JP4816444B2

JP4816444B2 - SOFT MAGNETIC MAGNETIC MEMBER, SOFT MAGNETIC MAGNETIC MEMBER LAMINATE AND METHOD FOR PRODUCING THEM

Info

Publication number: JP4816444B2
Application number: JP2006348297A
Authority: JP
Inventors: 政行梨木; 高広左右木; 哲也青木; 洋彦辰本
Original assignee: Denso Corp
Current assignee: Denso Corp
Priority date: 2006-12-25
Filing date: 2006-12-25
Publication date: 2011-11-16
Anticipated expiration: 2026-12-25
Also published as: JP2008159926A

Description

本発明は、回転電機や静止形磁気機器に採用される電磁鋼板やそれを積層してなる積層体などの軟磁性磁気部材に関し、特に低渦電流損特性を有する軟磁性磁気部材及びその製造方法に関する。 TECHNICAL FIELD The present invention relates to a soft magnetic magnetic member such as a magnetic steel sheet employed in a rotating electrical machine or a stationary magnetic device and a laminate formed by laminating the same, and in particular, a soft magnetic magnetic member having low eddy current loss characteristics and a method for manufacturing the same. About.

回転電機や静止形磁気機器の発熱低減と効率向上のため、その磁気回路を構成する軟磁性磁気部材の渦電流損の低減が要求されており、特に高周波電力が給電される場合にその必要性は深刻となる。たとえば、下記の特許文献１は、この種の絶縁被膜付きの電磁鋼板の製造方法を記載している。 In order to reduce the heat generation and improve the efficiency of rotating electrical machines and stationary magnetic equipment, it is required to reduce the eddy current loss of the soft magnetic magnetic members that make up the magnetic circuit, especially when high-frequency power is supplied. Will be serious. For example, Patent Document 1 below describes a method for manufacturing this type of electrical steel sheet with an insulating coating.

このため、従来、表面に絶縁被膜剤を塗布し、焼き付け処理が施された絶縁被膜付きの電磁鋼板を積層して使用している。更に高周波用途では、種々の軟磁性粉末混入の樹脂成形品などを用いたりしている。たとえば、下記の特許文献２は、この種の軟磁性粉末混入樹脂成形品（以下、ダストコア又は圧粉コアとも言う）を記載している。 For this reason, conventionally, an electromagnetic steel sheet with an insulating coating coated with an insulating coating agent on the surface and subjected to a baking process is laminated and used. Furthermore, for high frequency applications, resin molded products mixed with various soft magnetic powders are used. For example, Patent Document 2 below describes this type of soft magnetic powder-containing resin molded product (hereinafter also referred to as a dust core or a powder core).

電磁鋼板に被着される絶縁被膜の製造方法としては各種の方法が従来より用いられている。一般に、リン酸塩又はクロム酸塩を主成分とする無機系被膜剤を塗布するのが主流であるが、クロム酸塩をベースとして有機樹脂を添加配合する無機−有機系の塗布剤を用いたり、全量有機成分系の塗布剤を用いる場合もある。これらの塗布剤は塗布後に加熱（焼き付き）処理されるのが通常である。また、上記の絶縁被膜は単に電磁鋼板間の電気絶縁に加えて、積層電磁鋼板を加熱しつつ圧縮する熱圧着工程により電磁鋼板間の接着機能も奏している。 Various methods have been conventionally used as a method for producing an insulating coating to be applied to an electromagnetic steel sheet. In general, it is the mainstream to apply an inorganic coating agent mainly composed of phosphate or chromate, but an inorganic-organic coating agent in which an organic resin is added and blended based on chromate is used. In some cases, an organic component-based coating agent may be used. These coating agents are usually heated (baked in) after coating. In addition to the electrical insulation between the electromagnetic steel sheets, the insulating coating also exhibits an adhesion function between the electromagnetic steel sheets by a thermocompression bonding process in which the laminated electromagnetic steel sheets are compressed while being heated.

このような用途には、たとえば潜在性硬化剤を配合したアクリル変成エポキシ樹脂エマルジョンを主成分とする混合液を塗布し、不完全に焼きつけることを特徴とする接着用表面被覆電磁鋼板の製造方法(特許文献３）を採用することが好適である。また、電磁鋼板の代わりに非晶質合金薄帯の積層板(特許文献４)を作製する場合に、この非晶質合金薄帯に耐熱性接着剤を塗布して積層すれば、350℃以上の高温の磁場中焼鈍を行っても接着能が低下しないことも知られている。 For such an application, for example, a mixed liquid mainly composed of an acrylic modified epoxy resin emulsion blended with a latent curing agent is applied and burned incompletely. It is preferable to employ Patent Document 3). Further, when an amorphous alloy ribbon laminated plate (Patent Document 4) is produced instead of the electromagnetic steel sheet, if the amorphous alloy ribbon is laminated by applying a heat-resistant adhesive, it is 350 ° C. or higher. It is also known that the bonding ability does not decrease even if annealing is performed in a high temperature magnetic field.

更に、下記の特許文献５は、熱可塑性シロキサンポリマーを主成分とする耐熱樹脂皮膜を塗布し、焼き付けることを提案している。この耐熱樹脂皮膜は、良好な耐熱性をもつため樹脂皮膜の被着後に歪取り燒鈍（650℃以上850℃）を行ってもその接着状態及び電気絶縁性を保持できるとされている。無機ポリマーは、M(金属又は半金属)-O(酸素)-Mの無機結合で主骨格が構成されているポリマーである。MがSiの場合、Si-O結合をシロキサン結合と言う。なお、特許文献５で言うシロキサンポリマーとは無機成分がSiとOのみから成るポリマーを意味であり、特許文献５は、ある種のシロキサンポリマーが電磁鋼板塗布剤に好適な良好な熱可塑性を有することを記載している。
特開平５−６５６６３号公報特開平６−１７６９４６号公報特許第2613725号公報国際公開WO 86/05314号公報特開２００６−５４２４４号公報（Ｐ２００６−５４２４４Ａ） Furthermore, the following patent document 5 proposes to apply and bake a heat-resistant resin film mainly composed of a thermoplastic siloxane polymer. Since this heat-resistant resin film has good heat resistance, it is said that even if it is subjected to strain relief (650 ° C. or higher and 850 ° C.) after the resin film is applied, its adhesive state and electrical insulation can be maintained. The inorganic polymer is a polymer in which a main skeleton is constituted by inorganic bonds of M (metal or semimetal) -O (oxygen) -M. When M is Si, the Si—O bond is called a siloxane bond. In addition, the siloxane polymer referred to in Patent Document 5 means a polymer whose inorganic components are composed only of Si and O, and Patent Document 5 describes that a certain siloxane polymer has good thermoplasticity suitable for a magnetic steel sheet coating agent. It is described.
JP-A-5-65663 JP-A-6-176946 Japanese Patent No. 2613725 International Publication WO 86/05314 JP 2006-54244 A (P2006-54244A)

しかしながら、上記した電磁鋼板の渦電流損は比較的大きく、特に給電電力の周波数増大を図ると渦電流損が急増するという欠点があった。このため、その厚さ低減が図られているがそれには限界があり、かつ、電磁鋼板の厚さ低減による渦電流損低減効果にも限界があった。その他、磁気回路を３次元的に形成する必要がある場合においては積層電磁鋼板の厚さ方向に磁束が流さざるを得ないため、渦電流損が急増するという問題もあった。 However, the above-mentioned electrical steel sheet has a relatively large eddy current loss, and particularly has a drawback that the eddy current loss increases rapidly when the frequency of the feed power is increased. For this reason, although the thickness is reduced, there is a limit to this, and the eddy current loss reduction effect by reducing the thickness of the electromagnetic steel sheet is also limited. In addition, when it is necessary to form the magnetic circuit three-dimensionally, there is a problem that eddy current loss increases rapidly because magnetic flux must flow in the thickness direction of the laminated electrical steel sheet.

これに対して、圧粉コアは、積層電磁鋼板に比べて渦電流損を格段に低減でき、磁束を３次元的に流しても渦電流損の急増を回避できるものの、その透磁率及び磁束飽和密度が電磁鋼板に比べて格段に小さいため、同じ出力を得るため機器体格が大幅に増大する欠点、更には電磁鋼板に比べて製造工程が格段に複雑であり、高コストとなるという問題などがあった。更に、磁気特性改善のための７００〜８００℃の温度域での歪取り焼鈍工程の実施が困難であるという問題もあった。 On the other hand, the dust core can remarkably reduce eddy current loss as compared with laminated magnetic steel sheets, and can avoid a sudden increase in eddy current loss even when a magnetic flux is flowed three-dimensionally. Since the density is much smaller than electromagnetic steel sheets, there is a drawback that the equipment size is greatly increased to obtain the same output, and further, the manufacturing process is much more complicated than electromagnetic steel sheets and the cost is high. there were. Furthermore, there is a problem that it is difficult to carry out the strain relief annealing process in the temperature range of 700 to 800 ° C. for improving the magnetic characteristics.

本発明は上記問題点に鑑みなされたものであり、従来の積層電磁鋼板製の軟磁性磁気部材よりも格段に渦電流損が小さく、かつ、従来の圧粉コアよりも格段に低コストで軟磁性磁気部材としての実用性に優れた軟磁性磁気部材、軟磁性磁気部材の積層体及びそれらの製造方法を提供することをその目的としている。 The present invention has been made in view of the above problems, and has an eddy current loss much smaller than that of a soft magnetic magnetic member made of a conventional laminated electrical steel sheet, and is softer at a much lower cost than a conventional dust core. It is an object of the present invention to provide a soft magnetic magnetic member having excellent practicality as a magnetic magnetic member, a laminate of soft magnetic magnetic members, and a method for producing them.

上記課題を解決する第１の発明は、軟磁性金属材料を素材として板状に形成される軟磁性磁気部材において、軟磁性金属材料からなるとともに板厚方向と直角な第１の配列方向へ所定ピッチで互いに平行に配列されかつ、前記板厚方向と直角な第２の配列方向へ配列されてなる多数の軟磁性細片部と、前記軟磁性細片部の表面に被着乃至形成されて前記各軟磁性細片部間の電気抵抗値を増大させる無機系絶縁膜とを有し、前記軟磁性細片部は、前記絶縁膜を介して互いに機械的に結合されて板状に成形されており、前記絶縁膜は、互いに隣接する前記軟磁性細片部の間に位置して前記第１の配列方向及び前記第２の配列方向へそれぞれ所定ピッチで配列されていることを特徴としている。 First invention for solving the above-mentioned problems, a soft magnetic metal material in soft magnetic member formed in a plate shape as a material, the first arrangement direction perpendicular to the thickness direction together when made of a soft magnetic metal material A plurality of soft magnetic strips arranged in parallel to each other at a predetermined pitch and arranged in a second arrangement direction perpendicular to the plate thickness direction, and attached to or formed on the surface of the soft magnetic strips And an inorganic insulating film that increases an electrical resistance value between the soft magnetic strip portions, and the soft magnetic strip portions are mechanically coupled to each other through the insulating film and formed into a plate shape. The insulating film is located between the soft magnetic strip portions adjacent to each other, and is arranged at a predetermined pitch in each of the first arrangement direction and the second arrangement direction. Yes.

すなわち、この発明の軟磁性細片部は、板厚方向と略直角な２方向へ軟磁性板を分断して形成され、６つの平面を有する立体形状（たとえばサイコロ形状）をもつ。このようにすれば三次元空間のいずれの方向への磁束に対しても良好な渦電流損低減効果を奏することができる。 That is, the soft magnetic strip portion of the present invention is formed by dividing the soft magnetic plate in two directions substantially perpendicular to the plate thickness direction, and has a three-dimensional shape (for example, a dice shape) having six planes. In this way, a good eddy current loss reduction effect can be achieved with respect to the magnetic flux in any direction of the three-dimensional space.

