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TW201712699A - Dust core, method for producing said dust core, electric/electronic component provided with said dust core, and electric/electronic device on which said electric/electronic component is mounted - Google Patents

Dust core, method for producing said dust core, electric/electronic component provided with said dust core, and electric/electronic device on which said electric/electronic component is mounted Download PDF

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Publication number
TW201712699A
TW201712699A TW105120204A TW105120204A TW201712699A TW 201712699 A TW201712699 A TW 201712699A TW 105120204 A TW105120204 A TW 105120204A TW 105120204 A TW105120204 A TW 105120204A TW 201712699 A TW201712699 A TW 201712699A
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powder
magnetic core
magnetic material
mass
magnetic
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TW105120204A
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Chinese (zh)
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Ryo Nakabayashi
Seiichi Abiko
Akinori Kojima
Takao Mizushima
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Alps Electric Co Ltd
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Publication of TW201712699A publication Critical patent/TW201712699A/en

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/08Metallic powder characterised by particles having an amorphous microstructure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24After-treatment of workpieces or articles
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12Magnets 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
    • H01F1/14Magnets 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
    • H01F1/147Alloys characterised by their composition
    • H01F1/153Amorphous metallic alloys, e.g. glassy metals
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12Magnets 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
    • H01F1/14Magnets 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
    • H01F1/20Magnets 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
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12Magnets 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
    • H01F1/14Magnets 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
    • H01F1/20Magnets 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
    • H01F1/22Magnets 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
    • H01F1/24Magnets 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
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00Fixed inductances of the signal type 
    • H01F17/04Fixed inductances of the signal type  with magnetic core
    • H01F17/06Fixed inductances of the signal type  with magnetic core with core substantially closed in itself, e.g. toroid
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus 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
    • H01F41/02Apparatus 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

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Powder Metallurgy (AREA)
  • Soft Magnetic Materials (AREA)
  • Coils Or Transformers For Communication (AREA)

Abstract

Provided is a dust core which contains a powder of a crystalline magnetic material such as carbonyl iron, and which contains, as a dust core having excellent magnetic characteristics, a powder of a crystalline magnetic material and a powder of an amorphous magnetic material. This dust core is characterized in that a first mixing ratio, which is the mass ratio of the content of the powder of a crystalline magnetic material relative to the sum of the content of the powder of a crystalline magnetic material and the content of the powder of an amorphous magnetic material, is from 75% by mass to 95% by mass (inclusive).

Description

壓粉磁芯、該壓粉磁芯之製造方法、具備該壓粉磁芯之電氣‧電子零件及安裝有該電氣‧電子零件之電氣‧電子機器 Powder magnetic core, method for manufacturing the powder magnetic core, electric ‧ electronic parts including the powder magnetic core, and electric ‧ electronic machine with the electric ‧ electronic parts

本發明係關於一種壓粉磁芯、該壓粉磁芯之製造方法、具備該壓粉磁芯之電氣‧電子零件及安裝有該電氣‧電子零件之電氣‧電子機器。 The present invention relates to a powder magnetic core, a method of manufacturing the powder magnetic core, an electric ‧ electronic component including the powder magnetic core, and an electric ‧ electronic device equipped with the electrical ‧ electronic component

用於油電混合車等之升壓電路或發電、變電設備之電抗器、變壓器或扼流圈等中所使用之壓粉磁芯可藉由將大量之軟磁性粉末壓粉成形,並對所獲得之成形製造物進行熱處理而獲得。 A powder magnetic core used in a booster circuit of a hybrid electric vehicle or the like, a reactor for power generation, a transformer, a transformer, a choke coil, or the like can be formed by compacting a large amount of soft magnetic powder, and The obtained shaped product was obtained by heat treatment.

專利文獻1中,揭示有造粒物之製造方法及使用藉由該造粒物之製造方法所製造之造粒物之電感器,該造粒物之製造方法之特徵在於包括:混合物製造步驟,其係將該磁性粉末、樹脂、低沸點溶劑、及高沸點溶劑混合,製造漿狀混合物;第1乾燥步驟,其係對上述漿狀混合物進行加熱而使上述低沸點溶劑蒸發,製造糊狀混合物;整粒步驟,其係藉由使上述糊狀混合物通過篩網而將其壓碎而進行製粒,獲得粒子;及第2乾燥步驟,其係對上述粒子進行加熱而使上述高沸點溶劑蒸發,獲得磁性粒子。 Patent Document 1 discloses a method for producing a granulated product and an inductor using the granulated product produced by the method for producing the granulated product, the method for producing the granulated product comprising: a step of producing a mixture, The magnetic powder, the resin, the low boiling point solvent, and the high boiling point solvent are mixed to prepare a slurry mixture; and the first drying step is performed by heating the slurry mixture to evaporate the low boiling point solvent to produce a paste mixture. a granulation step of granulating by pulverizing the paste mixture through a sieve to obtain granules; and a second drying step of heating the particles to evaporate the high boiling solvent , obtaining magnetic particles.

[先前技術文獻] [Previous Technical Literature] [專利文獻] [Patent Literature]

[專利文獻1]日本專利特開2014-125655號公報 [Patent Document 1] Japanese Patent Laid-Open Publication No. 2014-125655

上述專利文獻1中,作為具體例,揭示有使用包含粒徑為3~5μm之羰基鐵粉(Carbonyl Iron Powder,以下,有時稱為「CIP」)之磁性粉末之情形。主要使用CIP會使磁導率較高且使直流重疊特性提高,故而較佳。 In the above-mentioned Patent Document 1, as a specific example, a case where a magnetic powder containing carbonyl iron powder (hereinafter referred to as "CIP") having a particle diameter of 3 to 5 μm is used is disclosed. The use of CIP mainly results in a higher magnetic permeability and an increase in DC superposition characteristics, which is preferable.

本發明之目的在於提供一種壓粉磁芯,其係含有如CIP般之結晶質磁性材料之粉末者,且具備優異之磁特性。本發明之課題亦在於提供一種該壓粉磁芯之製造方法、具備該壓粉磁芯之電氣‧電子零件及安裝有該電氣‧電子零件之電氣‧電子機器。 SUMMARY OF THE INVENTION An object of the present invention is to provide a powder magnetic core which contains a powder of a crystalline magnetic material such as CIP and which has excellent magnetic properties. Another object of the present invention is to provide a method for producing the powder magnetic core, an electric ‧ electronic component including the powder magnetic core, and an electric ‧ electronic device having the electric ‧ electronic component mounted thereon

為了解決上述問題,本發明者等人進行研究,結果得出如下之新的見解:藉由使壓粉磁芯不僅含有如CIP之結晶質磁性材料之粉末,亦含有特定量之非晶質磁性材料之粉末,可改善磁特性。 In order to solve the above problems, the inventors of the present invention conducted research and obtained a new finding that a powder magnetic core contains not only a powder of a crystalline magnetic material such as CIP but also a specific amount of amorphous magnetic material. A powder of material that improves magnetic properties.

基於該見解而完成之本發明於一態樣中係一種壓粉磁芯,其特徵在於:其係含有結晶質磁性材料之粉末及非晶質磁性材料之粉末者,且上述結晶質磁性材料之粉末之含量相對於上述結晶質磁性材料之粉末之含量與上述非晶質磁性材料之粉末之含量之總和之質量比率即第一混合比率為75質量%以上且95質量%以下。藉由使壓粉磁芯不僅含有結晶質磁性材料之粉末,亦含有特定量之非晶質磁性材料之粉末,而鐵損Pcv容易降低。 The present invention, which is completed based on the above findings, is a powder magnetic core characterized in that it contains a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, and the crystalline magnetic material is The mass ratio of the powder to the total of the content of the powder of the crystalline magnetic material and the powder of the amorphous magnetic material, that is, the first mixing ratio is 75 mass% or more and 95 mass% or less. The iron loss Pcv is easily lowered by causing the powder magnetic core to contain not only the powder of the crystalline magnetic material but also the powder of the specific amount of the amorphous magnetic material.

上述第一混合比率為80質量%以上且90質量%以下可更加穩定地改善壓粉磁芯之磁特性,故而較佳。 It is preferable that the first mixing ratio is 80% by mass or more and 90% by mass or less to more stably improve the magnetic properties of the powder magnetic core.

存在如下情形:上述結晶質磁性材料之粉末較佳為包含被實施絕緣處理之材料。 There is a case where the powder of the above crystalline magnetic material preferably contains a material subjected to insulation treatment.

亦可為,上述結晶質磁性材料包含選自由Fe-Si-Cr系合金、Fe-Ni系合金、Fe-Co系合金、Fe-V系合金、Fe-Al系合金、Fe-Si系合金、 Fe-Si-Al系合金、羰基鐵(CIP)及純鐵所組成之群中之1種或2種以上之材料。存在如下情形:該等中,上述結晶質磁性材料較佳為包含羰基鐵(CIP)。 The crystalline magnetic material may be selected from the group consisting of Fe-Si-Cr alloys, Fe-Ni alloys, Fe-Co alloys, Fe-V alloys, Fe-Al alloys, Fe-Si alloys, and One or two or more materials selected from the group consisting of Fe-Si-Al alloys, carbonyl iron (CIP), and pure iron. There are cases in which the above crystalline magnetic material preferably contains carbonyl iron (CIP).

亦可為,上述非晶質磁性材料包含選自由Fe-Si-B系合金、Fe-P-C系合金及Co-Fe-Si-B系合金所組成之群中之1種或2種以上之材料。存在如下情形:該等中,上述非晶質磁性材料較佳為包含Fe-P-C系合金。 The amorphous magnetic material may include one or more selected from the group consisting of Fe-Si-B alloys, Fe-PC alloys, and Co-Fe-Si-B alloys. . There are cases where the amorphous magnetic material preferably contains an Fe-P-C based alloy.

存在如下情形:上述非晶質磁性材料之粉末之中值粒徑D50較佳為20μm以下。 There is a case where the powder of the amorphous magnetic material has a median diameter D50 of preferably 20 μm or less.

亦可為,含有使上述結晶質磁性材料之粉末及上述非晶質磁性材料之粉末結合於上述壓粉磁芯中所含有之其他材料之結合成分。於該情形時,上述結合成分較佳為包含基於樹脂材料之成分。 The composition may be a combination of a powder of the crystalline magnetic material and a powder of the amorphous magnetic material bonded to another material contained in the powder magnetic core. In this case, the above-mentioned bonding component preferably contains a component based on a resin material.

本發明於另一態樣中係一種壓粉磁芯之製造方法,其特徵在於:其係上述本發明之壓粉磁芯之製造方法,且包括成形步驟,該成形步驟係藉由成形處理而獲得成形製造物,該成形處理包括對包含上述結晶質磁性材料之粉末及上述非晶質磁性材料之粉末與包含上述樹脂材料之黏合劑成分的混合物實施之加壓成形。 In another aspect, the present invention provides a method for manufacturing a powder magnetic core, which is characterized by the method for manufacturing the powder magnetic core of the present invention, and includes a forming step by a forming process. A molded article is obtained, which comprises press forming a mixture of the powder containing the crystalline magnetic material and the powder of the amorphous magnetic material and a binder component containing the resin material.

亦可為,藉由上述成形步驟所獲得之上述成形製造物為上述壓粉磁芯。或者,亦可為包括熱處理步驟,該熱處理步驟係藉由對由上述成形步驟獲得之上述成形製造物進行加熱之熱處理而獲得上述壓粉磁芯。 Alternatively, the above-mentioned molded article obtained by the above-described forming step may be the above-described powder magnetic core. Alternatively, it may include a heat treatment step of obtaining the above-mentioned powder magnetic core by heat-treating the above-mentioned formed product obtained by the above-described forming step.

本發明於另一態樣中係一種電氣‧電子零件,其係具備上述本發明之壓粉磁芯、線圈及與上述線圈之各個端部連接之連接端子者,且上述壓粉磁芯之至少一部分係以位於在經由上述連接端子於上述線圈流通電流時由上述電流所產生之感應磁場內之方式配置。該電氣‧電子零件基於上述壓粉磁芯之優異之特性而能夠降低鐵損。 In another aspect, the present invention is an electric ‧ electronic component comprising the powder magnetic core of the present invention, a coil, and a connection terminal connected to each end of the coil, and at least the powder magnetic core A part is disposed in an induced magnetic field generated by the current when a current flows through the connection terminal through the connection terminal. The electric ‧ electronic component can reduce iron loss based on the excellent characteristics of the above-mentioned powder magnetic core.

