WO2006077872A1 - Gap sheet and magnetic core having such gap sheet inserted therein - Google Patents
Gap sheet and magnetic core having such gap sheet inserted therein Download PDFInfo
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- WO2006077872A1 WO2006077872A1 PCT/JP2006/300622 JP2006300622W WO2006077872A1 WO 2006077872 A1 WO2006077872 A1 WO 2006077872A1 JP 2006300622 W JP2006300622 W JP 2006300622W WO 2006077872 A1 WO2006077872 A1 WO 2006077872A1
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- gap
- soft magnetic
- powder
- gap sheet
- sheet
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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
- H01F3/10—Composite arrangements of magnetic circuits
- H01F3/14—Constrictions; Gaps, e.g. air-gaps
Definitions
- the present invention relates to a magnetic core of an inductance component such as a choke coil or a transformer used for a switching power supply or the like, and particularly relates to a gap sheet inserted into a gap of the magnetic core.
- ferrite cores are mainly used as high-frequency magnetic cores, but ferrite cores have high initial permeability and low saturation magnetic flux density, whereas dust cores have initial permeability. It is characterized by material properties such as low magnetic susceptibility and high saturation magnetic flux density. For this reason, ferrite cores are used as EE cores or EI cores, for example, by forming a gap at the middle leg of an E-type core to reduce the decrease in inductance with respect to direct current.
- the gap width must be strictly controlled while applying force, and high-precision cutting is required, and the shape of the gap portion must be changed according to the required DC superposition characteristics. It was. In addition, since the gap width is narrow, the DC superimposition characteristic on the high current side is deteriorated. [0006] Further, as a method of improving the DC superposition characteristics on the high current side, a method of inserting a bond magnet into the gap has been proposed (for example, see Patent Document 2 or 3).
- Patent Document 1 Japanese Patent Application Laid-Open No. 11 340064
- Patent Document 2 Japanese Patent Laid-Open No. 2003-007520
- Patent Document 3 Japanese Patent Application Laid-Open No. 2004-247409
- Patent Document 2 or 3 The method described in Patent Document 2 or 3 is an excellent method for the purpose of improving DC superposition characteristics, and suppresses an increase in core loss of a magnetic core by insulating between rare earth magnet powders. There is a problem that it is difficult to cope with inductance that varies with the superimposed current depending on the application.
- the present invention has been made in view of such problems of the prior art, and an object of the present invention is to provide an inexpensive magnetic core that can easily cope with the required DC superposition characteristics! / Means to solve the problem
- the present invention is characterized in that soft magnetic properties are characterized in that they are inserted into a magnetic core having a gap in at least one location of a magnetic path and are formed of a composite material of soft magnetic powder and resin. It is a gap sheet.
- the surface of the soft magnetic powder may be insulated.
- the soft magnetic powder may be a mixed powder of two or more having different magnetic properties.
- a composite gap sheet can be formed by combining two or more gap sheets including at least one soft magnetic gap sheet.
- the composite gap sheet includes at least one gap sheet having magnetic properties different from those of the soft magnetic gap sheet!
- At least one gap sheet having a different resin from that contained in the soft magnetic gap sheet may be included!
- the present invention is a magnetic core having a gap in at least one part of a magnetic path, and a gap sheet having a composite material force of soft magnetic powder and resin is inserted in a gear.
- the gap sheet inserted into the magnetic core preferably includes at least one of the above-described soft magnetic gap sheet or composite gap sheet.
- the gap sheet to be inserted into the magnetic core having a gap in at least one part of the magnetic path is formed of the composite material of the soft magnetic powder and the resin, so that the low current region can be obtained. It is possible to obtain DC superposition characteristics that show high V ⁇ inductance and DC superposition characteristics that extend to the high current side, and it is possible to easily design the desired DC superposition characteristics.
- Fig. 1 is a graph showing the DC superposition characteristics of an EE core in the case where a gap sheet useful for the present invention is inserted into an EE core having a gap width of 3 mm.
- FIG. 2 is a graph showing the DC superposition characteristics of an EE core when a gap sheet that is useful for the present invention is inserted into an EE core having a gap width of 5 mm.
- FIG. 3 is a graph showing the DC superposition characteristics of an EE core when a gap sheet that is useful for the present invention is inserted into an EE core having a gap width of 4 mm.
- the inventors of the present application insert a soft magnetic gap sheet made of a composite material of soft magnetic powder and resin into the gap portion of the magnetic core.
- a desired DC superimposition characteristic can be easily designed.
- a magnetic core such as a choke coil or a transformer can be arbitrarily selected according to required characteristics as long as it has a soft magnetic property, and ferrite, sendust, carbon iron, silicon steel plate, amorphous, etc. are used. be able to.
- the shape of the magnetic core any shape such as a toroidal core, an EE core, or an EI core, which has a gap at one or more places in the magnetic path, can be applied.
- the gap width provided in the magnetic core is not particularly limited, but the gap width is determined according to the type of magnetic core material, the magnetic core shape, and the required DC superposition characteristics.
- the soft magnetic powder used for the soft magnetic gap sheet is not particularly limited as long as it is a material having soft magnetic properties.
- ferrite, sendust, carbonyl iron, permalloy, An amorphous powder or the like can be used.
- the resin used for the soft magnetic gap sheet is selected according to the manufacturing conditions, the usage environment, etc. as an inductance component that is not particularly limited as long as it can be combined with the soft magnetic powder.
- polyamide resin aromatic polyamide resin, polyimide resin, polyphenylene sulfide resin, liquid crystal resin, epoxy resin, acrylic resin, and the like can be used.
- a method of mixing and molding a filler with a general resin material which is not particularly limited in the method of forming a soft magnetic gap sheet by combining soft magnetic powder and resin.
- a doctor blade method, a hot press method, an injection molding method, or the like can be used.
- a mechanical method such as a plating method, a vacuum deposition method, a CVD method, a PVD method, or a ball mill is used, which is not particularly limited to the insulation treatment method. be able to. Moreover, you may use the method mentioned later.
- a plurality of soft magnetic powders can be used for the soft magnetic gap sheet, and the combination thereof is not particularly limited.
- a method of combining soft magnetic powders having different compositional forces a method of combining soft magnetic powders having the same composition but different crystal structures, a method of combining soft magnetic powders of different shapes, and soft magnetic materials having different particle sizes.
- a composite gap sheet by combining two or more gap sheets including at least one soft magnetic gap sheet, and the combination is not particularly limited.
- the combination is not particularly limited.
- the same resin that is not particularly limited in the combination of the resin used in the composite gap sheet.
- the gap sheets used may be combined, for example, a resin having a different linear expansion coefficient, a resin having a different insulating property, or a resin having a different elastic modulus!
- Soft magnetic materials include oxide-based materials such as ferrite, carbon iron, Fe-Si alloys, Ni-Fe alloys, and Fe-based or Co-based amorphous alloys. Material is included. It is preferable to use a soft magnetic amorphous alloy that is superior to crystalline materials in terms of corrosion resistance, wear resistance, strength, or soft magnetic properties such as high magnetic permeability and low coercive force.
- the soft magnetic amorphous alloy is not particularly limited, and a known amorphous alloy such as iron or cobalt can be used.
- Examples of the inorganic insulating material include Al 2 O, SiO, Y 2 O, MgO, and ZrO.
- Insulating metal or metalloid oxide such as 2 3 2 2 3 2, or glass material, or a mixture thereof can be used. Glass materials are preferred, and low-melting glass is particularly preferred. This is because it has a low softening temperature and can be fused to the soft magnetic amorphous alloy to cover the surface.