なお、好適には各軟磁性細片部の板厚方向と直角な面にも従来同様の絶縁被膜が設けられ、この絶縁被膜は、上記切断面に設けられる絶縁被膜と同工程にて形成されることが好適である。また、各軟磁性細片部同士は、上記絶縁被膜により接着することが好適であるが、他の機械的な結合手段を採用してもよい。絶縁被膜としては、上記した従来の電磁鋼板に採用される絶縁被膜を採用することができる。なお、軟磁性細片部の幅及び長さは自由であり、一つの軟磁性細片部をテープ状に形成したり、サイコロ状に形成したりすることができる。前者は後者に比べて一方向の磁気特性を改善でき、後者は前者に比べて三次元の各方向における渦電流損低減効果を向上できる。絶縁被膜は、軟磁性細片部の焼鈍前に行ってもよく、焼鈍後に行っても良い。また、軟磁性板から軟磁性細片部を形成した後、焼鈍を実施しなくても良く、軟磁性細片部形成前の軟磁性板を焼鈍してもよい。 Preferably, an insulating coating similar to the conventional one is also provided on the surface perpendicular to the plate thickness direction of each soft magnetic strip, and this insulating coating is formed in the same process as the insulating coating provided on the cut surface. Is preferable. Moreover, although it is suitable for each soft-magnetic strip part to adhere | attach with the said insulating film, you may employ | adopt another mechanical coupling | bonding means. As an insulating film, the insulating film employ | adopted as the above-mentioned conventional electromagnetic steel plate can be employ | adopted. In addition, the width | variety and length of a soft-magnetic strip part are free, and one soft-magnetic strip part can be formed in tape shape, or can be formed in dice shape. The former can improve the magnetic characteristics in one direction compared to the latter, and the latter can improve the effect of reducing eddy current loss in each of the three-dimensional directions compared to the former. The insulating coating may be performed before or after annealing the soft magnetic strip portion. Further, after forming the soft magnetic strip portion from the soft magnetic plate, annealing may not be performed, and the soft magnetic plate before forming the soft magnetic strip portion may be annealed.

本発明によれば、従来の電磁鋼板に比べてその板厚方向への交番磁束に対する渦電流損低減効果を大幅に向上することができるうえ、従来の電磁鋼板に比べてその板厚方向と直角方向へ交番磁束を流す場合にも渦電流回路の電気抵抗値を増大できるため渦電流損を低減することができる。 According to the present invention, the effect of reducing the eddy current loss with respect to the alternating magnetic flux in the thickness direction can be greatly improved as compared with the conventional electromagnetic steel sheet, and the perpendicular direction to the thickness direction compared with the conventional electromagnetic steel sheet. Even when alternating magnetic flux flows in the direction, the eddy current loss can be reduced because the electrical resistance value of the eddy current circuit can be increased.

好適な態様において、前記第１の配列方向及び第２の配列方向は、互いに直交している。このようにすれば、製造及びその後の必要形状の軟磁性磁気部材の作製が容易となる。 In a preferred aspect, the first arrangement direction and the second arrangement direction are orthogonal to each other. If it does in this way, manufacture and manufacture of the soft magnetic member of a required shape after that become easy.

第２の発明は、軟磁性金属材料を素材として板状に形成される軟磁性磁気部材の製造方法であって、前記軟磁性磁気部材は、軟磁性金属材料からなるとともに少なくとも板厚方向と直角な所定の配列方向へ所定ピッチで配列してなる多数の軟磁性細片部と、前記軟磁性細片部の表面に被着乃至形成されて前記各軟磁性細片部間の電気抵抗値を増大させる無機系絶縁膜と、を有し、前記軟磁性細片部は、前記絶縁膜を介して互いに機械的に結合されて板状に成形されており、長尺形状にそれぞれ形成されて前記板厚方向及び前記配列方向に対して直角の延在方向へそれぞれ延在しているものであり、電磁鋼板を所定幅に切断して帯状の前記軟磁性細片部を形成する第１工程と、前記帯状の軟磁性細片部の少なくとも切断面に前記絶縁膜を被着乃至形成する第２工程と、多数の前記帯状の軟磁性細片部を前記絶縁膜を介して互いに機械的に結合する第３工程と、を有し、前記電磁鋼板を所定幅に切断して形成された前記帯状の軟磁性細片部は、隣接する前記帯状の軟磁性細片部に対して板厚方向へ相対的に所定距離だけ変位させた後、前記絶縁膜の被着乃至形成を行ってから前記変位を解消させ、しかるのち前記機械的結合を行う。このようにすれば、連続工程により優れた生産性にて本発明の軟磁性磁気部材を製造することができる。 A second invention is a method of manufacturing a soft magnetic magnetic member formed in a plate shape from a soft magnetic metal material, wherein the soft magnetic magnetic member is made of a soft magnetic metal material and at least perpendicular to the plate thickness direction. A plurality of soft magnetic strips arranged at a predetermined pitch in a predetermined arrangement direction, and an electric resistance value between the soft magnetic strips formed on the surface of the soft magnetic strips. An inorganic insulating film to be increased, and the soft magnetic strip portions are mechanically coupled to each other through the insulating film and formed into a plate shape, each formed in a long shape, and A first step that extends in a plate thickness direction and an extending direction perpendicular to the arrangement direction, and cuts the electromagnetic steel sheet into a predetermined width to form the strip-shaped soft magnetic strip portion; The insulating film is deposited on at least the cut surface of the strip-shaped soft magnetic strip. And a second step of forming a third step of mechanically coupled together soft magnetic strip of a number of the strip through the insulating film, and formed by cutting the magnetic steel sheets to a predetermined width The strip-shaped soft magnetic strip portion is displaced by a predetermined distance relative to the adjacent strip-shaped soft magnetic strip portion in the thickness direction, and then the insulating film is deposited or formed. After that, the displacement is canceled, and then the mechanical coupling is performed. In this way, the soft magnetic magnetic member of the present invention can be manufactured with excellent productivity by a continuous process.

第３の発明は、軟磁性金属材料を素材として板状に形成される軟磁性磁気部材の製造方法であって、前記軟磁性磁気部材は、軟磁性金属材料からなるとともに少なくとも板厚方向と直角な所定の配列方向へ所定ピッチで配列してなる多数の軟磁性細片部と、前記軟磁性細片部の表面に被着乃至形成されて前記各軟磁性細片部間の電気抵抗値を増大させる無機系絶縁膜と、を有し、前記軟磁性細片部は、前記絶縁膜を介して互いに機械的に結合されて板状に成形されており、長尺形状にそれぞれ形成されて前記板厚方向及び前記配列方向に対して直角の延在方向へそれぞれ延在しているものであり、長尺の電磁鋼板を所定の搬送方向に搬送するとともに、搬送方向上流部にて、前記電磁鋼板を所定幅切断して帯状の軟磁性細片部を形成する第１工程を行い、搬送方向中流部にて、前記帯状の軟磁性細片部の少なくとも切断面に前記絶縁膜を被着乃至形成する第２工程を行い、搬送方向下流部にて、多数の前記帯状の軟磁性細片部を前記絶縁膜を介して互いに機械的に結合する第３工程を行う軟磁性磁気部材の製造方法において、前記長尺の電磁鋼板（テープ状の軟磁性板を含む）の前記搬送方向への移動につれて前記電磁鋼板を前記搬送方向へ切り裂くことにより前記軟磁性細片部を帯状に形成する。このようにすれば、切断による軟磁性細片部の形成を容易に行うことができる。 A third invention is a method for producing a soft magnetic magnetic member formed in a plate shape from a soft magnetic metal material, wherein the soft magnetic magnetic member is made of a soft magnetic metal material and at least perpendicular to the thickness direction. A plurality of soft magnetic strips arranged at a predetermined pitch in a predetermined arrangement direction, and an electric resistance value between the soft magnetic strips formed on the surface of the soft magnetic strips. An inorganic insulating film to be increased, and the soft magnetic strip portions are mechanically coupled to each other through the insulating film and formed into a plate shape, each formed in a long shape, and It extends in the plate thickness direction and the extending direction perpendicular to the arrangement direction, and conveys a long electromagnetic steel sheet in a predetermined conveying direction, and at the upstream portion in the conveying direction, the electromagnetic 1st which cuts a steel plate by predetermined width and forms a strip-shaped soft-magnetic strip part The second step of depositing or forming the insulating film on at least the cut surface of the strip-shaped soft magnetic strip portion at the midstream portion in the transport direction is performed, and a number of the strip-shaped portions are formed at the downstream portion in the transport direction In the method of manufacturing a soft magnetic member that performs the third step of mechanically coupling the soft magnetic strips of each other through the insulating film, the long electromagnetic steel plate (including the tape-shaped soft magnetic plate) As the movement in the conveyance direction, the magnetic steel sheet is cut in the conveyance direction to form the soft magnetic strip portion in a strip shape. In this way, it is possible to easily form the soft magnetic strip portion by cutting.

第４の発明は、軟磁性金属材料からなるとともに少なくとも板厚方向と直角な所定の配列方向へ所定ピッチで配列してなる多数の軟磁性細片部と、前記軟磁性細片部の表面に被着乃至形成されて前記各軟磁性細片部間の電気抵抗値を増大させる無機系絶縁膜と、を有し、前記軟磁性細片部が、前記絶縁膜を介して互いに機械的に結合されて形成された板状の軟磁性磁気部材を多数、板厚方向に積層してなる軟磁性磁気部材の積層体を形成する。このようにして形成された軟磁性磁気部材の積層体は、従来の積層電磁鋼板に比べて、その板厚方向への交番磁束に対する渦電流損低減効果を大幅に向上することができるうえ、板厚方向と直角方向へ交番磁束を流す場合にも渦電流回路の電気抵抗値を増大できるため渦電流損を低減することができる。 According to a fourth aspect of the present invention, there are provided a plurality of soft magnetic strip portions made of a soft magnetic metal material and arranged at a predetermined pitch in a predetermined arrangement direction perpendicular to the plate thickness direction, and on the surface of the soft magnetic strip portion. An inorganic insulating film that is deposited or formed to increase the electrical resistance between the soft magnetic strip portions, and the soft magnetic strip portions are mechanically coupled to each other through the insulating film. the soft magnetic member is formed plate-shaped with a large number to form a stack of formed by laminating a thickness direction soft magnetic member. The laminated body of soft magnetic members formed in this way can greatly improve the effect of reducing eddy current loss with respect to the alternating magnetic flux in the thickness direction compared to conventional laminated electromagnetic steel sheets. Even when alternating magnetic flux flows in the direction perpendicular to the thickness direction, the eddy current loss can be reduced because the electric resistance value of the eddy current circuit can be increased.

好適な態様において、積層される２枚の前記板状の軟磁性磁気部材の前記絶縁膜は互いに異なる方向に延在する。つまり、この態様では、積層される２枚の軟磁性磁気部材の軟磁性細片部は、異なる方向に延在する。このようにすれば、低磁束量においては、磁束方向に絶縁膜が配置されない板状の軟磁性磁気部材を磁束が流れるようにすることにより、積層体の磁気抵抗を低減することができるとともに、磁束量が増大しても各方向における平均の磁気抵抗を低減することができる。更に、積層体の各方向への強度も向上することができる。 In a preferred embodiment, the insulating films of the two laminated plate-like soft magnetic members extend in different directions. That is, in this aspect, the soft magnetic strips of the two soft magnetic members to be stacked extend in different directions. In this way, at a low magnetic flux amount, the magnetic resistance of the laminate can be reduced by allowing the magnetic flux to flow through a plate-like soft magnetic magnetic member in which no insulating film is arranged in the magnetic flux direction. Even if the amount of magnetic flux increases, the average magnetic resistance in each direction can be reduced. Furthermore, the strength in each direction of the laminate can also be improved.