本發明於進而另一態樣中係一種電氣‧電子機器,其係安裝有上述本發明之電氣‧電子零件者,且上述電氣‧電子零件藉由上述連接端子與基板連接。作為該電氣‧電子機器,可例示具備電源開關電路、電壓升降電路、平流電路等之電源裝置或小型可攜式通信裝置等。本發明之電氣‧電子機器具備上述本發明之電氣‧電子零件,故而容易應對大電流化、高速化。 In still another aspect of the invention, an electric/electronic device is mounted to the electric ‧ electronic component of the invention, and the electrical ‧ electronic component is connected to the substrate via the connection terminal As the electric ‧ electronic device, a power supply device such as a power switch circuit, a voltage step-up circuit, a smoothing circuit, or the like, a small portable communication device, or the like can be exemplified. Since the electric ‧ electronic device of the present invention includes the electric ‧ electronic component of the present invention described above, it is easy to cope with a large current and a high speed.

上述發明之壓粉磁芯可具有與具備包含結晶質磁性材料之粉末之磁性粉末之壓粉磁芯相比優異之磁特性。又,根據本發明,提供一種上述壓粉磁芯之製造方法、具備上述壓粉磁芯之電氣‧電子零件及安裝有該電氣‧電子零件之電氣‧電子機器。 The powder magnetic core of the above invention can have excellent magnetic properties as compared with a powder magnetic core having a magnetic powder containing a powder of a crystalline magnetic material. Moreover, according to the present invention, there is provided a method of manufacturing the powder magnetic core, an electric ‧ electronic component including the powder magnetic core, and an electric ‧ electronic device having the electrical ‧ electronic component mounted thereon

1‧‧‧壓粉磁芯(環形磁芯) 1‧‧‧Powder core (ring core)

2‧‧‧被覆導電線 2‧‧‧covered conductive wire

2a‧‧‧線圈 2a‧‧‧ coil

2b、2c‧‧‧露出端部 2b, 2c‧‧‧ exposed end

2d、2e‧‧‧線圈2a之端部 2d, 2e‧‧‧ end of coil 2a

3‧‧‧壓粉磁芯 3‧‧‧Powder core

3a‧‧‧壓粉磁芯3之安裝面 3a‧‧‧Moulding surface of powder core 3

3b、3c‧‧‧壓粉磁芯3之側面 3b, 3c‧‧‧ side of the powder core 3

4‧‧‧端子部 4‧‧‧ Terminals

5‧‧‧線圈 5‧‧‧ coil

5a‧‧‧線圈5之捲繞部 5a‧‧‧Winding section of coil 5

5b‧‧‧線圈5之引出端部 5b‧‧‧ lead end of coil 5

10‧‧‧環形線圈 10‧‧‧Circular coil

20‧‧‧電感元件 20‧‧‧Inductive components

30‧‧‧收納凹部 30‧‧‧ Storage recess

40‧‧‧連接端部 40‧‧‧Connecting end

42a‧‧‧第1曲折部 42a‧‧‧1st twist

42b‧‧‧第2曲折部 42b‧‧‧2nd twist

100‧‧‧安裝基板 100‧‧‧Installation substrate

110‧‧‧岸台部 110‧‧‧Taiwan Department

120‧‧‧焊料層 120‧‧‧ solder layer

200‧‧‧噴霧乾燥器裝置 200‧‧‧ spray dryer unit

201‧‧‧轉子 201‧‧‧Rotor

P‧‧‧造粒粉 P‧‧‧Powder powder

S‧‧‧漿料 S‧‧‧Slurry

圖1係概念性地表示本發明之一實施形態之壓粉磁芯之形狀的立體圖。 Fig. 1 is a perspective view conceptually showing the shape of a powder magnetic core according to an embodiment of the present invention.

圖2係概念性地表示製造造粒粉之方法之一例中所使用之噴霧乾燥器裝置及其動作之圖。 Fig. 2 is a view conceptually showing a spray dryer device used in an example of a method for producing a granulated powder and an operation thereof.

圖3係概念性地表示作為具備本發明之一實施形態之壓粉磁芯之電氣‧電子零件的環形磁芯之形狀的立體圖。 Fig. 3 is a perspective view conceptually showing the shape of a toroidal core as an electric/electronic part having a powder magnetic core according to an embodiment of the present invention.

圖4係局部透視地表示作為具備本發明之另一實施形態之壓粉磁芯之電氣‧電子零件的電感元件之整體構成的立體圖。 Fig. 4 is a perspective view partially showing the overall configuration of an inductance element as an electric/electronic part having a powder magnetic core according to another embodiment of the present invention.

圖5係表示將圖4中所示之電感元件安裝於安裝基板上之狀態之局部前視圖。 Fig. 5 is a partial front elevational view showing a state in which the inductance element shown in Fig. 4 is mounted on a mounting substrate.

圖6係表示含有中值粒徑D50為5μm之非晶質磁性材料之粉末之壓粉磁芯中之常數kh相對於第一混合比率之依存性之擬合結果的曲線圖。 Fig. 6 is a graph showing the results of fitting the dependence of the constant k h in the powder magnetic core of the powder of the amorphous magnetic material having a median diameter D50 of 5 μm with respect to the first mixing ratio.

圖7係表示含有中值粒徑D50為5μm之非晶質磁性材料之粉末之 壓粉磁芯中之常數ke相對於第一混合比率之依存性之擬合結果的曲線圖。 Fig. 7 is a graph showing the results of fitting the dependence of the constant k e in the powder magnetic core of the powder of the amorphous magnetic material having a median diameter D50 of 5 μm with respect to the first mixing ratio.

圖8係表示含有中值粒徑D50為8μm之非晶質磁性材料之粉末之壓粉磁芯中之常數kh相對於第一混合比率之依存性之擬合結果的曲線圖。 Fig. 8 is a graph showing the results of fitting the dependence of the constant k h in the powder magnetic core of the powder of the amorphous magnetic material having a median diameter D50 of 8 μm with respect to the first mixing ratio.

圖9係表示含有中值粒徑D50為8μm之非晶質磁性材料之粉末之壓粉磁芯中之常數ke相對於第一混合比率之依存性之擬合結果的曲線圖。 Fig. 9 is a graph showing the results of fitting the dependence of the constant k e in the powder magnetic core of the powder of the amorphous magnetic material having a median diameter D50 of 8 μm with respect to the first mixing ratio.

圖10係表示含有中值粒徑D50為5μm之非晶質磁性材料之粉末之壓粉磁芯中之相對磁導率μ'相對於第一混合比率之依存性之擬合結果的曲線圖。 Fig. 10 is a graph showing the results of fitting the dependence of the relative magnetic permeability μ' in the powder magnetic core of the powder of the amorphous magnetic material having a median diameter D50 of 5 μm with respect to the first mixing ratio.

圖11係表示含有中值粒徑D50為5μm之非晶質磁性材料之粉末之壓粉磁芯中之Isat相對於第一混合比率之依存性之擬合結果的曲線圖。 Fig. 11 is a graph showing the results of fitting the dependence of Isat on the powder mixture core of the powder of the amorphous magnetic material having a median diameter D50 of 5 μm with respect to the first mixing ratio.

圖12係對於含有中值粒徑D50為5μm之非晶質磁性材料之粉末且第一混合比率處於50質量%~100質量%之範圍內之壓粉磁芯彙總表示鐵損比、初始磁導率比及Isat比的曲線圖。 Figure 12 is a summary of the iron loss ratio and initial permeability of a powder magnetic core containing a powder of an amorphous magnetic material having a median diameter D50 of 5 μm and a first mixing ratio in the range of 50% by mass to 100% by mass. A plot of ratio and Isat ratio.

以下,對本發明之實施形態詳細地進行說明。 Hereinafter, embodiments of the present invention will be described in detail.

1.壓粉磁芯 Powder magnetic core

圖1中所示之本發明之一實施形態之壓粉磁芯1之外觀係環狀,含有結晶質磁性材料之粉末及非晶質磁性材料之粉末。本實施形態之壓粉磁芯1係藉由包括成形處理之製造方法所製造者,該成形處理包括包含該等粉末之混合物之加壓成形。作為不限定之一例,本實施形態之壓粉磁芯1含有使結晶質磁性材料之粉末及非晶質磁性材料之粉末結合於壓粉磁芯1中所含有之其他材料(既存在為同種材料之情形, 亦存在為異種材料之情形)之結合成分。以下,對該等成分進行說明。 The powder magnetic core 1 according to an embodiment of the present invention shown in Fig. 1 has a ring-like appearance and contains a powder of a crystalline magnetic material and a powder of an amorphous magnetic material. The powder magnetic core 1 of the present embodiment is manufactured by a manufacturing method including a forming process including press forming including a mixture of the powders. The powder magnetic core 1 of the present embodiment contains a powder of a crystalline magnetic material and a powder of an amorphous magnetic material in combination with other materials contained in the powder magnetic core 1 (the same material is present). Situation, There are also combinations of components in the case of heterogeneous materials. Hereinafter, the components will be described.

(1)結晶質磁性材料之粉末 (1) Powder of crystalline magnetic material

提供本發明之一實施形態之壓粉磁芯1所含有之結晶質磁性材料之粉末的結晶質磁性材料只要滿足結晶質(藉由通常之X射線繞射測定而獲得具有可特定出材料種類之程度之明確之波峰之繞射光譜)、及強磁性體之條件,則具體之種類無限定。作為結晶質磁性材料之具體例,可列舉Fe-Si-Cr系合金、Fe-Ni系合金、Fe-Co系合金、Fe-V系合金、Fe-Al系合金、Fe-Si系合金、Fe-Si-Al系合金、羰基鐵(CIP)及純鐵。上述結晶質磁性材料可包含1種材料,亦可包含複數種材料。提供結晶質磁性材料之粉末之結晶質磁性材料較佳為選自由上述材料所組成之群中之1種或2種以上之材料,該等中,較佳為含有CIP,更佳為由CIP所構成。 The crystalline magnetic material which provides the powder of the crystalline magnetic material contained in the powder magnetic core 1 of the embodiment of the present invention satisfies the crystal quality (determined by the usual X-ray diffraction measurement to have a specific material type) The diffraction spectrum of the peak of the degree is clearly defined, and the conditions of the ferromagnetic body are not limited in specific types. Specific examples of the crystalline magnetic material include Fe-Si-Cr alloy, Fe-Ni alloy, Fe-Co alloy, Fe-V alloy, Fe-Al alloy, Fe-Si alloy, and Fe. -Si-Al alloy, carbonyl iron (CIP) and pure iron. The above crystalline magnetic material may contain one material or a plurality of materials. The crystalline magnetic material which provides the powder of the crystalline magnetic material is preferably one or more selected from the group consisting of the above materials, and preferably contains CIP, more preferably CIP. Composition.

本發明之一實施形態之壓粉磁芯1所含有之結晶質磁性材料之粉末之形狀無限定。粉末之形狀可為球狀,亦可為非球狀。於為非球狀之情形時,可為鱗片狀、橢圓球狀、液滴狀、針狀等具有形狀各向異性之形狀,亦可為不具特別之形狀各向異性之不定形狀。作為不定形狀之粉體之例,可列舉複數個球狀之粉體相互接觸而結合、或以局部埋藏於其他粉體之方式結合之情形。此種不定形狀之粉體於為CIP時容易被觀察。 The shape of the powder of the crystalline magnetic material contained in the powder magnetic core 1 according to the embodiment of the present invention is not limited. The shape of the powder may be spherical or non-spherical. In the case of being non-spherical, it may have a shape having an anisotropic shape such as a scaly shape, an elliptical shape, a droplet shape, or a needle shape, or may be an indefinite shape having no special shape anisotropy. Examples of the powder of an indefinite shape include a case where a plurality of spherical powders are brought into contact with each other, or are joined in such a manner as to be partially buried in another powder. Such an irregularly shaped powder is easily observed when it is CIP.

粉末之形狀可為於製造粉末之階段中所獲得之形狀,亦可為藉由對所製造之粉末進行二次加工而獲得之形狀。作為前者之形狀,可例示球狀、橢圓球狀、液滴狀、針狀等,作為後者之形狀,可例示鱗片狀。 The shape of the powder may be a shape obtained in the stage of producing the powder, or may be a shape obtained by secondary processing of the produced powder. The shape of the former may be, for example, a spherical shape, an elliptical shape, a droplet shape, or a needle shape, and the shape of the latter may be scaly.

