WO2016010098A1 - 磁心、磁心の製造方法およびコイル部品 - Google Patents
磁心、磁心の製造方法およびコイル部品 Download PDFInfo
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- WO2016010098A1 WO2016010098A1 PCT/JP2015/070345 JP2015070345W WO2016010098A1 WO 2016010098 A1 WO2016010098 A1 WO 2016010098A1 JP 2015070345 W JP2015070345 W JP 2015070345W WO 2016010098 A1 WO2016010098 A1 WO 2016010098A1
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- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/255—Magnetic cores made from particles
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
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- 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
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
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- 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
- H01F1/14766—Fe-Si based alloys
- H01F1/14791—Fe-Si-Al based alloys, e.g. Sendust
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- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
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- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
- H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
- H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
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- 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
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- H01F1/33—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 mixtures of metallic and non-metallic particles; metallic particles having oxide skin
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- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F17/045—Fixed inductances of the signal type with magnetic core with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
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- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
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- H01F3/08—Cores, Yokes, or armatures made from powder
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/29—Terminals; Tapping arrangements for signal inductances
- H01F27/292—Surface mounted devices
Definitions
- the present invention relates to a magnetic core, a method of manufacturing a magnetic core, and a coil component.
- the coil component includes a magnetic core (magnetic core) and a coil wound around the magnetic core.
- a magnetic core magnetic core
- ferrite having excellent magnetic properties, flexibility in shape, and cost is widely used.
- magnetic alloy powders such as Fe—Si and Fe—Ni are used.
- a magnetic core obtained by consolidating a compact of such a magnetic alloy powder has a high saturation magnetic flux density, but has a low electrical resistivity because it is an alloy powder, and uses a magnetic alloy powder that has been pre-insulated.
- the present invention has been made in view of the above problems, and an object of the present invention is to provide a magnetic core that is excellent in manufacturability and can exhibit high magnetic permeability, a manufacturing method thereof, and a coil component using the magnetic core.
- the magnetic core of the present invention comprises Fe-based soft magnetic alloy powder, An oxide phase interposed between grains of the Fe-based soft magnetic alloy powder,
- the Fe-based soft magnetic alloy powder includes Fe-Al-Cr-based alloy powder and Fe-Si-Al-based alloy powder.
- the magnetic core contains Fe-Si-Al-based alloy powder as Fe-based soft magnetic alloy powder and Fe-Al-Cr-based alloy powder having better formability than this Fe-Si-Al-based alloy powder.
- the Fe—Al—Cr alloy powder can be plastically deformed during pressure forming to fill the voids between the Fe—Si—Al alloy powder, and the density can be increased. As a result, non-magnetic voids are reduced in the obtained magnetic core, and the magnetic permeability can be improved.
- Al is concentrated in the oxide phase from the Fe-based soft magnetic alloy powder. Since any Fe-based soft magnetic alloy powder contains Al, an oxide phase containing a large amount of Al can be interposed between the grains of the Fe-based soft magnetic alloy powder. Thereby, favorable insulation can be exhibited. In addition, Fe-based soft magnetic alloy powders can be bonded together by the oxide phase.
- the density of the magnetic core is preferably 5.4 ⁇ 10 3 kg / m 3 or more. By increasing the density to such a range, the strength and permeability of the magnetic core can be further improved.
- the average particle diameter (d50) of the Fe-based soft magnetic alloy powder is preferably 20 ⁇ m or less.
- the present invention is also a method of manufacturing the magnetic core, Forming a mixed powder containing Fe—Al—Cr alloy powder and Fe—Si—Al alloy powder to obtain a molded body;
- the present invention relates to a method of manufacturing a magnetic core including a step of heat-treating the molded body to form the oxide phase.
- the gaps between the alloy powders are filled and high density is obtained. Can be achieved.
- the oxide phase containing Al can be formed between the grains of the Fe-based soft magnetic alloy powder by heat treatment, and the insulation of the magnetic core can be improved.
- the present invention includes a coil component including the magnetic core and a coil provided on the magnetic core.
- the productivity of coil parts can be improved.
- a coil part having a high magnetic permeability can be obtained.
- FIG. 2B is a partial cross-sectional view taken along line A-A ′ in FIG. 2A. It is a perspective view which shows typically the toroidal-shaped magnetic core produced in the Example. It is explanatory drawing which shows the correlation with the density of a magnetic core in an Example, and Fe-Al-Cr type-alloy powder content.
- Sample No. of Example 3 is a SEM image of a cross section of 3 magnetic cores.
- Sample No. of Example 3 is a SEM image of a cross section of 3 magnetic cores.
- Sample No. of Example 3 is a SEM image of a cross section of 3 magnetic cores.
- Sample No. of Example 3 is a SEM image of a cross section of 3 magnetic cores.
- Sample No. of Example 3 is a SEM image of a cross section of 3 magnetic cores.
