JP5327765B2 - Powder core - Google Patents

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JP5327765B2
JP5327765B2 JP2011500551A JP2011500551A JP5327765B2 JP 5327765 B2 JP5327765 B2 JP 5327765B2 JP 2011500551 A JP2011500551 A JP 2011500551A JP 2011500551 A JP2011500551 A JP 2011500551A JP 5327765 B2 JP5327765 B2 JP 5327765B2
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JPWO2010095496A1 (en
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隆夫 水嶋
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Alps Green Devices Co Ltd
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/08—Cores, Yokes, or armatures made from powder
    • 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
    • B22F3/26—Impregnating
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • B22F5/106—Tube or ring forms
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C45/00—Amorphous alloys
    • C22C45/02—Amorphous alloys with iron as the major constituent
    • 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
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
    • H01F1/15358—Making agglomerates therefrom, e.g. by pressing
    • H01F1/15366—Making agglomerates therefrom, e.g. by pressing using a binder
    • H01F1/15375—Making agglomerates therefrom, e.g. by pressing using a binder using polymers
    • 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
    • H01F41/005—Impregnating or encapsulating

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  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Dispersion Chemistry (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Electromagnetism (AREA)
  • Powder Metallurgy (AREA)
  • Soft Magnetic Materials (AREA)

Description

本発明は、非晶質軟磁性合金粉末が結着材によって固化成形されてなる圧粉コアに関する。   The present invention relates to a powder core formed by solidifying and molding an amorphous soft magnetic alloy powder with a binder.

下記の特許文献１に示す圧粉コアは、非晶質軟磁性合金粉末が結着材により固化成形されたものである。非晶質軟磁性合金粉末を用いることで磁気特性を効果的に向上させることができる。   The dust core shown in Patent Document 1 below is obtained by solidifying and molding an amorphous soft magnetic alloy powder with a binder. By using amorphous soft magnetic alloy powder, the magnetic properties can be effectively improved.

しかしながら非晶質軟磁性合金粉末は硬質であるが故に、圧粉コアの製造過程での圧縮成形によっても塑性変形が小さく、粉末間の結着力が低下しやすかった。このため、前記非晶質軟磁性合金粉末を用いて形成された圧粉コアは、コア強度が低く、使用時や、組立工程等で破損しやすい問題が生じた。   However, since the amorphous soft magnetic alloy powder is hard, the plastic deformation is small even by the compression molding in the manufacturing process of the dust core, and the binding force between the powders tends to decrease. For this reason, the dust core formed using the amorphous soft magnetic alloy powder has a low core strength, and has a problem that it is easily damaged during use or in an assembly process.

下記の特許文献１に記載の発明では、ブチラールフェノール樹脂からなる保護層によりコア全体を被覆している。   In the invention described in Patent Document 1 below, the entire core is covered with a protective layer made of butyral phenol resin.

特開２００４−３６３２３５号公報JP 2004-363235 A

後述する実験に示すように、ブチラールフェノール樹脂からなる保護層によりコア全体を被覆した圧粉コアでは、前記保護層により被覆しない圧粉コアに比べてコア強度を向上させることが可能であるが、本発明者は、鋭意検討を重ねた結果、更にコア強度を向上させることが可能な圧粉コアの発明に至った。   As shown in the experiment described later, in the dust core in which the entire core is covered with a protective layer made of butyral phenol resin, it is possible to improve the core strength compared to the dust core not covered by the protective layer, As a result of intensive studies, the present inventor has arrived at the invention of a dust core capable of further improving the core strength.

本発明は、コア本体を覆う被覆層を改良して、磁気特性の低下を抑制しつつコア強度を効果的に向上させることが可能な圧粉コアを提供することを目的としている。   An object of the present invention is to provide a dust core capable of effectively improving the core strength while improving the coating layer covering the core body and suppressing the deterioration of the magnetic properties.

本発明における圧粉コアは、非晶質軟磁性合金粉末がアクリル樹脂の結着材によって固化成形されてなるとともに含浸によりメタクリル酸ジエステルからなる被覆層が形成されていることを特徴とするものである。これにより、磁気特性の低下を抑制しつつ従来に比べてコア強度を効果的に向上させることができる。 The dust core according to the present invention is characterized in that an amorphous soft magnetic alloy powder is solidified by an acrylic resin binder and a coating layer made of methacrylic acid diester is formed by impregnation. is there. Thereby, core strength can be effectively improved compared with the past, suppressing the fall of a magnetic characteristic.

本発明では、前記被覆層は真空含浸により形成されることが好ましい。これにより、非晶質軟磁性合金粉末が結着材によって固化成形されたコア本体内部に形成された空孔が、より効果的に、メタクリル酸ジエステルからなる樹脂層により埋められると考えられ、コア強度の更なる向上を図ることが出来る。   In the present invention, the coating layer is preferably formed by vacuum impregnation. As a result, it is considered that the voids formed inside the core body, in which the amorphous soft magnetic alloy powder is solidified by the binder, are more effectively filled with the resin layer made of methacrylic acid diester, The strength can be further improved.

また本発明では、前記非晶質軟磁性合金粉末は、Ｆｅを主成分とし、少なくともＰ、Ｃ、Ｂ、Ｓｉのうち２種以上を含むことが好ましく、具体的には、下記の組成式で形成されることが好ましい。   In the present invention, the amorphous soft magnetic alloy powder preferably contains Fe as a main component and contains at least two of P, C, B, and Si. Specifically, the amorphous soft magnetic alloy powder has the following composition formula: Preferably it is formed.

Ｆｅ100-a-b-x-y-z-w-tＣｏaＮｉbＭxＰyＣzＢwＳｉt
ただし、ＭはＣｒ、Ｍｏ、Ｗ、Ｖ、Ｎｂ、Ｔａ、Ｔｉ、Ｚｒ、Ｈｆ、Ｐｔ、Ｐｄ、Ａｕより選ばれる１種または２種以上の元素であり、組成比を示すａ、ｂ、ｘ、ｙ、ｚ、ｗ、ｔは、０原子％≦ｘ≦３原子％、０原子％≦ｙ≦１５原子％、０原子％≦ｚ≦８原子％、１原子％≦ｗ≦１２原子％、０．５原子％≦ｔ≦８原子％、０原子％≦ａ≦２０原子％、０原子％≦ｂ≦５原子％、７０原子％≦（１００−ａ−ｂ−ｘ−ｙ−ｚ−ｗ−ｔ）≦８０原子％を示す。 Fe 100-abxyzwt Co a Ni b M x P y C z B w Si t
However, M is one or more elements selected from Cr, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd, and Au, and a, b, x indicating the composition ratio , Y, z, w, t are 0 atomic% ≦ x ≦ 3 atomic%, 0 atomic% ≦ y ≦ 15 atomic%, 0 atomic% ≦ z ≦ 8 atomic%, 1 atomic% ≦ w ≦ 12 atomic%, 0.5 atomic% ≦ t ≦ 8 atomic%, 0 atomic% ≦ a ≦ 20 atomic%, 0 atomic% ≦ b ≦ 5 atomic%, 70 atomic% ≦ (100-ab-x-yz-w) -T) <= 80 atomic%.

