TWI759230B - 金屬粉末及其壓粉體以及此等之製造方法 - Google Patents
金屬粉末及其壓粉體以及此等之製造方法 Download PDFInfo
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Abstract
本發明提供一種金屬粉末,其可製作高飽和磁束密度、耐銹性優異且低鐵損之壓粉磁心。
該金屬粉未係含有以質量濃度計,Si:1.0~15.0%、Cr:1.0~13.0%、Cl:10~10000ppm、S(硫):100~10000ppm及O(氧):0.2~7.0%,且剩餘部分由Fe及不可避免的雜質所構成之金屬粉末,前述金屬粉末之平均粒徑為0.1~2.0μm。藉此,高磁束密度、耐銹性優異且低鐵損之壓粉磁心之製作係變容易。
Description
本發明關於金屬粉末及其壓粉體,尤其關於適合高頻所使用的電感器用核心之由鐵合金所成的金屬粉末及以樹脂結合其之壓粉體、以及此等之製造方法。
於攜帶式機器之領域,尤其以智慧型手機或平板電腦等為代表的小型攜帶式機器中,近年高機能化・多機能化係驚人地進展。伴隨其,對於搭載的電源電路之抗流線圈,強烈要求搭載台數之增加或積體電路IC之高機能化所伴隨的大電流化之對應。又,對應於攜帶式機器之更加小型化・薄型化之要求,線圈本身之小型化・低矮化之要求亦變強。
於抗流線圈,自以往以來使用肥粒鐵材料。然而,由於肥粒鐵的飽和磁束密度低,故若將核心小型化則因核心的飽和而直流疊加特性變差,不使大電流流動。因此,最近,作為小型電感器用核心(磁心)材料,飽和磁束密度高的鐵基金屬磁性微粒子係受到注目。
例如,專利文獻1中揭示一種軟磁性金屬粉末,其組成式為Fe
100-a-bSi
aCr
b(以重量%計,0≦a≦8、0<b≦3),粉末表面之一部分或全體被絕緣性氧化物所覆蓋,粉末表面的Cr濃度高於粉末中心部。又,含有絕緣性氧化物的軟磁性金屬粉末全體之氧量較佳為10質量%以下。此軟磁性金屬粉末係藉由混合原料粉與烷氧化物溶液,進行乾燥後,施予700℃以上的熱處理而製造,可大幅減低壓粉磁心的渦電流損失與磁滯損失之兩者。
又,專利文獻2中揭示一種鐵基軟磁性粉末材,其係結晶質,基本組成係以組成式Fe
100-x-ySi
xCr
y(惟,x:0~15at%,y:0~15at%,x+y:0~25at%)表示,相對於前述組成式之全體量100質量份,添加0.05~4.0質量份的選自Nb、V、Ta、Ti及W之4~6族過渡金屬群中的1種以上之磁性改質微量成分。藉由含有此磁性改質微量成分而減低磁異向性,減輕內部應變。以此專利文獻2中記載的鐵基軟質磁性粉末所製造之壓粉磁心,係可高磁導率化,而且磁心損失亦不增大。
另外,專利文獻3中揭示一種磁性材料,其係藉由將由Fe-Cr-Si系合金所成的金屬粒子在氧化性環境下熱處理而得之粒子成形體。而且,所使用的金屬粒子係關於成形前的金屬粒子之XPS測定的709.6eV、710.7eV及710.9eV之各波峰的積分值之和Fe
Oxide與706.9eV之波峰的積分值Fe
Metal,Fe
Metal/(Fe
Metal+Fe
Oxide)為0.2以上之Fe-Cr-Si系合金粒子。尚且,Cr之含有範圍為2.0~15wt%。所得之粒子成形體具有複數的金屬粒子、被覆金屬粒子的由金屬粒子之氧化物所成的氧化被膜與氧化物被膜彼此之結合部,藉此,成為高磁導率且高絕緣電阻之磁性材料。