- the low melting point glass is not particularly limited as long as it does not react with the soft magnetic powder and softens at a temperature lower than the crystallization start temperature of the soft magnetic amorphous alloy, preferably about 550 ° C or less. It is not limited. Examples include lead glass such as PbO—B 2 O glass, PO glass, ZnO—BaO
- Pb-based glass which is lead-free glass and gives a low soft spot, is preferred.
- thermoplastic resin or thermosetting resin can be used as the resin used.
- thermoplastic resin examples include polyolefins such as polyethylene and polypropylene, polybutyl alcohol, polyethylene oxide, polyphenylene sulfide (PPS), liquid crystal polymer, polyetheretherketone (PEEK), polyimide, and polyetherimide.
- PPS polyphenylene sulfide
- PEEK polyetheretherketone
- thermosetting resin for example, phenol resin, epoxy resin, unsaturated polyester resin, diallyl phthalate resin, melamine resin, urea resin, or a mixture thereof is used. Can be mentioned.
- shape of the resin material can be powdered or fibrous, but it is easy to mix and powdery is preferred.
- the surface of the soft magnetic powder is previously coated with an inorganic insulating material to form an inorganic insulating layer, and then the resin material is fused to the inorganic insulating layer.
- a powder coating method such as mechanofusion, a wet thin film manufacturing method such as an electroless metal sol-gel method, or sputtering
- a dry thin film manufacturing method or the like can be used as a method of forming an inorganic insulating layer by coating a soft magnetic powder with an inorganic insulating material.
- the powder coating method can be performed using, for example, a powder coating apparatus described in JP-A-2001-73062. According to this method, the soft magnetic powder and the low melting glass powder receive a strong compressive frictional force, and the soft magnetic powder is fused by fusing the soft magnetic powder and the low melting glass powder and welding the glass powder together. It is possible to obtain a composite powder whose surface is covered with an inorganic insulating layer made of a low-melting glass glass.
- the resin powder is added to and mixed with the soft magnetic powder having the inorganic insulating layer.
- the resin powder is melted by mechanical energy during mixing and fused to the inorganic insulating layer.
- a soft magnetic composite powder can be obtained.
- a known solid phase mixing method such as a ball mill can be used.
- the temperature at the time of mixing should just be room temperature or more, However, It is preferable to heat to the temperature more than the soft temperature of a resin material. This is because the fusion of the resin powder to the inorganic insulating layer is promoted.
- the particle diameter of the resin powder is smaller than that of the soft magnetic powder, and preferably not more than half.
- the soft magnetic powder When the particle size force is 300 ⁇ m or less, 150 m or less, and 45 ⁇ m or less, 150 ⁇ m or less, 75 ⁇ m or less, and 20 ⁇ m or less are preferred respectively.
- the composition of the composite powder is preferably such that the inorganic insulating material is 0.3 to 6% by weight, the resin material is 1 to 10% by weight, and the balance is a soft magnetic powder so that Material 0.4 ⁇ 3% by weight, resinous material 2-8% by weight, and more preferably inorganic insulating material 0.4 to 1% by weight, resinous material 3-8% by weight so that the balance becomes soft magnetic powder It is necessary to make the balance a soft magnetic powder. If necessary, 0.1 to 0.5% by weight of a lubricant can be added.
- a stearate such as zinc stearate or calcium stearate can be added and mixed as a lubricant.
- the composite powder can be filled in a predetermined mold and molded using various molding methods such as compacting, injection molding, and extrusion molding.
- soft magnetic composite powder is filled in a mold, press-molded at a predetermined pressure, and the compacted compact is fired to burn down the resin. You can get a body.
- the firing temperature needs to be set lower than the crystallization start temperature of the amorphous alloy.
- the resin to be added in order to ensure molding processability, it is necessary to add a resin powder to the soft magnetic composite powder and knead.
- the resin to be added the same resin as that in the composite powder or a different resin can be used.
- the resin used for injection molding can be selected from the examples of the thermoplastic resin mentioned above, such as polyolefins and polybulual alcohol, where heat-resistant resins with a deflection temperature under load specified in JIS K 7191 of 100 ° C or higher are preferred.
- Thermoplastic resins other than polyethylene oxide and the above-mentioned thermosetting resins can be used.
- thermosetting resin it is preferable to knead at a temperature not higher than its decomposition temperature, preferably not higher than 300 ° C.
- the content of the resin in the final molded body is preferably 5% by weight or more in order to ensure moldability.
- the shape of the gap sheet is not particularly limited, and for example, a disk, a ring, a rectangular parallelepiped or a hemisphere can be used. Also, by changing the shape of the gap sheet, it is possible to design the DC superposition characteristics according to the requirements.
- Gap position 1 location on the midfoot
- Gap width 3mm
- Ferrite powder and glass-coated amorphous powder were selected as soft magnetic powder, and PPS was selected as the resin.
- Glass coating on the amorphous powder was performed by mixing glass powder and amorphous powder and heating the glass powder to a temperature above the soft soft spot of the glass.
- the filling ratio of the soft magnetic powder into the fat was set to 90% by weight.
- DC superposition characteristics were measured under the following conditions.
- Powdered yarn (Fe0.97 Cr0.03) 76 (Si0.5 B0.2) 22 C2
- a soft magnetic powder and rosin were kneaded and pelletized to be injection molded.
- Table 1 shows the combinations of soft magnetic powder and sheet dimensions to be filled in the manufactured gap sheet.
- Fig. 2 shows the DC superposition characteristics when the gap width of the EE core is 5 mm and two sheets 1 are inserted.
- the graph in Fig. 2 shows good inductance on the large current side where the inductance value on the low current side is large.
- Gap position 1 location on the midfoot
- Gap width 4mm
- t3 ⁇ 4 length lmm, 2mm and 3mm
- the measuring apparatus, amorphous powder, resin, and gap sheet forming method were the same as in Example 1 described above, and the soft magnetic powder filled in the gap sheet was only amorphous powder.
- a desired direct current superposition characteristic can be easily designed according to demands, so that the present invention is useful as a magnetic core for an inductance component such as a choke coil or a transformer used for a switching power source or the like.
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Abstract
A gap sheet to be inserted into a magnetic core, which has a gap at least at one part in a magnetic path, is formed of a composite material of a soft magnetic powder and a resin.
Description
明 細 書 Specification
ギャップシート及び該ギャップシートが揷入された磁芯 Gap sheet and magnetic core inserted with the gap sheet
技術分野 Technical field
[0001] 本発明は、スイッチング電源等に使用されるチョークコイルやトランス等のインダクタ ンス部品の磁芯に関し、特に磁芯のギャップに挿入されるギャップシートに関するも のである。 The present invention relates to a magnetic core of an inductance component such as a choke coil or a transformer used for a switching power supply or the like, and particularly relates to a gap sheet inserted into a gap of the magnetic core.
背景技術 Background art
[0002] 従来、チョークコイルやトランス等の磁芯にぉ 、ては、通常、交流は直流に重畳して 印加されることから、この種の磁芯は、その用途 (例えば、スイッチング電源等）に必 要な直流重畳特性が求められる。高周波用の磁芯としては、主にフェライト磁芯ゃ圧 粉磁芯が使用されているが、フェライト磁芯は初透磁率が高く飽和磁束密度が小さい のに対し、圧粉磁芯は初透磁率が低く飽和磁束密度が高い、という材料物性に起因 する特徴を有している。そのため、フェライト磁芯は、例えば E型コアの中足部にギヤ ップを形成することで、直流電流に対するインダクタンス低下を少なくし、 EEコアある いは EIコア等として用いられる。 Conventionally, since an alternating current is usually applied to a magnetic core such as a choke coil or a transformer while being superimposed on a direct current, this type of magnetic core is used for its application (eg, a switching power supply). DC superimposition characteristics required for this are required. Ferrite cores are mainly used as high-frequency magnetic cores, but ferrite cores have high initial permeability and low saturation magnetic flux density, whereas dust cores have initial permeability. It is characterized by material properties such as low magnetic susceptibility and high saturation magnetic flux density. For this reason, ferrite cores are used as EE cores or EI cores, for example, by forming a gap at the middle leg of an E-type core to reduce the decrease in inductance with respect to direct current.
