TWI579867B - A dust core, a method for manufacturing the dust core, an electronic / electrical component provided with the dust core, and an electronic / electrical device to which the electronic / electrical component is mounted - Google Patents

Description

Powder iron core, method for manufacturing the powder core, electronic/electrical component having the powder core, and electronic/electrical device with the electronic/electric component mounted thereon

The present invention relates to a dust core, a method of manufacturing the powder core, an electronic/electrical component including the powder core, and an electronic/electrical device in which the electronic/electric component is mounted.

A booster circuit such as a hybrid electric vehicle, a reactor for power generation and a substation, a dust core for use in a transformer or a choke coil, and a plurality of soft magnetic powders are formed by powder molding, and the obtained molded body is obtained. It can be obtained by performing heat treatment. Patent Document 1 listed below discloses an example of a dust core.

Further, Patent Document 1 discloses an inductor including a core (powder core), which is an inductor having a higher core strength and insulation resistance and having less core loss, the core including mixed powder and insulation. When the mixture of materials is cured, the mixed powder is a mixed powder composed of a mixing ratio of 90 to 98 mass% of amorphous soft magnetic powder and 2 to 10 mass% of crystalline soft magnetic powder.

[Advanced technical literature] [Patent Literature]

[Patent Document 1] JP-A-2010-118486

Recently, electronic/electrical components such as inductors using a powdered iron core are required to be able to adapt to high frequency of operating frequency. However, in Patent Document 1, the excitation condition for evaluating the core loss of the toroidal core using the core (powder core) is only 300 kHz, and the crystalline soft magnetic powder is contained in the high frequency band of 1 MHz or more. Whether or not the material of the amorphous soft magnetic powder is suitable as the material of the core (powder core) is not mentioned at all.

An object of the present invention is to provide a dust core having a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, and a dust core having good magnetic characteristics even in a high frequency band of 1 MHz or more. An object of the present invention is to provide a method for producing the powdered iron core, an electronic/electrical component including the powdered iron core, and an electronic/electrical device to which the electronic/electrical component is mounted.

In order to solve the above problems, the inventors have found that the measured iron loss Pcv (unit: kW/m ³ ) versus frequency f (unit: kHz) measured under the condition that the effective maximum magnetic flux density B _m is 15 mT. In the formula of the dependency, the range of the two constants used in the equation is set to a specific range, and thus it is possible to provide a dust core having good magnetic characteristics even in a high frequency band of 1 MHz or more.

The invention completed in accordance with this finding is as follows.

The dust core of one aspect of the present invention is a powdered iron core containing a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, and the iron is determined under the condition of an effective maximum magnetic flux density B _m of 15 mT. The dependence of the loss Pcv (unit: kW/m ³ ) on the frequency f (unit: kHz) is expressed by the following formula (1) using two constants k _h and k _e , Pcv = k _h × f × B _m ^1.6 +k _e ×f ² ×B _m ² (1).

The constant k _h is 1.5 × 10 ^-3 kW / m ³ / kHz / (mT) ^1.6 or less, and the constant k _e is 3.0 × 10 ^-7 kW / m ³ / (kHz) ² / (mT) ² or less.

By setting the constants k _h and k _{e to} be within the above range, the degree of increase in the iron loss Pcv of the dust core due to the increase in the frequency f can be made smooth. Therefore, even if it is a high frequency of 1 MHz or more, the iron loss Pcv of the dust core is not easily increased.

Preferably, the mass ratio of the content of the powder of the crystalline magnetic material is 5% by mass or more based on the total of the content of the powder of the crystalline magnetic material and the content of the powder of the amorphous magnetic material. Below mass%. By setting the mass ratio within the above range, it is possible to more stably achieve an increase in the insulation resistance of the dust core or a decrease in the iron loss Pcv in the low frequency band.

A powdered iron core according to another aspect of the present invention is a powdered iron core comprising a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, characterized in that the content of the powder relative to the crystalline magnetic material is With The sum of the contents of the powder of the amorphous magnetic material is 5% by mass or more and 40% by mass or less based on the mass ratio of the powder of the crystalline magnetic material. By setting the mass ratio within the above range, the reduction of the iron loss Pcv of the dust core can be more stably achieved.