還有,專利文獻4中揭示一種Fe基軟磁性金屬粉體,其具有於Fe中以質量%計,Si:7~9%、Cr:2~8%連同不可避免的雜質之組成,平均粒徑D50設為1~40μm,將氧量抑制在0.60質量%以下。藉此,可得到高的磁導率,同時可成為壓低鐵損,耐蝕性亦優異之磁心。
又,專利文獻5中揭示一種軟磁性金屬粉末,其以鐵作為主成分之粉末,以質量%計,含有100~995ppm的碳、3~15%的Si,粒子內含有的氧較佳為500ppm以下,且可含有Ni:30~80%、Cr:10%以下。藉此,可成為保磁力低的軟磁性金屬粉末,藉由使用此軟磁性金屬粉末而改善壓粉核心之損失。
再者,專利文獻6中揭示一種金屬粉末,其係以Fe作為主成分,以質量%計,含有1~10%的Si、1~13%的Cr、10~10000ppm的Cl,較佳為以質量%計,含有1~7%的O(氧),且平均粒徑為0.1~3.0μm。藉此,作為電感器用,與以往的磁性體相比,低保磁力且與樹脂的親和性較高,耐銹性優異,而且可製造能製作且高飽和磁束密度、低鐵損的壓粉磁心之金屬粉末。
先前技術文獻
專利文獻
專利文獻1:日本特開2008-195986號公報
專利文獻2:日本發明專利第5354101號公報
專利文獻3:日本特開2013-26356號公報
專利文獻4:日本特開2014-78629號公報
專利文獻5:日本特開2017-92481號公報
專利文獻6:日本特開2020-76135號公報
發明所欲解決的課題
然而,於專利文獻1~5記載之技術中,金屬粉末與樹脂之親和性低,以樹脂被覆金屬粉末的表面全面者係困難,故金屬粉末彼此間的潤滑性差,無法一邊確保金屬粉末彼此的電絕緣,一邊提高金屬粉末的填充密度,故有無法提高作為壓粉磁心的磁導率及磁束密度之問題。
再者,於專利文獻6記載之技術中 ,藉由添加Cl,而提高與樹脂的親和性,填充密度升高,改善作為壓粉磁心的磁心損失(以下亦稱為「鐵損」)等之磁心特性,但在高頻使用的電感器用核心,係與發熱之戰鬥,對於更小型化、薄型化的嚴格要求,於低鐵損化(即發熱量減低)之觀點中的磁心特性係還有不能說是充分之問題。
本發明之目的在於解決該習知技術之問題,提供:作為高頻使用的電感器用核心,可製作對應於小型化、薄型化之更嚴格的要求之具有高磁束密度與低鐵損之優異磁心特性的壓粉磁心,低保磁力且與樹脂的親和性高,耐銹性優異,且高飽和磁化之金屬粉末及其壓粉體以及此等之製造方法。
解決課題的手段
本發明者們為了達成上述目的,專心致力地檢討壓粉體的磁特性與電特性。結果,發現重要的是成為在Fe中含有適當量的Si、Cr,進而含有適當量的Cl與S(硫)之金屬粉末(鐵合金粉末)。特別地,新穎地得知:適當量的Cl與S(硫)之存在,係提高與樹脂的親和性,提高粉末的填充密度,可使高磁束密度且低鐵損的壓粉磁心之製作成為容易。
本發明係以如此的知識見解為基礎,加以進一步的檢討而完成者。即,本發明之要旨係如以下。
[1] 一種金屬粉末,其係含有以質量濃度計,Si:1.0~15.0%、Cr:1.0~13.0%、Cl:10~10000ppm、S(硫):100~10000ppm及O(氧):0.2~7.0%,且剩餘部分由Fe及不可避免的雜質所構成之金屬粉末,其特徵在於:前述金屬粉末之平均粒徑為0.1~2.0μm。
[2] 一種壓粉體,其特徵為如[1]記載之前述金屬粉末與樹脂之結合物。
[3] 如[2]中之壓粉體,其中前述樹脂為熱硬化性樹脂、紫外線硬化型樹脂或熱塑性樹脂。