好適な態様において、前記２枚の板状の軟磁性磁気部材のうちの少なくとも一方の前記絶縁膜の延在方向は、ほぼ磁束通過方向に設定される。このようにすれば、磁束通過方向の磁気抵抗を低減しつつ、積層体の機械的強度も向上することができる。 In a preferred aspect, the extending direction of the insulating film of at least one of the two plate-like soft magnetic members is set substantially in the magnetic flux passing direction. If it does in this way, the mechanical strength of a layered product can also be improved, reducing the magnetic resistance of a magnetic flux passage direction.

好適な態様において、前記２枚の板状の軟磁性磁気部材の前記絶縁膜の延在方向は、互いに直交する。このようにすれば、三次元の各方向への磁気抵抗及び渦電流損を低減できるとともに、機械的強度も向上することができる。 In a preferred embodiment, the extending directions of the insulating films of the two plate-like soft magnetic members are orthogonal to each other. In this way, the magnetic resistance and eddy current loss in each of the three-dimensional directions can be reduced, and the mechanical strength can be improved.

好適な態様において、前記軟磁性磁気部材の積層体以外の軟磁性磁気部材と組み合わせられて磁気回路を構成する。このようにすれば、複雑な三次元形状の磁気回路を低渦電流損にて構成することができる。なお、この発明の軟磁性磁気部材の積層体以外の軟磁性磁気部材とは、たとえば圧粉コアや通常の積層電磁鋼板などを所望の要求に合わせて選択すればよい。 In a preferred embodiment, the magnetic circuit is configured by combining with a soft magnetic member other than the laminate of the soft magnetic members. In this way, a complicated three-dimensional magnetic circuit can be configured with low eddy current loss. In addition, what is necessary is just to select a powder magnetic core, a normal laminated electromagnetic steel plate, etc. according to a desired request | requirement as soft magnetic magnetic members other than the laminated body of the soft magnetic magnetic member of this invention, for example.

好適な態様において、軟磁性磁気部材の積層体は、電磁鋼板（軟磁性の非晶質合金テープでもよい）のごとき軟磁性磁気部材の積層体を所定幅に切断して帯状の前記軟磁性細片部の積層体を形成する第１工程と、前記帯状の軟磁性細片部の積層体の少なくとも切断面に前記絶縁膜を被着乃至形成する第２工程と、多数の前記帯状の軟磁性細片部の積層体を前記絶縁膜を介して互いに機械的に結合して前記軟磁性磁気部材の積層体を形成する第３工程とを有する。すなわち、この態様では、予め作製した軟磁性磁気部材の積層体を分断して上記と同様に軟磁性細片部の積層体を多数形成し、少なくとも分断面に絶縁膜を設けて軟磁性細片部の積層体同士を機械的に結合するため、生産性良く軟磁性磁気部材の積層体を製造することができる。 In a preferred embodiment, the laminated body of soft magnetic magnetic members is formed by cutting a laminated body of soft magnetic magnetic members such as electromagnetic steel plates (or soft magnetic amorphous alloy tapes) to a predetermined width. A first step of forming a laminate of pieces, a second step of depositing or forming the insulating film on at least a cut surface of the laminate of strip-like soft magnetic strips, and a number of the strip-like soft magnetism And a third step of mechanically coupling the laminated body of the thin piece portions to each other through the insulating film to form the laminated body of the soft magnetic magnetic members. In other words, in this embodiment, a soft magnetic magnetic member laminate prepared in advance is divided to form a large number of soft magnetic strip portions in the same manner as described above, and an insulating film is provided on at least a sectional surface to provide a soft magnetic strip. Therefore, the laminated body of soft magnetic members can be manufactured with high productivity.

好適な態様において、前記軟磁性磁気部材の積層体の前記切断面をその積層方向と直角方向へ形成する。これにより、切断回数を減らすことができる。 In a preferred embodiment, the cut surface of the laminate of the soft magnetic magnetic members is formed in a direction perpendicular to the lamination direction. Thereby, the frequency | count of cutting | disconnection can be reduced.

好適な態様において、多数の前記軟磁性磁気部材を所定の平面形状に順次切断し、切断された前記各軟磁性磁気部材を順次積層して所定の立体形状の軟磁性磁気部材の積層体を形成する。このようにすれば、切断が容易となる。 In a preferred embodiment, a large number of the soft magnetic magnetic members are sequentially cut into a predetermined planar shape, and the cut soft magnetic magnetic members are sequentially stacked to form a laminate of soft magnetic magnetic members having a predetermined three-dimensional shape. To do. In this way, cutting becomes easy.

本発明の軟磁性磁気部材、その積層体及びそれらの製造方法の好適実施形態を以下に説明する。ただし、本発明は下記の実施形態に限定解釈されるべきではなく、他の公知技術を組み合わせて本発明の技術思想を実現してもよいことはもちろんである。なお、以下の実施形態では、通常の電磁鋼板を素材として軟磁性磁気部材を作製する例を記載するが、通常の電磁鋼板に代えて軟鋼板や軟磁性のアモルファス合金シートなどを用いても良い。 Preferred embodiments of the soft magnetic member of the present invention, a laminate thereof, and a production method thereof will be described below. However, the present invention should not be construed as being limited to the following embodiments, and it goes without saying that the technical idea of the present invention may be realized by combining other known techniques. In the following embodiment, an example in which a soft magnetic magnetic member is produced using a normal electromagnetic steel sheet as a raw material is described. However, a soft steel sheet or a soft magnetic amorphous alloy sheet may be used instead of a normal electromagnetic steel sheet. .

（実施形態１）
実施形態１の軟磁性磁気部材及びその製造方法を以下に説明する。この軟磁性磁気部材は、従来の電磁鋼板同様、平板状に形成されている。もちろん、ハンドリングのためにこの板状の軟磁性磁気部材は、ロール状に巻き取られることができる。図１に示すこの軟磁性磁気部材の製造工程図を説明する。 (Embodiment 1)
The soft magnetic magnetic member and the manufacturing method thereof according to Embodiment 1 will be described below. This soft magnetic magnetic member is formed in a flat plate shape like a conventional electromagnetic steel plate. Of course, for handling, this plate-like soft magnetic member can be wound into a roll. A manufacturing process diagram of the soft magnetic magnetic member shown in FIG. 1 will be described.

まず電磁鋼板などの軟磁性の薄板（たとえば板厚０．５ｍｍ）１を準備する。この薄板１はロール状となっていても良い（工程a）。薄板１の表面には上記した絶縁被膜が被着されている。 First, a soft magnetic thin plate (for example, a plate thickness of 0.5 mm) 1 such as an electromagnetic steel plate is prepared. The thin plate 1 may be in the form of a roll (step a). The insulating coating described above is applied to the surface of the thin plate 1.

次に、この電磁鋼板の薄板１を長さ方向に所定ピッチ（たとえば１ｍｍピッチ）で幅方向に切断して多数の軟磁性細片部２を形成する（工程ｂ）。切断は、板厚方向に行われることが好適であるがそれに限定されるものではない。その後、各軟磁性細片部２の少なくとも切断面に絶縁膜を被着する。この絶縁膜は、上記した電磁鋼板の絶縁被膜と同じ方法で形成できる他、たとえば公知のCVD法やPVD法を用いて形成することができる。その他、樹脂液が充填された槽に軟磁性細片部２を浸漬し、乾燥させて樹脂絶縁膜を被着してもよい。 Next, the thin sheet 1 of the electromagnetic steel sheet is cut in the width direction at a predetermined pitch (for example, 1 mm pitch) in the length direction to form a large number of soft magnetic strip portions 2 (step b). The cutting is preferably performed in the thickness direction, but is not limited thereto. Thereafter, an insulating film is deposited on at least the cut surface of each soft magnetic strip portion 2. This insulating film can be formed by the same method as the above-described insulating coating of the electromagnetic steel sheet, or can be formed by using, for example, a known CVD method or PVD method. In addition, the soft magnetic strip portion 2 may be immersed in a tank filled with a resin liquid and dried to deposit the resin insulating film.

次に、各軟磁性細片部２を上記長さ方向へ並べてそれぞれ上記幅方向に延在させ、上記長さ方向へ熱圧着することにより、軟磁性磁気部材３を形成する（工程ｃ）。 Next, the soft magnetic strips 2 are arranged in the length direction, extend in the width direction, and are thermocompression bonded in the length direction to form the soft magnetic member 3 (step c).

このようにすれば、低渦電流損の軟磁性磁気部材を実現することができる。この軟磁性磁気部材は打ち抜きなどにより所定形状に形成された後、従来同様に板厚方向へ積層して所望形状の軟磁性磁気部材の積層体が形成される。 In this way, a soft magnetic magnetic member with low eddy current loss can be realized. The soft magnetic magnetic member is formed into a predetermined shape by punching or the like, and then laminated in the thickness direction as in the prior art to form a laminated body of soft magnetic magnetic members having a desired shape.

この実施形態の板状の軟磁性磁気部材３によれば、従来の電磁鋼板に比べてその板厚方向への交番磁束に対する渦電流損低減効果を大幅に向上することができるうえ、従来の電磁鋼板に比べてその板厚方向と直角方向へ交番磁束を流す場合にも渦電流回路の電気抵抗値を増大できるため渦電流損を低減することができる。絶縁膜として絶縁フィルムを採用することもできる。 According to the plate-like soft magnetic member 3 of this embodiment, the effect of reducing the eddy current loss with respect to the alternating magnetic flux in the plate thickness direction can be greatly improved as compared with the conventional electromagnetic steel plate, and the conventional electromagnetic Compared with a steel plate, the eddy current loss can be reduced because the electric resistance value of the eddy current circuit can be increased even when an alternating magnetic flux flows in a direction perpendicular to the plate thickness direction. An insulating film can also be employed as the insulating film.

なお、各軟磁性細片部は、上記した直線状の平行配列の他、折れ線状、波線状又はその他の曲線条に平行配列されることもでき、正方格子配列、市松配列などの種々の配列にて配列されることができ、更にそれらの組み合わせも自由である。その他、各軟磁性細片部を不等ピッチに配置してもよく、各軟磁性細片部間の境界線は互いに平行とならなくてもよい。上記した種々の軟磁性細片部配列方式のうちの一部の例を図２（a）〜（f）に示す。図２（a）〜（f）において破線は各軟磁性細片部の境界部を示す。 In addition to the above-described linear parallel arrangement, each soft magnetic strip portion can also be arranged in parallel with a polygonal line, a wavy line, or other curved lines, and various arrangements such as a square lattice arrangement, a checkered arrangement, etc. Further, combinations thereof are also free. In addition, the soft magnetic strip portions may be arranged at unequal pitches, and the boundary lines between the soft magnetic strip portions may not be parallel to each other. Some examples of the above-described various soft magnetic strip portion arrangement methods are shown in FIGS. 2A to 2F, the broken lines indicate the boundary portions of the soft magnetic strip portions.

（実施形態２）
実施形態２の軟磁性磁気部材及びその製造方法を以下に説明する。この軟磁性磁気部材は、従来の電磁鋼板同様、平板状に形成されている。もちろん、ハンドリングのためにこの板状の軟磁性磁気部材３は、ロール状に巻き取られることができる。この軟磁性磁気部材の模式斜視図を示す図３を参照して、この実施形態の軟磁性磁気部材を説明する。 (Embodiment 2)
The soft magnetic magnetic member and the manufacturing method thereof according to Embodiment 2 will be described below. This soft magnetic magnetic member is formed in a flat plate shape like a conventional electromagnetic steel plate. Of course, the plate-like soft magnetic member 3 can be wound up for handling. With reference to FIG. 3 showing a schematic perspective view of the soft magnetic member, the soft magnetic member of this embodiment will be described.

