からなる群から選ばれた１種または２種以上の材料であることが好ましく、これらの中でも、ＣＩＰを含有することが好ましく、ＣＩＰからなることがより好ましい。
(1) Powder of crystalline magnetic material The crystalline magnetic material that gives the powder of crystalline magnetic material contained in the dust core 1 according to one embodiment of the present invention is crystalline (general X-ray diffraction) The specific type is not limited as long as the diffraction spectrum having a clear peak that can identify the material type is obtained by measurement) and is a ferromagnetic substance. Specific examples of crystalline magnetic materials include Fe-Si-Cr alloys, Fe-Ni alloys, Fe-Co alloys, Fe-V alloys, Fe-Al alloys, Fe-Si alloys, Fe-Si. -Al-based alloys, carbonyl iron (CIP) and pure iron. Said crystalline magnetic material may be comprised from one type of material, and may be comprised from multiple types of material. The crystalline magnetic material that gives the powder of the crystalline magnetic material is preferably one or more materials selected from the group consisting of the above materials, and among these, preferably contains CIP, More preferably, it consists of CIP.
本発明の一実施形態に係る圧粉コア１が含有する結晶質磁性材料の粉末の形状は限定されない。粉末の形状は球状であってもよいし非球状であってもよい。非球状である場合には、鱗片状、楕円球状、液滴状、針状といった形状異方性を有する形状であってもよいし、特段の形状異方性を有しない不定形であってもよい。不定形の粉体の例として、球状の粉体の複数が、互いに接して結合していたり、他の粉体に部分的に埋没するように結合していたりする場合が挙げられる。このような不定形の粉体は、ＣＩＰにおいて観察されやすい。 The shape of the powder of the crystalline magnetic material contained in the dust core 1 according to the embodiment of the present invention is not limited. The shape of the powder may be spherical or non-spherical. In the case of a non-spherical shape, it may have a shape anisotropy such as a scale shape, an oval sphere shape, a droplet shape, a needle shape, or an indefinite shape having no special shape anisotropy. Good. Examples of the amorphous powder include a case where a plurality of spherical powders are bonded in contact with each other, or are bonded so as to be partially embedded in other powders. Such an amorphous powder is easily observed in CIP.
粉末の形状は、粉末を製造する段階で得られた形状であってもよいし、製造された粉末を二次加工することにより得られた形状であってもよい。前者の形状としては、球状、楕円球状、液滴状、針状などが例示され、後者の形状としては、鱗片状が例示される。 The shape of the powder may be a shape obtained at the stage of producing the powder, or may be a shape obtained by secondary processing of the produced powder. Examples of the former shape include a spherical shape, an oval shape, a droplet shape, and a needle shape, and examples of the latter shape include a scale shape.
本発明の一実施形態に係る圧粉コア１が含有する結晶質磁性材料の粉末の粒径は限定されない。かかる粒径を、メジアン径Ｄ５０（レーザー回折散乱法により測定された軟磁性粉末の粒径の体積分布における体積累積値が５０％のときの粒径）により規定すれば、通常、１μｍから２０μｍの範囲とされる。取扱い性を高める観点、圧粉コアにおける結晶質磁性材料の粉末の充填密度を高める観点などから、結晶質磁性材料の粉末のメジアン径Ｄ５０（本明細書において、「第一メジアン径ｄ１」ともいう。）は、１μｍ以上１５μｍ以下とすることが好ましく、１μｍ以上１０μｍ以下とすることがより好ましく、１μｍ以上５μｍ以下とすることが特に好ましい。 The particle size of the powder of the crystalline magnetic material contained in the powder core 1 according to the embodiment of the present invention is not limited. If this particle size is defined by the median diameter D50 (particle size when the volume cumulative value in the volume distribution of the soft magnetic powder measured by the laser diffraction scattering method is 50%), it is usually 1 μm to 20 μm. Scope. From the viewpoint of improving the handleability and the viewpoint of increasing the packing density of the crystalline magnetic material powder in the dust core, the median diameter D50 (also referred to as “first median diameter d1” in the present specification) of the crystalline magnetic material powder. .) Is preferably 1 μm or more and 15 μm or less, more preferably 1 μm or more and 10 μm or less, and particularly preferably 1 μm or more and 5 μm or less.
結晶質磁性材料の粉末の少なくとも一部は絶縁処理が施された材料からなることが好ましく、結晶質磁性材料の粉末は絶縁処理が施された材料からなることがより好ましい。結晶質磁性材料の粉末に絶縁処理が施されている場合には、圧粉コアの絶縁抵抗が向上する傾向がみられる。 At least a part of the crystalline magnetic material powder is preferably made of an insulating material, and the crystalline magnetic material powder is more preferably made of an insulating material. When insulation treatment is performed on the powder of the crystalline magnetic material, the insulation resistance of the dust core tends to be improved.
結晶質磁性材料の粉末に施す絶縁処理の種類は限定されない。リン酸処理、リン酸塩処理、酸化処理、ゾル・ゲル法などが例示される。 The type of insulation treatment applied to the crystalline magnetic material powder is not limited. Examples include phosphoric acid treatment, phosphate treatment, oxidation treatment, and sol-gel method.
結晶質磁性材料の粉末の含有量と非晶質磁性材料の粉末の含有量との総和に対する結晶質磁性材料の粉末の含有量の質量比率（単位：質量％、本明細書において、「第一混合比率」ともいう。）は、７５質量％以上９５質量％以下であることが好ましい。第一混合比率が上記の範囲内であることにより鉄損Ｐｃｖが低下しやすくなる傾向がみられる。透磁率など他の磁気特性とのバランスに優れる観点から、第一混合比率は、７８質量％以上９３質量％以下であることがより好ましく、８０質量％以上９０質量％以下であることがさらに好ましい。 The mass ratio of the content of the crystalline magnetic material powder to the sum of the content of the crystalline magnetic material powder and the content of the amorphous magnetic material powder (unit: mass%, in this specification, “first The mixing ratio ") is preferably 75% by mass or more and 95% by mass or less. When the first mixing ratio is within the above range, the iron loss Pcv tends to decrease. From the viewpoint of excellent balance with other magnetic properties such as magnetic permeability, the first mixing ratio is more preferably 78% by mass to 93% by mass, and further preferably 80% by mass to 90% by mass. .
（２）非晶質磁性材料の粉末
本発明の一実施形態に係る圧粉コア１が含有する非晶質磁性材料の粉末を与える非晶質磁性材料は、非晶質であること（一般的なＸ線回折測定により、材料種類を特定できる程度に明確なピークを有する回折スペクトルが得られないこと）、および強磁性体、特に軟磁性体であることを満たす限り、具体的な種類は限定されない。非晶質磁性材料の具体例として、Ｆｅ−Ｓｉ−Ｂ系合金、Ｆｅ−Ｐ−Ｃ系合金およびＣｏ−Ｆｅ−Ｓｉ−Ｂ系合金が挙げられる。上記の非晶質磁性材料は１種類の材料から構成されていてもよいし複数種類の材料から構成されていてもよい。非晶質磁性材料の粉末を構成する磁性材料は、上記の材料からなる群から選ばれた１種または２種以上の材料であることが好ましく、これらの中でも、Ｆｅ−Ｐ−Ｃ系合金を含有することが好ましく、Ｆｅ−Ｐ−Ｃ系合金からなることがより好ましい。
(2) Amorphous Magnetic Material Powder The amorphous magnetic material that provides the amorphous magnetic material powder contained in the dust core 1 according to an embodiment of the present invention is amorphous (generally As long as the X-ray diffraction measurement does not provide a diffraction spectrum with a clear peak that can identify the material type), and the material is a ferromagnetic material, particularly a soft magnetic material, the specific types are limited. Not. Specific examples of the amorphous magnetic material include an Fe-Si-B alloy, an Fe-PC-C alloy, and a Co-Fe-Si-B alloy. Said amorphous magnetic material may be comprised from one type of material, and may be comprised from multiple types of material. The magnetic material constituting the powder of the amorphous magnetic material is preferably one or more materials selected from the group consisting of the above materials, and among these, an Fe—PC alloy is used. It is preferable to contain it, and it is more preferable to consist of a Fe-PC system alloy.
Ｆｅ−Ｐ−Ｃ系合金の具体例として、組成式が、Ｆｅ１００原子％−ａ−ｂ−ｃ−ｘ−ｙ−ｚ−ｔＮｉａＳｎｂＣｒｃＰｘＣｙＢｚＳｉｔで示され、０原子％≦ａ≦１０原子％、０原子％≦ｂ≦３原子％、０原子％≦ｃ≦６原子％、６．８原子％≦ｘ≦１２．８原子％、２．２原子％≦ｙ≦１１．８原子％、０原子％≦ｚ≦９．６原子％、０原子％≦ｔ≦７原子％であるＦｅ基非晶質合金が挙げられる。上記の組成式において、Ｎｉ，Ｓｎ，Ｃｒ，ＢおよびＳｉは任意添加元素である。 Specific examples of the Fe-P-C-based alloy, composition formula, shown in Fe 100 atomic% -a-b-c-x -y-z-t Ni a Sn b Cr c P x C y B z Si t 0 atom% ≦ a ≦ 10 atom%, 0 atom% ≦ b ≦ 3 atom%, 0 atom% ≦ c ≦ 6 atom%, 6.8 atom% ≦ x ≦ 12.8 atom%, 2.2 atom Examples are Fe-based amorphous alloys in which% ≦ y ≦ 11.8 atomic%, 0 atomic% ≦ z ≦ 9.6 atomic%, and 0 atomic% ≦ t ≦ 7 atomic%. In the above composition formula, Ni, Sn, Cr, B, and Si are optional added elements.