本發明之一實施形態之壓粉磁芯1所含有之結晶質磁性材料之粉末之粒徑無限定。若利用中值粒徑D50(藉由雷射繞射散射法所測得之軟磁性粉末之粒徑之體積分佈中之體積累積值為50%時之粒徑)規定 該粒徑,則通常設為1μm~20μm之範圍。就提高操作性之觀點、提高壓粉磁芯中之結晶質磁性材料之粉末之填充密度之觀點等而言,結晶質磁性材料之粉末之中值粒徑D50(於本說明書中,亦稱為「第一中值粒徑d1」)較佳為設為1μm以上且15μm以下,更佳為設為1μm以上且10μm以下,尤佳為設為1μm以上且5μm以下。 The particle size of the powder of the crystalline magnetic material contained in the powder magnetic core 1 according to the embodiment of the present invention is not limited. If the median particle diameter D50 (particle size in the volume distribution of the particle diameter of the soft magnetic powder measured by the laser diffraction scattering method is 50%) The particle diameter is usually in the range of 1 μm to 20 μm. The powder of the crystalline magnetic material has a median diameter D50 (also referred to in the present specification as a viewpoint of improving the operability, the viewpoint of increasing the packing density of the powder of the crystalline magnetic material in the powder magnetic core, and the like). The "first median diameter d1") is preferably 1 μm or more and 15 μm or less, more preferably 1 μm or more and 10 μm or less, and particularly preferably 1 μm or more and 5 μm or less.

較佳為結晶質磁性材料之粉末之至少一部分由被實施過絕緣處理之材料所構成,更佳為結晶質磁性材料之粉末由被實施過絕緣處理之材料所構成。於對結晶質磁性材料之粉末實施有絕緣處理之情形時,觀察到壓粉磁芯之絕緣電阻提高之傾向。 Preferably, at least a part of the powder of the crystalline magnetic material is composed of a material subjected to insulation treatment, and more preferably a powder of the crystalline magnetic material is composed of a material subjected to insulation treatment. When the powder of the crystalline magnetic material was subjected to an insulating treatment, the tendency of the insulation resistance of the powder magnetic core to be improved was observed.

對結晶質磁性材料之粉末實施之絕緣處理之種類無限定。可例示磷酸處理、磷酸鹽處理、氧化處理、溶膠‧凝膠法等。 There is no limitation on the type of insulation treatment to be performed on the powder of the crystalline magnetic material. Phosphoric acid treatment, phosphate treatment, oxidation treatment, sol ‧ gel method, and the like can be exemplified.

結晶質磁性材料之粉末之含量相對於結晶質磁性材料之粉末之含量與非晶質磁性材料之粉末之含量之總和之質量比率(單位:質量%、於本說明書中亦稱為「第一混合比率」)較佳為75質量%以上且95質量%以下。藉由使第一混合比率為上述之範圍內,而觀察到鐵損Pcv容易降低之傾向。就與磁導率等其他磁特性之平衡性優異之觀點而言,第一混合比率更佳為78質量%以上且93質量%以下,進而較佳為80質量%以上且90質量%以下。 The mass ratio of the content of the powder of the crystalline magnetic material to the sum of the content of the powder of the crystalline magnetic material and the content of the powder of the amorphous magnetic material (unit: mass%, also referred to as "first mixing" in the present specification The ratio ") is preferably 75 mass% or more and 95 mass% or less. By setting the first mixing ratio within the above range, it is observed that the iron loss Pcv tends to be lowered. The first mixing ratio is preferably 78% by mass or more and 93% by mass or less, and more preferably 80% by mass or more and 90% by mass or less, from the viewpoint of excellent balance with other magnetic properties such as magnetic permeability.

(2)非晶質磁性材料之粉末 (2) Powder of amorphous magnetic material

提供本發明之一實施形態之壓粉磁芯1所含有之非晶質磁性材料之粉末的非晶質磁性材料只要滿足非晶質(藉由通常之X射線繞射測定而獲得具有可特定出材料種類之程度之明確之波峰之繞射光譜)、及強磁性體、尤其是軟磁性體之條件,則具體之種類無限定。作為非晶質磁性材料之具體例,可列舉Fe-Si-B系合金、Fe-P-C系合金及Co-Fe-Si-B系合金。上述非晶質磁性材料可包含1種材料,亦可包含複數種材料。構成非晶質磁性材料之粉末之磁性材料較佳為選自由上述材料 所組成之群中之1種或2種以上之材料,該等中,較佳為含有Fe-P-C系合金,更佳為由Fe-P-C系合金所構成。 The amorphous magnetic material which provides the powder of the amorphous magnetic material contained in the powder magnetic core 1 of the embodiment of the present invention satisfies the amorphous state (obtained by the usual X-ray diffraction measurement) The diffraction spectrum of the peak of the peak of the material type and the conditions of the ferromagnetic body, especially the soft magnetic body, are not limited in specific types. Specific examples of the amorphous magnetic material include an Fe—Si—B based alloy, an Fe—P—C based alloy, and a Co—Fe—Si—B based alloy. The amorphous magnetic material may include one material or a plurality of materials. The magnetic material constituting the powder of the amorphous magnetic material is preferably selected from the above materials One or two or more kinds of the constituents of the group preferably contain an Fe-P-C alloy, and more preferably an Fe-P-C alloy.

作為Fe-P-C系合金之具體例,可列舉組成式由Fe100原子%-a-b-c-x-y-z-t NiaSnbCrcPxCyBzSit表示、且0原子%≦a≦10原子%、0原子%≦b≦3原子%、0原子%≦c≦6原子%、6.8原子%≦x≦12.8原子%、2.2原子%≦y≦11.8原子%、0原子%≦z≦9.6原子%、0原子%≦t≦7原子%之Fe基非晶質合金。於上述組成式中,Ni、Sn、Cr、B及Si係任意添加元素。 Specific examples of the Fe-PC-based alloy include a composition formula of Fe 100 atom%-abcxyzt Ni a Sn b Cr c P x C y B z Si t , and 0 atom% ≦a ≦ 10 atom%, 0 atom. %≦b≦3 atom%, 0 atom%≦c≦6 atom%, 6.8 atom%≦x≦12.8 atom%, 2.2 atom%≦y≦11.8 atom%, 0 atom%≦z≦9.6 atom%, 0 atom % ≦t ≦ 7 atom% of Fe-based amorphous alloy. In the above composition formula, Ni, Sn, Cr, B, and Si are arbitrarily added elements.

Ni之添加量a較佳為設為0原子%以上且6原子%以下,更佳為設為0原子%以上且4原子%以下。Sn之添加量b較佳為設為0原子%以上且2原子%以下,更佳為設為1原子%以上且2原子%以下。Cr之添加量c較佳為設為0原子%以上且3原子%以下,更佳為設為1原子%以上且2.5原子%以下。亦存在P之添加量x較佳為設為8.8原子%以上之情形。亦存在C之添加量y較佳為設為5.8原子%以上且8.8原子%以下之情形。B之添加量z較佳為設為0原子%以上且9原子%以下,更佳為設為0原子%以上且8原子%以下。Si之添加量t較佳為設為0原子%以上且6原子%以下,更佳為設為0原子%以上且5.5原子%以下。 The amount of addition of a is preferably 0 atom% or more and 6 atom% or less, and more preferably 0 atom% or more and 4 atom% or less. The amount b of Sn added is preferably 0 atom% or more and 2 atom% or less, and more preferably 1 atom% or more and 2 atom% or less. The amount c of addition of Cr is preferably 0 atom% or more and 3 atom% or less, and more preferably 1 atom% or more and 2.5 atom% or less. The addition amount x of P is preferably set to 8.8 atom% or more. The addition amount y of C is preferably 5.8 atom% or more and 8.8 atom% or less. The amount of addition z of B is preferably 0 atom% or more and 9 atom% or less, and more preferably 0 atom% or more and 8 atom% or less. The addition amount t of Si is preferably 0 atom% or more and 6 atom% or less, and more preferably 0 atom% or more and 5.5 atom% or less.

本發明之一實施形態之壓粉磁芯1所含有之非晶質磁性材料之粉末之形狀無限定。關於粉末之形狀之種類,由於與結晶質磁性材料之粉末之情形相同,故而省略說明。亦存在因製造方法之關係而非晶質磁性材料容易製成球狀或橢圓球狀之情形。又,一般而言,非晶質磁性材料較結晶質磁性材料硬質,故而,亦存在較佳為將結晶質磁性材料設為非球狀而使其於加壓成形時容易變形之情形。 The shape of the powder of the amorphous magnetic material contained in the powder magnetic core 1 according to the embodiment of the present invention is not limited. The type of the shape of the powder is the same as that of the powder of the crystalline magnetic material, and thus the description thereof is omitted. There is also a case where the amorphous magnetic material is easily formed into a spherical shape or an ellipsoidal shape due to the relationship between the manufacturing methods. Further, in general, since the amorphous magnetic material is harder than the crystalline magnetic material, it is preferable that the crystalline magnetic material is made non-spherical and deformed easily during press molding.

本發明之一實施形態之壓粉磁芯1所含有之非晶質磁性材料之粉末之形狀可為於製造粉末之階段中所獲得之形狀,亦可為藉由對所製造之粉末進行二次加工而獲得之形狀。作為前者之形狀,可例示球 狀、橢圓球狀、針狀等,作為後者之形狀,可例示鱗片狀。 The shape of the powder of the amorphous magnetic material contained in the powder magnetic core 1 according to the embodiment of the present invention may be a shape obtained in the stage of producing the powder, or may be performed twice by the powder to be produced. The shape obtained by processing. As the shape of the former, the ball can be exemplified The shape, the elliptical shape, the needle shape, etc., as a shape of the latter, can be illustrated as a scale shape.

本發明之一實施形態之壓粉磁芯1所含有之非晶質磁性材料之粉末之粒徑無限定。若利用中值粒徑D50規定該粒徑,則有較佳為設為20μm以下之情形。就提高操作性之觀點而言,較佳為將非晶質磁性材料之粉末之中值粒徑D50(於本說明書中,亦稱為「第二中值粒徑d2」)設為1μm以上,更佳為設為2μm以上,尤佳為設為3μm以上。就提高壓粉磁芯1中之非晶質及結晶質之磁性材料之粉末之填充密度之觀點等而言,較佳為將非晶質磁性材料之粉末之中值粒徑D50設為15μm以下,更佳為設為12μm以下,尤佳為設為8μm以下。 The particle size of the powder of the amorphous magnetic material contained in the powder magnetic core 1 according to the embodiment of the present invention is not limited. When the particle diameter is defined by the median diameter D50, it is preferably 20 μm or less. From the viewpoint of improving the operability, it is preferable that the powder of the amorphous magnetic material has a median diameter D50 (also referred to as "second median diameter d2" in the present specification) of 1 μm or more. More preferably, it is 2 μm or more, and particularly preferably 3 μm or more. It is preferable to set the powder median diameter D50 of the amorphous magnetic material to 15 μm or less from the viewpoint of improving the packing density of the powder of the amorphous and crystalline magnetic material in the powder magnetic core 1 . More preferably, it is set to 12 μm or less, and particularly preferably set to 8 μm or less.

第一中值粒徑d1與第二中值粒徑d2之關係無限定。一般而言,非晶質磁性材料較結晶質磁性材料硬質,故而,亦存在較佳之情形為使第一中值粒徑d1相對較小,而使結晶質磁性材料之粉末容易填充於已填充有非晶質磁性材料之粉末時所產生之空隙部。於該情形時,d1/d2較佳為設為0.8以下,亦有較佳為設為0.5以下之情形。 The relationship between the first median diameter d1 and the second median diameter d2 is not limited. In general, an amorphous magnetic material is harder than a crystalline magnetic material, and therefore, it is preferable that the first median diameter d1 is relatively small, and the powder of the crystalline magnetic material is easily filled in the filled A void portion generated when a powder of an amorphous magnetic material is used. In this case, it is preferable that d1/d2 is set to 0.8 or less, and it is preferable to set it as 0.5 or less.