この軟磁性磁気部材３は、板厚方向に対して直角かつ互いに直角の２方向にそれぞれ所定ピッチで電磁鋼板を多数切断した多数のサイコロ状の軟磁性細片部２を形成した後、各軟磁性細片部２の少なくとも切断面に絶縁膜を形成し、その後、各軟磁性細片部２を熱圧着して平板状の軟磁性磁気部材を作製したものである。製造工程としては、図１に示す工程（ｂ）を切断方向を変えて２回連続して実施した他は、図１に示す実施形態１の製造工程と同じ方法にて製造することができる。 This soft magnetic member 3 is formed by forming a large number of dice-shaped soft magnetic strips 2 obtained by cutting a number of electromagnetic steel sheets at predetermined pitches in two directions perpendicular to the plate thickness direction and perpendicular to each other. An insulating film is formed on at least the cut surface of the magnetic strip portion 2, and then each soft magnetic strip portion 2 is thermocompression bonded to produce a flat soft magnetic member. As a manufacturing process, it can manufacture by the same method as the manufacturing process of Embodiment 1 shown in FIG. 1 except having implemented the process (b) shown in FIG. 1 twice continuously, changing the cutting direction.

図３において、４は一回目の切断方向を示し、５は２回目の切断方向を示す。なお、切断方向は、板厚方向に対して直角方向でなくてもよく、また、２つの切断方向４、５は互いに直角でなくてもよい。このようにすれば、低渦電流損の軟磁性磁気部材を作製することができる。 In FIG. 3, 4 indicates the first cutting direction, and 5 indicates the second cutting direction. The cutting direction may not be perpendicular to the plate thickness direction, and the two cutting directions 4 and 5 may not be perpendicular to each other. In this way, a soft magnetic magnetic member with low eddy current loss can be produced.

（実施形態３）
実施形態３の軟磁性磁気部材及びその製造方法を以下に説明する。この軟磁性磁気部材は、実施形態１の軟磁性磁気部材３の製造に好適である。この軟磁性磁気部材の製造工程を模式工程図である図４を参照して説明する。なお、電磁鋼板ではなく、その他の軟磁性板を用いても良いことは既述した通りである。 (Embodiment 3)
The soft magnetic magnetic member and the manufacturing method thereof according to Embodiment 3 will be described below. This soft magnetic member is suitable for manufacturing the soft magnetic member 3 of the first embodiment. The manufacturing process of this soft magnetic member will be described with reference to FIG. 4 which is a schematic process diagram. As described above, other soft magnetic plates may be used instead of electromagnetic steel plates.

製造装置は、長尺の電磁鋼板１００をその長手方向に搬送する搬送装置（図示せず）をもち、電磁鋼板は、搬送方向上流側から下流側へ長尺の電磁鋼板１００をインタバル移動させながら行われる。また、この製造装置は、切断装置６、ずらし装置（図示せず）、絶縁膜処理装置（図示せず）、ずらし解消装置（図示せず）、熱処理装置（図示せず）を搬送方向上流側から下流側へ順次有している。 The manufacturing apparatus has a conveying device (not shown) that conveys the long electromagnetic steel sheet 100 in the longitudinal direction, and the electromagnetic steel sheet moves the long electromagnetic steel sheet 100 in the interval from the upstream side to the downstream side in the conveying direction. Done. Further, this manufacturing apparatus includes a cutting device 6, a shift device (not shown), an insulating film processing device (not shown), a shift canceling device (not shown), and a heat treatment device (not shown) on the upstream side in the transport direction. Sequentially from downstream to downstream.

製造工程を説明すると、長尺の電磁鋼板１００は、切断装置６に投入されて幅方向所定ピッチに配列され搬送方向に長く延在する多数のテープ状の軟磁性細片部２に切断される（第１工程）。切断装置６から出た各軟磁性細片部２は、互いに隣接する２枚の軟磁性細片部２が板厚方向に板厚よりも大きくずれるようにずらされる。好適には、すべての軟磁性細片部２が板厚方向においてそれぞれ異なる位置にまでずらされる。 Explaining the manufacturing process, the long electromagnetic steel sheet 100 is put into the cutting device 6 and cut into a number of tape-shaped soft magnetic strips 2 arranged in a predetermined pitch in the width direction and extending long in the conveying direction. (First step). Each soft magnetic strip portion 2 that has come out of the cutting device 6 is shifted so that two soft magnetic strip portions 2 adjacent to each other are displaced in the plate thickness direction to be larger than the plate thickness. Preferably, all the soft magnetic strip portions 2 are shifted to different positions in the thickness direction.

その後、各軟磁性細片部２は、絶縁膜処理装置に搬送され、ここで少なくとも切断面に、好適には全面に絶縁膜が被着される（第２工程）。絶縁膜の被着方法は既述した方法で行えばよい。各軟磁性細片部２がその板厚方向にずらされているため、各切断面への絶縁膜の被着が容易となっている。その後、各軟磁性細片部２は、再度板厚方向ずらし解消向きに付勢され、これにより、各軟磁性細片部２は同一平面上に並べられる。その後、軟磁性細片部２を加熱する。この時、絶縁膜は隣接する２枚の軟磁性細片部２を機械的に結合する（第３工程）。なお、この時、軟磁性細片部２の焼鈍を行っても良い。上記熱処理の後、冷却される板状の軟磁性磁気部材３が形成されるが、続いてこの板状の軟磁性磁気部材３を打ち抜くなどして必要な形状の軟磁性磁気部材が得られる。 Thereafter, each soft magnetic strip portion 2 is transferred to an insulating film processing apparatus, where an insulating film is deposited on at least the cut surface, preferably the entire surface (second step). The insulating film may be deposited by the method described above. Since each soft magnetic strip portion 2 is shifted in the plate thickness direction, it is easy to attach an insulating film to each cut surface. Thereafter, the soft magnetic strip portions 2 are again urged in the direction of canceling the shift in the plate thickness direction, whereby the soft magnetic strip portions 2 are arranged on the same plane. Thereafter, the soft magnetic strip 2 is heated. At this time, the insulating film mechanically couples the two adjacent soft magnetic strip portions 2 (third step). At this time, the soft magnetic strip portion 2 may be annealed. After the heat treatment, a plate-shaped soft magnetic magnetic member 3 to be cooled is formed. Subsequently, the plate-shaped soft magnetic magnetic member 3 is punched out to obtain a soft magnetic magnetic member having a necessary shape.

（変形態様）
なお、図４に示す切断装置６は、搬送方向上流側に向いた多数の細刃をもつことができる。このようにすれば、電磁鋼板１００を搬送方向下流側に搬送することにより、これら細刃が電磁鋼板１を切り裂いて多数の軟磁性細片部２を自動的に形成することができる。 (Modification)
Note that the cutting device 6 shown in FIG. 4 can have a large number of fine blades facing upstream in the transport direction. If it does in this way, by conveying the electromagnetic steel plate 100 to the conveyance direction downstream, these fine blades can cut the electromagnetic steel plate 1 and can form many soft-magnetic strip parts 2 automatically.

（変形態様）
また、図４において、熱処理装置の下流側に軟磁性磁気部材から必要な形状を打ち抜くプレス装置（加工装置）を設けてもよい。このようにすれば、最終製品形状加工をコンパクトな製造ラインで行うことができる。 (Modification)
In FIG. 4, a press device (processing device) for punching a necessary shape from the soft magnetic member may be provided on the downstream side of the heat treatment device. In this way, final product shape processing can be performed on a compact production line.

（変形態様）
図４において、熱処理装置で各軟磁性細片部２を一体化して形成された平板状の軟磁性磁気部材を所定長さに切断し、その後で軟磁性磁気部材の幅方向すなわち上記搬送方向と直角な第２の搬送方向に送りつつ、この第２の搬送方向に所定ピッチでこの第２の搬送方向に対して直角方向に切れ目を順次入れ、切れ目に絶縁膜を設け、更にこの切れ目が解消するように熱圧着することにより、サイコロ状の軟磁性細片部をもつ軟磁性磁気部材を形成することができる。 (Modification)
In FIG. 4, a flat soft magnetic member formed by integrating the soft magnetic strips 2 with a heat treatment apparatus is cut into a predetermined length, and then the width direction of the soft magnetic member, that is, the conveying direction is as follows. While feeding in a second transport direction perpendicular to the second transport direction, cuts are sequentially made at a predetermined pitch in the second transport direction in a direction perpendicular to the second transport direction, an insulating film is provided at the cut, and this break is further eliminated. Thus, a soft magnetic member having a dice-like soft magnetic strip portion can be formed by thermocompression bonding.

（変形態様）
長尺の電磁鋼板の所定部位特に渦電流損の低減が重要な部位にのみ上記した多数の軟磁性細片部２を形成し、電磁鋼板のそれ以外の部位には軟磁性細片部２を形成しないか又はそのピッチを大きく形成しても良い。 (Modification)
The above-mentioned many soft magnetic strips 2 are formed only in predetermined portions of the long electromagnetic steel sheet, particularly in regions where reduction of eddy current loss is important, and soft magnetic strips 2 are formed in other portions of the electromagnetic steel plate. You may not form or may form the pitch large.

（種々の切断方法の説明）
上記した軟磁性細片部２の切断において採用できる種々の切断方法を以下に説明する。 (Description of various cutting methods)
Various cutting methods that can be employed in cutting the soft magnetic strip portion 2 will be described below.

切断は、溝切りローラやシャーリングマシンや回転砥石などの切断装置を用いて軟磁性細片部２を一つずつ電磁鋼板から切り離す方法で行われても良く、あるいは切断用の金型を用いて一方向の切断作業あるいは上記２方向の切断作業を一挙に行ってもよい。その他、ウオータージェットやレーザー光のようなビームを用いて切断してもよい。このようなビームを用いた切断は、電磁鋼板の一部領域にのみ多数の軟磁性細片部２を形成するのに適している。 The cutting may be performed by a method of separating the soft magnetic strips 2 from the magnetic steel sheet one by one using a cutting device such as a grooving roller, a shearing machine, or a rotating grindstone, or using a cutting die. One-way cutting work or the two-way cutting work may be performed at once. In addition, you may cut | disconnect using beams, such as a water jet and a laser beam. Cutting using such a beam is suitable for forming a large number of soft magnetic strip portions 2 only in a partial region of the electromagnetic steel sheet.

上記した切断方法の一部の例を図５〜図８に図示する。図５は金型切断の例を示す。電磁鋼板１００は金型１０１により高速切断されて一挙に細片化される。図６は電磁鋼板１００を回転するディスク状の一対のスリッター１０２の間に押し込み、これにより電磁鋼板１００を切断する例を示す。高速切断が可能となる。図７はたとえば炭酸ガスレーザー１０３により切断する例を示す。切断形状の自由度が向上する。図８はウオータージェットにより切断する例を示す。熱的悪影響を防止することができる。その他、ワイヤカット法にて切断してもよい。 Some examples of the cutting method described above are shown in FIGS. FIG. 5 shows an example of die cutting. The electromagnetic steel sheet 100 is cut at a high speed by the mold 101 and is cut into pieces at once. FIG. 6 shows an example in which the electromagnetic steel sheet 100 is cut by pushing it between a pair of disk-shaped slitters 102 that rotate. High speed cutting is possible. FIG. 7 shows an example of cutting by the carbon dioxide laser 103, for example. The degree of freedom of the cutting shape is improved. FIG. 8 shows an example of cutting with a water jet. Thermal adverse effects can be prevented. In addition, you may cut | disconnect by a wire cut method.

（変形態様）
上記した軟磁性磁気部材の製造に際しては、長尺の電磁鋼板１００をその切断装置以降において各軟磁性細片部２を互いに完全分離したが、切断装置から出た各軟磁性細片部２の一部が互いに連結されているようにしてもよい。このようにすると、ハンドリングが容易となる。また、この各軟磁性細片部２を連結する部分は、軟磁性磁気部材３により形成される磁気回路中、渦電流損が比較的問題とならない部位に配置することが好適である。 (Modification)
In manufacturing the above-described soft magnetic member, the long magnetic steel sheet 100 is completely separated from each other in each of the soft magnetic strips 2 after the cutting device. Some may be connected to each other. In this way, handling becomes easy. Further, it is preferable that the portion connecting the soft magnetic strip portions 2 is disposed in a portion where the eddy current loss does not cause a problem in the magnetic circuit formed by the soft magnetic member 3.