Ｎｉの添加量ａは、０原子％以上６原子％以下とすることが好ましく、０原子％以上４原子％以下とすることがより好ましい。Ｓｎの添加量ｂは、０原子％以上２原子％以下とすることが好ましく、１原子％以上２原子％以下とすることがより好ましい。Ｃｒの添加量ｃは、０原子％以上３原子％以下とすることが好ましく、１原子％以上２．５原子％以下とすることがより好ましい。Ｐの添加量ｘは、８．８原子％以上とすることが好ましい場合もある。Ｃの添加量ｙは、５．８原子％以上８．８原子％以下とすることが好ましい場合もある。Ｂの添加量ｚは、０原子％以上９原子％以下とすることが好ましく、０原子％以上８原子％以下とすることがより好ましい。Ｓｉの添加量ｔは、０原子％以上６原子％以下とすることが好ましく、０原子％以上５．５原子％以下とすることがより好ましい。 The addition amount a of Ni is preferably 0 atom% or more and 6 atom% or less, and more preferably 0 atom% or more and 4 atom% or less. The addition amount b of Sn is preferably 0 atom% or more and 2 atom% or less, and more preferably 1 atom% or more and 2 atom% or less. The addition amount c of Cr is preferably 0 atom% or more and 3 atom% or less, and more preferably 1 atom% or more and 2.5 atom% or less. In some cases, the addition amount x of P is preferably 8.8 atomic% or more. The addition amount y of C may be preferably 5.8 atomic% or more and 8.8 atomic% or less. The addition amount z of B is preferably 0 atom% or more and 9 atom% or less, and more preferably 0 atom% or more and 8 atom% or less. The addition amount t of Si is preferably 0 atom% or more and 6 atom% or less, and more preferably 0 atom% or more and 5.5 atom% or less.
本発明の一実施形態に係る圧粉コア１が含有する非晶質磁性材料の粉末の形状は限定されない。粉末の形状の種類については結晶質磁性材料の粉末の場合と同様であるから説明を省略する。製造方法の関係で非晶質磁性材料は球状または楕円球状とすることが容易である場合もある。また、一般論として非晶質磁性材料は結晶質磁性材料よりも硬質であるから、結晶質磁性材料を非球状として加圧成形の際に変形しやすいようにすることが好ましい場合もある。 The shape of the powder of the amorphous magnetic material contained in the dust core 1 according to the embodiment of the present invention is not limited. Since the kind of the powder shape is the same as that of the crystalline magnetic material powder, the description thereof is omitted. In some cases, the amorphous magnetic material can be easily formed into a spherical shape or an elliptical spherical shape because of the manufacturing method. In general, since an amorphous magnetic material is harder than a crystalline magnetic material, it may be preferable to make the crystalline magnetic material non-spherical so that it is easily deformed during pressure molding.
本発明の一実施形態に係る圧粉コア１が含有する非晶質磁性材料の粉末の形状は、粉末を製造する段階で得られた形状であってもよいし、製造された粉末を二次加工することにより得られた形状であってもよい。前者の形状としては、球状、楕円球状、針状などが例示され、後者の形状としては、鱗片状が例示される。 The shape of the powder of the amorphous magnetic material contained in the dust core 1 according to the embodiment of the present invention may be the shape obtained in the stage of producing the powder, or the produced powder is secondary The shape obtained by processing may be sufficient. Examples of the former shape include a sphere, an oval sphere, and a needle shape, and examples of the latter shape include a scale shape.
本発明の一実施形態に係る圧粉コア１が含有する非晶質磁性材料の粉末の粒径は限定されない。かかる粒径をメジアン径Ｄ５０により規定すれば、２０μｍ以下とすることが好ましい場合がある。取扱い性を高める観点から、非晶質磁性材料の粉末のメジアン径Ｄ５０（本明細書において、「第二メジアン径ｄ２」ともいう。）を、１μｍ以上とすることが好ましく、２μｍ以上とすることがより好ましく、３μｍ以上とすることが特に好ましい。圧粉コア１における非晶質および結晶質の磁性材料の粉末の充填密度を高める観点などから、非晶質磁性材料の粉末のメジアン径Ｄ５０を、１５μｍ以下とすることが好ましく、１２μｍ以下とすることがより好ましく、８μｍ以下とすることが特に好ましい。 The particle diameter of the powder of the amorphous magnetic material contained in the powder core 1 according to the embodiment of the present invention is not limited. If this particle diameter is defined by the median diameter D50, it may be preferable to be 20 μm or less. From the viewpoint of improving the handleability, the median diameter D50 (also referred to as “second median diameter d2” in this specification) of the powder of the amorphous magnetic material is preferably 1 μm or more, and preferably 2 μm or more. Is more preferable, and the thickness is particularly preferably 3 μm or more. From the viewpoint of increasing the packing density of the amorphous and crystalline magnetic material powder in the dust core 1, the median diameter D50 of the amorphous magnetic material powder is preferably 15 μm or less, and preferably 12 μm or less. It is more preferable that the thickness be 8 μm or less.
第一メジアン径ｄ１と第二メジアン径ｄ２との関係は限定されない。一般論として、非晶質磁性材料は結晶質磁性材料よりも硬質であるから、第一メジアン径ｄ１を相対的に小さくして、非晶質磁性材料の粉末が充填されたときに生じる空隙部を結晶質磁性材料の粉末が充填しやすいようにすることが好ましい場合もある。この場合において、ｄ１／ｄ２は０．８以下とすることが好ましく、０．５以下とすることが好ましいこともある。 The relationship between the first median diameter d1 and the second median diameter d2 is not limited. In general, since amorphous magnetic materials are harder than crystalline magnetic materials, voids formed when the first median diameter d1 is made relatively small and powders of amorphous magnetic materials are filled. In some cases, it is preferable that the crystalline magnetic material powder is easily filled. In this case, d1 / d2 is preferably 0.8 or less, and sometimes 0.5 or less.
（３）結着成分
結着成分は、本実施形態に係る圧粉コア１に含有される結晶質磁性材料の粉末および非晶質磁性材料の粉末（本明細書において、これらの粉末を「磁性粉末」と総称することもある。）を固定することに寄与する材料である限り、その組成は限定されない。結着成分を構成する材料として、樹脂材料および樹脂材料の熱分解残渣（本明細書において、これらを「樹脂材料に基づく成分」と総称する。）などの有機系の材料、無機系の材料などが例示される。樹脂材料として、アクリル樹脂、シリコーン樹脂、エポキシ樹脂、フェノール樹脂、尿素樹脂、メラミン樹脂などが例示される。無機系の材料からなる結着成分は水ガラスなどガラス系材料が例示される。結着成分は一種類の材料から構成されていてもよいし、複数の材料から構成されていてもよい。結着成分は有機系の材料と無機系の材料との混合体であってもよい。
(3) Binder Component The binder component includes a crystalline magnetic material powder and an amorphous magnetic material powder contained in the dust core 1 according to the present embodiment (in this specification, these powders are referred to as “magnetic The composition is not limited as long as it is a material that contributes to fixing. As a material constituting the binder component, an organic material such as a resin material and a thermal decomposition residue of the resin material (in this specification, these are collectively referred to as “components based on a resin material”), an inorganic material, and the like Is exemplified. Examples of the resin material include acrylic resin, silicone resin, epoxy resin, phenol resin, urea resin, and melamine resin. The binder component made of an inorganic material is exemplified by a glass-based material such as water glass. The binder component may be composed of one type of material or may be composed of a plurality of materials. The binder component may be a mixture of an organic material and an inorganic material.
結着成分として、通常、絶縁性の材料が使用される。これにより、圧粉コア１としての絶縁性を高めることが可能となる。 As the binding component, an insulating material is usually used. Thereby, it becomes possible to improve the insulation as the dust core 1.
２．圧粉コアの製造方法
上記の本発明の一実施形態に係る圧粉コア１の製造方法は特に限定されないが、次に説明する製造方法を採用すれば、圧粉コア１をより効率的に製造することが実現される。
2. Manufacturing method of powder core Although the manufacturing method of the powder core 1 which concerns on one embodiment of said this invention is not specifically limited, if the manufacturing method demonstrated below is employ | adopted, the powder core 1 will be manufactured more efficiently. Is realized.
本発明の一実施形態に係る圧粉コア１の製造方法は、次に説明する、成形工程を備え、さらに熱処理工程を備えていてもよい。 The manufacturing method of the powder core 1 which concerns on one Embodiment of this invention is equipped with the formation process demonstrated below, and may be further provided with the heat processing process.
（１）成形工程
まず、磁性粉末、および圧粉コア１において結着成分を与える成分を含む混合物を用意する。結着成分を与える成分（本明細書において、「バインダー成分」ともいう。）とは、結着成分そのものである場合もあれば、結着成分と異なる材料である場合もある。後者の具体例として、バインダー成分が樹脂材料であって、結着成分がその熱分解残渣である場合が挙げられる。
(1) Molding step First, a mixture containing magnetic powder and a component that provides a binding component in the powder core 1 is prepared. The component that gives the binding component (also referred to as “binder component” in this specification) may be the binding component itself or may be a material different from the binding component. Specific examples of the latter include a case where the binder component is a resin material and the binder component is a thermal decomposition residue thereof.
この混合物の加圧成形を含む成形処理により成形製造物を得ることができる。加圧条件は限定されず、バインダー成分の組成などに基づき適宜決定される。例えば、バインダー成分が熱硬化性の樹脂からなる場合には、加圧とともに加熱して、金型内で樹脂の硬化反応を進行させることが好ましい。一方、圧縮成形の場合には、加圧力が高いものの、加熱は必要条件とならず、短時間の加圧となる。 A molded product can be obtained by a molding process including pressure molding of the mixture. The pressurizing condition is not limited and is appropriately determined based on the composition of the binder component. For example, when the binder component is made of a thermosetting resin, it is preferable to heat the resin together with pressure to advance the resin curing reaction in the mold. On the other hand, in the case of compression molding, although the pressing force is high, heating is not a necessary condition and pressurization is performed for a short time.
以下、混合物が造粒粉であって、圧縮成形を行う場合について、やや詳しく説明する。造粒粉は取り扱い性に優れるため、成形時間が短く生産性に優れる圧縮成形工程の作業性を向上させることができる。 Hereinafter, the case where the mixture is granulated powder and compression molding will be described in some detail. Since the granulated powder is excellent in handleability, it is possible to improve the workability of the compression molding process in which the molding time is short and the productivity is excellent.