[4] 一種金屬粉末之製造方法,其特徵為藉由化學氣相法,生成金屬粉末,前述金屬粉末係含有以質量濃度計,Si:1.0~15.0%、Cr:1.0~13.0%、Cl:10~10000 ppm、S(硫):100~10000ppm及O(氧):0.2~7.0%,且剩餘部分由Fe及不可避免的雜質所構成之金屬粉末,前述金屬粉末之平均粒徑為0.1~2.0μm。
[5] 一種壓粉體之製造方法,其特徵為藉由化學氣相法,生成含有以質量濃度計,Si:1.0~15.0%、Cr:1.0~13.0%、Cl:10~10000ppm、S(硫):100~10000ppm及O(氧):0.2~7.0%,且剩餘部分由Fe及不可避免的雜質所構成之金屬粉末,於前述金屬粉末中,混合樹脂,進行壓縮成形。
[6] 如[5]中之製造方法,其中前述樹脂為熱硬化性樹脂、紫外線硬化型樹脂或熱塑性樹脂。
發明的效果
根據本發明,可使高磁束密度且低鐵損的壓粉磁心之製作成為容易,低保磁力、樹脂密著性優異、耐銹性亦優異的金屬粉末係可容易地製造,達成產業上顯著的效果。
實施發明的形態
以下,詳細說明本發明之實施態樣。
[金屬粉末之組成]
本發明之金屬粉末係以Fe作為主成分之金屬粉末(鐵合金粉末)。亦即,本發明之金屬粉末係含有以質量濃度計,Si:1.0~15.0%、Cr:1.0~13.0%、Cl:10~10000 ppm、S(硫):100~10000ppm及O(氧):0.2~7.0%,剩餘部分由Fe及不可避免的雜質所構成之金屬粉末,前述金屬粉末之平均粒徑為0.1~2.0μm。以下,組成中的%及ppm意指質量濃度。
以下,說明組成限定之理由。
[Si:1.0~15.0%]
於以Fe作為主成分的金屬粉末(鐵合金粉末)中,Si係固溶於金屬(Fe)中,有助於金屬粉末之電阻的增大與磁致伸縮的減小之元素。磁致伸縮係隨著Si含量之增大而減小,以6.5%左右之含量成為幾乎零,若進一步增大含量,則磁致伸縮進一步減小而成為負值。另一方面,電阻(比電阻)係隨著Si含量之增大而大幅增大。磁致伸縮的絕對值之減小係有助於磁滯損失的減低,電阻的增大係有助於渦電流損失的減低。
於直流磁場的使用或商用頻率程度之低頻的使用中,由於佔總損失中的磁滯損失之比例大,故在Si含量6.5%附近之組成,損失成為最小,此組成附近之含量為適宜。然而,於工作頻率更高的區域中,由於佔總損失中的渦電流損失之比例增大,故在Si含量更多之組成,損失成為最小而適宜。若工作頻率更上升,變成MHz之區域,則由於佔總損失中的渦電流損失之比例進一步增大,故在Si含量進一步多的組成,損失成為最小而適宜。
如此地,按照用途,Si係在寬廣的組成範圍中得到合適的效果,但Si之含量未達1.0%時,磁致伸縮的減低效果或電阻的增大皆不充分而不適合。又,Si之含量超過15.0%時,磁致伸縮的絕對值亦大,由於飽和磁化之降低亦非常大,故於製作壓粉磁心時,亦得不到所欲的磁特性。因此,Si係限定於1.0~15.0%之範圍,較佳為3.0~15.0%,更佳為6.0~14.0%。
[Cr:1.0~13.0%]
Cr雖然使金屬粉末的磁特性降低,但是為使耐蝕性提升之元素,於本發明之金屬粉末中為了得到耐蝕性之效果,較佳為含有1.0%以上。Cr為未達1.0%之少時,粒子表面變容易生銹。另一方面,超過13.0%而大量含有時,飽和磁化(emu/g)係降低。因此,Cr係限定於1.0~13.0%之範圍。尚且,較佳為1.0~6.0%。更佳為1.0~4.0%。此處,所謂耐蝕性,就是後述的耐銹性。
[Cl:10~10000ppm]