(3)結合成分 (3) Combination ingredients

結合成分只要為有助於將本實施形態之壓粉磁芯1中所含有之結晶質磁性材料之粉末及非晶質磁性材料之粉末(於本說明書中,亦有將該等粉末總稱為「磁性粉末」之情形)固定之材料,則其組成無限定。作為構成結合成分之材料,可例示樹脂材料及樹脂材料之熱分解殘渣(於本說明書中,將該等總稱為「基於樹脂材料之成分」)等有機系之材料、無機系之材料等。作為樹脂材料,可例示丙烯酸系樹脂、矽酮樹脂、環氧樹脂、酚樹脂、脲樹脂、三聚氰胺樹脂等。包含無機系之材料之結合成分可例示水玻璃等玻璃系材料。結合成分可包含一種材料,亦可包含複數種材料。結合成分亦可為有機系之材料與無機系之材料之混合體。 The binder component is a powder which contributes to the powder of the crystalline magnetic material and the amorphous magnetic material contained in the powder magnetic core 1 of the present embodiment (in the present specification, the powders are also collectively referred to as "the powder". In the case of a magnetic powder, the composition of the material is not limited. Examples of the material constituting the binder component include organic materials such as a thermal decomposition residue of the resin material and the resin material (referred to collectively as "components based on the resin material" in the present specification), inorganic materials, and the like. Examples of the resin material include an acrylic resin, an anthrone resin, an epoxy resin, a phenol resin, a urea resin, and a melamine resin. A glass-based material such as water glass can be exemplified as the bonding component of the inorganic-based material. The bonding component may comprise one material and may also comprise a plurality of materials. The bonding component may also be a mixture of an organic material and an inorganic material.

作為結合成分,通常使用絕緣性之材料。藉此,可提高作為壓 粉磁芯1之絕緣性。 As the bonding component, an insulating material is usually used. Thereby, the pressure can be increased The insulation of the powder core 1.

2.壓粉磁芯之製造方法 2. Method for manufacturing powder magnetic core

上述本發明之一實施形態之壓粉磁芯1之製造方法並無特別限定,只要採用以下所說明之製造方法,則實現更有效率地製造壓粉磁芯1。 The method for producing the powder magnetic core 1 according to the embodiment of the present invention is not particularly limited, and the powder magnetic core 1 can be more efficiently produced by the production method described below.

本發明之一實施形態之壓粉磁芯1之製造方法包括以下所說明之成形步驟,亦可進而包括熱處理步驟。 A method of manufacturing the powder magnetic core 1 according to an embodiment of the present invention includes the forming step described below, and may further include a heat treatment step.

(1)成形步驟 (1) Forming step

首先,準備包含磁性粉末、及於壓粉磁芯1中提供結合成分之成分的混合物。所謂提供結合成分之成分(於本說明書中,亦稱為「黏合劑成分」),既存在為結合成分本身之情形,亦存在為與結合成分不同之材料之情形。作為後者之具體例,可列舉黏合劑成分為樹脂材料,結合成分為其熱分解殘渣之情形。 First, a mixture containing a magnetic powder and a component which provides a bonding component in the powder magnetic core 1 is prepared. The component which provides a binding component (also referred to as "adhesive component" in the present specification) may be either a combination of the component itself or a material different from the bonding component. Specific examples of the latter include a case where the binder component is a resin material, and a binder component is a thermally decomposed residue.

可藉由包括該混合物之加壓成形的成形處理而獲得成形製造物。加壓條件無限定,係基於黏合劑成分之組成等而適當地決定。例如,於黏合劑成分包含熱固性樹脂之情形時,較佳為與加壓一併進行加熱,於模具內使樹脂進行硬化反應。另一方面,於壓縮成形之情形時,雖然加壓力較高,但加熱並非必需條件,加壓為短時間。 The shaped article can be obtained by a forming process including press forming of the mixture. The pressurization conditions are not limited, and are appropriately determined based on the composition of the binder component and the like. For example, when the binder component contains a thermosetting resin, it is preferred to heat it together with pressurization to harden the resin in the mold. On the other hand, in the case of compression molding, although the pressing force is high, heating is not an essential condition, and the pressurization is short.

以下,略詳細地對混合物為造粒粉且進行壓縮成形之情形進行說明。由於造粒粉之操作性優異,故而可提高成形時間較短且生產性優異之壓縮成形步驟之作業性。 Hereinafter, a case where the mixture is a granulated powder and compression-molded will be described in some detail. Since the granulated powder is excellent in handleability, workability in a compression molding step in which the molding time is short and the productivity is excellent can be improved.

(1-1)造粒粉 (1-1) Granulated powder

造粒粉含有磁性粉末及黏合劑成分。造粒粉中之黏合劑成分之含量並無特別限定。於該含量過低之情形時,黏合劑成分難以保持磁性粉末。又,於黏合劑成分之含量過低之情形時,於歷經熱處理步驟而獲得之壓粉磁芯1中,包含黏合劑成分之熱分解殘渣之結合成分難 以使複數個磁性粉末相互彼此絕緣。另一方面,於上述黏合劑成分之含量過高之情形時,歷經熱處理步驟而獲得之壓粉磁芯1中所含有之結合成分之含量容易變高。若壓粉磁芯1中之結合成分之含量變高,則壓粉磁芯1之磁特性容易降低。因此,造粒粉中之黏合劑成分之含量較佳為設為相對於造粒粉整體成為0.5質量%以上且5.0質量%以下之量。就更加穩定地使壓粉磁芯1之磁特性降低之可能性降低之觀點而言,造粒粉中之黏合劑成分之含量較佳為設為相對於造粒粉整體成為1.0質量%以上且3.5質量%以下之量,更佳為設為成為1.2質量%以上且3.0質量%以下之量。 The granulated powder contains magnetic powder and binder components. The content of the binder component in the granulated powder is not particularly limited. When the content is too low, it is difficult for the binder component to retain the magnetic powder. Further, when the content of the binder component is too low, in the powder magnetic core 1 obtained by the heat treatment step, the combination of the thermal decomposition residue containing the binder component is difficult. The plurality of magnetic powders are insulated from each other. On the other hand, when the content of the above-mentioned binder component is too high, the content of the binder component contained in the powder magnetic core 1 obtained through the heat treatment step tends to be high. When the content of the binder component in the powder magnetic core 1 becomes high, the magnetic properties of the powder magnetic core 1 are liable to lower. Therefore, the content of the binder component in the granulated powder is preferably 0.5% by mass or more and 5.0% by mass or less based on the total amount of the granulated powder. The content of the binder component in the granulated powder is preferably 1.0% by mass or more based on the total amount of the granulated powder, from the viewpoint of further reducing the possibility of reducing the magnetic properties of the powder magnetic core 1 more stably. The amount of 3.5% by mass or less is more preferably 1.2% by mass or more and 3.0% by mass or less.

造粒粉亦可含有上述磁性粉末及黏合劑成分以外之材料。作為此種材料,可例示潤滑劑、矽烷偶合劑、絕緣性之填料等。於含有潤滑劑之情形時,其種類並無特別限定。可為有機系之潤滑劑,亦可為無機系之潤滑劑。作為有機系之潤滑劑之具體例,可列舉硬脂酸鋅、硬脂酸鋁等金屬皂。認為此種有機系之潤滑劑會於熱處理步驟中汽化,幾乎不殘留於壓粉磁芯1。 The granulated powder may also contain materials other than the above magnetic powder and binder components. As such a material, a lubricant, a decane coupling agent, an insulating filler, or the like can be exemplified. In the case of containing a lubricant, the kind thereof is not particularly limited. It can be an organic lubricant or an inorganic lubricant. Specific examples of the organic-based lubricant include metal soaps such as zinc stearate and aluminum stearate. It is considered that such an organic lubricant is vaporized in the heat treatment step and hardly remains in the powder magnetic core 1.

造粒粉之製造方法並無特別限定。可將提供上述造粒粉之成分直接混練,並藉由公知之方法將所獲得之混練物粉碎等而獲得造粒粉,亦可藉由製備向上述成分中添加分散劑(作為一例,可列舉水)而成之漿料,使該漿料乾燥並進行粉碎而獲得造粒粉。亦可於粉碎後進行篩分或分級而控製造粒粉之粒度分佈。 The method for producing the granulated powder is not particularly limited. The granulated powder may be directly kneaded, and the obtained kneaded material may be pulverized or the like by a known method to obtain a granulated powder, or a dispersing agent may be added to the above components by preparation (for example, The slurry formed by water is dried and pulverized to obtain a granulated powder. The particle size distribution of the granulated powder can also be controlled by sieving or grading after pulverization.

作為自上述漿料獲得造粒粉之方法之一例,可列舉使用噴霧乾燥器之方法。如圖2所示,於噴霧乾燥器裝置200內設置有轉子201,自噴霧乾燥器裝置200之上部朝向轉子201注入漿料S。轉子201以特定之轉數旋轉,於噴霧乾燥器裝置200內部之腔室中藉由離心力使漿料S以小滴狀噴霧。進而,向噴霧乾燥器裝置200內部之腔室導入熱風,藉此,使小滴狀之漿料S中所含有之分散劑(水)於維持小滴形狀之狀 態下揮發。其結果,自漿料S形成造粒粉P。自噴霧乾燥器裝置200之下部將該造粒粉P回收。轉子201之轉數、導入噴霧乾燥器裝置200內之熱風溫度、腔室下部之溫度等各參數只要適當地設定即可。該等參數之設定範圍之具體例係作為轉子201之轉數,可列舉4000~6000rpm,作為導入噴霧乾燥器裝置200內之熱風溫度,可列舉130~170℃,作為腔室下部之溫度,可列舉80~90℃。又,腔室內之氛圍及其壓力亦只要適當地設定即可。作為一例,可列舉如下情況:將腔室內設為氣體(空氣)氛圍,將其壓力設為以與大氣壓之差壓計為2mmH2O(約0.02kPa)。亦可藉由篩分等而進而控制所獲得之造粒粉P之粒度分佈。 An example of a method of obtaining a granulated powder from the above slurry is a method using a spray dryer. As shown in FIG. 2, a rotor 201 is provided in the spray dryer device 200, and the slurry S is injected from the upper portion of the spray dryer device 200 toward the rotor 201. The rotor 201 is rotated at a specific number of revolutions, and the slurry S is sprayed in the form of droplets by centrifugal force in a chamber inside the spray dryer device 200. Further, hot air is introduced into the chamber inside the spray dryer device 200, whereby the dispersant (water) contained in the droplet-shaped slurry S is volatilized while maintaining the shape of the droplet. As a result, the granulated powder P is formed from the slurry S. The granulated powder P is recovered from the lower portion of the spray dryer device 200. The parameters such as the number of revolutions of the rotor 201, the temperature of the hot air introduced into the spray dryer device 200, and the temperature of the lower portion of the chamber may be appropriately set. Specific examples of the setting range of the parameters are as the number of revolutions of the rotor 201, and may be 4,000 to 6,000 rpm. The temperature of the hot air introduced into the spray dryer device 200 may be 130 to 170 ° C as the temperature of the lower portion of the chamber. List 80~90 °C. Further, the atmosphere and the pressure inside the chamber may be appropriately set. As an example, a gas (air) atmosphere is used in the chamber, and the pressure is set to 2 mmH 2 O (about 0.02 kPa) at a pressure difference from atmospheric pressure. The particle size distribution of the obtained granulated powder P can be further controlled by sieving or the like.

(1-2)加壓條件 (1-2) Pressurization conditions

壓縮成形中之加壓條件並無特別限定。只要考慮造粒粉之組成、藉由成形步驟而獲得之成形製造物之形狀等而適當地設定即可。於對造粒粉進行壓縮成形時之加壓力過低之情形時,成形製造物之機械強度會降低。因此,容易產生成形製造物之操作性降低、自成形製造物所獲得之壓粉磁芯1之機械強度降低等問題。又,亦存在壓粉磁芯1之磁特性降低或絕緣性降低之情形。另一方面,於對造粒粉進行壓縮成形時之加壓力過高之情形時,製作可耐受其壓力之成形模具變得困難。就更加穩定地使壓縮加壓步驟對壓粉磁芯1之機械特性或磁特性產生不良影響之可能性降低,容易在工業上進行大量生產之觀點而言,對造粒粉進行壓縮成形時之加壓力較佳為設為0.3GPa以上且2GPa以下,更佳為設為0.5GPa以上且2GPa以下,尤佳為設為0.8GPa以上且2GPa以下。 The pressing conditions in the compression molding are not particularly limited. The composition of the granulated powder, the shape of the molded article obtained by the molding step, and the like may be appropriately set. When the pressing force at the time of compression molding of the granulated powder is too low, the mechanical strength of the molded article is lowered. Therefore, there is a problem that the workability of the molded article is lowered, and the mechanical strength of the powder magnetic core 1 obtained from the molded article is lowered. Further, there is a case where the magnetic properties of the powder magnetic core 1 are lowered or the insulation property is lowered. On the other hand, in the case where the pressing force at the time of compression molding of the granulated powder is too high, it becomes difficult to produce a molding die which can withstand the pressure. Further, the possibility that the compression and pressurization step adversely affects the mechanical properties or magnetic properties of the powder magnetic core 1 is more stably lowered, and it is easy to industrially carry out mass production, and the granulated powder is subjected to compression molding. The pressing force is preferably 0.3 GPa or more and 2 GPa or less, more preferably 0.5 GPa or more and 2 GPa or less, and particularly preferably 0.8 GPa or more and 2 GPa or less.