（１−１）造粒粉
造粒粉は、磁性粉末およびバインダー成分を含有する。造粒粉におけるバインダー成分の含有量は特に限定されない。かかる含有量が過度に低い場合には、バインダー成分が磁性粉末を保持しにくくなる。また、バインダー成分の含有量が過度に低い場合には、熱処理工程を経て得られた圧粉コア１中で、バインダー成分の熱分解残渣からなる結着成分が、複数の磁性粉末を互いに他から絶縁しにくくなる。一方、上記のバインダー成分の含有量が過度に高い場合には、熱処理工程を経て得られた圧粉コア１に含有される結着成分の含有量が高くなりやすい。圧粉コア１中の結着成分の含有量が高くなると、圧粉コア１の磁気特性が低下しやすくなる。それゆえ、造粒粉中のバインダー成分の含有量は、造粒粉全体に対して、０．５質量％以上５．０質量％以下となる量にすることが好ましい。圧粉コア１の磁気特性が低下する可能性をより安定的に低減させる観点から、造粒粉中のバインダー成分の含有量は、造粒粉全体に対して、１．０質量％以上３．５質量％以下となる量にすることが好ましく、１．２質量％以上３．０質量％以下となる量にすることがより好ましい。
(1-1) Granulated powder Granulated powder contains magnetic powder and a binder component. The content of the binder component in the granulated powder is not particularly limited. When this content is too low, it becomes difficult for the binder component to hold the magnetic powder. In addition, when the content of the binder component is excessively low, in the powder core 1 obtained through the heat treatment step, the binder component composed of the thermal decomposition residue of the binder component causes a plurality of magnetic powders to be separated from each other. It becomes difficult to insulate. On the other hand, when the content of the binder component is excessively high, the content of the binder component contained in the powder core 1 obtained through the heat treatment step tends to be high. When the content of the binder component in the dust core 1 is increased, the magnetic properties of the dust core 1 are likely to be reduced. Therefore, the content of the binder component in the granulated powder is preferably set to an amount that is 0.5% by mass or more and 5.0% by mass or less with respect to the entire granulated powder. From the viewpoint of more stably reducing the possibility that the magnetic properties of the dust core 1 will decrease, the content of the binder component in the granulated powder is 1.0 mass% or more with respect to the entire granulated powder. The amount is preferably 5% by mass or less, and more preferably 1.2% by mass or more and 3.0% by mass or less.
造粒粉は、上記の磁性粉末およびバインダー成分以外の材料を含有してもよい。そのような材料として、潤滑剤、シランカップリング剤、絶縁性のフィラーなどが例示される。潤滑剤を含有させる場合において、その種類は特に限定されない。有機系の潤滑剤であってもよいし、無機系の潤滑剤であってもよい。有機系の潤滑剤の具体例として、ステアリン酸亜鉛、ステアリン酸アルミニウムなどの金属石鹸が挙げられる。こうした有機系の潤滑剤は、熱処理工程において気化し、圧粉コア１にはほとんど残留していないと考えられる。 The granulated powder may contain materials other than the above magnetic powder and binder component. Examples of such materials include lubricants, silane coupling agents, and insulating fillers. In the case of containing a lubricant, the type is not particularly limited. It may be an organic lubricant or an inorganic lubricant. Specific examples of the organic lubricant include metal soaps such as zinc stearate and aluminum stearate. It is considered that such an organic lubricant is vaporized in the heat treatment step and hardly remains in the powder core 1.
造粒粉の製造方法は特に限定されない。上記の造粒粉を与える成分をそのまま混錬し、得られた混練物を公知の方法で粉砕するなどして造粒粉を得てもよいし、上記の成分に分散媒（水が一例として挙げられる。）を添加してなるスラリーを調製し、このスラリーを乾燥させて粉砕することにより造粒粉を得てもよい。粉砕後にふるい分けや分級を行って、造粒粉の粒度分布を制御してもよい。 The manufacturing method of granulated powder is not specifically limited. The ingredients that give the granulated powder may be kneaded as they are, and the resulting kneaded product may be pulverized by a known method to obtain granulated powder, or a dispersion medium (water as an example) It is also possible to obtain a granulated powder by preparing a slurry to which is added, and drying and pulverizing the slurry. Screening and classification may be performed after pulverization to control the particle size distribution of the granulated powder.
上記のスラリーから造粒粉を得る方法の一例として、スプレードライヤーを用いる方法が挙げられる。図２に示されるように、スプレードライヤー装置２００内には回転子２０１が設けられ、スプレードライヤー装置２００の上部からスラリーＳを回転子２０１に向けて注入する。回転子２０１は所定の回転数により回転しており、スプレードライヤー装置２００内部のチャンバーにてスラリーＳを遠心力により小滴状として噴霧する。さらにスプレードライヤー装置２００内部のチャンバーに熱風を導入し、これにより小滴状のスラリーＳに含有される分散媒（水）を、小滴形状を維持したまま揮発させる。その結果、スラリーＳから造粒粉Ｐが形成される。この造粒粉Ｐをスプレードライヤー装置２００の下部から回収する。回転子２０１の回転数、スプレードライヤー装置２００内に導入する熱風温度、チャンバー下部の温度など各パラメータは適宜設定すればよい。これらのパラメータの設定範囲の具体例として、回転子２０１の回転数として４０００〜６０００ｒｐｍ、スプレードライヤー装置２００内に導入する熱風温度として１３０〜１７０℃、チャンバー下部の温度として８０〜９０℃が挙げられる。またチャンバー内の雰囲気およびその圧力も適宜設定すればよい。一例として、チャンバー内をエアー（空気）雰囲気として、その圧力を大気圧との差圧で２ｍｍＨ２Ｏ（約０．０２ｋＰａ）とすることが挙げられる。得られた造粒粉Ｐの粒度分布をふるい分けなどによりさらに制御してもよい。 As an example of a method for obtaining granulated powder from the above slurry, a method using a spray dryer can be mentioned. As shown in FIG. 2, a rotator 201 is provided in the spray dryer apparatus 200, and the slurry S is injected toward the rotor 201 from the upper part of the spray dryer apparatus 200. The rotor 201 rotates at a predetermined number of revolutions, and sprays the slurry S as droplets by centrifugal force in a chamber inside the spray dryer apparatus 200. Further, hot air is introduced into the chamber inside the spray dryer apparatus 200, whereby the dispersion medium (water) contained in the droplet-like slurry S is volatilized while maintaining the droplet shape. As a result, the granulated powder P is formed from the slurry S. The granulated powder P is collected from the lower part of the spray dryer apparatus 200. Each parameter such as the number of rotations of the rotor 201, the temperature of hot air introduced into the spray dryer apparatus 200, and the temperature at the bottom of the chamber may be set as appropriate. As specific examples of the setting ranges of these parameters, the rotation speed of the rotor 201 is 4000 to 6000 rpm, the hot air temperature introduced into the spray dryer apparatus 200 is 130 to 170 ° C., and the temperature at the bottom of the chamber is 80 to 90 ° C. . The atmosphere in the chamber and its pressure may be set as appropriate. As an example, the inside of the chamber is an air atmosphere, and the pressure is 2 mmH 2 O (about 0.02 kPa) as a differential pressure from the atmospheric pressure. You may further control the particle size distribution of the obtained granulated powder P by sieving.
（１−２）加圧条件
圧縮成形における加圧条件は特に限定されない。造粒粉の組成、成形工程により得られる成形製造物の形状などを考慮して適宜設定すればよい。造粒粉を圧縮成形する際の加圧力が過度に低い場合には、成形製造物の機械的強度が低下する。このため、成形製造物の取り扱い性が低下する、成形製造物から得られた圧粉コア１の機械的強度が低下する、といった問題が生じやすくなる。また、圧粉コア１の磁気特性が低下したり絶縁性が低下したりする場合もある。一方、造粒粉を圧縮成形する際の加圧力が過度に高い場合には、その圧力に耐えうる成形金型を作成するのが困難になってくる。圧縮加圧工程が圧粉コア１の機械特性や磁気特性に悪影響を与える可能性をより安定的に低減させ、工業的に大量生産を容易に行う観点から、造粒粉を圧縮成形する際の加圧力は、０．３ＧＰａ以上２ＧＰａ以下とすることが好ましく、０．５ＧＰａ以上２ＧＰａ以下とすることがより好ましく、０．８ＧＰａ以上２ＧＰａ以下とすることが特に好ましい。
(1-2) Pressing conditions The pressing conditions in compression molding are not particularly limited. What is necessary is just to set suitably in consideration of the composition of the granulated powder, the shape of the molded product obtained by the molding process, and the like. If the pressure applied when the granulated powder is compression-molded is excessively low, the mechanical strength of the molded product decreases. For this reason, it becomes easy to produce the problem that the handleability of a molded product falls and the mechanical strength of the powder core 1 obtained from the molded product falls. Moreover, the magnetic characteristics of the dust core 1 may deteriorate or the insulating properties may decrease. On the other hand, if the applied pressure during compression molding of the granulated powder is excessively high, it becomes difficult to create a molding die that can withstand the pressure. From the viewpoint of more stably reducing the possibility that the compression and pressurization process will adversely affect the mechanical properties and magnetic properties of the dust core 1 and facilitating mass production industrially, The applied pressure is preferably 0.3 GPa to 2 GPa, more preferably 0.5 GPa to 2 GPa, and particularly preferably 0.8 GPa to 2 GPa.
圧縮成形では、加熱しながら加圧を行ってもよいし、常温で加圧を行ってもよい。 In compression molding, pressurization may be performed while heating, or pressurization may be performed at room temperature.
（２）熱処理工程
成形工程により得られた成形製造物が本実施形態に係る圧粉コア１であってもよいし、次に説明するように成形製造物に対して熱処理工程を実施して圧粉コア１を得てもよい。
(2) Heat treatment step The molded product obtained in the molding step may be the powder core 1 according to the present embodiment, or the molded product may be subjected to a heat treatment step and pressed as described below. A powder core 1 may be obtained.
熱処理工程では、上記の成形工程により得られた成形製造物を加熱することにより、磁性粉末間の距離を修正することによる磁気特性の調整および成形工程において磁性粉末に付与された歪を緩和させて磁気特性の調整を行って、圧粉コア１を得る。 In the heat treatment process, the molded product obtained by the above molding process is heated to adjust the magnetic properties by correcting the distance between the magnetic powders and to relax the strain applied to the magnetic powder in the molding process. The powder core 1 is obtained by adjusting the magnetic characteristics.
熱処理工程は上記のように圧粉コア１の磁気特性の調整が目的であるから、熱処理温度などの熱処理条件は、圧粉コア１の磁気特性が最も良好となるように設定される。熱処理条件を設定する方法の一例として、成形製造物の加熱温度を変化させ、昇温速度および加熱温度での保持時間など他の条件は一定とすることが挙げられる。 Since the purpose of the heat treatment step is to adjust the magnetic properties of the dust core 1 as described above, the heat treatment conditions such as the heat treatment temperature are set so that the magnetic properties of the dust core 1 are the best. As an example of a method for setting the heat treatment conditions, it is possible to change the heating temperature of the molded product and to make other conditions constant, such as the heating rate and the holding time at the heating temperature.