[0003] し力しながら、最近の電子機器の小型化あるいは大電流化は、インダクタンス部品 に対して優れた直流重畳特性を要求しており、磁芯コアにギャップを形成する方法 は、高電流領域での直流重畳特性を向上させる方法としては一般に用いられている 力 インダクタンス値が低下するという問題がある。 [0003] However, the recent downsizing or increase in current of electronic devices requires excellent DC superposition characteristics for inductance components, and the method of forming a gap in a magnetic core is a high current. As a method for improving the DC superposition characteristics in the region, there is a problem that the force inductance value generally used is lowered.
[0004] その解決手段として、ギャップ部分の磁芯形状を変える方法が提案されて ヽる。こ の方法によれば、ギャップ部分の形状を変化させることで、低電流域から高電流域に かけてインダクタンスを変化させた直流重畳特性を得ることができる（例えば、特許文 献 1参照。）。 [0004] As a solution to this problem, a method of changing the magnetic core shape of the gap portion has been proposed. According to this method, by changing the shape of the gap portion, it is possible to obtain a DC superposition characteristic in which the inductance is changed from the low current region to the high current region (see, for example, Patent Document 1). .
[0005] し力しながら、ギャップ幅を厳密に管理しなければならず、高精度の切削加工が求 められるとともに、要求される直流重畳特性に応じてギャップ部分の形状を変更する 必要があった。また、ギャップ幅が狭い部分を有するために、高電流側の直流重畳 特性が悪くなると!ヽぅ問題もある。
[0006] また、高電流側の直流重畳特性を改善する方法として、ギャップにボンド磁石を挿 入する方法が提案されている（例えば、特許文献 2あるいは 3参照。；)。 [0005] However, the gap width must be strictly controlled while applying force, and high-precision cutting is required, and the shape of the gap portion must be changed according to the required DC superposition characteristics. It was. In addition, since the gap width is narrow, the DC superimposition characteristic on the high current side is deteriorated. [0006] Further, as a method of improving the DC superposition characteristics on the high current side, a method of inserting a bond magnet into the gap has been proposed (for example, see Patent Document 2 or 3).
[0007] 特許文献 1：特開平 11 340064号公報 [0007] Patent Document 1: Japanese Patent Application Laid-Open No. 11 340064
特許文献 2 :特開 2003— 007520号公報 Patent Document 2: Japanese Patent Laid-Open No. 2003-007520
特許文献 3：特開 2004— 247409号公報 Patent Document 3: Japanese Patent Application Laid-Open No. 2004-247409
発明の開示 Disclosure of the invention
発明が解決しょうとする課題 Problems to be solved by the invention
[0008] 特許文献 2あるいは 3に記載の方法は、直流重畳特性を向上させる目的では優れ た方法であり、希土類磁石粉末間を絶縁することで磁芯のコアロスの増大を抑制して いるが、用途に応じて重畳電流に対し変化するインダクタンスが求められると、対応 が難しいという問題があった。 [0008] The method described in Patent Document 2 or 3 is an excellent method for the purpose of improving DC superposition characteristics, and suppresses an increase in core loss of a magnetic core by insulating between rare earth magnet powders. There is a problem that it is difficult to cope with inductance that varies with the superimposed current depending on the application.
[0009] 本発明は、従来技術の有するこのような問題点に鑑みてなされたものであり、要求 される直流重畳特性への対応が容易で安価な磁芯を提供することを目的として!/ヽる 課題を解決するための手段 [0009] The present invention has been made in view of such problems of the prior art, and an object of the present invention is to provide an inexpensive magnetic core that can easily cope with the required DC superposition characteristics! / Means to solve the problem
[0010] 上記目的を達成するため、本発明は、磁路の少なくとも 1箇所にギャップを有する 磁芯に挿入され、軟磁性体粉末と榭脂の複合材料で形成したことを特徴とする軟磁 性ギャップシートである。 In order to achieve the above object, the present invention is characterized in that soft magnetic properties are characterized in that they are inserted into a magnetic core having a gap in at least one location of a magnetic path and are formed of a composite material of soft magnetic powder and resin. It is a gap sheet.
[0011] また、軟磁性体粉末の表面を絶縁処理してもよい。 [0011] Further, the surface of the soft magnetic powder may be insulated.
[0012] また、軟磁性体粉末は磁気特性の異なる 2種以上の混合粉末であってもよ 、。 [0012] Further, the soft magnetic powder may be a mixed powder of two or more having different magnetic properties.
[0013] また、上述した軟磁性ギャップシートを少なくとも 1枚含む 2枚以上のギャップシート を組み合わせて複合ギャップシートを形成することもできる。 [0013] In addition, a composite gap sheet can be formed by combining two or more gap sheets including at least one soft magnetic gap sheet.
[0014] この複合ギャップシートは、軟磁性ギャップシートとは異なる磁気特性を有するギヤ ップシートを少なくとも 1枚含んで!/、てもよ!/、。 [0014] The composite gap sheet includes at least one gap sheet having magnetic properties different from those of the soft magnetic gap sheet!
[0015] この場合、軟磁性ギャップシートに含まれた榭脂とは異なる榭脂を有するギャップシ ートが少なくとも 1枚含まれて 、てもよ!/、。 [0015] In this case, at least one gap sheet having a different resin from that contained in the soft magnetic gap sheet may be included!
[0016] さらに、本発明は、磁路の少なくとも 1箇所にギャップを有する磁芯であって、ギヤッ プに軟磁性体粉末と榭脂の複合材料力 なるギャップシートが挿入されていることを
特徴とする。 [0016] Further, the present invention is a magnetic core having a gap in at least one part of a magnetic path, and a gap sheet having a composite material force of soft magnetic powder and resin is inserted in a gear. Features.
[0017] この磁芯に挿入されるギャップシートは、上述した軟磁性ギャップシートあるいは複 合ギャップシートの少なくとも一つを含むのがよい。 [0017] The gap sheet inserted into the magnetic core preferably includes at least one of the above-described soft magnetic gap sheet or composite gap sheet.
発明の効果 The invention's effect
[0018] 本発明によれば、磁路の少なくとも 1箇所にギャップを有する磁芯に挿入されるギヤ ップシートを、軟磁性体粉末と榭脂の複合材料で形成することで、低電流域での高 Vヽインダクタンスを示す直流重畳特性や、高電流側に伸びた直流重畳特性を得るこ とができ、所望の直流重畳特性を容易に設計できる。 [0018] According to the present invention, the gap sheet to be inserted into the magnetic core having a gap in at least one part of the magnetic path is formed of the composite material of the soft magnetic powder and the resin, so that the low current region can be obtained. It is possible to obtain DC superposition characteristics that show high V ヽ inductance and DC superposition characteristics that extend to the high current side, and it is possible to easily design the desired DC superposition characteristics.