Cl(氯)係有助於金屬粒子表面與樹脂的親和性提升之元素,具有使成為壓粉磁心時的金屬粉末之填充密度提高,使壓粉磁心的磁束密度提高之效果。為了得到如此的效果,必須含有10ppm以上。Cl為未達10ppm之少時,金屬粉末的粒子表面與樹脂之親和性低,在金屬粉末粒子之周圍容易產生空隙,無法達成所欲的填充密度。另一方面,若Cl之含量超過10000ppm而大量地含有,則有因從表面的吸濕而促進生銹之虞。因此,Cl係限定於10~10000 ppm之範圍。尚且,較佳為10~1000ppm。更佳為10~500 ppm。
[S(硫):100~10000ppm]
S(硫)係於Cl之存在下添加,而使金屬粒子表面與樹脂之親和性進一步提升之元素,可使成為壓粉磁心時的金屬粉末之填充密度(亦即,樹脂中的金屬粉末之體積率%)比Cl單獨添加之情況更提高,此填充密度之提高係具有使壓粉磁心的磁導率大幅提高之效果。為了得到如此的效果,必須含有100ppm以上。S(硫)為未達100ppm之少時,看不到粉末粒子表面與樹脂的親和性改善之追加效果,僅能達成與Cl單獨添加之情況相同水準的70%之填充密度。另一方面,若S(硫)之含量之含量超過10000ppm而大量地含有,則因從表面的吸濕而生銹,與樹脂的親和性降低,填充密度亦降低。因此,於本發明中S(硫)係限定於100~10000ppm之範圍。尚且,較佳為200~8000ppm,更佳為300~6000ppm。
此處的壓粉磁心中的金屬粉末之體積率的改善幅度,係如由後述的實施例之數據可知,雖然從比較例的70%到發明例的72%之稱為2%的乍看很小的值,但是超越與單一尺寸的剛體球密填充模型幾何學的體積率之極界值74%之值接近的70%之上的更+2%,係形成壓粉體的骨架之大粒徑的粉末粒子被填充到接近幾何學的極限之狀態,為在其間隙中,若不實現更小的粒徑之粉末粒子填充的理想配置的話,則無法到達之體積率,從粉末粒子的填充率與粉末粒子表面的樹脂所致的絕緣之兼備為必要條件的限制來看,為在粉末粒子與樹脂之間存在空隙時實現困難的體積率。本發明者們發現於Cl之存在下的S(硫)之添加,即使為到此為止之緻密填充狀態,也具有不使樹脂從粒子之表面剝離而只追隨之賦予與樹脂的親和性之效果。
又,金屬粉末之體積率為超越70%之上的更+2%之改善,從磁特性之觀點看亦具有大的意義。鐵損係在Cl單獨添加(前述之專利文獻6)之階段中,已經為相當的水準,說起來使鐵損超過其地降低者為困難。
對於壓粉磁心之鐵損造成影響的要素之一個的壓粉磁心之飽和磁束密度,由於與壓粉磁心中的金屬粉末之體積率大致成比例,故從接近填充的體積率之上限的階段,無法期待超過其的大幅改善。可是,同樣對於壓粉磁心之鐵損造成大的影響之要素的壓粉磁心之磁導率,由於大幅受到粒子間之距離的影響,故隨著接近填充的極限(即粒子間的距離為零),去磁場(demagnetizing field)急劇地減少,磁導率急劇地增加。因此,金屬粉的體積率之踏實的改善係牽涉鐵損的降低,於體積率改善前之階段,在已經充分小的水準之壓粉磁心的鐵損,係藉由本發明帶來更大幅降低的結果。
[O(氧):0.2~7.0%]
O(氧)係在表面作為氧化物存在,具有抑制金屬粉末表面活化之作用。為了得到如此的效果,較佳為含有0.2%以上的O(氧)。由於O(氧)為少,對於粉末的磁特性沒有造成不良影響,但未達0.2%時,金屬粉末表面係因活性而容易起火,大氣中的操作變困難。另一方面,若超過7.0%而大量地含有,則飽和磁化係降低。因此,O(氧)係限定於0.2~7.0%之範圍。尚且,較佳為0.3~3.0%,更佳為1.0~2.0%。