熱処理条件を設定する際の圧粉コア１の磁気特性の評価基準は特に限定されない。評価項目の具体例として圧粉コア１の鉄損Ｐｃｖを挙げることができる。この場合には、圧粉コア１の鉄損Ｐｃｖが最低となるように成形製造物の加熱温度を設定すればよい。鉄損Ｐｃｖの測定条件は適宜設定され、一例として、周波数１００ｋＨｚ、最大磁束密度１００ｍＴとする条件が挙げられる。 The evaluation criteria for the magnetic properties of the dust core 1 when setting the heat treatment conditions are not particularly limited. The iron loss Pcv of the powder core 1 can be given as a specific example of the evaluation item. In this case, what is necessary is just to set the heating temperature of a molded product so that the iron loss Pcv of the powder core 1 may become the minimum. The measurement conditions of the iron loss Pcv are set as appropriate, and as an example, the conditions of a frequency of 100 kHz and a maximum magnetic flux density of 100 mT can be mentioned.
熱処理の際の雰囲気は特に限定されない。酸化性雰囲気の場合には、バインダー成分の熱分解が過度に進行する可能性や、磁性粉末の酸化が進行する可能性が高まるため、窒素、アルゴンなどの不活性雰囲気や、水素などの還元性雰囲気で熱処理を行うことが好ましい。 The atmosphere during the heat treatment is not particularly limited. In the case of an oxidizing atmosphere, the possibility of excessive thermal decomposition of the binder component and the possibility of progress of oxidation of the magnetic powder increases, so that an inert atmosphere such as nitrogen or argon, or a reducing property such as hydrogen Heat treatment is preferably performed in an atmosphere.
３．電気・電子部品
本発明の一実施形態に係る電気・電子部品は、上記の本発明の一実施形態に係る圧粉コア１、コイルおよびこのコイルのそれぞれの端部に接続された接続端子を備える。ここで、圧粉コア１の少なくとも一部は、接続端子を介してコイルに電流を流したときにこの電流により生じた誘導磁界内に位置するように配置されている。
3. Electrical / Electronic Component An electrical / electronic component according to an embodiment of the present invention includes a dust core 1 according to an embodiment of the present invention, a coil, and a connection terminal connected to each end of the coil. . Here, at least a part of the dust core 1 is disposed so as to be located in an induced magnetic field generated by the current when a current is passed through the coil via the connection terminal.
このような電気・電子部品の一例として、図３に示されるトロイダルコイル１０が挙げられる。トロイダルコイル１０は、リング状の圧粉コア（トロイダルコア）１に、被覆導電線２を巻回することによって形成されたコイル２ａを備える。被覆導電線２の両端部における導電線が露出した部分（露出端部）２ｂ，２ｃは接続端子を構成している。被覆導電線２におけるコイル２ａと露出端部２ｂ，２ｃとの間に位置する部分において、コイル２ａの端部２ｄ，２ｅを定義することができる。このように、本実施形態に係る電気・電子部品は、コイルを構成する部材と接続端子を構成する部材とが一つの部材から構成されていてもよい。 An example of such an electric / electronic component is the toroidal coil 10 shown in FIG. The toroidal coil 10 includes a coil 2 a formed by winding a coated conductive wire 2 around a ring-shaped dust core (toroidal core) 1. The portions (exposed end portions) 2b and 2c where the conductive wires are exposed at both ends of the covered conductive wire 2 constitute connection terminals. Ends 2d and 2e of the coil 2a can be defined in a portion of the coated conductive wire 2 located between the coil 2a and the exposed ends 2b and 2c. As described above, in the electrical / electronic component according to the present embodiment, the member constituting the coil and the member constituting the connection terminal may be constituted by one member.
本発明の一実施形態に係る電気・電子部品は、上記の本発明の一実施形態に係る圧粉コア１とは異なる形状を有する圧粉コアを備えていてもよい。そのような電気・電子部品の具体例として、図４に示されるインダクタンス素子２０が挙げられる。図４は、本発明の一実施形態に係るインダクタンス素子２０の全体構成を一部透視して示す斜視図である。図４では、インダクタンス素子２０の下面（実装面）が上向きの姿勢で示されている。図５は、図４に示すインダクタンス素子２０を実装基板１００上に実装した状態を示す部分正面図である。 The electric / electronic component according to an embodiment of the present invention may include a dust core having a shape different from that of the dust core 1 according to the embodiment of the present invention. A specific example of such an electric / electronic component is an inductance element 20 shown in FIG. FIG. 4 is a perspective view showing a part of the entire configuration of the inductance element 20 according to the embodiment of the present invention. In FIG. 4, the lower surface (mounting surface) of the inductance element 20 is shown in an upward posture. FIG. 5 is a partial front view showing a state in which the inductance element 20 shown in FIG. 4 is mounted on the mounting substrate 100.
図４に示すインダクタンス素子２０は、圧粉コア３と、圧粉コア３の内部に埋め込まれたコイル５と、溶接によってコイル５に電気的に接続される接続端子としての一対の端子部４とを備えて構成される。 The inductance element 20 shown in FIG. 4 includes a dust core 3, a coil 5 embedded in the dust core 3, and a pair of terminal portions 4 as connection terminals electrically connected to the coil 5 by welding. It is configured with.
コイル５は、絶縁被膜された導線を螺旋状に巻回して形成されたものである。コイル５は、巻回部５ａと巻回部５ａから引き出された引出端部５ｂ，５ｂとを有して構成される。コイル５の巻き数は必要なインダクタンスに応じて適宜設定される。 The coil 5 is formed by spirally winding a conductive wire with an insulating coating. The coil 5 includes a winding part 5a and lead-out end parts 5b and 5b drawn from the winding part 5a. The number of turns of the coil 5 is appropriately set according to the required inductance.
図４に示すように、圧粉コア３において、実装基板に対する実装面３ａに、端子部４の一部を収納するための収納凹部３０が形成されている。収納凹部３０は、実装面３ａの両側に形成されており、圧粉コア３の側面３ｂ，３ｃに向けて解放されて形成されている。圧粉コア３の側面３ｂ，３ｃから突出する端子部４の一部が実装面３ａに向けて折り曲げられて、収納凹部３０の内部に収納される。 As shown in FIG. 4, in the dust core 3, an accommodation recess 30 for accommodating a part of the terminal portion 4 is formed on the mounting surface 3 a for the mounting substrate. The storage recesses 30 are formed on both sides of the mounting surface 3 a and are formed to be released toward the side surfaces 3 b and 3 c of the powder core 3. Part of the terminal portion 4 protruding from the side surfaces 3 b and 3 c of the powder core 3 is bent toward the mounting surface 3 a and stored in the storage recess 30.
端子部４は、薄板状のＣｕ基材で形成されている。端子部４は圧粉コア３の内部に埋設されてコイル５の引出端部５ｂ，５ｂに電気的に接続される接続端部４０と、圧粉コア３の外面に露出し、前記圧粉コア３の側面３ｂ，３ｃから実装面３ａにかけて順に折り曲げ形成される第１曲折部４２ａおよび第２曲折部４２ｂとを有して構成される。接続端部４０は、コイル５に溶接される溶接部である。第１曲折部４２ａと第２曲折部４２ｂは、実装基板１００に対して半田接合される半田接合部である。半田接合部は、端子部４のうちの圧粉コア３から露出している部分であって、少なくとも圧粉コア３の外側に向けられる表面を意味している。 The terminal portion 4 is formed of a thin plate-like Cu base material. The terminal part 4 is embedded in the dust core 3 and exposed to the connection end 40 electrically connected to the lead-out ends 5b, 5b of the coil 5, and the outer surface of the dust core 3. The dust core 3 includes a first bent portion 42a and a second bent portion 42b that are bent in order from the side surfaces 3b and 3c to the mounting surface 3a. The connection end 40 is a welded portion that is welded to the coil 5. The first bent portion 42 a and the second bent portion 42 b are solder joint portions that are soldered to the mounting substrate 100. The solder joint portion is a portion of the terminal portion 4 that is exposed from the dust core 3 and means a surface that faces at least the outside of the dust core 3.
端子部４の接続端部４０とコイル５の引出端部５ｂとは、抵抗溶接によって接合されている。 The connection end portion 40 of the terminal portion 4 and the extraction end portion 5b of the coil 5 are joined by resistance welding.
図５に示すように、インダクタンス素子２０は、実装基板１００上に実装される。
実装基板１００の表面には外部回路と導通する導体パターンが形成され、この導体パターンの一部によって、インダクタンス素子２０を実装するための一対のランド部１１０が形成されている。
As shown in FIG. 5, the inductance element 20 is mounted on the mounting substrate 100.
A conductor pattern that is electrically connected to an external circuit is formed on the surface of the mounting substrate 100, and a pair of land portions 110 for mounting the inductance element 20 is formed by a part of the conductor pattern.
図５に示すように、インダクタンス素子２０においては、実装面３ａが実装基板１００側に向けられて、圧粉コア３から外部に露出している第１曲折部４２ａと第２曲折部４２ｂが実装基板１００のランド部１１０との間で半田層１２０にて接合される。 As shown in FIG. 5, in the inductance element 20, the mounting surface 3a is directed to the mounting substrate 100 side, and the first bent portion 42a and the second bent portion 42b that are exposed to the outside from the dust core 3 are mounted. The solder layer 120 is bonded to the land portion 110 of the substrate 100.
ハンダ付け工程は、ランド部１１０にペースト状の半田が印刷工程で塗布された後に、ランド部１１０に第２曲折部４２ｂが対面するようにしてインダクタンス素子２０が実装され、加熱工程で半田が溶融する。図４と図５に示すように、第２曲折部４２ｂは実装基板１００のランド部１１０に対向し、第１曲折部４２ａはインダクタンス素子２０の側面３ｂ，３ｃに露出しているため、フィレット状の半田層１２０は、ランド部１１０に固着するとともに、半田接合部である第２曲折部４２ｂと第１曲折部４２ａの双方の表面に十分に広がって固着される。 In the soldering process, after the solder paste is applied to the land part 110 in the printing process, the inductance element 20 is mounted so that the second bent part 42b faces the land part 110, and the solder melts in the heating process. To do. As shown in FIGS. 4 and 5, the second bent portion 42 b faces the land portion 110 of the mounting substrate 100, and the first bent portion 42 a is exposed on the side surfaces 3 b and 3 c of the inductance element 20. The solder layer 120 is fixed to the land portion 110 and is sufficiently spread and fixed to the surfaces of both the second bent portion 42b and the first bent portion 42a which are solder joint portions.