図面の簡単な説明 Brief Description of Drawings
[0019] [図 1]図 1は 3mmのギャップ幅を有する EEコアに本発明に力かるギャップシートを揷 入した場合の EEコアの直流重畳特性を示すグラフである。 [0019] [Fig. 1] Fig. 1 is a graph showing the DC superposition characteristics of an EE core in the case where a gap sheet useful for the present invention is inserted into an EE core having a gap width of 3 mm.
[図 2]図 2は 5mmのギャップ幅を有する EEコアに本発明に力かるギャップシートを揷 入した場合の EEコアの直流重畳特性を示すグラフである。 FIG. 2 is a graph showing the DC superposition characteristics of an EE core when a gap sheet that is useful for the present invention is inserted into an EE core having a gap width of 5 mm.
[図 3]図 3は 4mmのギャップ幅を有する EEコアに本発明に力かるギャップシートを揷 入した場合の EEコアの直流重畳特性を示すグラフである。 FIG. 3 is a graph showing the DC superposition characteristics of an EE core when a gap sheet that is useful for the present invention is inserted into an EE core having a gap width of 4 mm.
発明を実施するための最良の形態 BEST MODE FOR CARRYING OUT THE INVENTION
[0020] 以下、本発明の実施の形態について、図面を参照しながら説明する。 Hereinafter, embodiments of the present invention will be described with reference to the drawings.
本願発明者らは、上述した従来技術特有の課題を解決すべく鋭意検討した結果、 磁芯のギャップ部分に軟磁性体粉末と榭脂の複合材料カゝらなる軟磁性ギャップシー トを挿入することで、所望の直流重畳特性を容易に設計できることを見出した。 As a result of intensive investigations to solve the above-described problems peculiar to the prior art, the inventors of the present application insert a soft magnetic gap sheet made of a composite material of soft magnetic powder and resin into the gap portion of the magnetic core. Thus, it has been found that a desired DC superimposition characteristic can be easily designed.
[0021] チョークコイルやトランス等の磁芯としては、軟磁気特性を有する材料であれば要 求特性に応じて任意に選択でき、フェライト、センダスト、カーボ-ル鉄、珪素鋼板、 アモルファス等を用いることができる。磁芯の形状については、磁路の 1箇所以上に ギャップを有していればよぐトロイダルコア、 EEコア、 EIコア等どのような形状にも適 用できる。磁芯に設けられるギャップ幅に特に制限はないが、磁芯材料の種類、磁芯 形状、求められる直流重畳特性に応じてギャップ幅は決定される。 [0021] A magnetic core such as a choke coil or a transformer can be arbitrarily selected according to required characteristics as long as it has a soft magnetic property, and ferrite, sendust, carbon iron, silicon steel plate, amorphous, etc. are used. be able to. As for the shape of the magnetic core, any shape such as a toroidal core, an EE core, or an EI core, which has a gap at one or more places in the magnetic path, can be applied. The gap width provided in the magnetic core is not particularly limited, but the gap width is determined according to the type of magnetic core material, the magnetic core shape, and the required DC superposition characteristics.
[0022] 軟磁性ギャップシートに用いる軟磁性体粉末としては、軟磁気特性を有する材料で あれば特に制限はなぐ例えば、フェライト、センダスト、カーボニル鉄、パーマロイ、
アモルファス等の粉末を用いることができる。 [0022] The soft magnetic powder used for the soft magnetic gap sheet is not particularly limited as long as it is a material having soft magnetic properties. For example, ferrite, sendust, carbonyl iron, permalloy, An amorphous powder or the like can be used.
[0023] 一方、軟磁性ギャップシートに用いる榭脂は、軟磁性体粉末と複合化できるもので あれば特に制限はなぐインダクタンス部品としての製造条件、使用環境等に応じて 選択される。例えば、ポリアミド榭脂、芳香族ポリアミド榭脂、ポリイミド榭脂、ポリフエ- レンスルフイド榭脂、液晶榭脂、エポキシ榭脂、アクリル榭脂等を用いることができる。 [0023] On the other hand, the resin used for the soft magnetic gap sheet is selected according to the manufacturing conditions, the usage environment, etc. as an inductance component that is not particularly limited as long as it can be combined with the soft magnetic powder. For example, polyamide resin, aromatic polyamide resin, polyimide resin, polyphenylene sulfide resin, liquid crystal resin, epoxy resin, acrylic resin, and the like can be used.
[0024] また、軟磁性体粉末と榭脂を複合し軟磁性ギャップシートに形成する方法に特に制 限はなぐ一般的な榭脂材料に充填材を混合'成形する方法を用いることができ、例 えば、ドクターブレード法、熱プレス法、射出成形法等を用いることができる。 [0024] Further, there can be used a method of mixing and molding a filler with a general resin material, which is not particularly limited in the method of forming a soft magnetic gap sheet by combining soft magnetic powder and resin. For example, a doctor blade method, a hot press method, an injection molding method, or the like can be used.
[0025] 軟磁性体粉末の表面を絶縁する必要がある場合、その絶縁処理方法に特に制限 はなぐメツキ法、真空蒸着法、 CVD法、 PVD法、あるいはボールミル等の機械的な 方法を利用することができる。また、後述する方法を用いてもよい。 [0025] When it is necessary to insulate the surface of the soft magnetic powder, a mechanical method such as a plating method, a vacuum deposition method, a CVD method, a PVD method, or a ball mill is used, which is not particularly limited to the insulation treatment method. be able to. Moreover, you may use the method mentioned later.
[0026] また、複数の軟磁性体粉末を軟磁性ギャップシートに用いることも可能で、その組 合せに特に制限はない。例えば、異なる組成力 なる軟磁性体粉末を組み合わせる 方法や、同じ組成でも異なる結晶構造の軟磁性体粉末を組み合わせる方法や、異な る形状の軟磁性体粉末を組み合わせる方法や、異なる粒径の軟磁性体粉末を組み 合わせる方法等があり、これらの方法を組み合わせることもできる。 [0026] A plurality of soft magnetic powders can be used for the soft magnetic gap sheet, and the combination thereof is not particularly limited. For example, a method of combining soft magnetic powders having different compositional forces, a method of combining soft magnetic powders having the same composition but different crystal structures, a method of combining soft magnetic powders of different shapes, and soft magnetic materials having different particle sizes. There are methods such as combining body powders, and these methods can also be combined.
[0027] さらに、少なくとも 1枚の軟磁性ギャップシートを含む 2枚以上のギャップシートを組 み合わせて複合ギャップシートを製造することも可能で、特にその組合せに制限はな い。例えば、軟磁性体粉末の充填量が異なるギャップシートを組み合わせる方法や、 異なる軟磁性ギャップシートを組み合わせる方法や、非磁性のギャップシートを組み 合わせる方法や、ボンド磁石ギャップシートを組み合わせる方法等がある。 [0027] Further, it is possible to produce a composite gap sheet by combining two or more gap sheets including at least one soft magnetic gap sheet, and the combination is not particularly limited. For example, there are a method of combining gap sheets having different soft magnetic powder filling amounts, a method of combining different soft magnetic gap sheets, a method of combining non-magnetic gap sheets, and a method of combining bonded magnet gap sheets.
[0028] 複合ギャップシートの組み合わせ方にも特に制限はなぐ磁路方向に垂直にギヤッ プシートを積み重ねる方法や、磁路方向に平行にギャップシートを並べる方法や、あ るいは、磁路方向に角度を持たせるように組み合わせる方法等がある。 [0028] There are no particular restrictions on the method of combining the composite gap sheets. A method of stacking the gear sheets perpendicular to the magnetic path direction, a method of arranging the gap sheets parallel to the magnetic path direction, or an angle in the magnetic path direction. There is a method of combining them to give them.