本発明の圧粉コアによれば、磁気特性の低下を抑制しつつ従来に比べてコア強度を向上させることができる。   According to the dust core of the present invention, the core strength can be improved as compared with the conventional one while suppressing the deterioration of the magnetic properties.

（ａ）は本実施形態の圧粉コアの斜視図、（ｂ）は（ａ）のＡ−Ａ線から厚さ方向に切断したときの拡大断面図、(A) is a perspective view of the dust core of this embodiment, (b) is an enlarged cross-sectional view when cut in the thickness direction from the AA line of (a), コア強度の測定方法を示す説明図、Explanatory drawing showing the measurement method of core strength, 成形品１（結着材としてシリコーン樹脂を使用）の従来例（被覆なし）、第 １比較例（被覆層がブチラールフェノールからなる樹脂）及び第２比較例（被覆層がメタクリル酸ジエステルから成る樹脂）における周波数と透磁率との関係を示すグラフ、Conventional example of the molded article 1 (using a silicone resin as a binder) (uncoated), the resin first comparative example (resin coating layer is composed of butyral phenol) and a second comparative example (coating layer comprises methacrylic acid diester ) Is a graph showing the relationship between frequency and permeability in 成形品１（結着材としてシリコーン樹脂を使用）の従来例（被覆なし）、第 １比較例（被覆層がブチラールフェノールからなる樹脂）及び第２比較例（被覆層がメタクリル酸ジエステルから成る樹脂）における周波数とコアロスとの関係を示すグラフ、Conventional example of the molded article 1 (using a silicone resin as binder) (uncoated), the resin first comparative example (resin coating layer is composed of butyral phenol) and a second comparative example (coating layer consisting of methacrylic acid diester ) Graph showing the relationship between frequency and core loss in 成形品２（結着材としてアクリル樹脂を使用）の従来例（被覆なし）、第３比較例（被覆層がブチラールフェノールからなる樹脂）及び実施例（被覆層がメタクリル酸ジエステルから成る樹脂）における周波数と透磁率との関係を示すグラフ、In the conventional example (without coating) of the molded product 2 (using an acrylic resin as a binder), the third comparative example (resin whose coating layer is made of butyral phenol) and the example (resin whose coating layer is made of methacrylic acid diester) A graph showing the relationship between frequency and permeability, 成形品２（結着材としてアクリル樹脂を使用）の従来例（被覆なし）、第３比較例（被覆層がブチラールフェノールからなる樹脂）及び実施例（被覆層がメタクリル酸ジエステルから成る樹脂）における周波数とコアロスとの関係を示すグラフ。In the conventional example (without coating) of the molded product 2 (using an acrylic resin as a binder), the third comparative example (resin whose coating layer is made of butyral phenol) and the example (resin whose coating layer is made of methacrylic acid diester) The graph which shows the relationship between a frequency and a core loss.

図１（ａ）は、本実施形態における圧粉コアの斜視図、図１（ｂ）は図１（ａ）をＡ−Ａ線に沿って厚さ方向に切断したときの前記圧粉コアの拡大断面図である。   Fig.1 (a) is a perspective view of the powder core in this embodiment, FIG.1 (b) is the said powder core when FIG.1 (a) is cut | disconnected in the thickness direction along the AA line. It is an expanded sectional view.

図１（ａ）に示す圧粉コア１は、円環状で形成されているが、形状を限定するものでない。   Although the powder core 1 shown to Fig.1 (a) is formed in the annular | circular shape, it does not limit a shape.

図１（ｂ）に示すように圧粉コア１は、非晶質軟磁性合金粉末が結着材によって固化成形されたコア本体２と、前記コア本体２の表面全体を覆う被覆層３とで構成される。   As shown in FIG. 1B, the dust core 1 includes a core body 2 in which an amorphous soft magnetic alloy powder is solidified by a binder, and a coating layer 3 that covers the entire surface of the core body 2. Composed.

本実施形態の非晶質軟磁性合金粉末は、例えば、略球状あるいは楕円体状からなる。前記非晶質軟磁性合金粉末は、組織中に多数個存在し、各非晶質軟磁性合金粉末間が前記結着材にて絶縁された状態となっている。   The amorphous soft magnetic alloy powder of the present embodiment is, for example, substantially spherical or elliptical. A large number of the amorphous soft magnetic alloy powders exist in the structure, and the amorphous soft magnetic alloy powders are insulated from each other by the binder.

前記非晶質軟磁性合金粉末は、例えば、水アトマイズ法により形成されたものであり、Ｆｅを主成分とし、Ｐ、Ｃ、Ｂ、Ｓｉのうち少なくとも２種以上を含む非晶質相からなるものである。
具体的な前記非晶質軟磁性合金粉末の組成式は以下の通りである。The amorphous soft magnetic alloy powder is formed by, for example, a water atomization method, and is composed of an amorphous phase containing Fe as a main component and containing at least two of P, C, B, and Si. Is.
The specific composition formula of the amorphous soft magnetic alloy powder is as follows.

Ｆｅ100-a-b-x-y-z-w-tＣｏaＮｉbＭxＰyＣzＢwＳｉt
ただし、ＭはＣｒ、Ｍｏ、Ｗ、Ｖ、Ｎｂ、Ｔａ、Ｔｉ、Ｚｒ、Ｈｆ、Ｐｔ、Ｐｄ、Ａｕより選ばれる１種または２種以上の元素であり、組成比を示すａ、ｂ、ｘ、ｙ、ｚ、ｗ、ｔは、０原子％≦ｘ≦３原子％、０原子％≦ｙ≦１５原子％、０原子％≦ｚ≦８原子％、１原子％≦ｗ≦１２原子％、０．５原子％≦ｔ≦８原子％、０原子％≦ａ≦２０原子％、０原子％≦ｂ≦５原子％、７０原子％≦(１００−ａ−ｂ−ｘ−ｙ−ｚ−ｗ−ｔ)≦８０原子％を示す。 Fe 100-abxyzwt Co a Ni b M x P y C z B w Si t
However, M is one or more elements selected from Cr, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd, and Au, and a, b, x indicating the composition ratio , Y, z, w, t are 0 atomic% ≦ x ≦ 3 atomic%, 0 atomic% ≦ y ≦ 15 atomic%, 0 atomic% ≦ z ≦ 8 atomic%, 1 atomic% ≦ w ≦ 12 atomic%, 0.5 atomic% ≦ t ≦ 8 atomic%, 0 atomic% ≦ a ≦ 20 atomic%, 0 atomic% ≦ b ≦ 5 atomic%, 70 atomic% ≦ (100-ab-x-yz-w) −t) ≦ 80 atomic%.