[不可避免的雜質]
上述成分以外之剩餘部分為Fe及不可避免的雜質。
作為雜質元素,首先可舉出Ni。作為Fe源,使用Fe-Ni合金廢料或沃斯田鐵系不銹鋼廢料等作為原料時等,Ni係作為雜質元素混入。Ni作為副原料或雜質混入,而使Fe含量降低時,為使金屬粉末的飽和磁化降低之元素,宜儘量減低,但Ni係其他的雜質元素相比,使保磁力增加者亦少,且由於使飽和磁化降低的作用緩慢,故若為10%以下之含量則可容許。尚且,為了提高作為核心的飽和磁束密度,Ni更佳設為5%以下,尤佳為3%以下。
作為Ni以外之不可避免的雜質,可舉出C、N、P、Mn、Cu、Al等。此等元素係金屬粉末的飽和磁化降低之元素,只要合計為3%以下之含量,則由於不發生實用上可謂致命的磁特性之降低,故可容許,但合計更佳設為1%以下。
[金屬粉末之平均粒徑]
接著,本發明之金屬粉末具有上述組成,平均粒徑係設為0.1~2.0μm的粒子(粉末)。此處所言的「平均粒徑」,就是以掃描型電子顯微鏡(SEM)觀察金屬粉末粒子,拍攝影像,以倍率2萬倍且藉由測定粒子數1000~2000個的SEM影像解析,所求出的個數基準之D50。平均粒徑未達0.1μm時,與樹脂混煉時容易發生凝聚,由於填充率不上升,故作為壓粉磁心的飽和磁束密度係降低。另一方面,若平均粒徑超過2.0μm,則鐵損尤其高頻中的鐵損係增加。因此,本發明之金屬粉末之平均粒徑係限定於0.1~2.0μm之範圍。尚且,較佳為0.1~1.5μm。更佳為0.1~1.0μm。
[金屬粉末之磁特性]
[保磁力]
本發明中的金屬粉末之保磁力的測定,係將金屬粉末置入指定的容器中,使石蠟熔解、凝固而固定者,使用振動試料型磁力計(VSM),於外加磁場:1200kA/m之條件下測定它。於本發明目的之電感器或變壓器的磁心等之用途中,保磁力宜小。
[飽和磁化]
本發明中的金屬粉末之飽和磁化之測定,係與前述保磁力之測定同樣地,使用VSM,於外加磁場:1200kA/m之條件下測定。於本發明目的之電感器或變壓器的磁心等之用途中,飽和磁化宜大。
[金屬粉末之耐銹性]
作為金屬粉末之耐銹性測定方法,將金屬粉末埋入樹脂內而固定後,鏡面研磨剖面,當作耐銹性測定用試驗片,將此試驗片在恆溫恆濕槽中保持指定時間後,對於試驗片內之粒子,隨機選定20個,觀察有無生銹,算出生銹的粒子之比例(生銹率)。尚且,恆溫恆濕槽係在溫度:60℃、相對濕度:95%之條件下保持。又,恆溫恆濕槽中的保持時間係設為2000小時。如此所求出的本發明之金屬粉末的生銹率,從不發生使用上的不良狀況來看,較佳為10%以下。再者,更佳為5%以下。
[金屬粉末之製造方法]
接著,說明本發明之金屬粉末之製造方法。
本發明之金屬粉末係以氣體霧化法或水霧化法等皆可製造,但較佳為使用化學氣相法(Chemical Vapor
Deposition:以下稱為「CVD」)來製造。
CVD之製程係使Fe、Si及Cr的合金元素與高溫的氯氣反應,將所生成的各元素之氯化物氣體或Fe、Si及Cr的各元素之氯化物加熱至高溫而氣化的氯化物氣體,與使S(硫)在高溫下氣化的氣體,以指定的比率混合而成之混合氣體,使其在各自適合的溫度下與氫反應而將氯化物還原,得到含有Si、Cr、S(硫)之所欲組成的金屬粉末。本發明之金屬粉末的CVD之製造方法,由於可以成為所欲的平均粒徑之方式調整氯化物氣體的濃度、反應溫度及反應時間,因此較宜。