- Sample No. of Example 3 is a SEM image of a cross section of 3 magnetic cores.
- Sample No. of Example 3 is a SEM image of a cross section of 3 magnetic cores.
- Example 5 is a SEM image of a cross-section of 5 magnetic cores.
- Sample No. of Example 5 is a SEM image of a cross-section of 5 magnetic cores.
- Sample No. of Example 5 is a SEM image of a cross-section of 5 magnetic cores.
- Sample No. of Example 5 is a SEM image of a cross-section of 5 magnetic cores.
- Sample No. of Example 5 is a SEM image of a cross-section of 5 magnetic cores.
- FIG. 1A is a perspective view schematically showing a magnetic core of the present embodiment
- FIG. 1B is a front view thereof.
- the magnetic core 1 includes a cylindrical conductor winding part 5 for winding a coil, and a pair of flange parts 3a and 3b disposed to face both ends of the conductor winding part 5, respectively.
- the appearance of the magnetic core 1 has a drum shape.
- the cross-sectional shape of the conductive wire winding part 5 is not limited to a circle, and any shape such as a square, a rectangle, and an ellipse can be adopted.
- the collar part may be arrange
- the magnetic core of the present embodiment includes Fe-based soft magnetic alloy powder and an oxide phase interposed between grains of the Fe-based soft magnetic alloy powder, and the Fe-based soft magnetic alloy powder is Fe-Al-Cr-based Alloy powder and Fe-Si-Al alloy powder are included. Al is concentrated in the oxide phase from the Fe-based soft magnetic alloy powder.
- the composition of the Fe—Al—Cr alloy powder containing Fe, Cr, and Al as the three main elements having a high content ratio is not particularly limited as long as it can constitute a magnetic core.
- Al and Cr are elements that improve corrosion resistance and the like.
- Al contributes particularly to the formation of surface oxides.
- the content of Al in the Fe—Al—Cr alloy powder is preferably 2.0% by mass or more, more preferably 3.0% by mass or more.
- the Al content is preferably 10.0% by mass or less, more preferably 8.0% by mass or less, and even more preferably 7.0% by mass or less. It is.
- the Cr content in the Fe—Al—Cr alloy powder is preferably 1.0% by mass or more, more preferably 2.5% by mass or more.
- the Cr content is preferably 9.0% by mass or less, more preferably 7.0% by mass or less.
- the total content of Cr and Al is preferably 6.0% by mass or more. Further, since Al is significantly concentrated in the oxide layer on the surface as compared with Cr, it is more preferable to use Fe—Al—Cr alloy powder having a higher Al content than Cr.
- the balance other than Cr and Al is mainly composed of Fe, but may contain other elements as long as the Fe-Al-Cr alloy powder has advantages such as formability.
- the content of such other elements is preferably 1.0% by mass or less. If a large amount of Si is contained, the Fe—Al—Cr alloy particles become hard. Therefore, in this embodiment, an inevitable impurity level (preferably 0) that enters through a normal manufacturing process of the Fe—Al—Cr alloy powder. 0.5 mass% or less).
- the Fe—Al—Cr alloy powder is more preferably composed of Fe, Cr and Al except for inevitable impurities.
- Fe-Si-Al alloy powder The composition of the Fe—Si—Al-based alloy powder containing Fe, Si and Al as the three main elements having a high content ratio is not particularly limited as long as it can constitute a magnetic core.
- a typical example of the Fe—Si—Al based alloy powder is Fe-9.5Si-5.5Al.
- the content of Si in the Fe—Si—Al alloy, which has a small core loss and provides high permeability, is preferably about 5 mass% to 11 mass%, and the Al content is about 3 mass% to 8 mass%. preferable.
- Fe—Si—Al alloy particles having this composition are hard and difficult to be deformed by pressure during compression molding. In this embodiment, however, Fe—Al—Cr alloy powder having excellent formability is mixed. Thus, it is easy to increase the density, and a magnetic core having a high magnetic permeability can be efficiently formed.
- an Fe—Si—Al based alloy is a magnetic material having a high magnetic permeability
- a magnetic core using the Fe—Si—Al based alloy contains many voids because of its hardness. Since the air gap functions as a magnetic gap in the magnetic path, the magnetic permeability varies depending on the size of the air gap.
- the larger the content of the Fe—Al—Cr alloy powder the smaller the voids and the higher the magnetic permeability of the magnetic core. Therefore, the Fe—Al—Cr alloy powder and the Fe— The blending ratio of the Si—Al-based alloy powder may be increased to the extent that the desired characteristics can be obtained.
- the blending ratio of the Fe—Al—Cr alloy powder to the total amount of the Fe—Al—Cr alloy powder and the Fe—Si—Al alloy powder is preferably 20% by mass or more, more preferably 25% by mass or more, 50 mass% or more is more preferable.
- the strength of the magnetic core improves as the blending ratio of the Fe—Al—Cr alloy powder increases.