本実施形態の非晶質軟磁性合金粉末は、磁性を示すＦｅと、非晶質形成能を有するＰ、Ｃ、Ｂ等といった半金属元素を具備しているので、非晶質相を主相とするとともに優れた軟磁気特性を示す。   Since the amorphous soft magnetic alloy powder of the present embodiment includes Fe exhibiting magnetism and metalloid elements such as P, C, and B having an amorphous forming ability, the amorphous phase is the main phase. And excellent soft magnetic properties.

また、元素Ｍ（Ｃｒ、Ｍｏ、Ｗ、Ｖ、Ｎｂ、Ｔａ、Ｔｉ、Ｚｒ、Ｈｆ、Ｐｔ、Ｐｄ、Ａｕのうちの１種又は２種以上の元素素）を添加して耐食性を向上させることができる。   In addition, the element M (Cr, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd, Au, or one or more elemental elements) is added to improve the corrosion resistance. Can do.

更にこの非晶質軟磁性合金粉末は、ΔＴｘ＝Ｔｘ−Ｔｇ（ただしＴｘは結晶化開始温度、Ｔｇはガラス遷移温度を示す。）の式で表される過冷却液体の温度間隔ΔＴｘが２０Ｋ以上を示すが、組成によってはΔＴｘが３０Ｋ以上、さらには５０Ｋ以上という顕著な温度間隔を有し、また、軟磁性についても室温で優れた特性を有している。   Further, this amorphous soft magnetic alloy powder has a temperature interval ΔTx of the supercooled liquid expressed by the equation: ΔTx = Tx−Tg (where Tx is the crystallization start temperature and Tg is the glass transition temperature). However, depending on the composition, ΔTx has a remarkable temperature interval of 30K or more, further 50K or more, and soft magnetism also has excellent characteristics at room temperature.

また本実施形態の非晶質軟磁性合金粉末は、適度な条件で熱処理した場合に結晶質相を析出させることなく内部応力を緩和でき、軟磁気特性をより向上させることができる。   Moreover, the amorphous soft magnetic alloy powder of this embodiment can relieve internal stress without precipitating a crystalline phase when heat-treated under appropriate conditions, and can further improve soft magnetic properties.

本実施形態の非晶質軟磁性合金粉末のＦｅ量（１００−ａ−ｂ−ｘ−ｙ−ｚ−ｗ−ｔ）は、７０原子％以上８３原子％以下であることが好ましく、７０原子％以上８０原子％以下であることがより好ましく、７３原子％以上であることが更に好ましい。このようにＦｅ量が高いことで高い飽和磁化を示す。なおＦｅの添加量が８０原子％を越えると、合金の非晶質形成能の程度を示す換算ガラス化温度（Ｔｇ／Ｔｍ）が０．５４未満になり、非晶質形成能が低下するので好ましくない。なお、上記式においてＴｍは磁性粉末の融点を示す。   The amount of Fe (100-ab-x-yz-wt) in the amorphous soft magnetic alloy powder of this embodiment is preferably 70 atom% or more and 83 atom% or less, and 70 atom%. It is more preferably 80 atomic% or less, and further preferably 73 atomic% or more. Thus, high saturation magnetization is shown by the high amount of Fe. If the added amount of Fe exceeds 80 atomic%, the converted vitrification temperature (Tg / Tm) indicating the degree of amorphous forming ability of the alloy becomes less than 0.54, and the amorphous forming ability decreases. It is not preferable. In the above formula, Tm represents the melting point of the magnetic powder.

前記非晶質軟磁性合金粉末のＣｏ量ａは０〜２０原子％の範囲で可能であり、Ｎｉ量ｂは０〜５原子％の範囲で可能である。Ｃｏはキュリー温度Ｔｃを高めるとともに耐食性を高める効果を有する。しかし、２０原子％を超えるとその分、Ｆｅ量が減り、飽和磁化が１８０×１０-6Ｗｂｍ／Ｋｇ以下になるとともに、ＴｃがＴｇ近傍温度まで上昇し、熱処理し難くなるので望ましくない。Ｎｉは耐食性を向上させる（強磁性元素の中で最も耐食性が高い）が、６原子％以上では飽和磁化が低下する傾向となる。The Co amount a of the amorphous soft magnetic alloy powder can be in the range of 0 to 20 atomic%, and the Ni amount b can be in the range of 0 to 5 atomic%. Co has the effect of increasing the Curie temperature Tc and enhancing the corrosion resistance. However, if it exceeds 20 atomic%, the amount of Fe decreases accordingly, the saturation magnetization becomes 180 × 10 −6 Wbm / Kg or less, and Tc rises to a temperature near Tg, which makes it difficult to perform heat treatment. Ni improves corrosion resistance (highest corrosion resistance among ferromagnetic elements), but saturation magnetization tends to decrease at 6 atomic% or more.

Ｃ、Ｐ、Ｂ及びＳｉは、非晶質形成能を高める元素であり、このうち、少なくとも２種以上を添加すると好ましい。Ｆｅと上記元素Ｍにこれらの元素を添加して多元系とすることにより、Ｆｅと上記元素Ｍのみの２元系とした場合よりも安定して非晶質相が形成される。   C, P, B, and Si are elements that increase the ability to form an amorphous material, and it is preferable to add at least two of these elements. By adding these elements to Fe and the element M to form a multi-component system, an amorphous phase is formed more stably than in the case of a binary system composed of only Fe and the element M.

特にＰはＦｅと低温（約１０５０℃）で共晶組成を持つため、組織の全体が非晶質を形成しやすくなる。また、ＰとＳｉを同時に添加すると、過冷却液体の温度間隔ΔＴｘを発現し易くなって非晶質形成能が向上し、非晶質単相の組織を得る際の製造条件を比較的簡易な方向に緩和できる。   In particular, since P has a eutectic composition with Fe at a low temperature (about 1050 ° C.), the entire structure tends to form an amorphous state. Further, when P and Si are added simultaneously, the temperature interval ΔTx of the supercooled liquid is easily expressed, the amorphous forming ability is improved, and the production conditions for obtaining an amorphous single phase structure are relatively simple. Can relax in the direction.

Ｐの組成比ｙが１５原子％以下であれば、過冷却液体の温度間隔ΔＴｘが発現して合金粉末の非晶質形成能が向上する。   If the composition ratio y of P is 15 atomic% or less, the temperature interval ΔTx of the supercooled liquid is developed, and the amorphous forming ability of the alloy powder is improved.