於壓縮成形中,可一面進行加熱一面進行加壓,亦可於常溫下進行加壓。 In the compression molding, the pressure may be applied while heating, or may be performed at normal temperature.

(2)熱處理步驟 (2) Heat treatment step

藉由成形步驟所獲得之成形製造物可為本實施形態之壓粉磁芯1,亦可如以下所說明般對成形製造物實施熱處理步驟而獲得壓粉磁芯1。 The molded article obtained by the forming step can be the powder magnetic core 1 of the present embodiment, and the powder magnetic core 1 can be obtained by subjecting the molded article to a heat treatment step as described below.

於熱處理步驟中,藉由對藉由上述成形步驟所獲得之成形製造物進行加熱,而藉由修正磁性粉末間之距離進行磁特性之調整、及使於成形步驟中賦予至磁性粉末之應變緩和而進行磁特性之調整,從而獲得壓粉磁芯1。 In the heat treatment step, by heating the shaped article obtained by the above-described forming step, the magnetic properties are adjusted by correcting the distance between the magnetic powders, and the strain relief imparted to the magnetic powder in the forming step is performed. The magnetic characteristics are adjusted to obtain the powder magnetic core 1.

由於熱處理步驟係如上所述般以調整壓粉磁芯1之磁特性為目的,故而,熱處理溫度等熱處理條件係以壓粉磁芯1之磁特性成為最良好之方式進行設定。作為設定熱處理條件之方法之一例,可列舉如下方法:使成形製造物之加熱溫度變化,並將升溫速度及加熱溫度下之保持時間等其他條件設為固定。 Since the heat treatment step is for the purpose of adjusting the magnetic properties of the powder magnetic core 1 as described above, the heat treatment conditions such as the heat treatment temperature are set such that the magnetic properties of the powder magnetic core 1 are the best. As an example of the method of setting the heat treatment conditions, a heating temperature of the molded article is changed, and other conditions such as a temperature increase rate and a holding time at the heating temperature are fixed.

設定熱處理條件時之壓粉磁芯1之磁特性之評價標準並無特別限定。作為評價項目之具體例,可列舉壓粉磁芯1之鐵損Pcv。於該情形時,只要以壓粉磁芯1之鐵損Pcv成為最低之方式設定成形製造物之加熱溫度即可。鐵損Pcv之測定條件適當地設定,作為一例,可列舉設為頻率100kHz、最大磁通密度100mT之條件。 The evaluation criteria of the magnetic characteristics of the powder magnetic core 1 when the heat treatment conditions are set are not particularly limited. Specific examples of the evaluation item include the iron loss Pcv of the powder magnetic core 1. In this case, the heating temperature of the molded article may be set so that the iron loss Pcv of the powder magnetic core 1 is the lowest. The measurement conditions of the iron loss Pcv are appropriately set, and examples thereof include a condition of a frequency of 100 kHz and a maximum magnetic flux density of 100 mT.

熱處理時之氛圍並無特別限定。於氧化性氛圍之情形時,過度進行黏合劑成分之熱分解之可能性、或進行磁性粉末之氧化之可能性較高,故而較佳為於氮氣、氬氣等惰性氛圍、或氫氣等還原性氛圍中進行熱處理。 The atmosphere at the time of heat treatment is not particularly limited. In the case of an oxidizing atmosphere, the possibility of excessive thermal decomposition of the binder component or the possibility of oxidation of the magnetic powder is high. Therefore, it is preferably an inert atmosphere such as nitrogen or argon or a reducing property such as hydrogen. Heat treatment in the atmosphere.

3.電氣‧電子零件 3. Electrical ‧ electronic parts

本發明之一實施形態之電氣‧電子零件具備上述本發明之一實施形態之壓粉磁芯1、線圈及與該線圈之各個端部連接之連接端子。此處,壓粉磁芯1之至少一部分係以位於在經由連接端子於線圈流通電流時由該電流所產生之感應磁場內之方式配置。 An electric/electronic component according to an embodiment of the present invention includes the powder magnetic core 1, the coil, and a connection terminal connected to each end portion of the coil according to an embodiment of the present invention. Here, at least a part of the powder magnetic core 1 is disposed so as to be located in an induced magnetic field generated by the current when a current flows through the connection terminal through the connection terminal.

作為此種電氣‧電子零件之一例,可列舉圖3所示之環形線圈10。環形線圈10具備線圈2a,該線圈2a係藉由於環狀之壓粉磁芯(環形磁芯)1捲繞被覆導電線2而形成。被覆導電線2之兩端部中之導電線露出之部分(露出端部)2b、2c構成連接端子。於被覆導電線2中之位於線圈2a與露出端部2b、2c之間之部分,可定義線圈2a之端部2d、2e。如此,本實施形態之電氣‧電子零件亦可為構成線圈之構件與構成連接端子之構件由一個構件構成。 An example of such an electric/electronic component is the toroidal coil 10 shown in Fig. 3. The toroidal coil 10 is provided with a coil 2a which is formed by winding a coated conductive wire 2 by a ring-shaped powder magnetic core (annular core) 1. Portions (baked ends) 2b and 2c in which the conductive wires in the both ends of the covered conductive wire 2 are exposed constitute a connection terminal. The end portions 2d, 2e of the coil 2a can be defined in the portion of the covered conductive wire 2 between the coil 2a and the exposed end portions 2b, 2c. As described above, the electric ‧ electronic component of the present embodiment may be composed of one member for the member constituting the coil and the member constituting the connection terminal.

本發明之一實施形態之電氣‧電子零件亦可具備具有與上述本發明之一實施形態之壓粉磁芯1不同之形狀之壓粉磁芯。作為此種電氣‧電子零件之具體例,可列舉圖4所示之電感元件20。圖4係局部透視地表示本發明之一實施形態之電感元件20之整體構成的立體圖。圖4中,以電感元件20之下表面(安裝面)朝上之姿態進行表示。圖5係表示將圖4中所示之電感元件20安裝於安裝基板100上之狀態的局部前視圖。 The electric/electronic component according to an embodiment of the present invention may be provided with a powder magnetic core having a shape different from that of the powder magnetic core 1 according to the embodiment of the present invention. As a specific example of such an electric ‧ electronic component, the inductance element 20 shown in FIG. 4 is mentioned. Fig. 4 is a perspective view partially showing the entire configuration of an inductance element 20 according to an embodiment of the present invention. In Fig. 4, the lower surface (mounting surface) of the inductor element 20 is shown as being upward. Fig. 5 is a partial front elevational view showing a state in which the inductance element 20 shown in Fig. 4 is mounted on the mounting substrate 100.

圖4中所示之電感元件20係具備壓粉磁芯3、埋入壓粉磁芯3之內部之線圈5、作為藉由熔接而與線圈5電性連接之連接端子之一對端子部4而構成。 The inductance element 20 shown in FIG. 4 includes a powder magnetic core 3, a coil 5 embedded in the interior of the powder magnetic core 3, and one of the connection terminals electrically connected to the coil 5 by welding to the terminal portion 4. And constitute.

線圈5係將經絕緣被膜之導線螺旋狀地捲繞而形成者。線圈5係具有捲繞部5a、及自捲繞部5a引出之引出端部5b、5b而構成。線圈5之捲數係根據所需之電感而適當地設定。 The coil 5 is formed by spirally winding a wire of an insulating film. The coil 5 has a winding portion 5a and lead ends 5b and 5b drawn from the winding portion 5a. The number of turns of the coil 5 is appropriately set in accordance with the required inductance.

如圖4所示,於壓粉磁芯3中,於面對安裝基板之安裝面3a,形成有用以收納端子部4之一部分之收納凹部30。收納凹部30形成於安裝面3a之兩側,且係朝向壓粉磁芯3之側面3b、3c開放地形成。自壓粉磁芯3之側面3b、3c突出之端子部4之一部分朝向安裝面3a被彎折,從而被收納於收納凹部30之內部。 As shown in FIG. 4, in the powder magnetic core 3, a housing recess 30 for accommodating one of the terminal portions 4 is formed on the mounting surface 3a facing the mounting substrate. The housing recess 30 is formed on both sides of the mounting surface 3a and is formed to be open toward the side faces 3b, 3c of the powder magnetic core 3. One of the terminal portions 4 protruding from the side faces 3b and 3c of the powder magnetic core 3 is bent toward the mounting surface 3a, and is housed inside the housing recess 30.

端子部4係由薄板狀之Cu基材形成。端子部4構成為具有:連接 端部40,其埋設於壓粉磁芯3之內部並與線圈5之引出端部5b、5b電性連接;以及第1曲折部42a及第2曲折部42b,其等露出於壓粉磁芯3之外表面,且自上述壓粉磁芯3之側面3b、3c至安裝面3a依序彎折而形成。連接端部40係與線圈5熔接之熔接部。第1曲折部42a與第2曲折部42b係焊料接合於安裝基板100之焊料接合部。焊料接合部係指端子部4中之自壓粉磁芯3露出之部分且至少朝向壓粉磁芯3之外側之表面。 The terminal portion 4 is formed of a thin Cu-shaped base material. The terminal portion 4 is configured to have a connection The end portion 40 is embedded in the interior of the powder magnetic core 3 and electrically connected to the lead ends 5b and 5b of the coil 5; and the first meandering portion 42a and the second meandering portion 42b are exposed to the powder magnetic core The outer surface of 3 is formed by sequentially bending the side faces 3b and 3c of the powder magnetic core 3 to the mounting surface 3a. The connecting end portion 40 is a welded portion that is welded to the coil 5. The first meandering portion 42a and the second meandering portion 42b are solder bonded to the solder joint portion of the mounting substrate 100. The solder joint portion refers to a portion of the terminal portion 4 from which the powder magnetic core 3 is exposed and at least toward the outer side of the powder magnetic core 3.

端子部4之連接端部40與線圈5之引出端部5b藉由電阻熔接而接合。 The connection end portion 40 of the terminal portion 4 and the lead end portion 5b of the coil 5 are joined by resistance welding.

如圖5所示,電感元件20安裝於安裝基板100上。 As shown in FIG. 5, the inductance element 20 is mounted on the mounting substrate 100.

於安裝基板100之表面形成有與外部電路導通之導體圖案,藉由該導體圖案之一部分,形成有用以安裝電感元件20之一對岸台部110。 A conductor pattern that is electrically connected to the external circuit is formed on the surface of the mounting substrate 100, and one of the conductor patterns is formed to mount the one of the inductive elements 20 to the land portion 110.

如圖5所示,於電感元件20中,安裝面3a朝向安裝基板100側,自壓粉磁芯3露出於外部之第1曲折部42a與第2曲折部42b於與安裝基板100之岸台部110之間藉由焊料層120接合。 As shown in FIG. 5, in the inductance element 20, the mounting surface 3a faces the mounting substrate 100 side, and the first bent portion 42a and the second bent portion 42b which are exposed from the powder magnetic core 3 to the outside are placed on the mounting substrate 100. The portions 110 are joined by a solder layer 120.