[0029] また、複合ギャップシートの製造方法にも特に制限はなぐ別々に作製したギャップ シートを磁芯に挿入するときに組み合わせてもよ 、し、射出成形における 2層成形や インサート成形を用いてもょ 、。 [0029] In addition, there is no particular limitation on the manufacturing method of the composite gap sheet, and a separately manufactured gap sheet may be combined when inserted into the magnetic core, or by using two-layer molding or insert molding in injection molding. Well ...
[0030] さらに、複合ギャップシートに用いる榭脂の組合せにも特に制限はなぐ同じ榭脂を
用いたギャップシートを組み合わせてもよいし、例えば、線膨張係数の異なる榭脂、 絶縁性の異なる榭脂、弾性率の異なる榭脂を組み合わせてもよ!、。 [0030] Further, the same resin that is not particularly limited in the combination of the resin used in the composite gap sheet. The gap sheets used may be combined, for example, a resin having a different linear expansion coefficient, a resin having a different insulating property, or a resin having a different elastic modulus!
[0031] 次に、軟磁性体粉末の表面を被覆する電気絶縁性材料に無機絶縁性材料を用い る複合粉末の製造方法の一例を以下説明する。 [0031] Next, an example of a method for producing a composite powder using an inorganic insulating material as the electrically insulating material covering the surface of the soft magnetic powder will be described.
[0032] 軟磁性体には、フェライト等の酸ィ匕物系材料、カーボ-ル鉄、 Fe— Si合金、 Ni— F e合金、あるいは Fe系あるいは Co系の非晶質合金等の金属系材料が含まれる。耐 食性、耐摩耗性、強度、あるいは高透磁率や低保持力等の軟磁気特性が結晶系材 料に比べ優れた軟磁性非晶質合金を用いることが好ま ヽ。軟磁性非晶質合金は 特に限定されず、鉄系やコバルト系等の公知の非晶質合金を用いることができる。 [0032] Soft magnetic materials include oxide-based materials such as ferrite, carbon iron, Fe-Si alloys, Ni-Fe alloys, and Fe-based or Co-based amorphous alloys. Material is included. It is preferable to use a soft magnetic amorphous alloy that is superior to crystalline materials in terms of corrosion resistance, wear resistance, strength, or soft magnetic properties such as high magnetic permeability and low coercive force. The soft magnetic amorphous alloy is not particularly limited, and a known amorphous alloy such as iron or cobalt can be used.
[0033] また、無機絶縁性材料には、例えば、 Al O、 SiO、 Y O、 MgO、あるいは ZrO [0033] Examples of the inorganic insulating material include Al 2 O, SiO, Y 2 O, MgO, and ZrO.
2 3 2 2 3 2 等の絶縁性の金属又は半金属の酸ィ匕物、あるいはガラス材料、又はそれらの混合物 を用いることができる力 ガラス材料が好ましぐ特に低融点ガラスが好ましい。低い 軟化温度を有し、軟磁性非晶質合金に融着してその表面を被覆することができるか らである。 Insulating metal or metalloid oxide such as 2 3 2 2 3 2, or glass material, or a mixture thereof can be used. Glass materials are preferred, and low-melting glass is particularly preferred. This is because it has a low softening temperature and can be fused to the soft magnetic amorphous alloy to cover the surface.
[0034] 低融点ガラスは、軟磁性体粉末と反応せず、軟磁性非晶質合金の結晶化開始温 度よりも低温、好ましくは約 550°C以下で軟ィ匕するものであれば特に限定されない。 例を挙げれば、 PbO— B O系ガラス等の鉛系ガラス、 P O系ガラス、 ZnO-BaO [0034] The low melting point glass is not particularly limited as long as it does not react with the soft magnetic powder and softens at a temperature lower than the crystallization start temperature of the soft magnetic amorphous alloy, preferably about 550 ° C or less. It is not limited. Examples include lead glass such as PbO—B 2 O glass, PO glass, ZnO—BaO
2 3 2 5 2 3 2 5
系ガラス、そして ZnO— B O -SiO系ガラス等の公知の低融点ガラスを用いること Glass, and known low-melting glass such as ZnO—B 2 O—SiO glass
2 3 2 2 3 2
ができる。好ましくは、無鉛ガラスであって、低い軟ィ匕点を与える P o系ガラスが好ま Can do. Pb-based glass, which is lead-free glass and gives a low soft spot, is preferred.
2 5 twenty five
しい。例えば、 P O 60〜80%、Α1 Ο 10%以下、 ZnO 10〜20%、 Li O 10 That's right. For example, P O 60-80%, Α1 以下 10% or less, ZnO 10-20%, Li O 10
2 5 2 3 2 2 5 2 3 2
%以下、 Na O 10%以下の組成のものを用いることができる。 % Or less and Na 2 O 10% or less can be used.
2 2
[0035] また、使用する榭脂は、従来公知の熱可塑性榭脂又は熱硬化性榭脂を用いること ができる。 [0035] Further, as the resin used, conventionally known thermoplastic resin or thermosetting resin can be used.
[0036] 熱可塑性榭脂としては、例えば、ポリエチレンやポリプロピレン等のポリオレフイン、 ポリビュルアルコール、ポリエチレンオキサイド、ポリフエ-レンスルフイド（PPS)、液 晶ポリマー、ポリエーテルエーテルケトン（PEEK)、ポリイミド、ポリエーテルイミド、ポ リアセタール、ポリエーテルサルホン、ポリサルホン、ポリカーボネート、ポリエチレンテ レフタレート、ポリブチレンテレフタレート、ポリフエ-レンオキサイド、ポリフタールアミ
ド、ポリアミド等、あるいはそれらの混合物等を用いることができる。 [0036] Examples of the thermoplastic resin include polyolefins such as polyethylene and polypropylene, polybutyl alcohol, polyethylene oxide, polyphenylene sulfide (PPS), liquid crystal polymer, polyetheretherketone (PEEK), polyimide, and polyetherimide. Polyacetal, polyethersulfone, polysulfone, polycarbonate, polyethylene terephthalate, polybutylene terephthalate, polyphenylene oxide, polyphthalamide Or polyamide, or a mixture thereof.
[0037] 一方、熱硬化性榭脂としては、例えば、フエノール榭脂、エポキシ榭脂、不飽和ポリ エステル榭脂、ジァリルフタレート榭脂、メラミン榭脂、尿素樹脂等、あるいはそれらの 混合物を挙げることができる。また、榭脂材料の形状は、粉末状や繊維状のものを用 V、ることができるが、混合し易 、粉末状が好ま 、。 [0037] On the other hand, as the thermosetting resin, for example, phenol resin, epoxy resin, unsaturated polyester resin, diallyl phthalate resin, melamine resin, urea resin, or a mixture thereof is used. Can be mentioned. In addition, the shape of the resin material can be powdered or fibrous, but it is easy to mix and powdery is preferred.
[0038] 複合粉末の作製方法の一例を以下説明する。ここでは、軟磁性体粉末の表面を予 め無機絶縁性材料で被覆して無機絶縁層を形成し、次 、でその無機絶縁層に榭脂 材料を融着させている。 [0038] An example of a method for producing the composite powder will be described below. Here, the surface of the soft magnetic powder is previously coated with an inorganic insulating material to form an inorganic insulating layer, and then the resin material is fused to the inorganic insulating layer.