また、Ｃｒ、Ｍｏ、Ｗ、Ｖ、Ｎｂ、Ｔａ、Ｔｉ、Ｚｒ、Ｈｆに代表される元素Ｍは、合金粉末に不動態化酸化皮膜を形成でき、合金粉末の耐食性を向上できる。これらの元素のうち耐食性の向上に最も効果があるものはＣｒである。水アトマイズ法において、合金溶湯が直接水に触れたとき、更には合金粉末の乾燥工程において生じる腐食部分の発生を防ぐことができる（目視レベル）。また、これらの元素は単独添加するか、あるいは２種以上の組み合わせで複合添加しても良く、例えば、Ｍｏ、ＶとＭｏ、ＣｒとＶ、Ｃｒ及びＣｒ、Ｍｏ、Ｖ等の組合せで複合添加しても良い。これらの元素のうち、Ｍｏ，Ｖは耐食性がＣｒより若干劣るものの非晶質形成能が向上するため、必要に応じてこれらの元素を選択する。   Further, the element M represented by Cr, Mo, W, V, Nb, Ta, Ti, Zr, and Hf can form a passivated oxide film on the alloy powder, and can improve the corrosion resistance of the alloy powder. Among these elements, Cr is most effective for improving the corrosion resistance. In the water atomization method, when the molten alloy is in direct contact with water, it is possible to prevent the occurrence of a corroded portion that occurs in the drying step of the alloy powder (visual level). These elements may be added alone or in combination of two or more, for example, in combination of Mo, V and Mo, Cr and V, Cr and Cr, Mo, V, etc. You may do it. Among these elements, Mo and V are slightly inferior in corrosion resistance to Cr, but the amorphous forming ability is improved. Therefore, these elements are selected as necessary.

上記組成式中の元素Ｍとして採用される元素のうちガラス形成能はＺｒ、Ｈｆが最も高い。Ｔｉ、Ｚｒ、Ｈｆは酸化性が強いため、これらの元素が多く添加されていると、大気中で合金粉末原料を溶解すると原料溶解中に溶湯が酸化し、軟磁気特性（飽和磁化）が低下してしまう。これらの元素も粉末表面の不働態被膜形成に寄与し、耐食性を向上させる。   Of the elements employed as the element M in the composition formula, Zr and Hf have the highest glass-forming ability. Ti, Zr, and Hf are highly oxidizable, so if these elements are added in a large amount, melting the alloy powder raw material in the atmosphere will oxidize the molten metal during melting and lower the soft magnetic properties (saturation magnetization). Resulting in. These elements also contribute to the formation of a passive film on the powder surface and improve the corrosion resistance.

また、磁性粉末としての耐食性向上効果は、Ｐｔ、Ｐｄ、Ａｕのうちから選択される１種又は２種以上の貴金属元素の添加によっても得られ、これら貴金属元素を粉末表面に分散することにより、耐食性が向上する。また、これらの貴金属元素は単独添加あるいは上記のＣｒ等の耐食性向上効果のある元素との組み合わせて複合添加しても良い。上記の貴金属元素はＦｅと混じり合わないため、多く添加されているとガラス形成能が低下し、また、軟磁気特性（飽和磁化）も低下する。   Further, the effect of improving the corrosion resistance as the magnetic powder can be obtained by adding one or more kinds of noble metal elements selected from Pt, Pd and Au, and by dispersing these noble metal elements on the powder surface, Corrosion resistance is improved. These noble metal elements may be added alone or in combination with the above-described elements having an effect of improving corrosion resistance such as Cr. Since the above precious metal elements do not mix with Fe, if a large amount is added, the glass forming ability is lowered, and soft magnetic properties (saturation magnetization) are also lowered.

非晶質軟磁性合金粉末に耐食性を持たせるためには、上記元素Ｍの添加量は０．５原子％以上とすることが好適である。   In order to give the amorphous soft magnetic alloy powder corrosion resistance, it is preferable that the amount of the element M added is 0.5 atomic% or more.

なおＳｎ、Ｉｎ、Ｚｎ、Ｇａ等は、合金を軟化させる効果、アトマイズにて合金粉末を形成する際に球形の形状の粉末を得られ易くする効果があり、このような効果を訴求するために必要に応じて添加すると良い。   Sn, In, Zn, Ga, etc. have the effect of softening the alloy and the effect of making it easy to obtain a spherical powder when forming the alloy powder by atomization. It may be added as necessary.

次に、Ｓｉを添加すると熱的安定性が向上するため、必要に応じて、０．５原子％以上添加してもよい。また、Ｓｉの添加量が８原子％を超えると、融点が上昇してしまう。従ってＳｉ量ｔは、０．５原子％以上８原子％以下であることが必要であり、好ましくは２〜８原子％、より好ましくは３原子％以上７原子％以下の添加量である。   Next, when Si is added, the thermal stability is improved. Therefore, if necessary, 0.5 atomic% or more may be added. On the other hand, if the amount of Si added exceeds 8 atomic%, the melting point increases. Accordingly, the Si amount t needs to be 0.5 atomic% or more and 8 atomic% or less, preferably 2 to 8 atomic%, more preferably 3 atomic% or more and 7 atomic% or less.

このＳｉは本実施形態の非晶質軟磁性合金粉末において重要な元素であり、合金溶湯が水アトマイズ法により水の存在雰囲気で急冷されて非晶質合金化する過程において、非晶質軟磁性合金粉末が腐食されることを先の耐食性向上効果を奏する元素に加えてＳｉが防止する。   This Si is an important element in the amorphous soft magnetic alloy powder of the present embodiment, and in the process where the molten alloy is rapidly cooled in the presence of water by the water atomization method to form an amorphous alloy, Si prevents the alloy powder from being corroded in addition to the elements that have the effect of improving the corrosion resistance.

次に、Ｂ量ｗが１原子％未満では磁性粉末が得られ難く、１２原子％を超えると融点が上昇してしまう。従って、Ｂ量ｗは、１原子％以上１２原子％以下であることが好ましく、２原子％以上１０原子％以下であることがより好ましく、４原子％以上９原子％以下であることがさらに好ましい。   Next, when the B amount w is less than 1 atomic%, it is difficult to obtain a magnetic powder, and when it exceeds 12 atomic%, the melting point increases. Therefore, the B amount w is preferably 1 atom% or more and 12 atom% or less, more preferably 2 atom% or more and 10 atom% or less, and further preferably 4 atom% or more and 9 atom% or less. .