- the upper limit of the mixing ratio of the Fe—Al—Cr alloy powder can be arbitrarily set, and may be 99.5% by mass, 99% by mass, or 95% by mass.
- the blending ratio of the Fe—Al—Cr alloy powder to the total amount of the Fe—Al—Cr alloy powder and the Fe—Si—Al alloy powder is 90% by mass or less. Even more preferred.
- the average particle diameter of the Fe-based soft magnetic alloy powder (here, the median diameter d50 in the cumulative particle size distribution is used) is not particularly limited, but the strength of the magnetic core and high frequency characteristics are improved by reducing the average particle diameter. Therefore, for example, in applications where high-frequency characteristics are required, Fe-based soft magnetic alloy powder having an average particle size of 20 ⁇ m or less can be suitably used.
- the median diameter d50 is more preferably 18 ⁇ m or less, and still more preferably 16 ⁇ m or less.
- the median diameter d50 is more preferably 5 ⁇ m or more.
- a soft magnetic alloy powder that is at least under 32 ⁇ m (that is, has passed through a sieve having an opening of 32 ⁇ m).
- the average particle diameter of the Fe-based soft magnetic alloy powder may be varied depending on the blending ratio, etc., between the Fe-Si-Al-based alloy powder and the Fe-Al-Cr-based alloy powder so as to achieve dense packing. .
- an oxide phase is interposed between the grains of the Fe-based soft magnetic alloy powder, and Al is concentrated in this oxide phase from the region of the Fe-based soft magnetic alloy powder.
- SEM / EDX Scanning Electron Microscope / energy dispersive X-ray spectroscopy. It is observed that Al is concentrated in the oxide phase formed between the grains.
- the oxide phase is mainly composed of an Al oxide and a phase containing Fe, Cr, and Si. However, in addition to this, a phase mainly composed of Fe oxide, Cr oxide, and Si oxide may exist.
- the oxide phase is formed on the surface of the Fe-based soft magnetic alloy powder by oxidizing the Fe-based soft magnetic alloy powder by a heat treatment described later.
- Al in the Fe—Si—Al alloy powder and the Fe—Al—Cr alloy powder is concentrated on the surface layer, and the ratio of Al is higher in the oxide phase than in the alloy phase inside each alloy powder.
- this oxide phase is formed after forming a molded object, it can also contribute to the coupling
- a high-strength magnetic core can be obtained. The element distribution can be observed with an SEM image.
- the magnetic core according to the present embodiment is excellent in formability and suitable for realizing high magnetic core strength and magnetic permeability. Also, the oxide phase ensures insulation and realizes a core loss characteristic sufficient as a magnetic core.
- the density of the magnetic core is preferably as high as possible from the viewpoint of improving strength and permeability, and is preferably 5.4 ⁇ 10 3 kg / m 3 or more after heat treatment, more preferably 5.5 ⁇ 10 3 kg / m 3 or more. More preferably, it is 5.8 ⁇ 10 3 kg / m 3 or more.
- the Fe-Al-Cr alloy powder having good formability is blended with the relatively hard Fe-Si-Al alloy powder, so that the filling rate in the compact can be increased. It is possible to increase the density of the magnetic core.
- the method for manufacturing a magnetic core according to the present embodiment includes a step of forming a mixed powder containing Fe—Al—Cr alloy powder and Fe—Si—Al alloy powder to obtain a formed body (formed body forming step), A step (heat treatment step) of forming the oxide phase by heat-treating the compact.
- the Fe-based soft magnetic alloy powder used is Fe-Al-Cr-based alloy powder and Fe-Si-Al-based alloy powder.
- An oxide phase containing more Al than the phase is formed.
- Fe—Al—Cr alloy powder containing Cr and Al is more easily plastically deformed than Fe—Si—Al alloy powder. Therefore, the Fe—Al—Cr alloy powder can provide a magnetic core having a high density and strength even at a low molding pressure. Therefore, the enlargement and complexity of the molding machine can be avoided. In addition, since molding can be performed at a low pressure, damage to the mold is suppressed and productivity is improved.
- an insulating oxide can be formed on the surface of the soft magnetic alloy powder by a heat treatment after forming, as will be described later. Therefore, it is possible to omit the step of forming the insulating oxide before molding, and the method for forming the insulating coating is simplified, so that productivity is improved in this respect.
- the form of the Fe-based soft magnetic alloy powder is not particularly limited, but it is preferable to use granular powder represented by atomized powder from the viewpoint of fluidity and the like.
- Atomization methods such as gas atomization and water atomization are suitable for producing powders of alloys that have high malleability and ductility and are difficult to grind.
- the atomization method is also suitable for obtaining a substantially spherical soft magnetic alloy powder.
- a binder in order to bind the particles of the mixed powder of Fe-based soft magnetic alloy powder and to give the molded body the strength to withstand handling after molding in the present embodiment.