（実施形態４）
実施形態４の軟磁性磁気部材及びその製造方法を図４を参照して以下に説明する。図９はこの軟磁性磁気部材の模式平面図である。 (Embodiment 4)
A soft magnetic magnetic member and a manufacturing method thereof according to Embodiment 4 will be described below with reference to FIG. FIG. 9 is a schematic plan view of this soft magnetic magnetic member.

この実施形態では、既述した電磁鋼板を切り裂いて形成した多数の軟磁性細片部の代わりに１本乃至複数本の長い軟磁性細線７を用いる。図９では、予め絶縁膜がその外周面に被着された１本の軟磁性細線を用いた例を示す。この軟磁性細線７は最終的に方形板となるようにスパイラル状に巻回された後、熱処理されて軟磁性細線７の各ターンが一体化されている。 In this embodiment, one or more long soft magnetic wires 7 are used in place of a large number of soft magnetic strip portions formed by cutting the magnetic steel sheet described above. FIG. 9 shows an example using a single soft magnetic wire in which an insulating film is previously deposited on the outer peripheral surface thereof. The soft magnetic wire 7 is spirally wound so as to finally become a rectangular plate, and then heat-treated to integrate the turns of the soft magnetic wire 7.

この軟磁性細線７の巻回は、軟磁性細線７の直径より僅かに大きいギャップを軸方向に隔てて径方向にそれぞれ延在する２枚のディスクの間の上記ギャップに巻くことが好適である。巻芯の形状を角形とすれば角形の孔をもつ平板状の軟磁性磁気部材を形成でき、巻芯を円柱状とすれば円形孔をもつ輪板状の軟磁性磁気部材を形成することができる。なお、一本の軟磁性細線７の代わりに、複数本の軟磁性細線７を同時に巻回してもよいことはもちろんである。 The soft magnetic wire 7 is preferably wound around the gap between the two disks extending in the radial direction with a gap slightly larger than the diameter of the soft magnetic wire 7 separated in the axial direction. . If the core is square, a flat soft magnetic magnetic member having a square hole can be formed, and if the core is cylindrical, a ring-shaped soft magnetic magnetic member having a circular hole can be formed. it can. Of course, a plurality of soft magnetic wires 7 may be wound simultaneously instead of one soft magnetic wire 7.

（変形態様）
上記実施形態では、軟磁性細線７をスパイラル状に巻回したが、軸方向にコイル状に巻回してもよい。このようにすれば、円筒状又は角筒状の軟磁性磁気部材を形成することができる。 (Modification)
In the above embodiment, the soft magnetic wire 7 is wound in a spiral shape, but may be wound in a coil shape in the axial direction. In this way, a cylindrical or prismatic soft magnetic magnetic member can be formed.

（実施形態５）
実施形態５の軟磁性磁気部材及びその製造方法を図１０、図１１を参照して以下に説明する。図１０はこの軟磁性磁気部材の製造工程の一部を示す模式工程図、図１１は製造された平板状の軟磁性細線の模式斜視図である。 (Embodiment 5)
A soft magnetic magnetic member and a manufacturing method thereof according to Embodiment 5 will be described below with reference to FIGS. FIG. 10 is a schematic process diagram showing a part of the manufacturing process of the soft magnetic magnetic member, and FIG. 11 is a schematic perspective view of the manufactured flat soft magnetic wire.

この実施形態では、予め絶縁膜が被着された軟磁性細線７がそれぞれ一本ずつ巻き取られたロール８０が多数幅方向に所定ピッチで配列されている。なお、この実施形態では、各ロール８０の軸心は鉛直方向とされている。各ロール８０から引き出された各軟磁性細線７は互いに近づくように図示しないガイドローラによりガイドされ、最終的に各軟磁性細線７間のギャップはほぼ０とされる。軟磁性細線７の断面は角形とされることが好適であるが、種々の理由により丸形などそれ以外の断面形状であっても構わない。 In this embodiment, a large number of rolls 80 each having a single soft magnetic wire 7 with an insulating film previously deposited thereon are arranged at a predetermined pitch in the width direction. In this embodiment, the axis of each roll 80 is in the vertical direction. The respective soft magnetic wires 7 drawn from the respective rolls 80 are guided by guide rollers (not shown) so as to approach each other, and finally the gap between the respective soft magnetic wires 7 is substantially zero. The cross section of the soft magnetic wire 7 is preferably square, but may be other cross sectional shapes such as a round shape for various reasons.

ギャップがほぼ０の軟磁性細線７の列は、切断後、又は、そのまま、所定温度に加熱された後、冷却される熱処理工程を経て、各軟磁性細線７の絶縁膜は互いに一体化し、その結果として各軟磁性細線７は図１１に示すような平板状の軟磁性磁気部材３となる。 The rows of the soft magnetic wires 7 with almost zero gaps are cut, or after being heated to a predetermined temperature and then cooled, the insulating films of the soft magnetic wires 7 are integrated with each other. As a result, each soft magnetic thin wire 7 becomes a flat soft magnetic member 3 as shown in FIG.

（実施形態６）
実施形態６の軟磁性磁気部材及びその製造方法を図１２を参照して以下に説明する。図１２はこの軟磁性磁気部材の製造工程を示す模式工程図である。 (Embodiment 6)
A soft magnetic magnetic member and a manufacturing method thereof according to Embodiment 6 will be described below with reference to FIG. FIG. 12 is a schematic process diagram showing the manufacturing process of this soft magnetic magnetic member.

この実施形態では、予め絶縁膜が被着されたたとえば電磁鋼板などの軟磁性磁気部材８を積層してブロック状の積層電磁鋼板９を形成する（ａ）。次に、この積層電磁鋼板（軟磁性磁気部材の積層体）８をその積層方向へ切断し（ｂ）、軟磁性磁気部材（正確には軟磁性磁気部材の積層体）３を一枚ずつ形成する。切断工具としては図７に示すようなバイト１０を用いるが、その他、フライス盤を用いて切断してもよい。形成された軟磁性磁気部材３は積層電磁鋼板９の積層方向と直角方向へ所定幅の多数の軟磁性細片部をもち、この所定幅は軟磁性磁気部材３の厚さとなる。すなわち、それぞれ細幅に切断されて軟磁性磁気部材３を構成する多数の軟磁性細片部が、軟磁性磁気部材（正確には軟磁性磁気部材の積層体）３を構成する。 In this embodiment, a soft magnetic magnetic member 8 such as an electromagnetic steel plate, to which an insulating film is applied in advance, is laminated to form a block-like laminated electromagnetic steel plate 9 (a). Next, this laminated electromagnetic steel sheet (a laminated body of soft magnetic magnetic members) 8 is cut in the laminating direction (b), and soft magnetic magnetic members (more precisely, a laminated body of soft magnetic magnetic members) 3 are formed one by one. To do. A cutting tool 10 as shown in FIG. 7 is used as a cutting tool, but cutting may be performed using a milling machine. The formed soft magnetic magnetic member 3 has a large number of soft magnetic strips having a predetermined width in the direction perpendicular to the stacking direction of the laminated electromagnetic steel sheets 9, and this predetermined width is the thickness of the soft magnetic magnetic member 3. That is, a large number of soft magnetic strip portions each constituting a soft magnetic magnetic member 3 cut into a narrow width constitute a soft magnetic magnetic member (more precisely, a laminated body of soft magnetic magnetic members) 3.

この実施形態によれば、たとえば購入した電磁鋼板の絶縁膜を軟磁性細片部２間の絶縁膜として用いることができる。その他、電磁鋼板の代わりに軟鋼板の表面に絶縁フィルムを被着して電磁鋼板を代用したり、アモルファス合金シートの表面に絶縁フィルムを被着して電磁鋼板を代替してもよい。 According to this embodiment, for example, an insulating film of a purchased electrical steel sheet can be used as the insulating film between the soft magnetic strip portions 2. In addition, instead of the electromagnetic steel plate, an insulating film may be applied to the surface of the mild steel plate to substitute the electromagnetic steel plate, or an insulating film may be applied to the surface of the amorphous alloy sheet to replace the electromagnetic steel plate.

（実施形態７）
上記した平板状の軟磁性磁気部材３をその板厚方向に積層してなる積層体及びその製造方法について説明する。 (Embodiment 7)
A laminate formed by laminating the above-described flat soft magnetic magnetic member 3 in the thickness direction and a manufacturing method thereof will be described.

既述した平板状の軟磁性磁気部材３を積層することにより軟磁性磁気部材の積層体を製造することができることは、従来の積層電磁鋼板と同じである。この場合、平板状の軟磁性磁気部材３の主面には、既述の絶縁膜被着工程により絶縁膜を被着できるので、電磁鋼板ではなくたとえば軟鋼板を用いることができる。また、予め主面に絶縁膜が被着された電磁鋼板を用いて軟磁性磁気部材３を形成しても、軟磁性磁気部材３の主面は絶縁膜をもつ。 It is the same as a conventional laminated electrical steel sheet that a laminated body of soft magnetic members can be manufactured by laminating the flat soft magnetic members 3 described above. In this case, since the insulating film can be applied to the main surface of the flat soft magnetic magnetic member 3 by the above-described insulating film applying process, for example, a soft steel sheet can be used instead of the electromagnetic steel sheet. Moreover, even if the soft magnetic magnetic member 3 is formed using an electromagnetic steel plate having an insulating film previously deposited on the main surface, the main surface of the soft magnetic magnetic member 3 has an insulating film.

（実施形態８）
軟磁性磁気部材の積層体の他の構造を図１３を参照して説明する。図１３（a）は２枚の軟磁性磁気部材を積層した一例を示す分解斜視図、図１３（b）は４枚の軟磁性磁気部材を積層した一例を示す分解斜視図である。 (Embodiment 8)
Another structure of the laminated body of soft magnetic members will be described with reference to FIG. FIG. 13A is an exploded perspective view showing an example in which two soft magnetic magnetic members are laminated, and FIG. 13B is an exploded perspective view showing an example in which four soft magnetic magnetic members are laminated.

図１３（a）では、平板状の軟磁性磁気部材３を積層するに際して、互いに隣接する軟磁性磁気部材３Ａ、３Ｂの軟磁性細片部２の延在方向を異ならせて積層している。このようにすると、延在方向Ａへの磁束成分は低磁束密度の場合には軟磁性磁気部材３Ａを主として通過するため、磁気抵抗を低減することができる。同様に、延在方向Ｂへの磁束成分は低磁束密度の場合には軟磁性磁気部材３Ｂを主として通過するため、磁気抵抗を低減することができる。 In FIG. 13A, when the flat soft magnetic members 3 are laminated, the soft magnetic strip portions 2 of the soft magnetic members 3A and 3B adjacent to each other are laminated in different directions. In this way, since the magnetic flux component in the extending direction A mainly passes through the soft magnetic member 3A when the magnetic flux density is low, the magnetic resistance can be reduced. Similarly, since the magnetic flux component in the extending direction B mainly passes through the soft magnetic member 3B when the magnetic flux density is low, the magnetic resistance can be reduced.