また、Ｃを添加すると熱的安定性が向上するためＣが添加されていることが好ましい。また、Ｃ量ｚが８原子％を超えると、融点が上昇してしまう。従って、Ｃ量ｚは、８原子％以下であることが好ましく、０原子％を超えて６原子％以下であることがより好ましく、１原子％以上４原子％以下であることがさらに好ましい。   Moreover, since thermal stability improves when C is added, C is preferably added. On the other hand, when the C content z exceeds 8 atomic%, the melting point increases. Accordingly, the C amount z is preferably 8 atomic% or less, more preferably 0 atomic% to 6 atomic% or less, and further preferably 1 atomic% or more and 4 atomic% or less.

これらの半金属元素Ｃ、Ｐ、Ｂ及びＳｉの合計の組成比（ｙ＋ｚ＋ｗ＋ｔ）は、１７原子％以上２５原子％以下であることが好ましく、１８原子％以上２５原子％以下とすることが更に好ましい。   The total composition ratio (y + z + w + t) of these metalloid elements C, P, B and Si is preferably 17 atomic percent or more and 25 atomic percent or less, and more preferably 18 atomic percent or more and 25 atomic percent or less. .

半金属元素の合計の組成比が２５原子％を越えると、特にＦｅの組成比が相対的に低下し、飽和磁化が低下するので好ましくない。半金属元素の合計の組成比が１７原子％未満では、非晶質形成能が低下し非晶質相単相組織が得られにくい。   If the total composition ratio of the metalloid elements exceeds 25 atomic%, the composition ratio of Fe is particularly lowered and the saturation magnetization is lowered, which is not preferable. When the total composition ratio of the metalloid elements is less than 17 atomic%, the amorphous forming ability is lowered and it is difficult to obtain an amorphous phase single phase structure.

本実施形態の磁性粉末においては、上記の組成に、Ｇｅが４原子％以下含有されていてもよい。   In the magnetic powder of this embodiment, Ge may be contained in the above composition in an amount of 4 atomic% or less.

上記のいずれの場合の組成においても、本実施形態においては、Ｔｘ／Ｔｍの値が０．５以上、組成によっては０．５５以上が得られる。
また上記の組成で示される元素の他に不可避的不純物が含まれていても良い。In any of the above compositions, in this embodiment, the value of Tx / Tm is 0.5 or more, and depending on the composition, 0.55 or more is obtained.
Further, inevitable impurities may be included in addition to the elements represented by the above composition.

次に、本実施形態の非晶質軟磁性合金粉末は、アスペクト比の平均が１以上３．５以下であることが好ましく、アスペクト比の平均が１以上３以下であることがより好ましく、１．２以上２．５以下であることがさらに好ましい。アスペクト比の平均が３．５を超えると不定形粉末が多くなり、成形密度が低下する。またコア成形した際に非晶質軟磁性合金粉末間の絶縁が取り難くなる。   Next, the amorphous soft magnetic alloy powder of the present embodiment preferably has an average aspect ratio of 1 or more and 3.5 or less, more preferably 1 or more and 3 or less. More preferably, it is 2 or more and 2.5 or less. If the average aspect ratio exceeds 3.5, the amount of amorphous powder increases and the molding density decreases. Moreover, it becomes difficult to take insulation between the amorphous soft magnetic alloy powders when the core is formed.

また、本実施形態の非晶質軟磁性合金粉末は、平均粒径（Ｄ５０）が３０μｍ以下であることが好ましく、Ｄ５０が５μｍ以上、３０μｍ以下であることがより好ましく、９μｍ以上１９μｍ以下であることがさらに好ましい。非晶質軟磁性合金粉末のＤ５０が３０μｍを超えると粉末粒内に渦電流が発生し、コア損失が増加する。３０μｍよりも粒径が大きくなると粉末形状が徐々に異形状化してくる。これは成形密度の低下、透磁率、直流重畳特性の劣化につながる。また、５μｍ未満にすると粉末の反磁界が大きくなり、粉末、圧粉コアの透磁率が低下するとともに、見かけの酸素濃度が高くなる。   The amorphous soft magnetic alloy powder of the present embodiment preferably has an average particle size (D50) of 30 μm or less, more preferably D50 of 5 μm or more and 30 μm or less, and 9 μm or more and 19 μm or less. More preferably. When the D50 of the amorphous soft magnetic alloy powder exceeds 30 μm, eddy currents are generated in the powder grains and the core loss increases. When the particle size becomes larger than 30 μm, the powder shape gradually becomes irregular. This leads to a decrease in molding density, magnetic permeability, and deterioration of DC superimposition characteristics. On the other hand, when the thickness is less than 5 μm, the demagnetizing field of the powder increases, the magnetic permeability of the powder and the dust core decreases, and the apparent oxygen concentration increases.

また、本実施形態の非晶質軟磁性合金粉末は、タップ密度が３．７Ｍｇ／ｍ3以上であることが好ましく、３．８Ｍｇ／ｍ3以上であることがより好ましく、３．９Ｍｇ／ｍ3以上であることがさらに好ましい。このタップ密度が高いとコア本体２の密度が高くなるとともに、圧粉コア１の透磁率、直流重畳特性が向上し、成形体の強度も高まる。The amorphous soft magnetic alloy powder of the present embodiment preferably has a tap density of 3.7 Mg / m 3 or more, more preferably 3.8 Mg / m 3 or more, and 3.9 Mg / m. More preferably, it is 3 or more. When this tap density is high, the density of the core body 2 is increased, the magnetic permeability of the dust core 1 and the direct current superposition characteristics are improved, and the strength of the molded body is also increased.

また、本実施形態の非晶質軟磁性合金粉末は、酸素濃度が３０００ｐｐｍ以下であることが好ましく、２５００ｐｐｍ以下であることがより好ましく、２０００ｐｐｍ以下であることがさらに好ましい。酸素濃度が高くなりすぎると腐食により表面に錆が発生しやすくなり、粉末としての磁気特性を低下させ、圧粉コア１の損失増大、透磁率の低下を引き起こす。   Further, the amorphous soft magnetic alloy powder of the present embodiment preferably has an oxygen concentration of 3000 ppm or less, more preferably 2500 ppm or less, and further preferably 2000 ppm or less. If the oxygen concentration becomes too high, rust is likely to be generated on the surface due to corrosion, the magnetic properties as powder are reduced, and the loss of the dust core 1 is increased and the permeability is reduced.