- the kind of binder is not specifically limited, For example, various organic binders, such as polyethylene, polyvinyl alcohol, an acrylic resin, can be used.
- the organic binder is thermally decomposed by heat treatment after molding. Therefore, an inorganic binder such as a silicone resin that solidifies and remains after the heat treatment and binds the powders may be used in combination.
- the oxide phase formed in the heat treatment step has an effect of binding the Fe soft magnetic alloy powder particles, so the use of the inorganic binder is used. It is preferable to omit and simplify the process.
- the amount of the binder added may be an amount that can be sufficiently distributed between the Fe-based soft magnetic alloy powders or can ensure a sufficient compact strength. On the other hand, if the amount is too large, the density and strength are lowered. From this point of view, the amount of binder added is preferably 0.5 to 3.0 parts by weight, for example, with respect to 100 parts by weight of Fe-based soft magnetic alloy powder.
- Fe-based soft magnetic alloy powder Fe-Al-Cr-based alloy powder and Fe-Si-Al-based alloy powder are prepared, and both are mixed at the above-mentioned mixing ratio to obtain a mixed powder.
- a binder is added to the mixed powder as necessary.
- the mixing method of the Fe-based soft magnetic alloy powder and the binder in this step is not particularly limited, and conventionally known mixing methods and mixers can be used.
- the mixed powder is an agglomerated powder having a wide particle size distribution due to its binding action. By passing the mixed powder through a sieve using, for example, a vibration sieve or the like, a granulated powder having a desired secondary particle size suitable for molding can be obtained.
- a lubricant such as stearic acid or stearate.
- the addition amount of the lubricant is preferably 0.1 to 2.0 parts by weight with respect to 100 parts by weight of the Fe-based soft magnetic alloy powder.
- the lubricant can be applied to the mold.
- the obtained mixed powder is pressure-molded to obtain a molded body.
- the mixed powder obtained by the above procedure is preferably granulated as described above and subjected to a pressure forming step.
- the granulated mixed powder is pressure-molded into a predetermined shape such as a toroidal shape or a rectangular parallelepiped shape using a molding die.
- the pressure molding may be room temperature molding or warm molding performed by heating to such an extent that the binder does not disappear.
- the molding pressure during pressure molding is preferably 1.0 GPa or less. By molding at a low pressure, it is possible to realize a magnetic core having high magnetic properties and high strength while suppressing breakage of the mold.
- molding method of mixed powder are not limited above.
- heat treatment process Next, a heat treatment process for heat-treating the molded body obtained through the molded body forming process will be described.
- the molded body is subjected to heat treatment.
- an oxide phase enriched with Al is further formed on the surface of the Fe-based soft magnetic alloy powder.
- This oxide phase is grown by reacting Fe-based soft magnetic alloy powder and oxygen by heat treatment, and is formed by an oxidation reaction exceeding the natural oxidation of Fe-based soft magnetic alloy powder.
- Such heat treatment can be performed in an atmosphere in which oxygen exists, such as in the air or in a mixed gas of oxygen and an inert gas. Further, the heat treatment can be performed in an atmosphere in which water vapor exists, such as in a mixed gas of water vapor and inert gas. Of these, heat treatment in the air is simple and preferable.
- the heat treatment in this step may be performed at a temperature at which the oxide phase is formed.
- a magnetic core having excellent strength can be obtained by such heat treatment.
- the heat treatment in this step is preferably performed at a temperature at which the Fe-based soft magnetic alloy powder is not significantly sintered.
- the Fe-based soft magnetic alloy powder is sintered significantly, a part of the oxide phase in which Al is concentrated (the Al ratio is high) is surrounded by the alloy phase due to necking of the alloys so that it is isolated in an island shape. Become. Therefore, the function as an oxide phase separating the base alloy phases of the soft magnetic alloy powder is lowered, and the core loss is also increased.
- the specific heat treatment temperature is preferably in the range of 600 to 900 ° C, more preferably in the range of 700 to 800 ° C, and still more preferably in the range of 750 to 800 ° C.
- the holding time in the above temperature range is appropriately set depending on the size of the magnetic core, the processing amount, the allowable range of characteristic variations, and the like, and is set to 0.5 to 3 hours, for example.
- the Fe—Al—Cr alloy powder is formed during pressure forming by adopting the above-described process of forming an oxide phase rich in Al after pressure forming.
- the high formability possessed can be used effectively.
- FIG. 2A is a plan view schematically showing the coil component of the present embodiment
- FIG. 2B is a bottom view thereof
- FIG. 2C is a partial cross-sectional view along the line AA ′ in FIG. 2A.
- the coil component 10 includes a magnetic core 1 and a coil 20 wound around a conductive wire winding portion 5 of the magnetic core 1.