[0039] 軟磁性体粉末を無機絶縁性材料で被覆して無機絶縁層を形成する方法としては、 メカノフュージョン等の粉末コーティング法や、無電解メツキゃゾルーゲル法等の湿式 薄膜作製法、あるいはスパッタリング等の乾式薄膜作製法等を用いることができる。 粉末コーティング法は、例えば特開 2001— 73062号公報に記載された粉末コーテ イング装置を用いて行うことができる。この方法によれば、軟磁性体粉末と低融点ガラ ス粉末が強力な圧縮摩擦力を受け、軟磁性体粉末と低融点ガラス粉末との融合及 びガラス粉末同士の溶着により、軟磁性体粉末の表面が低融点ガラスカゝら成る無機 絶縁層で被覆された複合粉末を得ることができる。 [0039] As a method of forming an inorganic insulating layer by coating a soft magnetic powder with an inorganic insulating material, a powder coating method such as mechanofusion, a wet thin film manufacturing method such as an electroless metal sol-gel method, or sputtering For example, a dry thin film manufacturing method or the like can be used. The powder coating method can be performed using, for example, a powder coating apparatus described in JP-A-2001-73062. According to this method, the soft magnetic powder and the low melting glass powder receive a strong compressive frictional force, and the soft magnetic powder is fused by fusing the soft magnetic powder and the low melting glass powder and welding the glass powder together. It is possible to obtain a composite powder whose surface is covered with an inorganic insulating layer made of a low-melting glass glass.
[0040] 次 、で、無機絶縁層を有する軟磁性体粉末に榭脂粉末を添加して混合する。榭脂 粉末は混合時の機械的エネルギーにより溶融して無機絶縁層に融着する。これによ り軟磁性複合粉末を得ることができる。混合には、ボールミル等の公知の固相混合方 法を用いることができる。なお、混合時の温度は室温以上であれば良いが、榭脂材 料の軟ィ匕温度以上の温度に加熱することが好ましい。榭脂粉末の無機絶縁層への 融着が促進されるからである。 [0040] Next, the resin powder is added to and mixed with the soft magnetic powder having the inorganic insulating layer. The resin powder is melted by mechanical energy during mixing and fused to the inorganic insulating layer. Thereby, a soft magnetic composite powder can be obtained. For mixing, a known solid phase mixing method such as a ball mill can be used. In addition, the temperature at the time of mixing should just be room temperature or more, However, It is preferable to heat to the temperature more than the soft temperature of a resin material. This is because the fusion of the resin powder to the inorganic insulating layer is promoted.
[0041] ここで、無機絶縁層で被覆した軟磁性体粉末を用いる場合、榭脂粉末の粒径は軟 磁性体粉末の粒径より小さぐ好ましくは半分以下であり、例えば、軟磁性体粉末の 粒径力 300 μ m以下、 150 m以下、 45 μ m以下の場合、それぞれ 150 μ m以下、 75 μ m以下、 20 μ m以下が好まし!/ヽ。 [0041] Here, when the soft magnetic powder coated with the inorganic insulating layer is used, the particle diameter of the resin powder is smaller than that of the soft magnetic powder, and preferably not more than half. For example, the soft magnetic powder When the particle size force is 300 μm or less, 150 m or less, and 45 μm or less, 150 μm or less, 75 μm or less, and 20 μm or less are preferred respectively.
[0042] また、複合粉末の組成は、無機絶縁性材料 0. 3〜6重量％、榭脂材料 1〜10重量 %、そして残部が軟磁性体粉末となるように、より好ましくは、無機絶縁性材料 0. 4〜
3重量％、榭脂材料 2〜8重量％、そして残部が軟磁性体粉末となるように、さらに好 ましくは無機絶縁性材料 0. 4〜1重量％、榭脂材料 3〜8重量％、そして残部が軟磁 性体粉末となるようにする必要がある。なお、必要に応じて、 0. 1〜0. 5重量％の滑 剤を添加することもできる。 [0042] The composition of the composite powder is preferably such that the inorganic insulating material is 0.3 to 6% by weight, the resin material is 1 to 10% by weight, and the balance is a soft magnetic powder so that Material 0.4 ~ 3% by weight, resinous material 2-8% by weight, and more preferably inorganic insulating material 0.4 to 1% by weight, resinous material 3-8% by weight so that the balance becomes soft magnetic powder It is necessary to make the balance a soft magnetic powder. If necessary, 0.1 to 0.5% by weight of a lubricant can be added.
[0043] また、必要に応じて、潤滑剤としてステアリン酸亜鉛ゃステアリン酸カルシウム等の ステアリン酸塩を添加して混合することができる。 [0043] If necessary, a stearate such as zinc stearate or calcium stearate can be added and mixed as a lubricant.
[0044] また、複合粉末を所定の金型に充填し、圧粉成形、射出成形、そして押出成形等 の種々の成形方法を用いて成形することができる。 [0044] Further, the composite powder can be filled in a predetermined mold and molded using various molding methods such as compacting, injection molding, and extrusion molding.
[0045] 例えば、圧粉成形の場合、軟磁性複合粉末を金型内に充填し、所定の加圧圧力 でプレス成形し、成形した圧粉体を、焼成し、榭脂を焼失させて焼成体を得ることが できる。なお、軟磁性体粉末に非晶質合金粉末を用いる場合には、焼成温度を非晶 質合金の結晶化開始温度より低く設定する必要がある。 [0045] For example, in the case of compaction molding, soft magnetic composite powder is filled in a mold, press-molded at a predetermined pressure, and the compacted compact is fired to burn down the resin. You can get a body. When an amorphous alloy powder is used as the soft magnetic powder, the firing temperature needs to be set lower than the crystallization start temperature of the amorphous alloy.
[0046] また、射出成形の場合、成形加工性を確保するため、軟磁性複合粉末にさらに榭 脂粉末を添加して混練する必要がある。添加する榭脂は複合粉末中の樹脂と同じ、 あるいは別の榭脂を用いることができる。射出成形に用いる榭脂は、 JIS K 7191 で規定する荷重たわみ温度が 100°C以上の耐熱性榭脂が好ましぐ例を挙げれば、 上述の熱可塑性榭脂の中でポリオレフイン、ポリビュルアルコール、ポリエチレンォキ サイド以外の熱可塑性榭脂と、上述の熱硬化性榭脂を用いることができる。なお、混 練に際し、熱可塑性榭脂の場合、その軟化温度以上の温度で加熱して混練すること が好ましい。また、熱硬化性榭脂の場合、その分解温度以下の温度、好ましくは 300 °C以下の温度で混練することが好ましい。なお、射出成形の場合、成形加工性確保 のため、最終成形体中の榭脂の含有量が 5重量％以上となることが好ましい。 [0046] In addition, in the case of injection molding, in order to ensure molding processability, it is necessary to add a resin powder to the soft magnetic composite powder and knead. As the resin to be added, the same resin as that in the composite powder or a different resin can be used. The resin used for injection molding can be selected from the examples of the thermoplastic resin mentioned above, such as polyolefins and polybulual alcohol, where heat-resistant resins with a deflection temperature under load specified in JIS K 7191 of 100 ° C or higher are preferred. Thermoplastic resins other than polyethylene oxide and the above-mentioned thermosetting resins can be used. When kneading, it is preferable to knead by heating at a temperature equal to or higher than the softening temperature of thermoplastic resin. In the case of thermosetting resin, it is preferable to knead at a temperature not higher than its decomposition temperature, preferably not higher than 300 ° C. In the case of injection molding, the content of the resin in the final molded body is preferably 5% by weight or more in order to ensure moldability.
[0047] また、ギャップシートの形状には特に制限は無ぐ例えば、円盤、リング、直方体ある いは半球等を用いることができる。また、ギャップシートの形状を変えることで、要求に 応じた直流重畳特性を設計することができる。 [0047] The shape of the gap sheet is not particularly limited, and for example, a disk, a ring, a rectangular parallelepiped or a hemisphere can be used. Also, by changing the shape of the gap sheet, it is possible to design the DC superposition characteristics according to the requirements.