もちろん、互いに隣接する２枚の軟磁性磁気部材３Ａ、３Ｂの軟磁性細片部２の延在方向は直角でなく所定角度をもつこともでき、積奏された多数の軟磁性磁気部材３の軟磁性細片部２の延在方向をそれぞれ異ならせても良い。また、平板状の軟磁性磁気部材は、図８に示すような方形ではなく、所望形状とすることもできる。更に、図１３（b）に示すように、互いに隣接するかあるいは積層方向に離れた複数枚の軟磁性磁気部材の軟磁性細片部２の延在方向を一致させてもよい。要するに積層体の各軟磁性磁気部材の軟磁性細片部延在方向は自由である。この軟磁性細片部２の延在方向が異なる軟磁性磁気部材３を用いて積層体を構成することにより、磁気特性及び強度の両方を向上することができる。 Of course, the extending direction of the soft magnetic strip portions 2 of the two soft magnetic magnetic members 3A and 3B adjacent to each other can have a predetermined angle instead of a right angle. The extending directions of the soft magnetic strips 2 may be different. Further, the flat soft magnetic member can be formed in a desired shape instead of the square as shown in FIG. Furthermore, as shown in FIG. 13 (b), the extending directions of the soft magnetic strip portions 2 of the plurality of soft magnetic members adjacent to each other or separated in the stacking direction may be made to coincide. In short, the extending direction of the soft magnetic strip portion of each soft magnetic member of the laminate is free. By constructing a laminated body using the soft magnetic magnetic members 3 in which the extending directions of the soft magnetic strip portions 2 are different, both the magnetic characteristics and the strength can be improved.

（実施形態９）
軟磁性磁気部材の積層体の他の構造を図１４を参照して説明する。 (Embodiment 9)
Another structure of the laminated body of soft magnetic members will be described with reference to FIG.

この実施形態では、平板状の軟磁性磁気部材３を積層して積層体３０を形成するに際して、各軟磁性磁気部材３の板厚方向と直角方向（面方向）の形状を最終製品の立体形状に合わせて変更したことをその特徴としている。このようにすれば、従来の積層電磁鋼板のようにすべての電磁鋼板が同一の面形状をもつのに対して、複雑な立体形状の磁気部材を軟磁性磁気部材の積層体により構成することができる。 In this embodiment, when forming the laminated body 30 by laminating the flat soft magnetic magnetic members 3, the shape of each soft magnetic magnetic member 3 in the direction perpendicular to the plate thickness direction (plane direction) is the three-dimensional shape of the final product. The feature is that it has been changed to match. In this way, while all the electromagnetic steel sheets have the same surface shape as in the conventional laminated electromagnetic steel sheet, a complicated three-dimensional magnetic member can be composed of a laminate of soft magnetic magnetic members. it can.

更に説明すると、既述した多数の軟磁性細片部により形成された平板状の軟磁性磁気部材３は、その板厚方向へ磁束が通過する場合でも比較的小さい渦電流損をもつため、このようなそれぞれ異なる面形状の軟磁性磁気部材３を積層して複雑な立体形状の磁気部材を渦電流損を抑止しつつ実現できる訳である。 To explain further, the flat-plate-shaped soft magnetic magnetic member 3 formed by a large number of the soft-magnetic strips described above has a relatively small eddy current loss even when a magnetic flux passes in the plate thickness direction. Thus, it is possible to realize a complicated three-dimensional magnetic member while suppressing eddy current loss by laminating soft magnetic magnetic members 3 having different surface shapes.

（変形態様）
なお、立体形状の磁気部材を構成する場合に、その一部を上記した軟磁性磁気部材の積層体以外の磁気部材、たとえばアモルファス合金からなる磁気部材や通常の積層電磁鋼板で構成してもよい。 (Modification)
In the case of constituting a three-dimensional magnetic member, a part of the magnetic member may be constituted by a magnetic member other than the above-described laminated body of soft magnetic magnetic members, for example, a magnetic member made of an amorphous alloy or a normal laminated electrical steel sheet. .

（実施形態１０）
軟磁性磁気部材の他の構造を図１５を参照して説明する。図１５（ａ）はその製造工程の要部を示す模式図、図１５（ｂ）は軟磁性磁気部材１１の一例断面図、図１５（ｃ）は束ねられて形成された軟磁性磁気部材１１の他例断面図である。 (Embodiment 10)
Another structure of the soft magnetic member will be described with reference to FIG. FIG. 15A is a schematic diagram showing the main part of the manufacturing process, FIG. 15B is an example cross-sectional view of the soft magnetic magnetic member 11, and FIG. 15C is a bundle of soft magnetic magnetic members 11 formed. It is other example sectional drawing.

この実施形態では、予め絶縁膜が被着された軟磁性細線７を多数束ねた後、熱処理を行って各軟磁性細線７を接着し、ロープ状の軟磁性磁気部材１１を構成する。このロープ状の軟磁性磁気部材１１は、更に巻回したり、並べたりされて所望形状の磁気部材の積層体が形成される。このようにすれば、生産性よく軟磁性磁気部材の積層体を構成することができる。ロープ状の軟磁性磁気部材１１の断面は、図１５（ｂ）に示すように断面円形としてもよく、図１５（ｃ）に示すように断面方形としてもよく、その他、筒状断面など任意の断面とすることができる。この軟磁性磁気部材の積層体は、更に巻回して筒状の磁気部材やディスク状の磁気部材を構成するのが好適である。また、複数のロープ状の軟磁性磁気部材１１を異なる方向に配置して目的とする磁気部材を構成することもできる。たとえば、複数のロープ状の軟磁性磁気部材１１を編んだり織ったり、並べたりしてもよい。 In this embodiment, after bundling a large number of soft magnetic wires 7 to which an insulating film is applied in advance, a heat treatment is performed to bond the soft magnetic wires 7 to form a rope-like soft magnetic magnetic member 11. The rope-shaped soft magnetic magnetic member 11 is further wound or arranged to form a laminated body of magnetic members having a desired shape. In this way, a laminate of soft magnetic magnetic members can be constructed with high productivity. The cross section of the rope-shaped soft magnetic magnetic member 11 may be circular as shown in FIG. 15B, square as shown in FIG. 15C, or any other shape such as a cylindrical cross section. It can be a cross section. The laminated body of soft magnetic members is preferably further wound to form a cylindrical magnetic member or a disk-like magnetic member. Moreover, the target magnetic member can also be comprised by arrange | positioning several rope-shaped soft-magnetic magnetic members 11 in a different direction. For example, a plurality of rope-shaped soft magnetic magnetic members 11 may be knitted, woven, or arranged.

（実施形態１１）
実施形態１１の軟磁性磁気部材を図１６を参照して説明する。図１６はステータコアの一部（１磁極分）を示す部分正面図である。 (Embodiment 11)
The soft magnetic magnetic member of Embodiment 11 will be described with reference to FIG. FIG. 16 is a partial front view showing a part of the stator core (for one magnetic pole).

この実施形態では、軟磁性磁気部材３は、モータのステータコアを構成するべく輪板状に形成されている一枚の電磁鋼板からなり、各軟磁性磁気部材３は、従来同様に軸方向に積層されて、ステータコアを形成している。 In this embodiment, the soft magnetic magnetic member 3 is composed of a single electromagnetic steel plate formed in a ring shape so as to constitute a stator core of a motor, and each soft magnetic magnetic member 3 is laminated in the axial direction as in the prior art. Thus, a stator core is formed.

この実施形態では、図１６に示すように、一枚の電磁鋼板を略輪板形状のステータコアの形状に打ち抜く際に同時に、その所定部位に多数の切れ目（スリット）１２、１３を設けている。略輪板形状の軟磁性磁気部材３は、求心方向に突出するティース（磁極部と考えても良い）１４と環状のヨーク１５とをもつ。 In this embodiment, as shown in FIG. 16, a number of slits (slits) 12 and 13 are provided at a predetermined portion at the same time when a single electromagnetic steel sheet is punched into the shape of a substantially annular plate-shaped stator core. The substantially ring-shaped soft magnetic magnetic member 3 has teeth (which may be considered magnetic pole portions) 14 and an annular yoke 15 protruding in the centripetal direction.

スリット１２は、ティース１４にティース１４の延在方向と平行に多数切り込まれ、スリット１３はヨーク１５のティース１４が存在しない環状部分に周方向に多数切り込まれている。 A large number of slits 12 are cut into the teeth 14 in parallel with the extending direction of the teeth 14, and a large number of slits 13 are cut into the annular portion of the yoke 15 where the teeth 14 do not exist in the circumferential direction.

これにより、多数の軟磁性細片部１６が略輪板形状の軟磁性磁気部材３のティース１４の部分に形成され、多数の軟磁性細片部１７が略輪板形状の軟磁性磁気部材３のヨーク１５のティース以外の部分に形成される。 As a result, a large number of soft magnetic strips 16 are formed on the teeth 14 of the soft magnetic magnetic member 3 having a substantially annular plate shape, and a large number of soft magnetic strips 17 are formed on the soft magnetic magnetic member 3 having a substantially annular plate shape. The yoke 15 is formed at a portion other than the teeth.

各軟磁性細片部１６、１７を隔てる切れ目（スリット）には、既述した方法により絶縁膜が形成され、隣接する軟磁性細片部１６、１７同士を結合してステータコアの剛性向上を実現するとともにそれらの間の電気絶縁性能の向上を図っている。 An insulating film is formed on the cuts (slits) separating the soft magnetic strips 16 and 17 by the method described above, and the adjacent soft magnetic strips 16 and 17 are joined together to improve the rigidity of the stator core. In addition, the electrical insulation performance between them is improved.

これらの軟磁性細片部１６、１７の延在方向は、磁束方向とほぼ一致するため、渦電流損を低減しつつステータコアの磁気抵抗の増大を最小限とすることができる。 Since the extending direction of the soft magnetic strip portions 16 and 17 substantially coincides with the magnetic flux direction, the increase in the magnetic resistance of the stator core can be minimized while reducing the eddy current loss.

なお、各スリット１２、１３は平板状の電磁鋼板から略輪板形状の軟磁性磁気部材３を打ち抜いた後で切り込んでも良く、この際、各スリットを順次乃至複数回に分けて形成してもよい。スリット形成において、切断工具を移動しても良く、軟磁性磁気部材３を直線移動乃至回転移動させてもよい。ただし、熱処理は各スリット１２、１３を切り込んだ後で最後に行うことが好適である。 Each of the slits 12 and 13 may be cut after punching out the substantially ring-shaped soft magnetic magnetic member 3 from a flat electromagnetic steel plate. In this case, the slits may be formed sequentially or divided into a plurality of times. Good. In forming the slit, the cutting tool may be moved, or the soft magnetic member 3 may be moved linearly or rotationally. However, the heat treatment is preferably performed lastly after the slits 12 and 13 are cut.

また、積層方向に隣接する２枚の略輪板形状の軟磁性磁気部材３に設けた各スリット１２の位置は互いに周方向に異なることが好適であり、同じく各スリット１３の位置は互いに径方向に異なることが好適である。 Moreover, it is preferable that the positions of the slits 12 provided in the two substantially circular plate-shaped soft magnetic magnetic members 3 adjacent to each other in the stacking direction are different from each other in the circumferential direction. It is preferable to be different.

（実施形態１２）
実施形態１２の軟磁性磁気部材の積層体及びその製造方法を図１７を参照して以下に説明する。図１７は、軟磁性細線７を巻回してなる円筒状積層体１８であり、この円筒状積層体１８は、たとえば回転電機のバックヨークやトロイダルコアなどとして用いることができる。 Embodiment 12
The laminated body of the soft magnetic magnetic member of Embodiment 12 and its manufacturing method are demonstrated below with reference to FIG. FIG. 17 shows a cylindrical laminated body 18 formed by winding the soft magnetic thin wire 7, and this cylindrical laminated body 18 can be used as, for example, a back yoke or a toroidal core of a rotating electric machine.