熔接步驟係藉由印刷步驟於岸台部110塗佈糊狀之焊料後,使第2曲折部42b面對岸台部110地安裝電感元件20,並藉由加熱步驟使焊料溶融。如圖4與圖5所示,第2曲折部42b與安裝基板100之岸台部110對向,第1曲折部42a露出於電感元件20之側面3b、3c,故而填角狀之焊料層120固著於岸台部110,並且於作為焊料接合部之第2曲折部42b與第1曲折部42a兩者之表面充分地擴散而固著。 In the welding step, the paste-like solder is applied to the land portion 110 by the printing step, and then the second bent portion 42b is attached to the land portion 110 to mount the inductance element 20, and the solder is melted by the heating step. As shown in FIGS. 4 and 5, the second meandering portion 42b faces the land portion 110 of the mounting substrate 100, and the first meandering portion 42a is exposed on the side faces 3b and 3c of the inductance element 20, so that the solder layer 120 is filled in the shape of a corner. The surface of the land portion 110 is fixed to the land portion 110 and is sufficiently diffused and fixed to the surface of both the second meander portion 42b and the first meander portion 42a as the solder joint portion.

4.電氣‧電子機器 4. Electrical ‧ electronic machine

本發明之一實施形態之電氣‧電子機器係安裝有具備上述本發明之一實施形態之壓粉磁芯之電氣‧電子零件者。作為此種電氣‧電子機器,可例示流通大電流(例如,於數mm見方左右之小型電感器之情形時,為約1A以上)之具備電源開關電路、電壓升降電路、平流電 路等之電源裝置。 An electric ‧ electronic device according to an embodiment of the present invention is provided with an electric ‧ electronic component including the powder magnetic core of one embodiment of the present invention As such an electric ‧ electronic device, a power switch circuit, a voltage rise and fall circuit, and a smooth current can be exemplified as a large current (for example, in the case of a small inductor of several mm square or so, about 1 A or more) Power supply device such as road.

於在具備電源開關電路、電壓升降電路、平流電路等之電源裝置中流通大電流之情形時,若組入電源裝置中之電氣‧電子零件所具備之壓粉磁芯之鐵損Pcv較高,則發熱之程度變高,裝置之可靠性顯著降低。因此,強烈要求降低該壓粉磁芯之鐵損Pcv而使其為高效率。用於本發明之一實施形態之電氣‧電子機器所具備之電氣‧電子零件之壓粉磁芯之鐵損Pcv較低,故而為高效率,即便於電氣‧電子機器中流通大電流之情形時,發熱之程度亦相對較低。因此,本發明之一實施形態之電氣‧電子機器之可靠性優異。 When a large current flows through a power supply device including a power switch circuit, a voltage riser circuit, a smoothing circuit, etc., the iron loss Pcv of the powder magnetic core provided in the electric/electronic parts incorporated in the power supply device is high, The degree of heat generation becomes high, and the reliability of the device is remarkably lowered. Therefore, it is strongly required to reduce the iron loss Pcv of the powder magnetic core to make it highly efficient. The powder magnetic core of the electric ‧ electronic component provided in the electric ‧ electronic device according to the embodiment of the present invention has a low iron loss Pcv, so that it is highly efficient, even when a large current flows in an electric ‧ electronic device The degree of fever is also relatively low. Therefore, the electrical and electronic equipment according to an embodiment of the present invention is excellent in reliability.

以上所說明之實施形態係為了使本發明容易理解而記載者,並非為了限定本發明而記載者。因此,主旨係上述實施形態中所揭示之各要素亦包括屬於本發明之技術範圍之所有設計變更或同等物。 The embodiments described above are described in order to facilitate the understanding of the present invention and are not intended to limit the invention. Therefore, it is intended that all the elements disclosed in the above-described embodiments include all design changes or equivalents falling within the technical scope of the invention.

[實施例] [Examples]

以下,藉由實施例等更加具體地對本發明進行說明,但本發明之範圍不受該等實施例等限定。 Hereinafter, the present invention will be more specifically described by the examples, but the scope of the present invention is not limited by the examples and the like.

(實施例1) (Example 1)

(1)Fe基非晶質合金粉末之製作 (1) Fabrication of Fe-based amorphous alloy powder

使用水霧化法,製作以成為Fe71原子%Ni6原子%Cr2原子%P11原子%C8原子%B2原子%之組成之方式進行稱量而獲得之非晶質磁性材料之粉末作為磁性粉末。第一混合比率(結晶質磁性材料之粉末之含量相對於結晶質磁性材料之粉末之含量與非晶質磁性材料之粉末之含量之總和之質量比率)為0質量%。所獲得之磁性粉末之粒度分佈係使用日機裝公司製造之「Microtrac粒度分佈測定裝置MT3300EX」以體積分佈進行測定。其結果,於體積分佈中達到50%之粒徑即中值粒徑D50為5μm。 A powder of an amorphous magnetic material obtained by weighing with a composition of Fe 71 atom% Ni 6 atom% Cr 2 atom% P 11 atom% C 8 atom% B 2 atom% by a water atomization method As a magnetic powder. The first mixing ratio (the mass ratio of the content of the powder of the crystalline magnetic material to the sum of the content of the powder of the crystalline magnetic material and the content of the powder of the amorphous magnetic material) was 0% by mass. The particle size distribution of the obtained magnetic powder was measured by volume distribution using "Microtrac particle size distribution measuring apparatus MT3300EX" manufactured by Nikkiso Co., Ltd. As a result, the particle diameter of 50% which is 50% in the volume distribution, that is, the median diameter D50 is 5 μm.

(2)造粒粉之製作 (2) Production of granulated powder

將上述非晶質磁性材料之粉末97.2質量份、包含丙烯酸系樹脂及 酚樹脂之絕緣性結合材料2.5質量份、及潤滑劑0.3質量份混合於作為溶劑之水中而獲得漿料。使用噴霧乾燥器裝置對所獲得之漿料進行乾燥、造粒,獲得中值粒徑D50為80μm之造粒粉。 97.2 parts by mass of the powder of the amorphous magnetic material, comprising an acrylic resin and 2.5 parts by mass of the insulating binder of the phenol resin and 0.3 parts by mass of the lubricant were mixed in water as a solvent to obtain a slurry. The obtained slurry was dried and granulated using a spray dryer apparatus to obtain a granulated powder having a median diameter D50 of 80 μm.

(3)壓縮成形 (3) compression forming

將所獲得之造粒粉填充於模具中,以面壓1.0GPa進行加壓成形,獲得具有外徑20mm×內徑12mm×厚度3mm之環形狀之成形製造物。 The obtained granulated powder was filled in a mold, and subjected to press molding at a surface pressure of 1.0 GPa to obtain a molded article having a ring shape of an outer diameter of 20 mm, an inner diameter of 12 mm, and a thickness of 3 mm.

(4)熱處理 (4) Heat treatment

進行如下熱處理而獲得包含壓粉磁芯之環形磁芯,即,將所獲得之成形製造物載置於氮氣流氛圍之爐內,以升溫速度10℃/分鐘將爐內溫度自室溫(23℃)加熱至400℃,於該溫度下保持1小時,其後,於爐內冷卻至室溫。 The heat treatment is performed to obtain a toroidal core including a powder magnetic core, that is, the obtained shaped product is placed in a nitrogen gas atmosphere furnace, and the furnace temperature is from room temperature (23 ° C) at a heating rate of 10 ° C / min. The mixture was heated to 400 ° C, maintained at this temperature for 1 hour, and then cooled to room temperature in a furnace.

(實施例2~6) (Examples 2 to 6)

於製備磁性粉末時,使用將實施例1中所使用之非晶質磁性材料之粉末與包含被實施過絕緣處理之羰基鐵(CIP)之結晶質磁性材料之粉末(中值粒徑D50:4.3μm)混合且第一混合比率成為下述值之磁性粉末,除此以外,以與實施例1同樣之方式製造環形磁芯。 For the preparation of the magnetic powder, the powder of the amorphous magnetic material used in Example 1 and the powder containing the crystalline magnetic material of the carbonyl iron (CIP) subjected to the insulating treatment (median diameter D50: 4.3) were used. A toroidal core was produced in the same manner as in Example 1 except that the magnetic powder having the following mixing ratio was mixed and the first mixing ratio was changed to the following value.

實施例2 5質量% Example 2 5 mass%

實施例3 10質量% Example 3 10% by mass

實施例4 15質量% Example 4 15% by mass

實施例5 20質量% Example 5 20% by mass

實施例6 30質量% Example 6 30% by mass

(實施例7) (Example 7)

於製備磁性粉末時,全量使用實施例2等中所使用之被實施過絕緣處理之CIP代替實施例1中所使用之非晶質磁性材料之粉末,即,將磁性粉末之第一混合比率設為100質量%,除此以外,以與實施例1同 樣之方式製造環形磁芯。 In the preparation of the magnetic powder, the CIP which was subjected to the insulating treatment used in Example 2 or the like was used in place of the powder of the amorphous magnetic material used in Example 1, that is, the first mixing ratio of the magnetic powder was set. 100% by mass, except for the same as in the first embodiment The toroidal core is fabricated in the same manner.

(實施例8) (Example 8)

中值粒徑D50為8μm,除此以外,以與實施例1之製造方法同樣之方式製備非晶質磁性材料之粉末。使用該非晶質磁性材料之粉末,以與實施例1同樣之方式製造環形磁芯。 A powder of an amorphous magnetic material was prepared in the same manner as in the production method of Example 1, except that the median diameter D50 was 8 μm. A toroidal core was produced in the same manner as in Example 1 using the powder of the amorphous magnetic material.

(試驗例1)鐵損Pcv之測定及模擬 (Test Example 1) Measurement and simulation of iron loss Pcv

對於在藉由實施例1~8所製作之環形磁芯上將被覆銅線分別於一次側捲繞15次,於二次側捲繞10次而獲得之環形線圈,使用BH分析儀(岩崎通信機公司製造之「SY-8217」)於將有效最大磁通密度Bm設為15mT之條件下測定鐵損Pcv(單位:kW/m3)之頻率依存性(測定頻率範圍:100kHz~3MHz)。 The toroidal coil obtained by winding the coated copper wire 15 times on the primary side and winding 10 times on the secondary side on the toroidal magnetic core produced in the first to eighth embodiments, using a BH analyzer (Iwasaki communication) "SY-8217" manufactured by the company, the frequency dependence of the iron loss Pcv (unit: kW/m 3 ) is measured under the condition that the effective maximum magnetic flux density B m is 15 mT (measurement frequency range: 100 kHz to 3 MHz) .

作為表示鐵損Pcv之頻率依存性之式之一例,可列舉下述式(1)所示之式。 An example of the formula showing the frequency dependence of the iron loss Pcv is a formula represented by the following formula (1).

Pcv=kh×f×Bm 1.6+ke×f2×Bm 2 (1) Pcv=k h ×f×B m 1.6 +k e ×f 2 ×B m 2 (1)

此處,f係頻率(單位:kHz),Bm係有效最大磁通密度(單位:mT),kh及ke係常數,前者(常數kh)之單位係kW/m3/kHz/(mT)1.6以下,後者(常數ke)之單位係kW/m3/(kHz)2/(mT)2Here, f is the frequency (unit: kHz), B m is the effective maximum magnetic flux density (unit: mT), k h and k e constant, and the unit of the former (constant k h ) is kW/m 3 /kHz/ (mT) 1.6 or less, the unit of the latter (constant k e ) is kW/m 3 /(kHz) 2 /(mT) 2 .

使用實施例1~7之環形線圈之鐵損Pcv之測定結果中頻率為1MHz~3MHz之範圍之測定結果,針對每個實施例求出2個常數kh及ke。將其結果示於表1中。表1中,省略了常數kh及常數ke之單位之記載。 Using the measurement results of the range of the frequency of 1 MHz to 3 MHz in the measurement results of the iron loss Pcv of the loop coils of Examples 1 to 7, two constants k h and k e were obtained for each of the examples. The results are shown in Table 1. In Table 1, the description of the unit of the constant k h and the constant k e is omitted.