また、本発明の非晶質軟磁性合金粉末は比表面積が０．４０ｍ2／ｇ以下であることが好ましく、０．３８ｍ2／ｇ以下であることがより好ましく、０．３５ｍ2／ｇ以下であることがさらに好ましい。比表面積が高い粉末は粉末形状に凹凸が多くなり、比表面積が高い粉末は酸素濃度が高くなる。比表面積が高いと粉末間の絶縁がとり難くなり、粉末間の絶縁が取り難くなり、圧粉コア１の成形密度が低下する。透磁率、直流重畳特性も低下する。It is preferable that the amorphous soft magnetic alloy powder of the present invention the specific surface area is less than 0.40 m 2 / g, more preferably not more than 0.38m 2 / g, 0.35m 2 / g or less More preferably. A powder with a high specific surface area has many irregularities in the powder shape, and a powder with a high specific surface area has a high oxygen concentration. When the specific surface area is high, it becomes difficult to take insulation between powders, making it difficult to take insulation between powders, and the molding density of the powder core 1 is lowered. Magnetic permeability and direct current superimposition characteristics also deteriorate.

また、前記結着材はアクリル樹脂からなる。 Further, the binder is an acrylic resin.

図１（ｂ）に示すように、コア本体２の表面には含浸によりメタクリル酸ジエステルからなる被覆層３が形成されている。これにより、磁気特性の低下を抑制しつつ従来に比べてコア強度を向上させることができる。被覆層３の種類によっては、コア強度を向上させることができても磁気特性が劣化したり、磁気特性の劣化は小さいが、コア強度を向上させることができないことがある。これに対して、本実施形態によれば、被覆層３を設けずコア本体２のみで形成した形態（従来例）や、被覆層３をブチラールフェノール樹脂で形成した形態（特許文献１の形態；比較例）と同等の実用レベルの磁気特性を得ることができ、且つ、前記の従来例や比較例に比べてコア強度を大きくすることができる。従来例に対しては約２倍以上、比較例に対しては約１．５倍以上の大きいコア強度が得られることが後述の実験によりわかっている。   As shown in FIG. 1B, a coating layer 3 made of methacrylic acid diester is formed on the surface of the core body 2 by impregnation. Thereby, core intensity | strength can be improved compared with the past, suppressing the fall of a magnetic characteristic. Depending on the type of the coating layer 3, even if the core strength can be improved, the magnetic properties are deteriorated or the deterioration of the magnetic properties is small, but the core strength may not be improved. On the other hand, according to this embodiment, the form (conventional example) formed only by the core main body 2 without providing the coating layer 3, or the form (form of Patent Document 1) in which the coating layer 3 is formed of butyral phenol resin; It is possible to obtain a magnetic property at a practical level equivalent to that of the comparative example) and to increase the core strength as compared with the conventional example and the comparative example. Experiments to be described later show that a large core strength of about 2 times or more is obtained for the conventional example and about 1.5 times or more for the comparative example.

メタクリル酸ジエステルからなる被覆層３は、メタクリル酸ジエステルを主成分としており、メタクリル酸ジエステル以外に微量添加物や不可避的添加物を含むことを除外するものでない。   The coating layer 3 made of methacrylic acid diester contains methacrylic acid diester as a main component, and does not exclude inclusion of a trace additive or unavoidable additive in addition to the methacrylic acid diester.

例えば、前記被覆層３は、アセック株式会社製のＡＳ６７０１の含浸液にコア本体２を浸漬させて形成することができる。   For example, the coating layer 3 can be formed by immersing the core body 2 in an AS6701 impregnating solution manufactured by ASEC Corporation.

また、本実施形態では、前記被覆層３を真空含浸により形成することが好適である。非晶質軟磁性合金粉末が結着材によって固化成形されたコア本体２の内部には空孔が存在する。真空含浸により、より効果的に前記空孔がメタクリル酸ジエステルによる樹脂層で埋められると考えられ、コア強度の更なる向上を図ることが可能になる。   In the present embodiment, it is preferable to form the coating layer 3 by vacuum impregnation. There are pores inside the core body 2 in which the amorphous soft magnetic alloy powder is solidified by the binder. By vacuum impregnation, it is considered that the pores are more effectively filled with a resin layer of methacrylic acid diester, and the core strength can be further improved.

例えばチョークコイルとして本実施形態の圧粉コア１に直にコイルを巻回形成したり、あるいは前記圧粉コア１を樹脂ケースに入れた状態でコイルを巻回形成する。このように圧粉コア１にコイルを巻回したり、圧粉コア１を樹脂ケースに入れるとき、あるいは使用時において、本実施形態の圧粉コア１はコア強度が高いため、従来に比べて破損しにくくできる。   For example, as a choke coil, the coil is wound directly on the dust core 1 of the present embodiment, or the coil is wound while the dust core 1 is placed in a resin case. In this way, when the coil is wound around the dust core 1 or when the dust core 1 is put in a resin case or in use, the dust core 1 of the present embodiment has a higher core strength and is therefore damaged compared to the conventional case. Can be difficult.

続いて圧粉コア１の製造方法を説明する。
まず、上記した組成を備える非晶質軟磁性合金粉末をアトマイズ法により形成する。アトマイズ法には水アトマイズ法あるいはガスアトマイズ法を使用することが好適である。ここで、例えば、水アトマイズ法にて前記非晶質軟磁性合金粉末を製造する際、水の噴射圧力、噴射流量、合金溶湯流量等をコントロールすることにより、目的とする非晶質軟磁性合金粉末のアスペクト比や平均粒径（Ｄ５０）を得ることができる。Then, the manufacturing method of the powder core 1 is demonstrated.
First, an amorphous soft magnetic alloy powder having the above composition is formed by an atomizing method. As the atomization method, it is preferable to use a water atomization method or a gas atomization method. Here, for example, when producing the amorphous soft magnetic alloy powder by the water atomization method, the target amorphous soft magnetic alloy is controlled by controlling the water injection pressure, the injection flow rate, the molten alloy flow rate, etc. The aspect ratio and average particle size (D50) of the powder can be obtained.

続いて、非晶質軟磁性合金粉末を大気雰囲気中で加熱乾燥した後、これらの粉末を分級して、所定の平均粒径を有する球状あるいは球状に近い形状の非晶質軟磁性合金粉末を得る。   Subsequently, after the amorphous soft magnetic alloy powder is heated and dried in the air atmosphere, these powders are classified to obtain a spherical or nearly spherical amorphous soft magnetic alloy powder having a predetermined average particle size. obtain.

得られた非晶質軟磁性合金粉末は必要に応じて熱処理しても良い。熱処理をすることで合金粉末の内部応力が緩和され、非晶質軟磁性合金粉末の磁気特性をより向上できる。   The obtained amorphous soft magnetic alloy powder may be heat-treated as necessary. By performing the heat treatment, the internal stress of the alloy powder is relaxed, and the magnetic properties of the amorphous soft magnetic alloy powder can be further improved.