この円筒状積層体１８は、予め絶縁膜が被着された一本乃至複数本の軟磁性細線７を径方向及び軸方向に多数回巻回して形成されている。軟磁性細線７の断面は角形とされることが好適であるが、種々の理由により丸形などそれ以外の断面形状であっても構わない。磁束は、主として周方向に流れることを想定しているが、磁束を径方向乃至その他の方向に流してもよい。このようにすれば、従来の積層電磁鋼板により同形状のものに比べて渦電流損を格段に低減することができる。 The cylindrical laminated body 18 is formed by winding one or more soft magnetic wires 7 previously coated with an insulating film in the radial direction and the axial direction many times. The cross section of the soft magnetic wire 7 is preferably square, but may be other cross sectional shapes such as a round shape for various reasons. Although it is assumed that the magnetic flux flows mainly in the circumferential direction, the magnetic flux may flow in the radial direction or other directions. In this way, the eddy current loss can be remarkably reduced by the conventional laminated electromagnetic steel sheet as compared with the same shape.

なお、図１７では軟磁性細線７を巻回して軟磁性磁気部材の積層体として円筒状積層体１８を構成したが、既述した予め束ねたロープ状の軟磁性磁気部材を巻回して同様の形状を構成することができることはもちろんである。 In FIG. 17, the soft magnetic thin wire 7 is wound to form the cylindrical laminated body 18 as a laminated body of soft magnetic magnetic members. However, the rope-like soft magnetic magnetic member previously bundled is wound to obtain the same structure. Of course, the shape can be configured.

（実施形態１３）
実施形態１３の軟磁性磁気部材及びその製造方法を図１８を参照して以下に説明する。図１８は、積層電磁鋼板からなるステータコアの一部（１磁極分）を示す部分正面図である。 (Embodiment 13)
A soft magnetic magnetic member and a manufacturing method thereof according to Embodiment 13 will be described below with reference to FIG. FIG. 18 is a partial front view showing a part (one magnetic pole part) of a stator core made of laminated electromagnetic steel sheets.

この実施形態では、軟磁性磁気部材３は、モータのステータコアを構成するべく略輪板状に形成され、多数枚の略輪板形状の軟磁性磁気部材３を軸方向に積層してステータコアが形成されている。 In this embodiment, the soft magnetic magnetic member 3 is formed in a substantially annular plate shape to constitute a stator core of a motor, and a stator core is formed by laminating a plurality of substantially magnetic plate-shaped soft magnetic magnetic members 3 in the axial direction. Has been.

この実施形態では、図１８に示すように、軟磁性磁気部材３は、予め絶縁膜が被着された多数の軟磁性細線７を径方向に延在する平面上に全体として略輪板形状の軟磁性磁気部材３を形成するように並べた後、熱圧着して略輪板形状の軟磁性磁気部材３を形成している。 In this embodiment, as shown in FIG. 18, the soft magnetic magnetic member 3 has a substantially annular plate shape as a whole on a plane extending in the radial direction with a large number of soft magnetic thin wires 7 to which an insulating film is applied in advance. The soft magnetic magnetic members 3 are arranged so as to be formed, and then thermocompression-bonded to form the substantially magnetic plate-shaped soft magnetic magnetic members 3.

重要な点は、各軟磁性細線７が径方向延在平面内において、必要部位において必要な曲率で湾曲乃至屈曲されていることである。軟磁性細線７はたとえば一辺が０．５ｍｍの角形断面をもち、極めて細いため柔軟に曲げることができる。 The important point is that each soft magnetic wire 7 is curved or bent with a necessary curvature at a necessary portion in a radially extending plane. The soft magnetic wire 7 has a square cross section with a side of 0.5 mm, for example, and is extremely thin and can be flexibly bent.

図１８に示すように、ステータコアのバックヨーク（ヨーク）１５の部分のうち、その径方向内側を周方向に延在する軟磁性細線７は、ステータコアのティース（磁極部と考えても良い）１４の周方向外側に配置されてティース１４の径方向内端に達している。 As shown in FIG. 18, among the portions of the back yoke (yoke) 15 of the stator core, the soft magnetic fine wires 7 extending radially inward in the circumferential direction are teeth of the stator core (which may be considered as magnetic pole portions) 14. It is arrange | positioned in the circumferential direction outer side, and has reached the radial direction inner end of the teeth 14. FIG.

また、ステータコアのバックヨーク１５の部分のうち、その径方向外側を周方向に延在する軟磁性細線７は、ステータコアのティース（磁極部と考えても良い）１４の周方向中央部に配置されてティース１４の径方向内端に達している。 Further, among the portions of the back yoke 15 of the stator core, the soft magnetic fine wire 7 extending radially outward in the circumferential direction is disposed at the center in the circumferential direction of the teeth (which may be considered as magnetic pole portions) 14 of the stator core. The tooth 14 reaches the inner end in the radial direction.

更に、ステータコアのバックヨーク１５の部分のうち、その径方向最外側を周方向に延在する軟磁性細線７は、ステータコアのティース（磁極部と考えても良い）１４に入ることなく、周方向へ延在している。 Further, among the portions of the back yoke 15 of the stator core, the soft magnetic fine wires 7 extending in the circumferential direction on the radially outermost side do not enter the teeth (which may be considered as magnetic pole portions) 14 of the stator core, and thus in the circumferential direction. It extends to.

このようにすれば、従来の略輪板形状の電磁鋼板を積層したステータコアに比べて格段に渦電流損を低減でき、圧粉コアと同程度の渦電流損特性を達成できるため、高周波モータの効率向上を低コストに実現できる。また、上記した各実施形態の技術思想を静止機器（たとえば柱上トランス）に応用する場合にも、圧粉コアに比べて格段に低コストでかつ積層電磁鋼板に比べて格段に低損失のコアを実現することができ、省エネ効果を産業界に広くもたらすことができる。 In this way, the eddy current loss can be significantly reduced compared to the conventional stator core laminated with a substantially ring-shaped electromagnetic steel sheet, and the eddy current loss characteristics comparable to the dust core can be achieved. Efficiency improvement can be realized at low cost. In addition, when the technical ideas of the above-described embodiments are applied to a stationary device (for example, a transformer on a pillar), the core is much lower in cost than the dust core and much lower in loss than the laminated electrical steel sheet. Can be realized, and energy saving effect can be widely brought to the industry.

実施形態１を示す軟磁性磁気部材の模式製造工程図である。FIG. 3 is a schematic manufacturing process diagram of the soft magnetic magnetic member showing the first embodiment. （a）〜（f）はそれぞれ、図１の軟磁性細片部の配列方式を示す軟磁性磁気部材の模式平面図である。(A)-(f) is a schematic plan view of the soft-magnetic member which shows the arrangement | sequence system of the soft-magnetic strip part of FIG. 1, respectively. 実施形態２を示す軟磁性磁気部材の模式斜視図である。6 is a schematic perspective view of a soft magnetic magnetic member showing Embodiment 2. FIG. 実施形態３を示す軟磁性磁気部材の模式製造工程図である。FIG. 6 is a schematic manufacturing process diagram of a soft magnetic magnetic member showing Embodiment 3. 軟磁性細片部製造のための金型による切断例を示す模式斜視図である。It is a model perspective view which shows the example of a cutting | disconnection by the metal mold | die for soft-magnetic strip part manufacture. 軟磁性細片部製造のためのスリッターによる切断例を示す模式斜視図である。It is a model perspective view which shows the example of a cutting | disconnection by the slitter for soft-magnetic strip part manufacture. 軟磁性細片部製造のためのレーザーによる切断例を示す模式斜視図である。It is a model perspective view which shows the example of a cutting | disconnection by the laser for soft-magnetic strip part manufacture. 軟磁性細片部製造のためのウオータージェットによる切断例を示す模式斜視図である。It is a model perspective view which shows the example of a cutting | disconnection by the water jet for soft-magnetic strip part manufacture. 実施形態４を示す軟磁性磁気部材の模式平面図である。6 is a schematic plan view of a soft magnetic magnetic member showing Embodiment 4. FIG. 実施形態５を示す軟磁性磁気部材の製造工程の一部を示す模式工程図である。FIG. 10 is a schematic process diagram illustrating a part of the manufacturing process of the soft magnetic magnetic member according to the fifth embodiment. 実施形態５の軟磁性細線の模式斜視図である。10 is a schematic perspective view of a soft magnetic wire according to Embodiment 5. FIG. 実施形態６の軟磁性磁気部材製造工程を示す模式工程図である。FIG. 10 is a schematic process diagram showing a soft magnetic magnetic member manufacturing process of Embodiment 6. 実施形態８の軟磁性磁気部材の積層体を示す説明図であり、（a）は二枚を積層した分解斜視図、（b）は４枚を積層した分解斜視図である。It is explanatory drawing which shows the laminated body of the soft-magnetic magnetic member of Embodiment 8, (a) is the exploded perspective view which laminated | stacked two sheets, (b) is the exploded perspective view which laminated | stacked four sheets. 実施形態９の軟磁性磁気部材の積層体を示す説明図である。FIG. 10 is an explanatory view showing a laminated body of soft magnetic magnetic members according to Embodiment 9. 実施形態１０を示す図であり、図１５（ａ）はその製造工程の要部を示す模式図、図１５（ｂ）は軟磁性磁気部材１１の一例断面図、図１５（ｃ）は束ねられて形成された軟磁性磁気部材１１の他例断面図である。FIGS. 15A and 15B are schematic views showing a main part of the manufacturing process, FIG. 15B is an example cross-sectional view of the soft magnetic member 11, and FIG. 15C is bundled. It is other example sectional drawing of the soft-magnetic magnetic member 11 formed in this way. 実施形態１１の軟磁性磁気部材を示す部分正面図である。It is a partial front view which shows the soft-magnetic magnetic member of Embodiment 11. 実施形態１２の軟磁性磁気部材の積層体を示す説明図である。FIG. 16 is an explanatory view showing a laminated body of soft magnetic magnetic members of Embodiment 12. 実施形態１３の軟磁性磁気部材を示す説明図である。It is explanatory drawing which shows the soft-magnetic magnetic member of Embodiment 13.

符号の説明Explanation of symbols

１薄板
２軟磁性細片部
３軟磁性磁気部材
３Ａ軟磁性磁気部材
３Ｂ軟磁性磁気部材
４、５切断方向
６切断装置
７軟磁性細線
８軟磁性磁気部材
９積層電磁鋼板
１０バイト
１１軟磁性磁気部材
１２スリット
１３スリット
１４ティース
１５バックヨーク（ヨーク）
１６軟磁性細片部
１７軟磁性細片部
１８円筒状積層体
３０積層体
８０ロール
１００電磁鋼板 DESCRIPTION OF SYMBOLS 1 Thin plate 2 Soft-magnetic strip part 3 Soft-magnetic member 3A Soft-magnetic member 3B Soft-magnetic member 4, 5 Cutting direction 6 Cutting device 7 Soft-magnetic thin wire 8 Soft-magnetic member 9 Laminated electrical steel sheet 10 Byte 11 Soft-magnetic magnet Member 12 Slit 13 Slit 14 Teeth 15 Back yoke (yoke)
16 Soft magnetic strip portion 17 Soft magnetic strip portion 18 Cylindrical laminated body 30 Laminated body 80 Roll 100 Electrical steel sheet

Claims

軟磁性金属材料を素材として板状に形成される軟磁性磁気部材において、
軟磁性金属材料からなるとともに板厚方向と直角な第１の配列方向へ所定ピッチで配列され、
かつ、前記板厚方向と直角な第２の配列方向へ所定ピッチで配列されてなる多数の軟磁性細片部と、
前記軟磁性細片部の表面に被着乃至形成されて前記各軟磁性細片部間の電気抵抗値を増大させる無機系絶縁膜と、
を有し、
前記軟磁性細片部は、前記絶縁膜を介して互いに機械的に結合されて板状に成形されており、
前記絶縁膜は、互いに隣接する前記軟磁性細片部の間に位置して前記第１の配列方向及び前記第２の配列方向へそれぞれ所定ピッチで配列されていることを特徴とする軟磁性磁気部材。 In a soft magnetic magnetic member formed in a plate shape using a soft magnetic metal material as a raw material,
In together when made of a soft magnetic metallic material to a thickness direction perpendicular to the first arrangement direction are arranged at a predetermined pitch,
And a large number of soft magnetic strip portions arranged at a predetermined pitch in a second arrangement direction perpendicular to the plate thickness direction ,
An inorganic insulating film that is deposited or formed on the surface of the soft magnetic strip portion to increase the electrical resistance between the soft magnetic strip portions;
Have
The soft magnetic strips are mechanically coupled to each other through the insulating film and formed into a plate shape ,
The insulating film is located between the soft magnetic strip portions adjacent to each other, and is arranged at a predetermined pitch in the first arrangement direction and the second arrangement direction, respectively. Element.