- the mounting surface of the flange portion 3b of the magnetic core 1 is provided with metal terminals 50a and 50b at the edge portion at the target position across the center of gravity, and one free end of the metal terminals 50a and 50b protruding from the mounting surface is Each of them rises at right angles to the height direction of the magnetic core 1.
- a coil component having such a magnetic core and a coil is used as, for example, a choke, an inductor, a reactor, or a transformer.
- the magnetic core may be manufactured in the form of a single magnetic core obtained by press-molding only the soft magnetic alloy powder mixed with a binder or the like as described above, or may be manufactured in a form in which a coil is arranged inside.
- the latter configuration is not particularly limited.
- a magnetic core of a coil encapsulating structure using a method in which soft magnetic alloy powder and a coil are integrally formed by pressure, or a lamination process such as a sheet lamination method or a printing method is used. It can be manufactured in the form.
- a magnetic core was produced as follows.
- Fe-based soft magnetic alloy powder Fe-Al-Cr-based alloy powder and Fe-Si-Al-based alloy powder (“Alloy Powder PF18” manufactured by Epson Atmix) were used.
- the Fe—Al—Cr alloy powder was a granular atomized powder, and its composition was Fe—5.0% Al—4.0% Cr in mass percentage. Further, the Fe—Si—Al based alloy powder was a granular atomized powder, and its composition was Fe-9.8% Si-6.0% Al by mass percentage.
- Fe-Al-Cr-based alloy powder and Fe-Si-Al-based alloy powder are mixed at a predetermined blending ratio, and an emulsion acrylic resin-based binder (made by Showa Polymer Co., Ltd.) is added to 100 parts by weight of the mixed powder.
- Polysol AP-604 solid content 40%
- This mixed powder was dried at 120 ° C. for 10 hours, and the dried mixed powder was passed through a sieve to obtain granulated powder.
- zinc stearate was added and mixed at a ratio of 0.4 parts by weight with respect to 100 parts by weight of the soft magnetic alloy powder to obtain a mixture for molding.
- the obtained mixed powder was press-molded at room temperature with a molding pressure of 0.91 GPa using a press machine to obtain a toroidal shaped molded body shown in FIG.
- This molded body was heat-treated in the atmosphere at a heat treatment temperature of 750 ° C. for 1 hour to obtain magnetic cores (Sample Nos. 1 to 4).
- the outer dimensions of the magnetic core were an outer diameter of 13.4 mm, an inner diameter of 7.74 mm, and a height of 4.3 mm.
- FIGS. 4 to 9, 10A to 10F, and 11A to 11E. 4 to 9 are explanatory diagrams showing the correlation of each evaluation item with the Fe—Al—Cr alloy powder content in the examples.
- 10A to 10F show sample Nos.
- 3 is a SEM image of a cross section of 3 magnetic cores.
- 11A to 11E show sample Nos.
- 5 is a SEM image of a cross-section of 5 magnetic cores.
- a coil part is formed by winding 15 turns of primary and secondary windings on a toroidal magnetic core.
- the maximum magnetic flux density is 30 mT and the frequency is 300 kHz. It was measured.
- a disk-shaped magnetic core (outer diameter: 13.5 mm, thickness: 4 mm) is prepared as an object to be measured, and a conductive adhesive is applied to the two opposing planes. After drying and solidification, the object to be measured is placed between the electrodes. I set it.
- the toroidal magnetic core was cut and the cut surface was observed with a scanning electron microscope (SEM / EDX) (magnification: 2000 times).
- No. 1 prepared using Fe—Al—Cr alloy powder and Fe—Si—Al alloy powder.
- the magnetic core of No. 4 is made of No. 4 using Fe—Si—Al alloy powder alone. Compared to the magnetic core No. 5, the crumbling strength and the magnetic permeability were significantly increased. It has been found that the configuration according to the above embodiment is extremely advantageous in obtaining excellent crushing strength and magnetic permeability. That is, according to the structure which concerns on the said Example, the magnetic core which has high intensity
- the core loss (especially hysteresis loss) increases with the increase in the proportion of Fe—Al—Cr alloy powder, all are 500 kW / m 3 or less and are practically usable. It was.
- the specific resistance decreased as the blending ratio of the Fe—Al—Cr alloy powder increased, all of them were 5 k ⁇ m or more and were practically usable without problems.
- FIG. 10A shows the evaluation results of cross-section observation using a scanning electron microscope (SEM / EDX) for the magnetic core No. 3, and FIGS. 10B to 10F show the evaluation results of the distribution of each constituent element.
- SEM / EDX scanning electron microscope
- FIGS. 10B to 10F are mappings showing distributions of Fe (iron), Al (aluminum), O (oxygen), Si (silicon), and Cr (chromium), respectively.
- the brighter the color, the greater the number of target elements. Therefore, the determination of the concentration of Al in this example is based on whether or not the brightness of Al in the region occupied by the oxide phase is higher than the brightness of Al in the region occupied by the alloy powder in the observation image of the element distribution. This can be done simply by visual inspection.