根據表1中所示之結果,針對含有中值粒徑D50為5μm之非晶質磁性材料之粉末之壓粉磁芯之2個常數kh及ke各者,求出相對於第一混合比率之依存性。其結果,如圖6所示,常數kh相對於第一混合比率之依存性之擬合結果為由下述式(2)所示之式。下述式(2)之相關係數為0.9980。另一方面,如圖7所示,常數ke相對於第一混合比率之依存性之擬合結果為由下述式(3)所示之式。下述式(3)之相關係數為0.9816。再者,於下述式(2)及(3)中,x係第一混合比率(單位:質量%)。 According to the results shown in Table 1, the two constants k h and k e of the powder magnetic core containing the powder of the amorphous magnetic material having a median diameter D50 of 5 μm were determined relative to the first mixture. The dependence of the ratio. As a result, as shown in FIG. 6, the result of fitting the dependence of the constant k h with respect to the first mixing ratio is a formula represented by the following formula (2). The correlation coefficient of the following formula (2) is 0.9980. On the other hand, as shown in FIG. 7, the result of fitting the dependence of the constant k e with respect to the first mixing ratio is a formula represented by the following formula (3). The correlation coefficient of the following formula (3) is 0.9816. Further, in the following formulas (2) and (3), x is the first mixing ratio (unit: mass%).

kh=2.290×10-7x2+4.737×10-6x-3.748×10-5 (2) k h =2.290×10 -7 x 2 +4.737×10 -6 x-3.748×10 -5 (2)

ke=2.193×10-11x2-6.411×10-10x+2.499×10-7 (3) k e =2.193×10 -11 x 2 -6.411×10 -10 x+2.499×10 -7 (3)

根據上述式(2)及(3),於第一混合比率為50質量%~100質量%之範圍下求出含有中值粒徑D50為5μm之非晶質磁性材料之粉末之壓粉磁芯之2個常數kh及ke。然後,根據以此方式求出之2個常數kh及ke,算出含有中值粒徑D50為5μm之非晶質磁性材料之粉末且第一混合比率處於50質量%~100質量%之範圍內之壓粉磁芯之鐵損Pcv(頻率f:2MHz、有效最大磁通密度Bm:15mT)。將其結果示於表2中。表2中,示出利用第一混合比率為100質量%之情形時之壓粉磁芯之鐵損Pcv將第一混合比率為50質量%~90質量%之情形時之壓粉磁芯之鐵損Pcv標準化而得之值作為鐵損比。 According to the above formulas (2) and (3), the powder magnetic core containing the powder of the amorphous magnetic material having a median diameter D50 of 5 μm is obtained in the range of the first mixing ratio of 50% by mass to 100% by mass. The two constants k h and k e . Then, based on the two constants k h and k e obtained in this manner, a powder containing an amorphous magnetic material having a median diameter D50 of 5 μm is calculated and the first mixing ratio is in the range of 50% by mass to 100% by mass. The iron loss Pcv of the powder magnetic core (frequency f: 2 MHz, effective maximum magnetic flux density B m : 15 mT). The results are shown in Table 2. In Table 2, the iron powder Pcv of the powder magnetic core when the first mixing ratio is 100% by mass is used, and the iron powder of the powder core is used when the first mixing ratio is 50% by mass to 90% by mass. The value obtained by normalizing the loss Pcv is taken as the iron loss ratio.

使用實施例8之環形線圈之鐵損Pcv之測定結果中頻率為1MHz~ 3MHz之範圍之測定結果,求出2個常數kh及ke。將其結果示於表3中。 Using the measurement results of the range of the frequency of 1 MHz to 3 MHz in the measurement result of the iron loss Pcv of the loop coil of Example 8, two constants k h and k e were obtained . The results are shown in Table 3.

表3中所示之實施例8之2個常數kh及ke之結果為與表1中所示之實施例1之2個常數kh及ke之結果相近之結果。因此,使用實施例8、實施例2~6、及實施例7中之常數kh及常數ke之結果,針對含有中值粒徑D50為8μm之非晶質磁性材料之粉末之壓粉磁芯之2個常數kh及ke各者,求出相對於第一混合比率之依存性。其結果,如圖8所示,常數kh相對於第一混合比率之依存性之擬合結果為由下述式(4)所示之式。下述式(4)之相關係數為0.9980。另一方面,如圖9所示,常數ke相對於第一混合比率之依存性之擬合結果為由下述式(5)所示之式。下述式(5)之相關係數為0.9843。再者,於下述式(4)及(5)中,x係第一混合比率(單位:質量%)。 In the embodiment shown in Table 38 of the constant k 2 and k H is the result e of similarities with the results of Example 1 shown in Table 1 of the H k 2 and k are constants e is the result. Therefore, using the results of the constant k h and the constant k e in Example 8, Examples 2 to 6, and Example 7, the powder magnetic powder of the amorphous magnetic material having a median diameter D50 of 8 μm was used. The two constants k h and k e of the core determine the dependence on the first mixing ratio. As a result, as shown in FIG. 8, the result of fitting the dependence of the constant k h with respect to the first mixing ratio is a formula represented by the following formula (4). The correlation coefficient of the following formula (4) is 0.9980. On the other hand, as shown in FIG. 9, the result of fitting the dependence of the constant k e with respect to the first mixing ratio is a formula represented by the following formula (5). The correlation coefficient of the following formula (5) is 0.9843. Further, in the following formulas (4) and (5), x is the first mixing ratio (unit: mass%).

kh=2.290×10-7x2+4.737×10-6x-3.748×10-5 (4) k h =2.290×10 -7 x 2 +4.737×10 -6 x-3.748×10 -5 (4)

ke=2.032×10-11x2-4.509×10-10x+2.468×10-7 (5) k e =2.032×10 -11 x 2 -4.509×10 -10 x+2.468×10 -7 (5)

根據上述式(4)及(5),於第一混合比率為50質量%~100質量%之範圍下求出含有中值粒徑D50為8μm之非晶質磁性材料之粉末之壓粉磁芯之2個常數kh及ke。然後,根據以此方式求出之2個常數kh及ke,算出含有中值粒徑D50為8μm之非晶質磁性材料之粉末且第一混合比率處於50質量%~100質量%之範圍內之壓粉磁芯之鐵損Pcv(頻率f:2MHz、有效最大磁通密度Bm:15mT)。將其結果及以與表2同樣之方式求出之鐵損比示於表4中。 According to the above formulas (4) and (5), the powder magnetic core containing the powder of the amorphous magnetic material having a median diameter D50 of 8 μm is obtained in the range of the first mixing ratio of 50% by mass to 100% by mass. The two constants k h and k e . Then, based on the two constants k h and k e obtained in this manner, a powder containing an amorphous magnetic material having a median diameter D50 of 8 μm is calculated and the first mixing ratio is in the range of 50% by mass to 100% by mass. The iron loss Pcv of the powder magnetic core (frequency f: 2 MHz, effective maximum magnetic flux density B m : 15 mT). The results and the iron loss ratios obtained in the same manner as in Table 2 are shown in Table 4.

(試驗例2)磁導率之測定 (Test Example 2) Measurement of magnetic permeability

對於在藉由實施例1~8所製作之環形磁芯上將被覆銅線分別於一次側捲繞40次,於二次側捲繞10次而獲得之環形線圈,使用阻抗分析儀(HP公司製造之「4192A」)於100kHz之條件下測定初始磁導率μ'。將結果示於表5中。於表5中之D50之行,示出壓粉磁芯中所含有之非晶質磁性材料之粉末之中值粒徑D50。 The toroidal coil obtained by winding the coated copper wire 40 times on the primary side and winding 10 times on the secondary side on the toroidal magnetic core produced in Examples 1 to 8, using an impedance analyzer (HP company) The manufactured "4192A") was measured at an initial permeability μ' at 100 kHz. The results are shown in Table 5. In the row of D50 in Table 5, the powder median diameter D50 of the amorphous magnetic material contained in the powder magnetic core is shown.

根據表5中所示之結果,求出含有中值粒徑D50為5μm之非晶質磁性材料之粉末之壓粉磁芯之初始磁導率μ'相對於第一混合比率之依存性。其結果,如圖10所示,初始磁導率μ'相對於第一混合比率之依存性之擬合結果為由下述式(6)所示之式。下述式(6)之相關係數為0.9934。再者,於下述式(6)中,x係第一混合比率(單位:質量%)。 From the results shown in Table 5, the dependence of the initial magnetic permeability μ' of the powder magnetic core containing the powder of the amorphous magnetic material having a median diameter D50 of 5 μm with respect to the first mixing ratio was determined. As a result, as shown in FIG. 10, the fitting result of the dependence of the initial magnetic permeability μ' with respect to the first mixing ratio is a formula represented by the following formula (6). The correlation coefficient of the following formula (6) is 0.9934. Further, in the following formula (6), x is the first mixing ratio (unit: mass%).

μ'=-7.244×10-4x2+1.529×10-1x+2.859×101 (6) μ'=-7.244×10 -4 x 2 +1.529×10 -1 x+2.859×10 1 (6)

根據上述式(6),算出含有中值粒徑D50為5μm之非晶質磁性材料 之粉末且第一混合比率處於50質量%~100質量%之範圍內之壓粉磁芯之初始磁導率μ'。將其結果示於表6中。表6中,示出利用第一混合比率為100質量%之情形時之壓粉磁芯之初始磁導率μ'將第一混合比率為50質量%~90質量%之情形時之壓粉磁芯之初始磁導率μ'標準化而得之值作為初始磁導率比。 An amorphous magnetic material having a median diameter D50 of 5 μm was calculated according to the above formula (6) The powder has a powder and the first mixing ratio is in the range of 50% by mass to 100% by mass of the initial magnetic permeability μ' of the powder magnetic core. The results are shown in Table 6. In Table 6, the powder magnetic property when the initial magnetic permeability μ' of the powder magnetic core in the case where the first mixing ratio is 100% by mass is used, and the first mixing ratio is 50% by mass to 90% by mass. The value obtained by normalizing the initial magnetic permeability μ' of the core is taken as the initial permeability ratio.

假定含有中值粒徑D50為8μm之非晶質磁性材料之粉末之壓粉磁芯之初始磁導率μ'相對於第一混合比率之依存性係由一次直線表示,根據實施例8及7之初始磁導率μ'之測定結果,算出含有中值粒徑D50為8μm之非晶質磁性材料之粉末之壓粉磁芯之第一混合比率為50質量%~100質量%之範圍時之初始磁導率μ'。將其結果及以與表5同樣之方式求出之初始磁導率比示於表7中。 It is assumed that the dependence of the initial magnetic permeability μ' of the powder magnetic core containing the powder of the amorphous magnetic material having a median diameter D50 of 8 μm with respect to the first mixing ratio is represented by a straight line, according to Examples 8 and 7. When the first mixing ratio of the powder magnetic core containing the powder of the amorphous magnetic material having a median diameter D50 of 8 μm is in the range of 50% by mass to 100% by mass, the result of the measurement of the initial magnetic permeability μ' is calculated. Initial permeability μ'. The results and the initial permeability ratios obtained in the same manner as in Table 5 are shown in Table 7.

(試驗例3)直流重疊特性之測定 (Test Example 3) Measurement of DC superposition characteristics

使用由藉由實施例1~8所製作之環形磁芯形成之環形線圈,依據JIS C2560-2,於環形線圈上重疊直流電流。藉由電感L之變化量△L 相對於重疊電流之施加前(初始)之電感L之值L0的比例(△L/L0)達到30%時之施加電流值Isat(單位:A),評價直流重疊特性。將結果示於表8中。於表8中之D50之行,示出壓粉磁芯中所含有之非晶質磁性材料之粉末之中值粒徑D50。 A toroidal coil formed by the toroidal cores produced by the embodiments 1 to 8 was used, and a direct current was superposed on the toroidal coil in accordance with JIS C2560-2. The applied current value Isat (unit: A) when the ratio (ΔL/L 0 ) of the inductance L of the inductance L to the value L 0 of the inductance L before the application of the overlap current (initial) reaches 30%, Evaluate DC overlap characteristics. The results are shown in Table 8. In the row of D50 in Table 8, the powder median diameter D50 of the amorphous magnetic material contained in the powder magnetic core is shown.

根據表8中所示之結果,求出含有中值粒徑D50為5μm之非晶質磁性材料之粉末之壓粉磁芯之Isat相對於第一混合比率之依存性。其結果,如圖11所示,Isat相對於第一混合比率之依存性之擬合結果為由下述式(7)所示之式。下述式(7)之相關係數為0.9954。再者,於下述式(7)中,x係第一混合比率(單位:質量%)。 From the results shown in Table 8, the dependence of the Isat of the powder magnetic core containing the powder of the amorphous magnetic material having a median diameter D50 of 5 μm with respect to the first mixing ratio was determined. As a result, as shown in FIG. 11, the result of fitting the dependence of Isat with respect to the first mixing ratio is a formula represented by the following formula (7). The correlation coefficient of the following formula (7) is 0.9954. Further, in the following formula (7), x is the first mixing ratio (unit: mass%).