反應(還原反應)後,所得之金屬粉末係進一步施予洗淨步驟。洗淨步驟係使用溶劑,洗淨所得之金屬粉末,將Cl調整至10000ppm以下之步驟。此處,作為所使用的溶劑,較佳為使用能溶解未還原的氯化物或因還原反應而生成的副生成物之溶劑。作為如此之溶劑,可例示水等之水溶性無機溶劑,或者乙醇等之脂肪族醇類般的有機溶劑。
[壓粉體]
藉由使本發明之金屬粉末在樹脂中分散,可容易製作填充密度高的低磁心損失之壓粉體。
作為壓粉體之製造方法,並沒有特別的限制,可用眾所周知之方法來製造。首先,混合前述金屬粉末與作為黏合劑的樹脂,得到前述金屬粉末分散於樹脂中之混合物。又,視需要亦可將所得之混合物造粒而成為造粒物。藉由將該混合物或造粒物壓縮成形,而得到成形體(壓粉體)。
作為黏合劑混合的樹脂,較佳為與前述金屬粉末表面的親和性提升之樹脂,具體而言,較佳為熱硬化性樹脂、紫外線硬化型樹脂或熱塑性樹脂。作為熱硬化性樹脂,可舉出環氧樹脂、酚樹脂、尿素樹脂、三聚氰胺樹脂、不飽和聚酯樹脂、聚胺基甲酸酯樹脂、鄰苯二甲酸二烯丙酯樹脂等。又,作為紫外線硬化型樹脂,可舉出胺基甲酸酯丙烯酸酯樹脂、環氧丙烯酸酯樹脂、聚酯丙烯酸酯樹脂等。再者,作為熱塑性樹脂,可舉出聚苯硫樹脂、尼龍樹脂(聚醯胺系樹脂)。此等樹脂顯示提高與前述金屬粉末表面的親和性之效果。
然後,將混合物或造粒粉填充於模具內,進行壓縮成形,得到具有應製作的壓粉體之形狀的成形體(壓粉磁心)。尚且,使用熱硬化性樹脂作為樹脂時,宜在50~200℃下進行熱處理。所得之壓粉體係前述金屬粉末與樹脂緊密結合之結合物。
[壓粉體之鐵損]
磁心損失(鐵損)係於具有磁性材的磁心之電感器或變壓器等之線圈中,由於其磁心的物性而發生的損失,為使變壓器等之效率降低的主要因素之一。鐵損之測定係將在環氧樹脂中混合分散有金屬粉末之混合粉填充於環狀模具(外徑:13.0mm、內徑:8.0mm),於加壓成型後,使樹脂硬化,成為厚度:3.0mm的環形核心(壓粉磁心),給予1次側20匝、2次側20匝的捲線而成為線圈。對於該線圈,使用B-H分析儀(岩通計測股份有限公司製SY-8218),於磁束密度0.025T、頻率1MHz之條件下測定鐵損。本發明之壓粉體的鐵損為500kW/m
3以下。更佳為450kW/m
3以下。
實施例
以下,舉出前述金屬粉末之製造方法的一實施態樣之CVD製程的實施例,具體地說明本發明。惟,本發明不受以下說明的實施例所僅限定。
首先,作為原料,分別準備Fe的氯化物、Si的氯化物、Cr的氯化物。然後,藉由CVD反應裝置,將此等氯化物加熱至高溫(900~1200℃,較佳為1000℃左右),使氯化物氣化,生成各元素的氯化物氣體。再者,以高溫(900~1200℃)使S(硫)氣化・加熱而生成氣體。將所生成的各元素之氯化物氣體與使S(硫)氣化之氣體,以成為目的之金屬粉末之組成的方式,使混合比率變化而混合,得到以金屬氯化物作為主體的混合氣體。將所得之混合氣體與氫氣及成為載體氣體的氮氣(氣體溫度:900~1200℃,氣體流量10~500Nl/min)一起送到CVD反應爐,於指定的反應爐溫度(900~1200℃)下使其反應,而將氯化物還原,得到金屬粉末。金屬粉末之組成係如前述,以金屬氯化物氣體等之混合比率來控制,平均粒徑係藉由原料的氯化物氣體濃度、反應溫度的高低及反應時間的長短來控制。
接著,於所得之金屬粉末,施予使用純水洗淨的洗淨步驟,而調整Cl含量。
表1中顯示所製作的金屬粉末之組成及其粉末特性,以及壓粉體的特性。