４．電気・電子機器
本発明の一実施形態に係る電気・電子機器は、上記の本発明の一実施形態に係る圧粉コアを備える電気・電子部品が実装されたものである。そのような電気・電子機器として、大電流（例えば数ｍｍ角程度の小型インダクタの場合は１Ａ程度以上）が流れる、電源スイッチング回路、電圧昇降回路、平滑回路等を備えた電源装置が例示される。
4). Electrical / Electronic Device An electrical / electronic device according to an embodiment of the present invention is mounted with an electrical / electronic component including the dust core according to the embodiment of the present invention. As such an electric / electronic device, a power supply device including a power switching circuit, a voltage raising / lowering circuit, a smoothing circuit, etc., through which a large current (for example, about 1 A or more in the case of a small inductor of several mm square) flows is exemplified. .
電源スイッチング回路、電圧昇降回路、平滑回路などを備える電源装置に大電流を流した場合に、電源装置に組み込まれた電気・電子部品が備える圧粉コアの鉄損Ｐｃｖが高いと発熱の程度が高くなり、装置の信頼性が著しく低下する。このため、かかる圧粉コアの鉄損Ｐｃｖを低くして高効率とすることが強く求められている。本発明の一実施形態に係る電気・電子機器が備える電気・電子部品に用いられている圧粉コアは鉄損Ｐｃｖが低いため、高効率であり、電気・電子機器に大電流を流した場合であっても、発熱の程度が比較的低い。このため、本発明の一実施形態に係る電気・電子機器は信頼性に優れる。 When a large current is passed through a power supply device including a power supply switching circuit, a voltage raising / lowering circuit, a smoothing circuit, etc., if the iron loss Pcv of the dust core included in the electric / electronic component incorporated in the power supply device is high, the degree of heat generation And the reliability of the device is significantly reduced. For this reason, it is strongly required to reduce the iron loss Pcv of the dust core and increase the efficiency. The dust core used in the electrical / electronic component included in the electrical / electronic device according to the embodiment of the present invention has high iron loss Pcv, and thus has high efficiency, and a large current flows through the electrical / electronic device. Even so, the degree of heat generation is relatively low. For this reason, the electrical / electronic device according to an embodiment of the present invention is excellent in reliability.
以上説明した実施形態は、本発明の理解を容易にするために記載されたものであって、本発明を限定するために記載されたものではない。したがって、上記実施形態に開示された各要素は、本発明の技術的範囲に属する全ての設計変更や均等物をも含む趣旨である。 The embodiment described above is described for facilitating understanding of the present invention, and is not described for limiting the present invention. Therefore, each element disclosed in the above embodiment is intended to include all design changes and equivalents belonging to the technical scope of the present invention.
以下、実施例等により本発明をさらに具体的に説明するが、本発明の範囲はこれらの実施例等に限定されるものではない。 EXAMPLES Hereinafter, although an Example etc. demonstrate this invention further more concretely, the scope of the present invention is not limited to these Examples etc.
（実施例１）
（１）Ｆｅ基非晶質合金粉末の作製
水アトマイズ法を用いて、Ｆｅ７１原子％Ｎｉ６原子％Ｃｒ２原子％Ｐ１１原子％Ｃ８原子％Ｂ２原子％なる組成になるように秤量して得られた非晶質磁性材料の粉末を磁性粉末として作製した。第一混合比率（結晶質磁性材料の粉末の含有量と非晶質磁性材料の粉末の含有量との総和に対する結晶質磁性材料の粉末の含有量の質量比率）は０質量％であった。得られた磁性粉末の粒度分布は、日機装社製「マイクロトラック粒度分布測定装置 ＭＴ３３００ＥＸ」を用いて体積分布で測定した。その結果、体積分布において５０％となる粒径であるメジアン径Ｄ５０は５μｍであった。
Example 1
(1) Preparation of Fe-based amorphous alloy powder Using a water atomization method, weighed so as to have a composition of Fe 71 atomic% Ni 6 atomic% Cr 2 atomic% P 11 atomic% C 8 atomic% B 2 atomic% The amorphous magnetic material powder thus obtained was prepared as a magnetic powder. The first mixing ratio (the mass ratio of the content of the crystalline magnetic material powder to the total content of the crystalline magnetic material powder and the amorphous magnetic material powder) was 0% by mass. The particle size distribution of the obtained magnetic powder was measured by volume distribution using “Microtrack particle size distribution measuring device MT3300EX” manufactured by Nikkiso Co., Ltd. As a result, the median diameter D50, which is a particle diameter of 50% in the volume distribution, was 5 μm.
（２）造粒粉の作製
上記の非晶質磁性材料の粉末９７．２質量部と、アクリル樹脂およびフェノール樹脂からなる絶縁性結着材２．５質量部と、潤滑剤を０．３質量部とを、溶媒としての水に混合してスラリーを得た。得られたスラリーをスプレードライヤー装置を用いて乾燥、造粒し、メジアン径Ｄ５０が８０μｍの造粒粉を得た。
(2) Production of granulated powder 97.2 parts by mass of the above-mentioned amorphous magnetic material powder, 2.5 parts by mass of an insulating binder made of acrylic resin and phenol resin, and 0.3 mass of lubricant Were mixed with water as a solvent to obtain a slurry. The obtained slurry was dried and granulated using a spray dryer device to obtain a granulated powder having a median diameter D50 of 80 μm.
（３）圧縮成形
得られた造粒粉を金型に充填し、面圧１．０ＧＰａで加圧成形して、外径２０ｍｍ×内径１２ｍｍ×厚さ３ｍｍのリング形状を有する成形製造物を得た。
(3) Compression molding The obtained granulated powder is filled in a mold and press-molded at a surface pressure of 1.0 GPa to obtain a molded product having a ring shape with an outer diameter of 20 mm, an inner diameter of 12 mm and a thickness of 3 mm. It was.
（４）熱処理
得られた成形製造物を、窒素気流雰囲気の炉内に載置し、炉内温度を、室温（２３℃）から昇温速度１０℃／分で４００℃まで加熱し、この温度にて１時間保持し、その後、炉内で室温まで冷却する熱処理を行い、圧粉コアからなるトロイダルコアを得た。
(4) Heat treatment The obtained molded product was placed in a furnace in a nitrogen stream atmosphere, and the furnace temperature was heated from room temperature (23 ° C.) to 400 ° C. at a heating rate of 10 ° C./min. Was held for 1 hour, and then a heat treatment was performed to cool to room temperature in the furnace to obtain a toroidal core composed of a dust core.
（実施例２から６）
磁性粉末を調製する際に、実施例１において使用した非晶質磁性材料の粉末と、絶縁処理が施されたカルボニル鉄（ＣＩＰ）からなる結晶質磁性材料の粉末（メジアン径Ｄ５０：４．３μｍ）とを混合して、第一混合比率が次の値となる磁性粉末を用いたこと以外は、実施例１と同様にして、トロイダルコアを製造した。
実施例２ ５質量％
実施例３ １０質量％
実施例４ １５質量％
実施例５ ２０質量％
実施例６ ３０質量％
(Examples 2 to 6)
When preparing the magnetic powder, the powder of the amorphous magnetic material used in Example 1 and the powder of the crystalline magnetic material made of carbonyl iron (CIP) subjected to insulation treatment (median diameter D50: 4.3 μm) ) And a toroidal core was produced in the same manner as in Example 1 except that the magnetic powder having the following first mixing ratio was used.
Example 2 5% by mass
Example 3 10% by mass
Example 4 15% by mass
Example 5 20% by mass
Example 6 30% by mass
（実施例７）
磁性粉末を調製する際に、実施例１において使用した非晶質磁性材料の粉末に代えて、実施例２などで使用した、絶縁処理が施されたＣＩＰを全量用いたこと、すなわち磁性粉末の第一混合比率を１００質量％としたこと以外は、実施例１と同様にして、トロイダルコアを製造した。
(Example 7)
When the magnetic powder was prepared, instead of the amorphous magnetic material powder used in Example 1, all of the CIP subjected to insulation treatment used in Example 2 was used. A toroidal core was produced in the same manner as in Example 1 except that the first mixing ratio was 100% by mass.
（実施例８）
メジアン径Ｄ５０が８μｍであること以外は実施例１の製造方法と同様にして非晶質磁性材料の粉末を調製した。この非晶質磁性材料の粉末を用いて、実施例１と同様にして、トロイダルコアを製造した。
(Example 8)
An amorphous magnetic material powder was prepared in the same manner as in the production method of Example 1 except that the median diameter D50 was 8 μm. Using this amorphous magnetic material powder, a toroidal core was produced in the same manner as in Example 1.
（試験例１）鉄損Ｐｃｖの測定およびシミュレーション
実施例１から８により作製したトロイダルコアに被覆銅線をそれぞれ１次側１５回、２次側１０回巻いて得られたトロイダルコイルについて、ＢＨアナライザー（岩崎通信機社製「ＳＹ−８２１７」）を用いて、実効最大磁束密度Ｂｍを１５ｍＴとする条件で、鉄損Ｐｃｖ（単位：ｋＷ／ｍ３）の周波数依存性（測定周波数範囲：１００ｋＨｚ〜３ＭＨｚ）を測定した。
(Test Example 1) Measurement and Simulation of Iron Loss Pcv For the toroidal coils obtained by winding the coated copper wires on the toroidal cores produced in Examples 1 to 8 15 times on the primary side and 10 times on the secondary side, respectively, the BH analyzer (Iwasaki Tsushinki Co., Ltd. “SY-8217”), the frequency dependence of the iron loss Pcv (unit: kW / m 3 ) under the condition that the effective maximum magnetic flux density B m is 15 mT (measurement frequency range: 100 kHz) ~ 3MHz) was measured.
鉄損Ｐｃｖの周波数依存性を表す式の一例として、下記式（１）に示される式が挙げられる。
Ｐｃｖ＝ｋｈ×ｆ×Ｂｍ １．６＋ｋｅ×ｆ２×Ｂｍ ２ （１）
ここで、ｆは周波数（単位：ｋＨｚ）、Ｂｍは実効最大磁束密度（単位：ｍＴ）であり、ｋｈおよびｋｅは常数であって、単位は、前者（常数ｋｈ）がｋＷ／ｍ３／ｋＨｚ／（ｍＴ）１．６以下、後者（常数ｋｅ）がｋＷ／ｍ３／（ｋＨｚ）２／（ｍＴ）２である。
As an example of a formula representing the frequency dependence of the iron loss Pcv, a formula shown in the following formula (1) is given.