- a detailed analysis of the Al composition is performed for the necessary locations in the alloy powder and in the oxide phase by increasing the measurement time with SEM / EDX. You can also know by doing.
- FIG. 10D shows that the surface of the Fe-based soft magnetic alloy powder is rich in oxygen and oxides are formed, and that each Fe-based soft magnetic alloy powder is bonded to each other through this oxide. . From FIG. 10C, the concentration of Al on the surface of the soft magnetic alloy powder is remarkably high. From these facts, it was confirmed that an oxide phase having a higher Al ratio than the internal alloy phase was formed on the surface of the soft magnetic alloy powder.
- FIG. 11A shows the evaluation result of cross-sectional observation using a scanning electron microscope (SEM / EDX) for the magnetic core No. 5, but only the Fe—Si—Al based alloy powder having poor formability is used. It can be seen that there are many voids between the powders and the adhesion between the alloy powders is low.
- SEM / EDX scanning electron microscope
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Abstract
Description
前記Fe系軟磁性合金粉の粒間に介在する酸化物相と
を備え、
前記Fe系軟磁性合金粉は、Fe-Al-Cr系合金粉とFe-Si-Al系合金粉とを含む。
Fe-Al-Cr系合金粉とFe-Si-Al系合金粉とを含む混合粉を成形して成形体を得る工程と、
前記成形体を熱処理して前記酸化物相を形成する工程を含む磁心の製造方法に関する。
図1Aは、本実施形態の磁心を模式的に示す斜視図であり、図1Bはその正面図である。磁心1は、コイルを巻回するための円柱状の導線巻回部5と、導線巻回部5の両端部にそれぞれ対向配設された一対の鍔部3a、3bを備える。磁心1の外観はドラム型を呈する。導線巻回部5の断面形状は円形に限らず、正方形、矩形、楕円形等の任意の形状を採用し得る。また、鍔部は導線巻回部5の両端部に配設されていてもよく、一方の端部にのみ配設されていてもよい。
含有比率の高い三つの主要元素としてFe、CrおよびAlを含むFe-Al-Cr系合金粉の組成は、磁心を構成できるものであれば、特に限定されるものではない。AlおよびCrは耐食性等を高める元素である。また、Alは特に表面酸化物の形成に寄与する。かかる観点から、Fe-Al-Cr系合金粉中のAlの含有量は、好ましくは2.0質量%以上、より好ましくは3.0質量%以上である。一方、Alが多くなりすぎると飽和磁束密度が低下するため、Alの含有量は、好ましくは10.0質量%以下、より好ましくは8.0質量%以下、さらに好ましくは7.0質量%以下である。Crは上述のように耐食性を高める元素である。かかる観点から、Fe-Al-Cr系合金粉中のCrの含有量は、好ましくは1.0質量%以上、より好ましくは2.5質量%以上である。一方、Crが多くなりすぎると飽和磁束密度が低下し、合金粉が硬くなるため、Crの含有量は、好ましくは9.0質量%以下、より好ましくは7.0質量%以下である。
含有比率の高い三つの主要元素としてFe、SiおよびAlを含むFe-Si-Al系合金粉の組成は、磁心を構成できるものであれば、特に限定されるものではない。Fe-Si-Al系合金粉の代表例には、Fe-9.5Si-5.5Alが挙げられる。コアロスが小さくて高透磁率が得られるFe-Si-Al合金中のSiの含有量は、5質量%~11質量%程度が好ましく、Alの含有量は、3質量%~8質量%程度が好ましい。この組成のFe-Si-Al合金粒子は、硬質であって、圧縮成形時の圧力で変形し難くなるが、本実施形態では、成形性に優れるFe-Al-Cr系合金粉を混合することで、高密度化しやすく、高透磁率の磁心を効率よく成形することができる。