請求項１記載の軟磁性磁気部材において、
前記第１の配列方向及び第２の配列方向は、互いに直交している軟磁性磁気部材。 The soft magnetic magnetic member according to claim 1 ,
The soft magnetic magnetic member in which the first arrangement direction and the second arrangement direction are orthogonal to each other.

軟磁性金属材料を素材として板状に形成される軟磁性磁気部材の製造方法であって、
前記軟磁性磁気部材は、軟磁性金属材料からなるとともに少なくとも板厚方向と直角な所定の配列方向へ所定ピッチで配列してなる多数の軟磁性細片部と、
前記軟磁性細片部の表面に被着乃至形成されて前記各軟磁性細片部間の電気抵抗値を増大させる無機系絶縁膜と、
を有し、
前記軟磁性細片部は、前記絶縁膜を介して互いに機械的に結合されて板状に成形されており、長尺形状にそれぞれ形成されて前記板厚方向及び前記配列方向に対して直角の延在方向へそれぞれ延在しているものであり、
電磁鋼板を所定幅に切断して帯状の前記軟磁性細片部を形成する第１工程と、
前記帯状の軟磁性細片部の少なくとも切断面に前記絶縁膜を被着乃至形成する第２工程
と、
多数の前記帯状の軟磁性細片部を前記絶縁膜を介して互いに機械的に結合する第３工程
と、
を有し、
前記電磁鋼板を所定幅に切断して形成された前記帯状の軟磁性細片部は、隣接する前記帯状の軟磁性細片部に対して板厚方向へ相対的に所定距離だけ変位させた後、前記絶縁膜の被着乃至形成を行ってから前記変位を解消させ、しかるのち前記機械的結合を行う軟磁性磁気部材の製造方法。 A method of manufacturing a soft magnetic magnetic member formed in a plate shape from a soft magnetic metal material,
The soft magnetic magnetic member is made of a soft magnetic metal material and at least a plurality of soft magnetic strip portions arranged at a predetermined pitch in a predetermined arrangement direction perpendicular to the plate thickness direction,
An inorganic insulating film that is deposited or formed on the surface of the soft magnetic strip portion to increase the electrical resistance between the soft magnetic strip portions;
Have
The soft magnetic strips are mechanically coupled to each other via the insulating film and formed into a plate shape, each of which is formed into a long shape and perpendicular to the plate thickness direction and the arrangement direction. Each extending in the direction of extension,
A first step of cutting the magnetic steel sheet into a predetermined width to form the strip-shaped soft magnetic strip portion;
Second step of depositing or forming the insulating film on at least the cut surface of the strip-shaped soft magnetic strip portion
When,
A third step of mechanically coupling a number of the strip-shaped soft magnetic strips to each other through the insulating film
And
Have
The strip-shaped soft magnetic strip portion formed by cutting the electromagnetic steel sheet to a predetermined width is displaced by a predetermined distance relative to the adjacent strip-shaped soft magnetic strip portion in the plate thickness direction. A method of manufacturing a soft magnetic member in which the displacement is eliminated after the insulating film is deposited or formed, and then the mechanical coupling is performed.

軟磁性金属材料を素材として板状に形成される軟磁性磁気部材の製造方法であって、
前記軟磁性磁気部材は、軟磁性金属材料からなるとともに少なくとも板厚方向と直角な所定の配列方向へ所定ピッチで配列してなる多数の軟磁性細片部と、
前記軟磁性細片部の表面に被着乃至形成されて前記各軟磁性細片部間の電気抵抗値を増大させる無機系絶縁膜と、
を有し、
前記軟磁性細片部は、前記絶縁膜を介して互いに機械的に結合されて板状に成形されており、長尺形状にそれぞれ形成されて前記板厚方向及び前記配列方向に対して直角の延在方向へそれぞれ延在しているものであり、
長尺の電磁鋼板を所定の搬送方向に搬送するとともに、搬送方向上流部にて、前記電磁鋼板を所定幅に切断して帯状の軟磁性細片部を形成する第１工程を行い、
搬送方向中流部にて、前記帯状の軟磁性細片部の少なくとも切断面に前記絶縁膜を被着乃至形成する第２工程を行い、
搬送方向下流部にて、多数の前記帯状の軟磁性細片部を前記絶縁膜を介して互いに機械的に結合する第３工程を行う軟磁性磁気部材の製造方法において、
前記長尺の電磁鋼板の前記搬送方向への移動につれて前記電磁鋼板を前記搬送方向へ切り裂くことにより前記軟磁性細片部を帯状に形成する軟磁性磁気部材の製造方法。 A method of manufacturing a soft magnetic magnetic member formed in a plate shape from a soft magnetic metal material,
The soft magnetic magnetic member is made of a soft magnetic metal material and at least a plurality of soft magnetic strip portions arranged at a predetermined pitch in a predetermined arrangement direction perpendicular to the plate thickness direction,
An inorganic insulating film that is deposited or formed on the surface of the soft magnetic strip portion to increase the electrical resistance between the soft magnetic strip portions;
Have
The soft magnetic strips are mechanically coupled to each other via the insulating film and formed into a plate shape, each of which is formed into a long shape and perpendicular to the plate thickness direction and the arrangement direction. Each extending in the direction of extension,
Along with conveying a long electromagnetic steel sheet in a predetermined conveying direction, at the upstream part in the conveying direction, performing a first step of cutting the electromagnetic steel sheet into a predetermined width to form a strip-shaped soft magnetic strip part,
Performing a second step of depositing or forming the insulating film on at least the cut surface of the strip-shaped soft magnetic strip portion at the midstream portion in the transport direction;
In the method of manufacturing a soft magnetic member that performs a third step of mechanically coupling a number of the strip-shaped soft magnetic strip portions to each other via the insulating film at a downstream portion in the transport direction,
The manufacturing method of the soft-magnetic magnetic member which forms the said soft-magnetic strip part in strip | belt shape by tearing the said electromagnetic steel plate to the said conveyance direction as the said long electromagnetic steel plate moves to the said conveyance direction.

軟磁性金属材料を素材とする積層体において、
軟磁性金属材料からなるとともに少なくとも板厚方向と直角な所定の配列方向へ所定ピッチで配列してなる多数の軟磁性細片部と、
前記軟磁性細片部の表面に被着乃至形成されて前記各軟磁性細片部間の電気抵抗値を増大させる無機系絶縁膜と、
を有し、
前記軟磁性細片部が、前記絶縁膜を介して互いに機械的に結合されて板状に成形されている軟磁性磁気部材を多数、板厚方向に積層してなる軟磁性磁気部材の積層体。 In laminates made of soft magnetic metal materials,
A large number of soft magnetic strips made of a soft magnetic metal material and arranged at a predetermined pitch in a predetermined arrangement direction at least perpendicular to the plate thickness direction;
An inorganic insulating film that is deposited or formed on the surface of the soft magnetic strip portion to increase the electrical resistance between the soft magnetic strip portions;
Have
A laminated body of soft magnetic magnetic members in which a plurality of soft magnetic magnetic members, in which the soft magnetic strip portions are mechanically coupled to each other via the insulating film and formed into a plate shape, are laminated in the plate thickness direction. .

請求項５記載の軟磁性磁気部材の積層体において、
積層される２枚の前記板状の軟磁性磁気部材の前記絶縁膜は互いに異なる方向に延在する軟磁性磁気部材の積層体。 The laminate of soft magnetic magnetic members according to claim 5 ,
A laminated body of soft magnetic magnetic members in which the insulating films of the two laminated plate-like soft magnetic magnetic members extend in different directions.

請求項６記載の軟磁性磁気部材の積層体において、
前記２枚の板状の軟磁性磁気部材のうちの少なくとも一方の前記絶縁膜の延在方向は、ほぼ磁束通過方向に設定される軟磁性磁気部材の積層体。 The laminate of soft magnetic magnetic members according to claim 6 ,
A laminated body of soft magnetic magnetic members in which an extending direction of at least one of the two plate-like soft magnetic magnetic members is set to a substantially magnetic flux passing direction.

請求項６記載の軟磁性磁気部材の積層体において、
前記２枚の板状の軟磁性磁気部材の前記絶縁膜の延在方向は、互いに直交する軟磁性磁気部材の積層体。 The laminate of soft magnetic magnetic members according to claim 6 ,
A laminate of the soft magnetic magnetic members in which the extending directions of the insulating films of the two plate-like soft magnetic magnetic members are orthogonal to each other.

前記軟磁性磁気部材の積層体以外の軟磁性磁気部材と組み合わせられて磁気回路を構成する請求項５記載の軟磁性磁気部材の積層体。 6. The laminated body of soft magnetic magnetic members according to claim 5, wherein a magnetic circuit is constituted by being combined with a soft magnetic magnetic member other than the laminated body of soft magnetic members.

請求項５記載の軟磁性磁気部材の積層体の製造方法において、
軟磁性磁気部材の積層体を所定幅に切断して帯状の前記軟磁性細片部の積層体を形成する第１工程と、
前記帯状の軟磁性細片部の積層体の少なくとも切断面に前記絶縁膜を被着乃至形成する第２工程と、
多数の前記帯状の軟磁性細片部の積層体を前記絶縁膜を介して互いに機械的に結合して前記軟磁性磁気部材の積層体を形成する第３工程と、
を有する軟磁性磁気部材の積層体の製造方法。 In the manufacturing method of the laminated body of the soft-magnetic magnetic member of Claim 5 ,
A first step of cutting a laminated body of soft magnetic members into a predetermined width to form a laminated body of the strip-shaped soft magnetic strip portions;
A second step of depositing or forming the insulating film on at least a cut surface of the laminate of the strip-shaped soft magnetic strip portion;
A third step of forming a laminate of the soft magnetic magnetic members by mechanically coupling a plurality of laminates of the strip-shaped soft magnetic strip portions with each other through the insulating film;
A method of manufacturing a laminate of soft magnetic magnetic members having

請求項１０記載の軟磁性磁気部材の積層体の製造方法において、
前記軟磁性磁気部材の積層体の前記切断面をその積層方向と直角方向へ形成する軟磁性磁気部材の積層体の製造方法。 In the manufacturing method of the laminated body of the soft-magnetic magnetic member of Claim 10 ,
A method for producing a laminate of soft magnetic magnetic members, wherein the cut surface of the laminate of soft magnetic magnetic members is formed in a direction perpendicular to the lamination direction.

請求項６記載の軟磁性磁気部材の積層体の製造方法において、
多数の前記軟磁性磁気部材を所定の平面形状に順次切断し、
切断された前記各軟磁性磁気部材を順次積層して所定の立体形状の軟磁性磁気部材の積層体を形成する軟磁性磁気部材の積層体の製造方法。 In the manufacturing method of the laminated body of the soft-magnetic magnetic member of Claim 6 ,
A number of the soft magnetic members are sequentially cut into a predetermined planar shape,
A method of manufacturing a laminated body of soft magnetic magnetic members, wherein the cut soft magnetic magnetic members are sequentially laminated to form a laminated body of soft magnetic magnetic members having a predetermined three-dimensional shape.