Pcv = k h × f × B m 1.6 + k e × f 2 × B m 2 (1)
Here, f is the frequency (unit: kHz), B m is the effective maximum magnetic flux density (unit: mT) is, k h and k e is a constant, and the unit, the former (constant k h) is kW / m 3 / kHz / (mT) 1.6 or less, and the latter (constant k e ) is kW / m 3 / (kHz) 2 / (mT) 2 .
実施例１から７に係るトロイダルコイルの鉄損Ｐｃｖの測定結果のうち、周波数が１ＭＨｚから３ＭＨｚの範囲の測定結果を用いて、２つの常数ｋｈおよびｋｅを実施例ごとに求めた。その結果を表１に示す。表１では、常数ｋｈおよび常数ｋｅの単位の記載を省略している。 Among the measurement results of the iron loss Pcv of the toroidal coil according Examples 1 to 7, frequency using the measurement results of 3MHz ranging from 1 MHz, to determine the two constants k h and k e for each Example. The results are shown in Table 1. In Table 1, it is omitted in units of constant k h and constant k e.
表１に示される結果から、メジアン径Ｄ５０が５μｍの非晶質磁性材料の粉末を含有する圧粉コアにおける２つの常数ｋｈおよびｋｅのそれぞれについて、第一混合比率に対する依存性を求めた。その結果、図６に示されるように、常数ｋｈの第一混合比率に対する依存性のフィッティング結果は下記式（２）により示される式となった。下記式（２）の相関係数は０．９９８０であった。一方、図７に示されるように、常数ｋｅの第一混合比率に対する依存性のフィッティング結果は下記式（３）により示される式となった。下記式（３）の相関係数は０．９８１６であった。なお、下記式（２）および（３）において、ｘは第一混合比率（単位：質量％）である。
ｋｈ＝２．２９０×１０-７ｘ２＋４．７３７×１０-６ｘ−３．７４８×１０-５ （２）
ｋｅ＝２．１９３×１０-１１ｘ２−６．４１１×１０-１０ｘ＋２．４９９×１０-７ （３）
From the results shown in Table 1, for each of the two constants k h and k e in the dust core of the median diameter D50 contains a powder of amorphous magnetic material 5 [mu] m, it was determined the dependence on the first mixing ratio . As a result, as shown in FIG. 6, the dependence of the fitting result for the first mixing ratio of the constant k h became formula given by the following formula (2). The correlation coefficient of the following formula (2) was 0.9980. On the other hand, as shown in FIG. 7, dependence of the fitting result for the first mixing ratio of the constant k e became formula given by equation (3). The correlation coefficient of the following formula (3) was 0.9816. In the following formulas (2) and (3), x is the first mixing ratio (unit: mass%).
k h = 2.290 × 10 -7 x 2 + 4.737 × 10 -6 x-3.748 × 10 -5 (2)
k e = 2.193 × 10 −11 x 2 −6.411 × 10 −10 x + 2.499 × 10 −7 (3)
上記式（２）および（３）に基づいて、メジアン径Ｄ５０が５μｍの非晶質磁性材料の粉末を含有する圧粉コアの２つの常数ｋｈおよびｋｅを、第一混合比率が５０質量％から１００質量％の範囲で求めた。そして、こうして求めた２つの常数ｋｈおよびｋｅから、メジアン径Ｄ５０が５μｍの非晶質磁性材料の粉末を含有し、第一混合比率が５０質量％から１００質量％の範囲にある圧粉コアの鉄損Ｐｃｖ（周波数ｆ：２ＭＨｚ、実効最大磁束密度Ｂｍ：１５ｍＴ）を算出した。その結果を表２に示す。表２には、第一混合比率が５０質量％から９０質量％の場合における圧粉コアの鉄損Ｐｃｖを、第一混合比率が１００質量％の場合における圧粉コアの鉄損Ｐｃｖで規格化した値を鉄損比として示した。 Based on the above formulas (2) and (3), the two constants k h and k e of the powder core containing the powder of the amorphous magnetic material having a median diameter D50 of 5 μm are used, and the first mixing ratio is 50 mass. % To 100% by mass. Then, from the two constants k h and k e thus obtained, a powder of an amorphous magnetic material having a median diameter D50 of 5 μm is contained, and the first mixing ratio is in the range of 50% by mass to 100% by mass. The core iron loss Pcv (frequency f: 2 MHz, effective maximum magnetic flux density B m : 15 mT) was calculated. The results are shown in Table 2. In Table 2, the iron loss Pcv of the dust core when the first mixing ratio is 50% to 90% by mass is normalized with the iron loss Pcv of the dust core when the first mixing ratio is 100% by mass. The obtained value was shown as the iron loss ratio.
実施例８に係るトロイダルコイルの鉄損Ｐｃｖの測定結果のうち、周波数が１ＭＨｚから３ＭＨｚの範囲の測定結果を用いて、２つの常数ｋｈおよびｋｅを求めた。その結果を表３に示す。 Among the measurement results of the iron loss Pcv of the toroidal coil according to Example 8, two constants k h and k e were obtained using the measurement results in the frequency range of 1 MHz to 3 MHz. The results are shown in Table 3.
表３に示される実施例８に係る２つの常数ｋｈおよびｋｅの結果は、表１に示される実施例１に係る２つの常数ｋｈおよびｋｅの結果と近い結果となった。そこで、実施例８、実施例２から６、および実施例７における常数ｋｈおよび常数ｋｅの結果を用いて、メジアン径Ｄ５０が８μｍの非晶質磁性材料の粉末を含有する圧粉コアにおける２つの常数ｋｈおよびｋｅのそれぞれについて、第一混合比率に対する依存性を求めた。その結果、図８に示されるように、常数ｋｈの第一混合比率に対する依存性のフィッティング結果は下記式（４）により示される式となった。下記式（４）の相関係数は０．９９８０であった。一方、図９に示されるように、常数ｋｅの第一混合比率に対する依存性のフィッティング結果は下記式（５）により示される式となった。下記式（５）の相関係数は０．９８４３であった。なお、下記式（４）および（５）において、ｘは第一混合比率（単位：質量％）である。
ｋｈ＝２．２９０×１０-７ｘ２＋４．７３７×１０-６ｘ−３．７４８×１０-５ （４）
ｋｅ＝２．０３２×１０-１１ｘ２−４．５０９×１０-１０ｘ＋２．４６８×１０-７ （５）
The results of the two constants k h and k e according to Example 8 shown in Table 3 were close to the results of the two constants k h and k e according to Example 1 shown in Table 1. Accordingly, Example 8, using the results of constant k h and constant k e in Examples 2 6 and Example 7, in the dust core of the median diameter D50 contains a powder of amorphous magnetic material of 8μm The dependence on the first mixing ratio was determined for each of the two constants k h and k e . As a result, as shown in FIG. 8, dependence of the fitting result for the first mixing ratio of the constant k h became formula given by the following equation (4). The correlation coefficient of the following formula (4) was 0.9980. On the other hand, as shown in FIG. 9, the dependence of the fitting result for the first mixing ratio of the constant k e became formula given by equation (5). The correlation coefficient of the following formula (5) was 0.9843. In the following formulas (4) and (5), x is the first mixing ratio (unit: mass%).
k h = 2.290 × 10 -7 x 2 + 4.737 × 10 -6 x-3.748 × 10 -5 (4)
k e = 2.032 × 10 −11 x 2 −4.509 × 10 −10 x + 2.468 × 10 −7 (5)
上記式（４）および（５）に基づいて、メジアン径Ｄ５０が８μｍの非晶質磁性材料の粉末を含有する圧粉コアの２つの常数ｋｈおよびｋｅを、第一混合比率が５０質量％から１００質量％の範囲で求めた。そして、こうして求めた２つの常数ｋｈおよびｋｅから、メジアン径Ｄ５０が８μｍの非晶質磁性材料の粉末を含有し、第一混合比率が５０質量％から１００質量％の範囲にある圧粉コアの鉄損Ｐｃｖ（周波数ｆ：２ＭＨｚ、実効最大磁束密度Ｂｍ：１５ｍＴ）を算出した。その結果および表２と同様にして求めた鉄損比を表４に示す。 Based on the above formulas (4) and (5), two constants k h and k e of the powder core containing the powder of the amorphous magnetic material having a median diameter D50 of 8 μm are used, and the first mixing ratio is 50 mass. % To 100% by mass. Then, thus two constants k h and k e obtained, a powder of median diameter D50 of containing a powder of amorphous magnetic material of 8 [mu] m, the first mixture ratio is in the range of 50 wt% of 100 wt% The core iron loss Pcv (frequency f: 2 MHz, effective maximum magnetic flux density B m : 15 mT) was calculated. Table 4 shows the results and the iron loss ratio obtained in the same manner as in Table 2.
（試験例２）透磁率の測定
実施例１から８により作製したトロイダルコアに被覆銅線をそれぞれ１次側４０回、２次側１０回巻いて得られたトロイダルコイルについて、インピーダンスアナライザー（ＨＰ社製「４１９２Ａ」）を用いて、１００ｋＨｚの条件で、初透磁率μ’を測定した。結果を表５に示す。表５におけるＤ５０の列には、圧粉コアに含有される非晶質磁性材料の粉末のメジアン径Ｄ５０を示した。
(Test Example 2) Measurement of magnetic permeability For a toroidal coil obtained by winding a coated copper wire 40 times on the primary side and 10 times on the secondary side respectively on the toroidal core produced in Examples 1 to 8, an impedance analyzer (HP Corporation) was obtained. Using the product “4192A”), the initial permeability μ ′ was measured under the condition of 100 kHz. The results are shown in Table 5. In the column of D50 in Table 5, the median diameter D50 of the powder of the amorphous magnetic material contained in the dust core is shown.