Fe-Si-Al系合金は高透磁率の磁性体であるものの、その硬さからそれを用いた磁心は多くの空隙を含むものとなる。前記空隙は磁路において磁気ギャップとして機能するので、透磁率は空隙の多少によって変化する。これに対し、本実施形態の磁心では、Fe-Al-Cr系合金粉の含有量が多いほど空隙が減じられて磁心の透磁率が高くなるので、Fe-Al-Cr系合金粉とFe-Si-Al系合金粉との配合割合は、目的とする特性が得られる程度までFe-Al-Cr系合金粉の配合割合を高めればよい。Fe-Al-Cr系合金粉とFe-Si-Al系合金粉との合計量に対するFe-Al-Cr系合金粉の配合比としては20質量%以上が好ましく、25質量%以上がより好ましく、50質量%以上がさらに好ましい。またFe-Al-Cr系合金粉の配合割合が高くなるほど磁心の強度が向上する。Fe-Al-Cr系合金粉の配合比の上限は任意に設定することができ、99.5質量%でもよく、99質量%でもよく、95質量%でもよい。一方でコアロス増加の抑制の観点から、Fe-Al-Cr系合金粉とFe-Si-Al系合金粉との合計量に対するFe-Al-Cr系合金粉の配合比としては90質量%以下が一層好ましい。
Fe系軟磁性合金粉の平均粒径(ここでは、累積粒度分布におけるメジアン径d50を用いる)は特に限定されるものではないが、平均粒径を小さくすることで磁心の強度、高周波特性が改善されるので、例えば、高周波特性が要求される用途では、20μm以下の平均粒径を有するFe系軟磁性合金粉を好適に用いることができる。メジアン径d50はより好ましくは18μm以下、さらに好ましくは16μm以下である。一方、平均粒径が小さい場合は透磁率が低くなるため、メジアン径d50はより好ましくは5μm以上である。また、篩等を用いて軟磁性合金粉から粗い粒子を除くことがより好ましい。この場合、少なくとも32μmアンダーの(すなわち、目開き32μmの篩を通過した)軟磁性合金粉を用いることが好ましい。
本実施形態の磁心では、Fe系軟磁性合金粉の粒間に酸化物相が介在しており、Fe系軟磁性合金粉の領域よりこの酸化物相にAlが濃化している。成形体を熱処理後、走査型電子顕微鏡(SEM/EDX:Scanning Electron Microscope/energy dispersive X-ray spectroscopy)を用いて磁心の断面の観察と各構成元素の分布を調べると、Fe系軟磁性合金粒の粒間に形成された酸化物相ではAlが濃化していることが観察される。酸化物相は主にAl酸化物を主体としてFe、Cr、Siを含む相からなる。ただし、これ以外にも、Fe酸化物、Cr酸化物、Si酸化物を主体とする相が存在していても良い。
本実施形態に係る磁心は、成形性に優れ、高い磁心強度及び透磁率を実現する上で好適である。また、その酸化物相によって絶縁性が確保され、磁心として十分なコアロス特性が実現される。
本実施形態の磁心の製造方法は、Fe-Al-Cr系合金粉とFe-Si-Al系合金粉とを含む混合粉を成形して成形体を得る工程(成形体形成工程)と、前記成形体を熱処理して前記酸化物相を形成する工程(熱処理工程)を含む。使用するFe系軟磁性合金粉はFe-Al-Cr系合金粉およびFe-Si-Al系合金粉であり、熱処理工程によって、Fe系軟磁性合金粉の粒表面に、質量比で内部の合金相よりもAlを多く含む酸化物相を形成する。
CrおよびAlを含むFe-Al-Cr系の合金粉は、Fe-Si-Al系合金粉に比べて塑性変形しやすい。したがって、Fe-Al-Cr系の合金粉は、低い成形圧力でも高い密度と強度を備えた磁心を得ることができる。そのため、成形機の大型化・複雑化も回避することができる。また、低圧で成形できるため、金型の破損も抑制され、生産性が向上する。
次に、前記成形体形成工程を経て得られた成形体を熱処理する熱処理工程について説明する。成形等で導入された応力歪を緩和して良好な磁気特性を得るために、成形体に対して熱処理が施される。かかる熱処理によって、さらに、Fe系軟磁性合金粉の表面にAlが濃化した酸化物相を形成する。この酸化物相は、熱処理によりFe系軟磁性合金粉と酸素とを反応させ成長させたものであり、Fe系軟磁性合金粉の自然酸化を超える酸化反応により形成される。かかる熱処理は、大気中、酸素と不活性ガスの混合気体中など、酸素が存在する雰囲気中で行うことができる。また、水蒸気と不活性ガスの混合気体中など、水蒸気が存在する雰囲気中で熱処理を行うこともできる。これらのうち大気中の熱処理が簡便であり好ましい。
本実施形態の製造方法では、成形体形成工程や熱処理工程以外の工程を追加することも可能である。例えば、成形体形成工程の前に、熱処理やゾルゲル法等によってFe系軟磁性合金粉に絶縁被膜を形成する予備工程を付加してもよい。ただし、本実施形態に係る磁心の製造方法においては、熱処理工程によってFe系軟磁性合金粉の表面に酸化物相を形成することができるため、上記のような予備工程を省略して製造工程を簡略化することがより好ましい。また、酸化物相自体は塑性変形しにくいので、加圧成形後に上述のAlに富む酸化物相を形成するプロセスを採用することで、加圧成形の際にFe-Al-Cr系合金粉が持つ高い成形性を有効に利用することができる。