続いて、前記非晶質軟磁性合金と、結着材及び潤滑材を有してなる添加材とを混合する。混合物中の前記結着材の混合率は、０．３質量％〜５質量％の範囲内であることが好適である。また混合物中の潤滑材の混合率は、０．１質量％〜２質量％の範囲内であることが好適である。前記潤滑材には例えばステアリン酸亜鉛を使用できる。   Subsequently, the amorphous soft magnetic alloy is mixed with an additive having a binder and a lubricant. The mixing ratio of the binder in the mixture is preferably in the range of 0.3% by mass to 5% by mass. The mixing ratio of the lubricant in the mixture is preferably in the range of 0.1% by mass to 2% by mass. For example, zinc stearate can be used as the lubricant.

前記非晶質軟磁性合金と添加材とを混合した後、乾燥・粉砕して造粒粉を得る。
前記造粒粉を、プレス成型の金型に充填しやすいように分級する。例えば目開き３００μｍ以上８５０μｍ以下のふるいを用い分級して得られる３００〜８５０μｍの造粒粉を使用する。The amorphous soft magnetic alloy and the additive are mixed and then dried and pulverized to obtain a granulated powder.
The granulated powder is classified so as to be easily filled in a press mold. For example, granulated powder of 300 to 850 μm obtained by classification using a sieve having an opening of 300 μm or more and 850 μm or less is used.

続いて、前記造粒粉を金型に充填し、圧力を印加しつつ、室温又は所定の温度まで加熱して圧縮成形して所定形状のコア前駆体を得る。例えばプレス圧は２０ｔ／ｃｍ2である。またコア前駆体は例えば図１のような円環形状であり、一例を示すと、外径：２０ｍｍ、内径：１２ｍｍ、高さ：６．８ｍｍである。Subsequently, the granulated powder is filled into a mold, and while applying pressure, it is heated to room temperature or a predetermined temperature and compression molded to obtain a core precursor having a predetermined shape. For example, the press pressure is 20 t / cm 2 . The core precursor has an annular shape as shown in FIG. 1, for example, and has an outer diameter of 20 mm, an inner diameter of 12 mm, and a height of 6.8 mm.

続いて前記コア前駆体を熱処理する。熱処理条件の一例を示すと、Ｎ2ガス雰囲気下で、昇温速度を４０℃／ｍｉｎとし５１０℃で１時間加熱する。これにより、圧縮成形により前記非晶質軟磁性合金粉末に生じた内部応力を除去することができる。Subsequently, the core precursor is heat-treated. As an example of the heat treatment conditions, heating is performed at 510 ° C. for 1 hour under a N 2 gas atmosphere with a temperature increase rate of 40 ° C./min. Thereby, internal stress generated in the amorphous soft magnetic alloy powder by compression molding can be removed.

上記により製造したコア本体２をメタクリル酸ジエステルを溶媒に溶解した含浸液に浸漬し、浸漬した状態で真空排気する。続いて、前記コア本体２を含浸液から引き上げ、洗浄した後、乾燥を行う。これにより、コア本体２の表面にメタクリル酸ジエステルからなる被覆層３を形成することが出来る。   The core body 2 produced as described above is immersed in an impregnating solution obtained by dissolving methacrylic acid diester in a solvent, and evacuated in the immersed state. Subsequently, the core body 2 is pulled up from the impregnating solution, washed, and then dried. Thereby, the coating layer 3 made of methacrylic acid diester can be formed on the surface of the core body 2.

実験では、水アトマイズ法によりＦｅ74at%Ｃｒ2%Ｐ9at%Ｃ2at%Ｂ8at%Ｓｉ5at%の略球状の非晶質磁性粉末を形成した。In the experiment, a substantially spherical amorphous magnetic powder of Fe 74 at% Cr 2% P 9 at% C 2 at% B 8 at% Si 5 at% was formed by a water atomization method.

結着材にシリコーン樹脂を用いて圧粉コア（成形品１）を形成した。また、結着材にアクリル樹脂を用いて圧粉コア（成形品２）を形成した。   A dust core (molded product 1) was formed using a silicone resin as a binder. Moreover, the compacting core (molded product 2) was formed using an acrylic resin as the binder.

そして各成形品を次の３種類にて製造した。
（従来例）・・被覆層を形成しない圧粉コア。
（第１比較例および第３比較例）・・被覆層をブチラールフェノール樹脂で形成した圧粉コア。
（第２比較例および実施例）・・被覆層をメタクリル酸ジエステルで形成した圧粉コア。 And each molded article was manufactured with the following three types.
(Conventional example) ··· A dust core that does not form a coating layer.
( First comparative example and third comparative example) ·· A dust core having a coating layer formed of butyral phenol resin.
( 2nd comparative example and Example) ..- A dust core in which the coating layer is formed of methacrylic acid diester.

第２比較例および実施例では、図１に示すコア本体２をアセック株式会社製のＡＳ６７０１の含浸液中に浸しながら、７分間、真空排気した。続いてコア本体２を含浸液から引き上げ、エタノールにて洗浄した。そして、乾燥炉にて１５０℃で３０分間、乾燥を行った。第１比較例および第３比較例では、ブチラールフェノール樹脂を溶媒に溶解した含浸液を用いた以外、実施例と同じ条件で被覆層を形成した。 In the second comparative example and the example, the core body 2 shown in FIG. 1 was evacuated for 7 minutes while being immersed in the impregnating solution of AS6701 manufactured by ASEC Corporation. Subsequently, the core body 2 was pulled up from the impregnation liquid and washed with ethanol. And it dried for 30 minutes at 150 degreeC with the drying furnace. In the first comparative example and the third comparative example, a coating layer was formed under the same conditions as in the examples except that an impregnating solution obtained by dissolving butyral phenol resin in a solvent was used.

実験では、従来例、比較例及び実施例の各成形品の透磁率及びコアロスを測定した。また従来例、比較例及び実施例の各成形品のコア強度を測定した。コア強度の測定法は、図２に示すようにして行った。そして、成形品が破壊したときに加えた加圧力をコア強度とした。
成形品１（結着材にシリコーン樹脂を使用）に対する実験結果を以下の表１に示す。In the experiment, the magnetic permeability and core loss of each molded product of the conventional example, the comparative example, and the example were measured. Further, the core strength of each molded product of the conventional example, the comparative example, and the example was measured. The core strength was measured as shown in FIG. The pressure applied when the molded product broke was defined as the core strength.
Table 1 below shows the experimental results for the molded product 1 (using a silicone resin as the binder).

Figure 0005327765
Figure 0005327765

表１に示す周波数と透磁率との関係をグラフ化にしたものが図３、表１に示す周波数とコアロスをグラフ化にしたものが図４である。   FIG. 3 is a graph showing the relationship between the frequency and permeability shown in Table 1, and FIG. 4 is a graph showing the frequency and core loss shown in Table 1.