表５に示される結果から、メジアン径Ｄ５０が５μｍの非晶質磁性材料の粉末を含有する圧粉コアにおける初透磁率μ’の第一混合比率に対する依存性を求めた。その結果、図１０に示されるように、初透磁率μ’の第一混合比率に対する依存性のフィッティング結果は下記式（６）により示される式となった。下記式（６）の相関係数は０．９９３４であった。なお、下記式（６）において、ｘは第一混合比率（単位：質量％）である。
μ’＝−７．２４４×１０-４ｘ２＋１．５２９×１０-１ｘ＋２．８５９×１０１ （６）
From the results shown in Table 5, the dependency of the initial permeability μ ′ on the first mixing ratio in a dust core containing powder of an amorphous magnetic material having a median diameter D50 of 5 μm was determined. As a result, as shown in FIG. 10, the fitting result of the dependence of the initial permeability μ ′ on the first mixing ratio is an expression shown by the following expression (6). The correlation coefficient of the following formula (6) was 0.9934. In addition, in following formula (6), x is a 1st mixing ratio (unit: mass%).
μ ′ = − 7.44 × 10 −4 x 2 + 1.529 × 10 −1 x + 2.859 × 10 1 (6)
上記式（６）に基づいて、メジアン径Ｄ５０が５μｍの非晶質磁性材料の粉末を含有し、第一混合比率が５０質量％から１００質量％の範囲にある圧粉コアの初透磁率μ’を算出した。その結果を表６に示す。表６には、第一混合比率が５０質量％から９０質量％の場合における圧粉コアの初透磁率μ’を、第一混合比率が１００質量％の場合における圧粉コアの初透磁率μ’で規格化した値を初透磁率比として示した。 Based on the above formula (6), the initial permeability μ of the dust core containing a powder of an amorphous magnetic material having a median diameter D50 of 5 μm and a first mixing ratio in the range of 50% by mass to 100% by mass. 'Calculated. The results are shown in Table 6. Table 6 shows the initial permeability μ ′ of the dust core when the first mixing ratio is 50 mass% to 90 mass%, and the initial permeability μ of the dust core when the first mixing ratio is 100 mass%. The value normalized by 'is shown as the initial permeability ratio.
メジアン径Ｄ５０が８μｍの非晶質磁性材料の粉末を含有する圧粉コアにおける初透磁率μ’の第一混合比率に対する依存性は一次直線により表されると仮定して、実施例８および７の初透磁率μ’の測定結果から、メジアン径Ｄ５０が８μｍの非晶質磁性材料の粉末を含有する圧粉コアにおける第一混合比率が５０質量％から１００質量％の範囲での初透磁率μ’を算出した。その結果および表５と同様にして求めた初透磁率比を表７に示す。 Assuming that the dependence of the initial permeability μ ′ on the first mixing ratio in a dust core containing powder of an amorphous magnetic material with a median diameter D50 of 8 μm is represented by a linear line, Examples 8 and 7 From the measurement results of the initial permeability μ ′, the initial permeability in the powder mixture core containing the powder of the amorphous magnetic material having a median diameter D50 of 8 μm is in the range of 50% by mass to 100% by mass. μ ′ was calculated. Table 7 shows the results and the initial permeability ratio obtained in the same manner as in Table 5.
（試験例３）直流重畳特性の測定
実施例１から８により作製したトロイダルコアから形成されたトロイダルコイルを用いて、ＪＩＳ Ｃ２５６０−２に準拠して、直流電流をトロイダルコイルに重畳した。重畳電流の印加前（初期）のインダクタンスＬの値Ｌ０に対するインダクタンスＬの変化量ΔＬの割合（ΔＬ／Ｌ０）が３０％となったときの印加電流値Ｉｓａｔ（単位：Ａ）により、直流重畳特性を評価した。結果を表８に示す。表８におけるＤ５０の列には、圧粉コアに含有される非晶質磁性材料の粉末のメジアン径Ｄ５０を示した。
(Test Example 3) Measurement of DC superposition characteristics Using the toroidal coil formed from the toroidal core produced in Examples 1 to 8, a DC current was superimposed on the toroidal coil in accordance with JIS C2560-2. From the applied current value Isat (unit: A) when the ratio (ΔL / L 0 ) of the change amount ΔL of the inductance L to the value L 0 of the inductance L before application of the superimposed current (initial) is 30%, DC The superposition characteristics were evaluated. The results are shown in Table 8. The column D50 in Table 8 shows the median diameter D50 of the amorphous magnetic material powder contained in the dust core.
表８に示される結果から、メジアン径Ｄ５０が５μｍの非晶質磁性材料の粉末を含有する圧粉コアにおけるＩｓａｔの第一混合比率に対する依存性を求めた。その結果、図１１に示されるように、Ｉｓａｔの第一混合比率に対する依存性のフィッティング結果は下記式（７）により示される式となった。下記式（７）の相関係数は０．９９５４であった。なお、下記式（７）において、ｘは第一混合比率（単位：質量％）である。
Ｉｓａｔ＝６．６０２×１０-２ｘ＋１．１４９×１０１ （７）
From the results shown in Table 8, the dependency of Isat on the first mixing ratio in a powder core containing powder of an amorphous magnetic material having a median diameter D50 of 5 μm was determined. As a result, as shown in FIG. 11, the fitting result of the dependence on the first mixing ratio of Isat was expressed by the following formula (7). The correlation coefficient of the following formula (7) was 0.9954. In addition, in following formula (7), x is a 1st mixing ratio (unit: mass%).
Isat = 6.602 × 10 −2 x + 1.149 × 10 1 (7)
上記式（７）に基づいて、メジアン径Ｄ５０が５μｍの非晶質磁性材料の粉末を含有し、第一混合比率が５０質量％から１００質量％の範囲にある圧粉コアのＩｓａｔを算出した。その結果を表９に示す。表９には、第一混合比率が５０質量％から９０質量％の場合における圧粉コアのＩｓａｔを、第一混合比率が１００質量％の場合における圧粉コアのＩｓａｔで規格化した値をＩｓａｔ比として示した。 Based on the above formula (7), the Isat of the powder core containing the powder of the amorphous magnetic material having a median diameter D50 of 5 μm and the first mixing ratio in the range of 50% by mass to 100% by mass was calculated. . The results are shown in Table 9. Table 9 shows the Isat of the dust core when the first mixing ratio is 50% to 90% by mass, and the value Isat normalized by the Isat of the dust core when the first mixing ratio is 100% by mass. Shown as a ratio.
メジアン径Ｄ５０が８μｍの非晶質磁性材料の粉末を含有する圧粉コアにおけるＩｓａｔの第一混合比率に対する依存性は一次直線により表されると仮定して、実施例８および７のＩｓａｔの測定結果から、メジアン径Ｄ５０が８μｍの非晶質磁性材料の粉末を含有し、第一混合比率が５０質量％から１００質量％の範囲にある圧粉コアのＩｓａｔを算出した。その結果および表９と同様にして求めたＩｓａｔ比を表１０に示す。 Measurement of Isat of Examples 8 and 7 assuming that the dependence of Isat on the first mixing ratio in a powder core containing powder of amorphous magnetic material having a median diameter D50 of 8 μm is represented by a linear line From the results, Isat was calculated for a dust core containing a powder of an amorphous magnetic material having a median diameter D50 of 8 μm and a first mixing ratio in the range of 50 mass% to 100 mass%. Table 10 shows the results and Isat ratios obtained in the same manner as in Table 9.
図１２は、メジアン径Ｄ５０が５μｍの非晶質磁性材料の粉末を含有し、第一混合比率が５０質量％から１００質量％の範囲にある圧粉コアについて、鉄損比、初透磁率比およびＩｓａｔ比を一つのグラフにまとめて示したものである。図１２に示されるように、磁性粉末がＣＩＰからなる圧粉コア（実施例７）との対比で、圧粉コアに含有される磁性粉末に非晶質磁性材料の粉末を含ませると、鉄損比、初透磁率比およびＩｓａｔ比のいずれも低下するが、鉄損比が他の２つの比に比べて大きく低減することが確認された。この結果は、磁性粉末がＣＩＰからなる圧粉コアに非晶質磁性材料の粉末からなる磁性粉末を混ぜることにより、初透磁率やＩｓａｔの低下を少なくしつつ、鉄損を大きく低減させることが可能であることを示している。そして、図１２から明らかなように、圧粉コアに混ぜる非晶質磁性材料の粉末からなる磁性粉末の割合が大きくなるほど、鉄損Ｐｃｖの低下は顕著となる。 FIG. 12 shows an iron loss ratio and an initial permeability ratio for a dust core containing a powder of an amorphous magnetic material having a median diameter D50 of 5 μm and a first mixing ratio in the range of 50% by mass to 100% by mass. And Isat ratio are collectively shown in one graph. As shown in FIG. 12, in contrast to the powder core (Example 7) in which the magnetic powder is made of CIP, when the magnetic powder contained in the powder core includes an amorphous magnetic material powder, Although all of the loss ratio, the initial permeability ratio, and the Isat ratio are reduced, it has been confirmed that the iron loss ratio is greatly reduced as compared with the other two ratios. This result shows that by mixing magnetic powder made of amorphous magnetic material powder into a powder core made of CIP, the iron loss can be greatly reduced while reducing the initial permeability and Isat. It shows that it is possible. As is clear from FIG. 12, the iron loss Pcv decreases more significantly as the ratio of the magnetic powder made of the amorphous magnetic material powder mixed in the dust core increases.
鉄損Ｐｃｖの低下の程度が他の磁気特性の低下の程度とどのような関係にあるかを確認するために、下記式（８）および下記式（９）により評価した。
Ｒ１ｉ＝（１−Ｃｉ）／（１−Ｐｉ） （８）
Ｒ２ｉ＝（１−Ｃｉ）／（１−Ｉｉ） （９）
In order to confirm the relationship between the degree of decrease in the iron loss Pcv and the degree of decrease in other magnetic characteristics, evaluation was performed using the following formula (8) and the following formula (9).
R1 i = (1-C i ) / (1-P i ) (8)
R2 i = (1-C i ) / (1-I i ) (9)
ここで、Ｃｉは第一混合比率がｉ質量％のときの鉄損比であり、Ｐｉは第一混合比率がｉ質量％のときの初透磁率比である。したがって、Ｒ１ｉは、第一混合比率がｉ質量％のときに、初透磁率μ’の低下量を基準にして鉄損Ｐｃｖがどの程度低下したかを示す指標である。また、Ｉｉは第一混合比率がｉ質量％のときのＩｓａｔ比である。したがって、Ｒ２ｉは、第一混合比率がｉ質量％のときに、Ｉｓａｔの低下量を基準にして鉄損Ｐｃｖがどの程度低下したかを示す指標である。これらの算出結果を表１１に示す。 Here, C i is the iron loss ratio when the first mixing ratio is i mass%, and P i is the initial permeability ratio when the first mixing ratio is i mass%. Therefore, R1 i is an index indicating how much the iron loss Pcv has decreased with reference to the amount of decrease in the initial permeability μ ′ when the first mixing ratio is i mass%. I i is the Isat ratio when the first mixing ratio is i mass%. Therefore, R2 i is an index indicating how much the iron loss Pcv is reduced based on the decrease amount of Isat when the first mixing ratio is i mass%. Table 11 shows the calculation results.