図2Aは、本実施形態のコイル部品を模式的に示す平面図であり、図2Bはその底面図であり、図2Cは、図2AにおけるA-A’線一部断面図である。コイル部品10は、磁心1と、磁心1の導線巻回部5に巻き付けられたコイル20を備える。磁心1の鍔部3bの実装面にはその重心を挟んで対象位置にある縁部に金属端子50a、50bが設けられており、実装面からはみ出す金属端子50a、50bの一方の自由端部はそれぞれ磁心1の高さ方向に直角に立ち上がっている。これらの金属端子50a、50bの立ち上がった自由端部のそれぞれとコイルの端部25a、25bとがそれぞれ接合されることで、両者の電気的接続が図られている。このような磁心とコイルとを有するコイル部品は、例えばチョーク、インダクタ、リアクトル、トランス等として用いられる。
以下のようにして、磁心を作製した。Fe系軟磁性合金粉として、Fe-Al-Cr系合金粉およびFe-Si-Al系合金粉(エプソンアトミックス製「合金パウダーPF18」)を用いた。レーザー回折散乱式粒度分布測定装置(堀場製作所製LA-920)で測定した軟磁性合金粉の平均粒径(メジアン径d50)は、Fe-Al-Cr系合金粉で16.8μm、Fe-Si-Al系合金粉で9μmであった。Fe-Al-Cr系合金粉は粒状のアトマイズ粉であり、その組成は質量百分率でFe-5.0%Al-4.0%Crであった。また、Fe-Si-Al系合金粉は粒状のアトマイズ粉であり、その組成は質量百分率でFe-9.8%Si-6.0%Alであった。
以上の工程により作製した各磁心について以下の評価を行った。評価結果を表1及び図4~9、10A~10F及び11A~11Eに示す。図4~9は、実施例における各評価項目のFe-Al-Cr系合金粉含有量への相関性を示す説明図である。図10A~10Fは、実施例の試料No.3の磁心の断面のSEM画像である。図11A~11Eは、実施例の試料No.5の磁心の断面のSEM画像である。
各磁心の密度(kg/m3)をその寸法および質量から算出した。
トロイダル形状の磁心の外周側面から直径方向に荷重をかけ、破壊時の最大加重P(N)を測定し、次式から圧環強度σr(MPa)を求めた。
σr=P(D-d)/(Id2)
(ここで、D:コアの外径(mm)、d:コアの肉厚(mm)、I:コアの高さ(mm)である。)
トロイダル形状の磁心に導線を30ターン巻回してコイル部品とし、周波数100kHzでヒューレット・パッカード社製4285AによりインダクタンスLを測定して初透磁率μiを次式により算出した。
初透磁率μi=(le×L)/(μ0×Ae×N2)
(le:磁路長(m)、L:試料のインダクタンス(H)、μ0:真空の透磁率=4π×10-7(H/m)、Ae:磁心の断面積(m2)、N:コイルの巻数)
トロイダル形状の磁心に、一次側と二次側それぞれ巻線を15ターン巻回してコイル部品とし、岩通計測株式会社製B-HアナライザーSY-8232により、最大磁束密度30mT、周波数300kHzの条件で測定した。
円板状(外径φ13.5mm、厚み4mm)の磁心を被測定物として作製し、その対向する二平面に導電性接着剤を塗り、乾燥・固化の後、被測定物を電極の間にセットした。電気抵抗測定装置(株式会社エーディーシー製8340A)を用いて、50Vの直流電圧を印加し、抵抗値R(Ω)を測定した。被測定物の平面の面積A(m2)と厚みt(m)とを測定し、次式により比抵抗ρ(Ωm)を算出した。
比抵抗ρ(Ωm)=R×(A/t)
トロイダル形状の磁心を切断し、切断面を走査型電子顕微鏡(SEM/EDX)により観察した(倍率:2000倍)。
3a、3b 鍔部
5 導線巻回部
10 コイル部品
20 コイル
25a、25b コイルの端部
50a、50b 金属端子
Claims (6)
- Fe系軟磁性合金粉と、
前記Fe系軟磁性合金粉の粒間に介在する酸化物相と
を備える磁心であって、
前記Fe系軟磁性合金粉は、Fe-Al-Cr系合金粉とFe-Si-Al系合金粉とを含む磁心。 - 前記Fe系軟磁性合金粉より前記酸化物相にAlが濃化している請求項1に記載の磁心。
- 密度が5.4×103kg/m3以上である請求項1又は2に記載の磁心。
- 前記Fe系軟磁性合金粉の平均粒径が20μm以下である請求項1~3のいずれか1項に記載の磁心。
- 請求項1~4のいずれか1項に記載の磁心の製造方法であって、
Fe-Al-Cr系合金粉とFe-Si-Al系合金粉とを含む混合粉を成形して成形体を得る工程と、
前記成形体を熱処理して前記酸化物相を形成する工程を含む磁心の製造方法。 - 請求項1~4のいずれか1項に記載の磁心と、前記磁心に設けられたコイルとを備えるコイル部品。
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JPWO2016010098A1 (ja) | 2017-04-27 |
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US20170207017A1 (en) | 2017-07-20 |
CN106663513B (zh) | 2019-09-27 |
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