此處,金屬粉末中含有的合金元素(Si、Cr)之含量,係使用ICP(感應耦合電漿)進行測定。尚且,金屬粉末中含有的Cl、S(硫)及O(氧)係使用燃燒法進行測定。又,對於所得之金屬粉末,使用SEM,藉由前述方法・條件進行觀察及拍攝,藉由影像解析求出D50,當作平均粒徑。
對於所得之各自的金屬粉末,調查磁特性(保磁力、飽和磁化)及耐銹性以及金屬粉末的壓粉體之填充密度(體積率)及鐵損。調査方法係如前述,但具體而言如以下。
關於磁特性,對於所得之各種金屬粉末,使用振動試料型磁力計(東英工業公司製),測定保磁力、飽和磁化。
關於耐銹性,對於所得之各種金屬粉末,藉由前述耐銹性測定試驗,觀察有無生銹,算出生銹的粒子之比例(生銹率)。
填充密度係以樹脂中之金屬粉末的體積基準之比例(體積率:%)表示。
關於鐵損,亦以前述方法及條件進行測定。
表1中一併記載所得之結果。
本發明例皆為12Oe以下的低保磁力,保持170emu/g以上的高飽和磁化,耐銹性優異之金屬粉末,再者成為壓粉磁心時,達成能製作鐵損為500kW/m
3以下的鐵損低之壓粉磁心的顯著效果。
另一方面,本發明之範圍以外的比較例,係保磁力超過12Oe之高,或飽和磁化未達170emu/g之低,或耐銹性降低之金屬粉末,或者作為壓粉磁心時的樹脂中之金屬粉末的體積率為70%以下之低,鐵損超過650kW/m
3而成為鐵損高的壓粉磁心。
此處,於表1中,金屬粉末No.1~9係O(氧)為0.3%,使Si變化之數據,No.10~20係O(氧)為1.0%,使Si變化之數據,No.21~28係使Cr變化,使一部分Si亦變化之數據,No.29~37係使Cl變化,使一部分Si亦變化之數據,No.38~49係使S(硫)變化,使一部分Si亦變化之數據,No.50~54係使O(氧)變化之數據,No.55~75係使平均粒徑變化,使一部分Si亦變化之數據。又,畫底線之數據表示合適範圍外,再者,例如「50<」意指「大於50」。
Claims (6)
- 一種金屬粉末,其係含有以質量濃度計,Si:1.0~15.0%、Cr:1.0~13.0%、Cl:10~10000ppm、S(硫):100~10000ppm及O(氧):0.2~7.0%,且剩餘部分由Fe及不可避免的雜質所構成之金屬粉末,其特徵在於:前述金屬粉末之平均粒徑為0.1~2.0μm。
- 一種壓粉體,其特徵為如請求項1之前述金屬粉末與樹脂之結合物。
- 如請求項2之壓粉體,其中前述樹脂為熱硬化性樹脂、紫外線硬化型樹脂或熱塑性樹脂。
- 一種金屬粉末之製造方法,其特徵為藉由化學氣相法,生成金屬粉末,前述金屬粉末係含有以質量濃度計,Si:1.0~15.0%、Cr:1.0~13.0%、Cl:10~10000ppm、S(硫):100~10000ppm及O(氧):0.2~7.0%,且剩餘部分由Fe及不可避免的雜質所構成之金屬粉末,前述金屬粉末之平均粒徑為0.1~2.0μm。
- 一種壓粉體之製造方法,其特徵為藉由化學氣相法,生成含有以質量濃度計,Si:1.0~15.0%、Cr:1.0~13.0%、Cl:10~10000ppm、S(硫):100~10000ppm及O(氧):0.2~7.0%,且剩餘部分由Fe及不可避免的雜質所構成之金屬粉末,於前述金屬粉末中,混合樹脂,進行壓縮成形。
- 如請求項5之壓粉體之製造方法,其中前述樹脂為熱硬化性樹脂、紫外線硬化型樹脂或熱塑性樹脂。
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