表１１から、第一混合比率が大きいほど、すなわち、磁性粉末がＣＩＰからなる圧粉コアに非晶質磁性材料の粉末からなる磁性粉末を混ぜる程度を少なくすることにより、より効果的に（他の磁気特性が受ける影響を少なくして）鉄損Ｐｃｖを低下させることができることが理解される。 From Table 11, the larger the first mixing ratio, that is, by reducing the degree of mixing the magnetic powder made of amorphous magnetic material powder into the powder core made of CIP, the magnetic powder becomes more effective (others It is understood that the iron loss Pcv can be reduced (with less influence on the magnetic properties).
本発明の圧粉コアを用いた電気・電子部品は、ハイブリッド自動車等の昇圧回路や、発電、変電設備に用いられるリアクトル、トランスやチョークコイル等として好適に使用されうる。 The electric / electronic component using the dust core of the present invention can be suitably used as a booster circuit for a hybrid vehicle or the like, a reactor, a transformer, a choke coil, or the like used for power generation or substation facilities.
１…圧粉コア（トロイダルコア）
１０…トロイダルコイル
２…被覆導電線
２ａ…コイル
２ｂ，２ｃ…露出端部
２ｄ，２ｅ…コイル２ａの端部
２０…インダクタンス素子
３…圧粉コア
３ａ…圧粉コア３の実装面
３ｂ，３ｃ…圧粉コア３の側面
４…端子部
５…コイル
５ａ…コイル５の巻回部
５ｂ…コイル５の引出端部
３０…収納凹部
４０…接続端部
４２ａ…第１曲折部
４２ｂ…第２曲折部
１００…実装基板
１１０…ランド部
１２０…半田層
２００…スプレードライヤー装置
２０１…回転子
Ｓ…スラリー
Ｐ…造粒粉
1 ... Compact core (toroidal core)
DESCRIPTION OF SYMBOLS 10 ... Toroidal coil 2 ... Coated conductive wire 2a ... Coils 2b, 2c ... Exposed end part 2d, 2e ... End part 20 of coil 2a ... Inductance element 3 ... Powder core 3a ... Mounting surface 3b, 3c of powder core 3 ... Side surface 4 of dust core 3 ... Terminal portion 5 ... Coil 5a ... Winding portion 5b of coil 5 ... Pull-out end 30 of coil 5 ... Storage recess 40 ... Connection end 42a ... First bent portion 42b ... Second bent portion DESCRIPTION OF SYMBOLS 100 ... Mounting board 110 ... Land part 120 ... Solder layer 200 ... Spray dryer apparatus 201 ... Rotor S ... Slurry P ... Granulated powder
Claims (15)
前記結晶質磁性材料の粉末の含有量と前記非晶質磁性材料の粉末の含有量との総和に対する前記結晶質磁性材料の粉末の含有量の質量比率である第一混合比率が、７５質量％以上９５質量％以下であることを特徴とする圧粉コア。 A powder core containing a powder of crystalline magnetic material and a powder of amorphous magnetic material,
The first mixing ratio, which is a mass ratio of the content of the crystalline magnetic material powder to the sum of the content of the crystalline magnetic material powder and the content of the amorphous magnetic material powder, is 75% by mass. A dust core characterized by being 95% by mass or less.
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2015171074A JP2018170304A (en) | 2015-08-31 | 2015-08-31 | Dust core, method of producing the dust core, electrical/electronic component including the dust core, and electrical/electronic equipment including the electrical/electronic component mounted thereon |
| TW105120204A TW201712699A (en) | 2015-08-31 | 2016-06-27 | Dust core, method for producing said dust core, electric/electronic component provided with said dust core, and electric/electronic device on which said electric/electronic component is mounted |
| PCT/JP2016/071488 WO2017038295A1 (en) | 2015-08-31 | 2016-07-22 | Dust core, method for producing said dust core, electric/electronic component provided with said dust core, and electric/electronic device on which said electric/electronic component is mounted |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2015171074A JP2018170304A (en) | 2015-08-31 | 2015-08-31 | Dust core, method of producing the dust core, electrical/electronic component including the dust core, and electrical/electronic equipment including the electrical/electronic component mounted thereon |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JP2018170304A true JP2018170304A (en) | 2018-11-01 |
Family
ID=58187237
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2015171074A Pending JP2018170304A (en) | 2015-08-31 | 2015-08-31 | Dust core, method of producing the dust core, electrical/electronic component including the dust core, and electrical/electronic equipment including the electrical/electronic component mounted thereon |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JP2018170304A (en) |
| TW (1) | TW201712699A (en) |
| WO (1) | WO2017038295A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2021039967A (en) * | 2019-08-30 | 2021-03-11 | 太陽誘電株式会社 | Coil component and manufacturing method thereof |
| WO2023149454A1 (en) * | 2022-02-07 | 2023-08-10 | パナソニックＩｐマネジメント株式会社 | Magnetic resin composition, magnetic sheet, and inductor component |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109979740A (en) * | 2018-12-24 | 2019-07-05 | 海安南京大学高新技术研究院 | Low-loss iron sial metal magnetic powder core insulating coating method |
| CN111370214A (en) * | 2019-11-20 | 2020-07-03 | 横店集团东磁股份有限公司 | Method for preparing magnetic powder core from alloy composite powder |
| CN113192716B (en) * | 2021-04-29 | 2022-09-06 | 深圳顺络电子股份有限公司 | Soft magnetic alloy material and preparation method thereof |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2004197218A (en) * | 2002-11-22 | 2004-07-15 | Toko Inc | Composite magnetic material, core using the same, and magnetic element |
| JP2005294458A (en) * | 2004-03-31 | 2005-10-20 | Nec Tokin Corp | High-frequency composite magnetic powder material, high-frequency dust core and method for manufacturing the same |
| JP5063861B2 (en) * | 2005-02-23 | 2012-10-31 | 戸田工業株式会社 | Composite dust core and manufacturing method thereof |
| JP2007134381A (en) * | 2005-11-08 | 2007-05-31 | Nec Tokin Corp | Composite magnetic material, dust core using the same, and magnetic element |
| JP5288405B2 (en) * | 2008-11-13 | 2013-09-11 | Ｎｅｃトーキン株式会社 | Inductor and method of manufacturing inductor |
-
2015
- 2015-08-31 JP JP2015171074A patent/JP2018170304A/en active Pending
-
2016
- 2016-06-27 TW TW105120204A patent/TW201712699A/en unknown
- 2016-07-22 WO PCT/JP2016/071488 patent/WO2017038295A1/en active Application Filing
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2021039967A (en) * | 2019-08-30 | 2021-03-11 | 太陽誘電株式会社 | Coil component and manufacturing method thereof |
| JP7374669B2 (en) | 2019-08-30 | 2023-11-07 | 太陽誘電株式会社 | Coil parts and their manufacturing method |
| WO2023149454A1 (en) * | 2022-02-07 | 2023-08-10 | パナソニックＩｐマネジメント株式会社 | Magnetic resin composition, magnetic sheet, and inductor component |
Also Published As
| Publication number | Publication date |
|---|---|
| TW201712699A (en) | 2017-04-01 |
| WO2017038295A1 (en) | 2017-03-09 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| JP6513458B2 (en) | Dust core, method of manufacturing the dust core, electronic / electrical component comprising the dust core, and electronic / electrical device on which the electronic / electrical component is mounted | |
| JP6393345B2 (en) | Dust core, method for producing the dust core, electric / electronic component including the dust core, and electric / electronic device on which the electric / electronic component is mounted | |
| WO2017038295A1 (en) | Dust core, method for producing said dust core, electric/electronic component provided with said dust core, and electric/electronic device on which said electric/electronic component is mounted | |
| WO2016185940A1 (en) | Dust core, method for producing said dust core, inductor provided with said dust core, and electronic/electrical device on which said inductor is mounted | |
| KR102104701B1 (en) | Compressed powder core, method of manufacturing the compressed powder core, inductor comprising the compressed powder core and electronic-electric device mounted with the inductor | |
| JP2017108098A (en) | Dust core, method of producing dust core, inductor including dust core, and electronic/electrical apparatus mounting inductor | |
| CN105304259B (en) | Compressed-core and its manufacture method, electronic and electric components and electronic electric equipment | |
| JP2017041507A (en) | Dust core and electronic/electric component having the dust core, and electronic/electric equipment on which the electronic/electric component is mounted | |
| US20170309387A1 (en) | Powder core, manufacturing method of powder core, inductor including powder core, and electronic/electric device having inductor mounted therein | |
| WO2018207521A1 (en) | Dust core, method for producing said dust core, inductor provided with said dust core, and electronic/electrical device on which said inductor is mounted | |
| JP6035490B2 (en) | Compact core, electrical / electronic components and electrical / electronic equipment | |
| KR102069475B1 (en) | Green powder core, the manufacturing method of the green powder core, the electrical / electronic component provided with this powder core, and the electrical / electronic device in which the electrical / electronic component was mounted. | |
| JP6093941B2 (en) | Compact core, electrical / electronic components and electrical / electronic equipment | |
| WO2019044698A1 (en) | Dust core, method for producing said dust core, electrical/electronic component provided with said dust core, and electrical/electronic device equipped with said electrical/electronic component | |
| JP6326185B1 (en) | Dust core, method for producing the dust core, electric / electronic component including the dust core, and electric / electronic device on which the electric / electronic component is mounted | |
| JP7152504B2 (en) | Compacted core, method for manufacturing the compacted core, inductor provided with the compacted core, and electronic/electrical device mounted with the inductor | |
| JP6944313B2 (en) | Magnetic powder, powder core, inductor, and electronic and electrical equipment | |
| WO2017221475A1 (en) | Magnetic powder, powder mixture, dust core, method for producing dust core, inductor, and electronic/electrical device |