実施例 1 Example 1
[0048] エアギャップを有する EERコアに対して、以下の形状のギャップシートを作製して E ERコアのエアギャップに挿入し、直流重畳特性を調べた。
•EERコア形状 [0048] For the EER core having an air gap, a gap sheet having the following shape was manufactured and inserted into the air gap of the E ER core, and the DC superposition characteristics were examined. • EER core shape
FEER35B (日本電子材料工業会標準規格） FEER35B (Japan Electronic Materials Industry Standard)
ギャップ位置：中足部に 1箇所 Gap position: 1 location on the midfoot
ギャップ幅： 3mm Gap width: 3mm
•ギャップシート試料形状 • Gap sheet sample shape
外径： 10mm Outside diameter: 10mm
高さ： 1mm及び 2mm Height: 1mm and 2mm
フェライト粉末及びガラスコーティングしたアモルファス粉末を軟磁性体粉末として 選定し、榭脂として PPSを選定した。アモルファス粉末へのガラスコーティングは、ガ ラス粉末とアモルファス粉末を混合し、これをガラスの軟ィ匕点以上に加熱することで 行った。軟磁性体粉末の榭脂への充填率は、重量で 90%に設定した。直流重畳特 性の測定は以下の条件で行った。 Ferrite powder and glass-coated amorphous powder were selected as soft magnetic powder, and PPS was selected as the resin. Glass coating on the amorphous powder was performed by mixing glass powder and amorphous powder and heating the glass powder to a temperature above the soft soft spot of the glass. The filling ratio of the soft magnetic powder into the fat was set to 90% by weight. DC superposition characteristics were measured under the following conditions.
，測定装置 ,measuring device
ヒューレットパッカード社製 HP-4284A HP-4284A manufactured by Hewlett-Packard Company
ヒューレットパッカード社製 HP-42841A HP-42841A manufactured by Hewlett-Packard Company
(2台を 1組として使用） (Use two units as one set)
•周波数： 10kHz • Frequency: 10kHz
•直流重畳電流： 0から 20A • DC superimposed current: 0 to 20A
•測定室温度： 23°C • Measurement room temperature: 23 ° C
•測定室湿度： 50% • Measuring room humidity: 50%
•EEコア材質 • EE core material
Mn— Zn系フェライト Mn—Zn ferrite
•アモルファス粉末 • Amorphous powder
粉末糸且成： (Fe0.97 Cr0.03)76 (Si0.5 B0.2) 22 C2 Powdered yarn: (Fe0.97 Cr0.03) 76 (Si0.5 B0.2) 22 C2
平均粒径： 20 m Average particle size: 20 m
ガラスコーティング量： 2重量％ Glass coating amount: 2% by weight
ガラス組成： (P2O5)70(A12O3)5(ZnO)15(Li2O)5(Na2O)5 Glass composition: (P2O5) 70 (A12O3) 5 (ZnO) 15 (Li2O) 5 (Na2O) 5
'フェライト粉末
粉末組成： (MnZn)O · Fe203 'Ferrite powder Powder composition: (MnZn) O · Fe203
平均粒径： 5 m Average particle size: 5 m
'樹脂 'Resin
カネボウ製： 6ナイロン Kanebo: 6 nylon
•ギャップシート成形方法 • Gap sheet forming method
軟磁性体粉末と榭脂を混練し、ペレットにしたものを射出成形した。作製したギヤ ップシートに充填する軟磁性体粉末とシート寸法の組合せは表 1の通りである。 A soft magnetic powder and rosin were kneaded and pelletized to be injection molded. Table 1 shows the combinations of soft magnetic powder and sheet dimensions to be filled in the manufactured gap sheet.
<表 1 > <Table 1>
[0050] EEコアのギャップにシート 1を 2枚挿入した試料 I、シート 2を 2枚揷入した試料 II、 1 枚のシート 1と 1枚のシート 2を磁路方向に垂直に重ねて挿入した試料 III、シート 3を 1 枚挿入した試料 IVについて、直流重畳特性を測定した結果を図 1に示す。 EEコアは 同じものを使用し、ギャップシートを差し替えて測定を行った。また、比較例として、ェ ァギャップのみのデータを示す。 [0050] Sample I with two sheets 1 inserted into the gap of the EE core, Sample II with two sheets 2 inserted, one sheet 1 and one sheet 2 stacked vertically in the magnetic path direction Figure 1 shows the results of measuring the DC superposition characteristics of sample III and sample IV with one sheet 3 inserted. The same EE core was used, and the measurement was performed with the gap sheet replaced. In addition, as a comparative example, only data on an air gap is shown.
[0051] 図 1のグラフ力 分力るように、ギャップシートを挿入すると、試料 Iでは、低電流側か ら中電流域まで高いインダクタンスを保持しているのに対して、試料 IIでは低電流側 のみインダクタンスが大きく改善されている。一方、試料 mと試料 IVでは、低電流域か ら高電流域にかけてインダクタンスが直線的に低下している力 両者の傾きは相違し ている。全体としては、高電流側でのインダクタンス値が低くなる傾向を示しており、 エアギャップ幅が小さ過ぎたために、この傾向が生じたものと考えられる。 [0051] When the gap sheet is inserted as shown by the graph force in Fig. 1, Sample I retains a high inductance from the low current side to the medium current range, whereas Sample II has a low current. On the side only, the inductance is greatly improved. On the other hand, sample m and sample IV have different slopes of the force with which the inductance decreases linearly from the low current region to the high current region. As a whole, the inductance value on the high current side tends to be low, and this tendency is thought to have occurred because the air gap width was too small.
[0052] そこで、 EEコアのギャップ幅を 5mmとし、シート 1を 2枚挿入したときの直流重畳特 性を図 2に示す。図 2のグラフは、低電流側のインダクタンス値が大きぐ大電流側も 良好なインダクタンスを示して ヽる。 [0052] Fig. 2 shows the DC superposition characteristics when the gap width of the EE core is 5 mm and two sheets 1 are inserted. The graph in Fig. 2 shows good inductance on the large current side where the inductance value on the low current side is large.
[0053] このように、ギャップ幅と本発明に力かるギャップシートを組み合わせることで、制御
された磁性コアの直流重畳特性を得ることができる。 [0053] In this way, the control is achieved by combining the gap width and the gap sheet that is useful for the present invention. The DC superposition characteristics of the magnetic core thus obtained can be obtained.
実施例 2 Example 2
[0054] 次に、エアギャップを有する EERコアに対して、以下の形状のギャップシートを作製 して EERコアのエアギャップに挿入し、直流重畳特性を調べた。 [0054] Next, for the EER core having an air gap, a gap sheet having the following shape was manufactured and inserted into the air gap of the EER core, and the DC superposition characteristics were examined.
•EERコア形状 • EER core shape
コア材： PC40EER28—Z (市販品） Core material: PC40EER28—Z (commercially available)
ギャップ位置：中足部に 1箇所 Gap position: 1 location on the midfoot
ギャップ幅： 4mm Gap width: 4mm
•ギャップシート試料形状（円盤） • Gap sheet sample shape (disk)
外径： 10mm Outer diameter: 10mm
t¾さ： lmm、 2mm及び 3mm t¾ length: lmm, 2mm and 3mm
•ギャップシート試料形状 (リング） • Gap sheet sample shape (ring)
外径： 10mm Outer diameter: 10mm
内径： 5. 8mm Inner diameter: 5.8mm
高さ： 3mm Height: 3mm
[0055] なお、測定装置、アモルファス粉末、榭脂、ギャップシート成形方法は、上述した実 施例 1と同じであり、ギャップシートに充填する軟磁性粉末はアモルファス粉末のみと した。 [0055] The measuring apparatus, amorphous powder, resin, and gap sheet forming method were the same as in Example 1 described above, and the soft magnetic powder filled in the gap sheet was only amorphous powder.