表１及び図３に示すように、第２比較例では、従来例及び第１比較例に比べてやや透磁率が低くなるが第２比較例でも実用レベルをキープしており大差ないことがわかった。また表１及び図３に示すように、第２比較例では、従来例及び第１比較例に比べてややコアロスが大きくなるが第２比較例でも実用レベルをキープしており大差ないことがわかった。 As shown in Table 1 and FIG. 3, in the second comparative example , the permeability is slightly lower than that in the conventional example and the first comparative example, but the practical level is maintained in the second comparative example , and it is understood that there is no great difference. It was. Further, as shown in Table 1 and FIG. 3, in the second comparative example , the core loss is slightly larger than in the conventional example and the first comparative example, but the practical level is maintained in the second comparative example , and it is understood that there is no great difference. It was.

一方、表１に示すコア強度については第２比較例では、従来例の約２倍、第１比較例の約１．５倍に大きくなることがわかった。 On the other hand, the core strength shown in Table 1 in the second comparative example, approximately twice that of the conventional example, it was found that increased about 1.5 times of the first comparative example.

また市販品である結晶性のＦｅ−Ａｌ−Ｓｉ系軟磁性合金粉末を使用した圧粉コアのコア強度は２１９Ｎであったが、第２比較例では市販品とほぼ同等のコア強度が得られた。
次に成形品２（結着材にアクリル樹脂を使用）に対する実験結果を以下の表２に示す。 The core strength of the powder core using the crystalline Fe-Al-Si soft magnetic alloy powder, which is a commercial product, was 219 N. However, in the second comparative example , the core strength almost equal to that of the commercial product was obtained. It was.
Next, Table 2 below shows experimental results for the molded product 2 (using an acrylic resin as a binder).

Figure 0005327765
Figure 0005327765

表２に示す周波数と透磁率との関係をグラフ化にしたものが図５、表２に示す周波数とコアロスをグラフ化にしたものが図６である。   FIG. 5 is a graph showing the relationship between the frequency and magnetic permeability shown in Table 2, and FIG. 6 is a graph showing the frequency and core loss shown in Table 2.

表２及び図５に示すように、実施例では、従来例及び第３比較例に比べてやや透磁率が低くなるが実施例でも実用レベルをキープしており大差ないことがわかった。また表２及び図６に示すように、実施例では、従来例及び第３比較例に比べてややコアロスが大きくなるが実施例でも実用レベルをキープしており大差ないことがわかった。 As shown in Table 2 and FIG. 5, it was found that the magnetic permeability in the example was slightly lower than that in the conventional example and the third comparative example, but the practical level was also maintained in the example and there was no significant difference. Further, as shown in Table 2 and FIG. 6, it was found that the core loss in the example was slightly larger than that in the conventional example and the third comparative example, but the practical level was maintained in the example and there was no significant difference.

なお結着材としてアクリル樹脂を用いた成形品２では、シリコーン樹脂を用いた成形品１に比べて、透磁率が若干劣るものの、コアロスを効果的に改善できることがわかった。   In addition, it turned out that the core loss can be effectively improved in the molded product 2 using the acrylic resin as the binder, although the permeability is slightly inferior to the molded product 1 using the silicone resin.

そして、表２に示すコア強度において、実施例では、従来例の約２．６倍、第３比較例の約１．７倍に大きくなることがわかった。また市販品である結晶性のＦｅ−Ａｌ−Ｓｉ系合金粉末を使用した圧粉コア（コア強度は２１９Ｎ）に対しても約１．３倍に大きくなることがわかった。 The core strength shown in Table 2 was found to be about 2.6 times that of the conventional example and about 1.7 times that of the third comparative example. Moreover, it turned out that it becomes about 1.3 times larger also with respect to the compacting core (core intensity | strength is 219N) which uses the crystalline Fe-Al-Si type alloy powder which is a commercial item.

１ 圧粉コア
２ コア本体
３ 被覆層1 Powder core 2 Core body 3 Coating layer

Claims (4)

非晶質軟磁性合金粉末がアクリル樹脂の結着材によって固化成形されてなるとともに含浸によりメタクリル酸ジエステルからなる被覆層が形成されていることを特徴とする圧粉コア。 A powder core, characterized in that amorphous soft magnetic alloy powder is solidified and formed by an acrylic resin binder and a coating layer made of methacrylic acid diester is formed by impregnation. 前記被覆層は真空含浸により形成される請求項１記載の圧粉コア。   The dust core according to claim 1, wherein the coating layer is formed by vacuum impregnation. 前記非晶質軟磁性合金粉末は、Ｆｅを主成分とし、少なくともＰ、Ｃ、Ｂ、Ｓｉのうち２種以上を含む請求項１又は２に記載の圧粉コア。   3. The powder core according to claim 1, wherein the amorphous soft magnetic alloy powder contains Fe as a main component and includes at least two of P, C, B, and Si. 前記非晶質軟磁性合金粉末は、下記の組成式で形成される請求項３記載の圧粉コア。
Ｆｅ100-a-b-x-y-z-w-tＣｏaＮｉbＭxＰyＣzＢwＳｉt
ただし、ＭはＣｒ、Ｍｏ、Ｗ、Ｖ、Ｎｂ、Ｔａ、Ｔｉ、Ｚｒ、Ｈｆ、Ｐｔ、Ｐｄ、Ａｕより選ばれる１種または２種以上の元素であり、組成比を示すａ、ｂ、ｘ、ｙ、ｚ、ｗ、ｔは、０原子％≦ｘ≦３原子％、０原子％≦ｙ≦１５原子％、０原子％≦ｚ≦８原子％、１原子％≦ｗ≦１２原子％、０．５原子％≦ｔ≦８原子％、０原子％≦ａ≦２０原子％、０原子％≦ｂ≦５原子％、７０原子％≦（１００−ａ−ｂ−ｘ−ｙ−ｚ−ｗ−ｔ）≦８０原子％を示す。 4. The dust core according to claim 3, wherein the amorphous soft magnetic alloy powder is formed by the following composition formula.
Fe 100-abxyzwt Co a Ni b M x P y C z B w Si t
However, M is one or more elements selected from Cr, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd, and Au, and a, b, x indicating the composition ratio , Y, z, w, t are 0 atomic% ≦ x ≦ 3 atomic%, 0 atomic% ≦ y ≦ 15 atomic%, 0 atomic% ≦ z ≦ 8 atomic%, 1 atomic% ≦ w ≦ 12 atomic%, 0.5 atomic% ≦ t ≦ 8 atomic%, 0 atomic% ≦ a ≦ 20 atomic%, 0 atomic% ≦ b ≦ 5 atomic%, 70 atomic% ≦ (100-ab-x-yz-w) -T) <= 80 atomic%.
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