Isat=6.602×10-2x+1.149×101 (7) Isat=6.602×10 -2 x+1.149×10 1 (7)

根據上述式(7),算出含有中值粒徑D50為5μm之非晶質磁性材料之粉末且第一混合比率處於50質量%~100質量%之範圍內之壓粉磁芯之Isat。將其結果示於表9中。表9中,示出利用第一混合比率為100質量%之情形時之壓粉磁芯之Isat將第一混合比率為50質量%~90質量%之情形時之壓粉磁芯之Isat標準化而得之值作為Isat比。 According to the above formula (7), Isat containing a powder of an amorphous magnetic material having a median diameter D50 of 5 μm and having a first mixing ratio in the range of 50% by mass to 100% by mass is calculated. The results are shown in Table 9. In Table 9, it is shown that the Isat of the powder magnetic core is normalized when the first mixing ratio is 50% by mass to 90% by mass in the case where the first mixing ratio is 100% by mass. The value obtained is the Isat ratio.

假定含有中值粒徑D50為8μm之非晶質磁性材料之粉末之壓粉磁芯之Isat相對於第一混合比率之依存性係由一次直線表示,根據實施例8及7之Isat之測定結果,算出含有中值粒徑D50為8μm之非晶質磁性材料之粉末且第一混合比率處於50質量%~100質量%之範圍內之壓粉磁芯之Isat。將其結果及以與表9同樣之方式求出之Isat比示於表10中。 It is assumed that the dependency of Isat on the powder magnetic core containing the powder of the amorphous magnetic material having a median diameter D50 of 8 μm with respect to the first mixing ratio is represented by a straight line, and the measurement results of Isat according to Examples 8 and 7 The Isat of the powder magnetic core containing the powder of the amorphous magnetic material having a median diameter D50 of 8 μm and having the first mixing ratio in the range of 50% by mass to 100% by mass was calculated. The results and the Isat ratios obtained in the same manner as in Table 9 are shown in Table 10.

圖12係於一個曲線圖中對於含有中值粒徑D50為5μm之非晶質磁性材料之粉末且第一混合比率處於50質量%~100質量%之範圍內之壓粉磁芯彙總表示鐵損比、初始磁導率比及Isat比的圖。如圖12所示,根據與磁性粉末由CIP所構成之壓粉磁芯(實施例7)之對比,可確認:若使壓粉磁芯中所含有之磁性粉末中包含非晶質磁性材料之粉末,則鐵損比、初始磁導率比及Isat比均降低,鐵損比與另外2個比相比大幅降低。該結果顯示:藉由向磁性粉末由CIP所構成之壓粉磁芯中混合包含非晶質磁性材料之粉末之磁性粉末,可減少初始磁導率或Isat之降低,並且大幅降低鐵損。並且,自圖12可知,混合於壓粉磁芯中之包含非晶質磁性材料之粉末之磁性粉末之比例越大,鐵損Pcv之降低越顯著。 Figure 12 is a graph showing the iron loss of a powder magnetic core containing a powder of an amorphous magnetic material having a median diameter D50 of 5 μm and a first mixing ratio in the range of 50% by mass to 100% by mass. Ratio, initial permeability ratio, and Isat ratio plot. As shown in Fig. 12, according to the comparison with the powder magnetic core composed of CIP (Example 7), it was confirmed that the magnetic powder contained in the powder magnetic core contains amorphous magnetic material. In the powder, the iron loss ratio, the initial permeability ratio, and the Isat ratio were both lowered, and the iron loss ratio was significantly lower than the other two ratios. This result shows that by mixing a magnetic powder containing a powder of an amorphous magnetic material into a powder magnetic core composed of a magnetic powder of CIP, the initial magnetic permeability or the decrease in Isat can be reduced, and the iron loss can be greatly reduced. Further, as is clear from Fig. 12, the larger the proportion of the magnetic powder of the powder containing the amorphous magnetic material mixed in the powder magnetic core, the more remarkable the decrease in the iron loss Pcv.

為了確認鐵損Pcv之降低之程度與其他磁特性之降低之程度存在 何種關係,而藉由下述式(8)及下述式(9)進行評價。 In order to confirm the degree of decrease in the iron loss Pcv and the degree of decrease in other magnetic properties What kind of relationship is evaluated by the following formula (8) and the following formula (9).

R1i=(1-Ci)/(1-Pi) (8) R1 i =(1-C i )/(1-P i ) (8)

R2i=(1-Ci)/(1-Ii) (9) R2 i =(1-C i )/(1-I i ) (9)

此處,Ci係第一混合比率為i質量%時之鐵損比,Pi係第一混合比率為i質量%時之初始磁導率比。因此,R1i係表示於第一混合比率為i質量%時,以初始磁導率μ'之降低量為標準而鐵損Pcv降低了多少之指標。又,Ii係第一混合比率為i質量%時之Isat比。因此,R2i係表示於第一混合比率為i質量%時,以Isat之降低量為標準而鐵損Pcv降低了多少之指標。將該等算出結果示於表11中。 Here, C i is an iron loss ratio when the first mixing ratio is i% by mass, and P i is an initial magnetic permeability ratio when the first mixing ratio is i% by mass. Therefore, R1 i is an index indicating how much the iron loss Pcv is decreased by the amount of decrease in the initial magnetic permeability μ' as a standard when the first mixing ratio is i% by mass. Further, I i is an Isat ratio when the first mixing ratio is i% by mass. Therefore, R2 i is an index indicating how much the iron loss Pcv is decreased by the amount of reduction of Isat as the standard when the first mixing ratio is i% by mass. The results of these calculations are shown in Table 11.

根據表11,可理解:藉由使第一混合比率越大,即,使向磁性粉末由CIP所構成之壓粉磁芯中混合包含非晶質磁性材料之粉末之磁性粉末之程度降低,越可更有效地(減小其他磁特性所受到之影響)降低鐵損Pcv。 According to Table 11, it can be understood that by increasing the first mixing ratio, that is, the degree of mixing the magnetic powder containing the powder of the amorphous magnetic material into the powder magnetic core composed of the CIP is reduced, The iron loss Pcv can be reduced more effectively (reducing the influence of other magnetic properties).

[產業上之可利用性] [Industrial availability]

使用本發明之壓粉磁芯之電氣‧電子零件可較佳地用作用於油電混合車等之升壓電路或發電、變電設備中之電抗器、變壓器或扼流圈等。 The electric ‧ electronic component using the powder magnetic core of the present invention can be preferably used as a booster circuit for a hybrid electric vehicle or the like, a reactor in a power generation and a substation, a transformer or a choke coil, and the like.

1‧‧‧壓粉磁芯(環形磁芯) 1‧‧‧Powder core (ring core)

Claims (15)

一種壓粉磁芯,其特徵在於:其係含有結晶質磁性材料之粉末及非晶質磁性材料之粉末者,且上述結晶質磁性材料之粉末之含量相對於上述結晶質磁性材料之粉末之含量與上述非晶質磁性材料之粉末之含量之總和之質量比率即第一混合比率為75質量%以上且95質量%以下。 A powder magnetic core characterized in that it contains a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, and the content of the powder of the crystalline magnetic material is relative to the content of the powder of the crystalline magnetic material. The mass ratio of the sum of the contents of the powder of the amorphous magnetic material, that is, the first mixing ratio is 75 mass% or more and 95 mass% or less. 如請求項1之壓粉磁芯,其中上述第一混合比率為80質量%以上且90質量%以下。 The powder magnetic core of claim 1, wherein the first mixing ratio is 80% by mass or more and 90% by mass or less. 如請求項1或2之壓粉磁芯,其中上述結晶質磁性材料之粉末包含被實施過絕緣處理之材料。 A powder magnetic core according to claim 1 or 2, wherein the powder of the above crystalline magnetic material comprises a material subjected to an insulation treatment. 如請求項1或2之壓粉磁芯,其中上述結晶質磁性材料包含選自由Fe-Si-Cr系合金、Fe-Ni系合金、Fe-Co系合金、Fe-V系合金、Fe-Al系合金、Fe-Si系合金、Fe-Si-Al系合金、羰基鐵及純鐵所組成之群中之1種或2種以上之材料。 A powder magnetic core according to claim 1 or 2, wherein said crystalline magnetic material comprises a material selected from the group consisting of Fe-Si-Cr alloy, Fe-Ni alloy, Fe-Co alloy, Fe-V alloy, Fe-Al One or two or more materials selected from the group consisting of alloys, Fe-Si alloys, Fe-Si-Al alloys, carbonyl iron, and pure iron. 如請求項4之壓粉磁芯,其中上述結晶質磁性材料包含羰基鐵。 The powder magnetic core of claim 4, wherein the crystalline magnetic material comprises carbonyl iron. 如請求項1或2之壓粉磁芯,其中上述非晶質磁性材料包含選自由Fe-Si-B系合金、Fe-P-C系合金及Co-Fe-Si-B系合金所組成之群中之1種或2種以上之材料。 The powder magnetic core according to claim 1 or 2, wherein the amorphous magnetic material comprises a group selected from the group consisting of Fe-Si-B alloys, Fe-PC alloys, and Co-Fe-Si-B alloys. One or more materials. 如請求項6之壓粉磁芯,其中上述非晶質磁性材料包含Fe-P-C系合金。 The powder magnetic core of claim 6, wherein the amorphous magnetic material comprises an Fe-P-C alloy. 如請求項1或2之壓粉磁芯,其中上述非晶質磁性材料之粉末之中值粒徑D50為20μm以下。 The powder magnetic core according to claim 1 or 2, wherein the amorphous magnetic material has a powder median diameter D50 of 20 μm or less. 如請求項1或2之壓粉磁芯,其含有使上述結晶質磁性材料之粉末及上述非晶質磁性材料之粉末結合於上述壓粉磁芯中所含有之其他材料之結合成分。 The powder magnetic core according to claim 1 or 2, which comprises a binding component which binds the powder of the crystalline magnetic material and the powder of the amorphous magnetic material to other materials contained in the powder magnetic core. 如請求項9之壓粉磁芯,其中上述結合成分包含基於樹脂材料之成分。 The powder magnetic core of claim 9, wherein the above-mentioned bonding component comprises a component based on a resin material. 一種壓粉磁芯之製造方法,其特徵在於:其係如請求項10之壓粉磁芯之製造方法,且包括成形步驟,該成形步驟係藉由成形處理而獲得成形製造物,該成形處理包括對包含上述結晶質磁性材料之粉末及上述非晶質磁性材料之粉末與包含上述樹脂材料之黏合劑成分的混合物實施之加壓成形。 A method of manufacturing a powder magnetic core, characterized in that it is a method of manufacturing a powder magnetic core according to claim 10, and includes a forming step of obtaining a shaped article by a forming process, the forming process The pressure molding is performed on a mixture of the powder containing the crystalline magnetic material and the powder of the amorphous magnetic material and the binder component containing the resin material. 如請求項11之製造方法,其中藉由上述成形步驟所獲得之上述成形製造物係上述壓粉磁芯。 The manufacturing method of claim 11, wherein the above-mentioned shaped article obtained by the above-described forming step is the above-mentioned powder magnetic core. 如請求項11之製造方法,其包括熱處理步驟,該熱處理步驟係藉由對由上述成形步驟獲得之上述成形製造物進行加熱之熱處理而獲得上述壓粉磁芯。 The manufacturing method of claim 11, which comprises a heat treatment step of obtaining the above-described powder magnetic core by heat-treating the above-mentioned shaped article obtained by the above-described forming step. 一種電氣‧電子零件,其係具備如請求項1或2之壓粉磁芯、線圈及與上述線圈之各個端部連接之連接端子者,且上述壓粉磁芯之至少一部分係以位於在經由上述連接端子於上述線圈流通電流時由上述電流所產生之感應磁場內之方式配置。 An electric ‧ electronic component comprising the powder magnetic core of claim 1 or 2, a coil, and a connection terminal connected to each end of the coil, and at least a portion of the powder magnetic core is located therethrough The connection terminal is disposed in the induced magnetic field generated by the current when the current flows through the coil. 一種電氣‧電子機器,其係安裝有如請求項14之電氣‧電子零件者,且上述電氣‧電子零件以上述連接端子與基板連接。 An electric ‧ electronic machine equipped with an electric ‧ electronic component as claimed in claim 14 , wherein the electrical ‧ electronic component is connected to the substrate by the connection terminal
TW105120204A 2015-08-31 2016-06-27 Dust core, method for producing said dust core, electric/electronic component provided with said dust core, and electric/electronic device on which said electric/electronic component is mounted TW201712699A (en)

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