[0056] EERコアのギャップに高さ lmmの円盤ギャップシートを挿入した試料 V、高さ 2mm の円盤ギャップシートを挿入した試料 VI、高さ 3mmの円盤ギャップシートを挿入した 試料 VII及びリングギャップシートを挿入した試料 VIIIにつ 、て、直流重畳特性を測定 した結果を図 3に示す。 [0056] Sample V with lmm height disc gap sheet inserted into EER core gap, Sample VI with 2mm height disc gap sheet inserted, Sample VII and ring gap sheet with 3mm height disc gap sheet inserted Fig. 3 shows the results of measuring the DC superposition characteristics of sample VIII into which is inserted.
[0057] 図 3のグラフからわかるように、試料 V、 VI、 VIIとギャップシートの厚みを増すことで 低電流側から中電流域のインダクタンスが改善される一方で、高電流側のインダクタ ンスが低くなる。一方試料 VIIIでは、試料 VIIと比べ低電流側のインダクタンスだけが 改善され、中電流域力 高電流域は略同等のインダクタンスを示す。このようにギヤッ プシートの形状をリング状にすることで、特定の電流領域のインダクタンスを改善する ことも可會 になる。
産業上の利用可能性 [0057] As can be seen from the graph in Fig. 3, increasing the thickness of samples V, VI, and VII and the gap sheet improves the inductance from the low current side to the mid-current range, while the inductance on the high current side Lower. On the other hand, in Sample VIII, only the inductance on the low current side is improved compared to Sample VII, and the mid-current range power and high-current range show substantially the same inductance. By making the shape of the gear sheet into a ring shape in this way, it is possible to improve the inductance in a specific current region. Industrial applicability
本発明によれば、要求に応じて所望の直流重畳特性を容易に設計できるので、ス イッチング電源等に使用されるチョークコイルやトランス等のインダクタンス部品の磁 芯として有用である。
According to the present invention, a desired direct current superposition characteristic can be easily designed according to demands, so that the present invention is useful as a magnetic core for an inductance component such as a choke coil or a transformer used for a switching power source or the like.
Claims
[1] 磁路の少なくとも 1箇所にギャップを有する磁芯に挿入されるギャップシートであって [1] A gap sheet to be inserted into a magnetic core having a gap in at least one part of a magnetic path,
、軟磁性体粉末と榭脂の複合材料で形成したことを特徴とする軟磁性ギャップシート A soft magnetic gap sheet formed of a composite material of soft magnetic powder and rosin
[2] 前記軟磁性体粉末の表面が絶縁処理されて 、ることを特徴とする請求項 1に記載の 軟磁性ギャップシート。 2. The soft magnetic gap sheet according to claim 1, wherein the surface of the soft magnetic powder is subjected to insulation treatment.
[3] 前記軟磁性体粉末が、磁気特性の異なる 2種以上の混合粉末であることを特徴とす る請求項 1あるいは 2に記載の軟磁性ギャップシート。 [3] The soft magnetic gap sheet according to [1] or [2], wherein the soft magnetic powder is a mixed powder of two or more having different magnetic properties.
[4] 請求項 1乃至 3のいずれか 1項に記載の軟磁性ギャップシートを少なくとも 1枚含む 2 枚以上のギャップシートを組み合わせたことを特徴とする複合ギャップシート。 [4] A composite gap sheet obtained by combining two or more gap sheets including at least one soft magnetic gap sheet according to any one of claims 1 to 3.
[5] 前記軟磁性ギャップシートとは異なる磁気特性を有するギャップシートが少なくとも 1 枚含まれていることを特徴とする請求項 4に記載の複合ギャップシート。 5. The composite gap sheet according to claim 4, wherein at least one gap sheet having a magnetic property different from that of the soft magnetic gap sheet is included.
[6] 前記軟磁性ギャップシートに含まれた榭脂とは異なる榭脂を有するギャップシートが 少なくとも 1枚含まれていることを特徴とする請求項 4あるいは 5に記載の複合ギヤッ プシート。 6. The composite gear sheet according to claim 4 or 5, wherein at least one gap sheet having a different resin from that contained in the soft magnetic gap sheet is included.
[7] 磁路の少なくとも 1箇所にギャップを有する磁芯であって、前記ギャップに軟磁性体 粉末と榭脂の複合材料カゝらなるギャップシートが挿入されていることを特徴とする磁 芯。 [7] A magnetic core having a gap in at least one location of a magnetic path, wherein a gap sheet made of a composite material of soft magnetic powder and resin is inserted into the gap. .
[8] 前記ギャップシートが、請求項 1乃至 6のいずれ力 1項に記載の軟磁性ギャップシート あるいは複合ギャップシートの少なくとも一つを含むことを特徴とする請求項 7に記載 の磁芯。
[8] The magnetic core according to [7], wherein the gap sheet includes at least one of the soft magnetic gap sheet or the composite gap sheet according to any one of claims 1 to 6.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2005010711 | 2005-01-18 | ||
| JP2005-010711 | 2005-01-18 |
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| Publication Number | Publication Date |
|---|---|
| WO2006077872A1 true WO2006077872A1 (en) | 2006-07-27 |
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ID=36692261
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/JP2006/300622 WO2006077872A1 (en) | 2005-01-18 | 2006-01-18 | Gap sheet and magnetic core having such gap sheet inserted therein |
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| Country | Link |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2012094924A (en) * | 2012-02-16 | 2012-05-17 | Sumitomo Electric Ind Ltd | Reactor |
| JP2015023158A (en) * | 2013-07-19 | 2015-02-02 | Ｎｅｃトーキン株式会社 | Reactor and dc voltage converter |
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|---|---|---|---|---|
| JPH05217761A (en) * | 1992-01-31 | 1993-08-27 | Sony Corp | Magnetic core with gap and inductance element |
| JPH08167519A (en) * | 1994-12-13 | 1996-06-25 | Kobe Steel Ltd | High frequency dust core |
| JP2002373811A (en) * | 2001-06-15 | 2002-12-26 | Toyota Industries Corp | Core, core coil, and transformer |
| JP2003282328A (en) * | 2002-03-25 | 2003-10-03 | Matsushita Electric Ind Co Ltd | Thin magnetic element, its manufacturing method, and power source module using the same |
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2006
- 2006-01-18 WO PCT/JP2006/300622 patent/WO2006077872A1/en not_active Application Discontinuation
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05217761A (en) * | 1992-01-31 | 1993-08-27 | Sony Corp | Magnetic core with gap and inductance element |
| JPH08167519A (en) * | 1994-12-13 | 1996-06-25 | Kobe Steel Ltd | High frequency dust core |
| JP2002373811A (en) * | 2001-06-15 | 2002-12-26 | Toyota Industries Corp | Core, core coil, and transformer |
| JP2003282328A (en) * | 2002-03-25 | 2003-10-03 | Matsushita Electric Ind Co Ltd | Thin magnetic element, its manufacturing method, and power source module using the same |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2012094924A (en) * | 2012-02-16 | 2012-05-17 | Sumitomo Electric Ind Ltd | Reactor |
| JP2015023158A (en) * | 2013-07-19 | 2015-02-02 | Ｎｅｃトーキン株式会社 | Reactor and dc voltage converter |
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