The crystalline magnetic material may include Fe-Si-Cr alloy, Fe-Ni alloy, Fe-Co alloy, Fe-V alloy, Fe-Al alloy, Fe-Si alloy, Fe-Si. One or two or more selected materials selected from the group consisting of an Al-based alloy, a carbonyl iron, and a pure iron.

Preferably, the crystalline magnetic material is composed of carbonyl iron.

The amorphous magnetic material may include one or two or more selected from the group consisting of Fe-Si-B alloys, Fe-P-C alloys, and Co-Fe-Si-B alloys.

Preferably, the amorphous magnetic material is composed of an Fe-P-C alloy.

Preferably, the powder of the above crystalline magnetic material is composed of a material to which an insulating treatment is applied. By being set in the above range, it is possible to more stably achieve an increase in the insulation resistance of the dust core or a decrease in the iron loss Pcv in the low frequency band.

It is preferable that the amorphous magnetic material has a median size D50 of 6 μm or less. By setting the median diameter D50 to 6 μm or less, the constant k _e can be easily reduced. It is preferable that the amorphous magnetic material has a powder median diameter D50 of 5 μm or less. By setting the median diameter D50 to 5 μm or less, it is easy to reduce the iron loss Pcv in the high frequency band, and it is easy to improve the DC superposition characteristics.

The dust core may contain a binder component that bonds the powder of the crystalline magnetic material and the powder of the amorphous magnetic material to other materials included in the dust core.

Preferably, the above-mentioned binder component contains a component based on a resin material.

According to another aspect of the invention, there is provided a method of producing a dust core according to the invention, comprising: a molding process for obtaining a molded article by a press forming process comprising a mixture comprising a mixture of the crystalline magnetic material; a powder and a powder of the amorphous magnetic material and a binder component composed of the resin material. The above-described powdered iron core can be more efficiently produced by this manufacturing method.

In the above manufacturing method, the above-mentioned molded article obtained by the above-described forming process may be the above-mentioned dust core. Alternatively, the heat treatment process is performed by heating the above-described molded article obtained by the above-described forming process by heat treatment to obtain the dust core.

According to still another aspect of the present invention, the electronic/electrical component includes the dust core, the coil, and a connection terminal connected to each end of the coil, and at least a portion of the dust core is located in an induced magnetic field. The method is such that the induced magnetic field is generated by the current when the current flows into the coil through the connection terminal. When the electronic/electrical component is an inductive component, it is possible to achieve both high frequency, good DC superposition characteristics, and low loss in accordance with the excellent characteristics of the dust core.

Another aspect of the present invention is an electronic/electrical machine that is installed An electronic/electrical device having the above electronic/electrical component, wherein the electronic/electrical component is connected to the substrate via the connection terminal. An example of the electronic/electrical device may be a power supply device including a power switch circuit, a voltage step-up circuit, a smoothing circuit, or a small mobile communication device. The electronic/electrical machine of the present invention has the above-mentioned electronic/electrical components, and thus is easy to cope with miniaturization. High speed.

The dust core of the above invention has good magnetic characteristics even in a high frequency band of 1 MHz or more. Moreover, according to the present invention, it is possible to provide the method for producing the dust core, the electronic/electrical component including the dust core, and the electronic/electrical device to which the electronic/electric component is mounted.

1‧‧‧Powder core (ring core)

10‧‧‧Circular coil

2‧‧‧covered conductive wire

2a‧‧‧ coil

2b, 2c‧‧‧ covered end of conductive wire 2

2d, 2e‧‧‧ end of coil 2a

20‧‧‧Inductive parts

3‧‧‧Powder core

3a‧‧‧Installation surface of powder core 3

3b, 3c‧‧‧ side of the powder core 3

4‧‧‧ Terminals

5‧‧‧Air core coil

5a‧‧‧Winding section of air core coil 5

5b‧‧‧End of the air core coil 5

30‧‧‧ Storage recess

40‧‧‧Connecting end

42a‧‧‧1st bend

42b‧‧‧2nd bend

100‧‧‧Installation substrate

110‧‧‧ Island Department

120‧‧‧ solder layer

200‧‧‧ spray dryer unit

201‧‧‧ Rotator

S‧‧·Pulp

P‧‧‧Powder powder

Fig. 1 is a conceptual perspective view showing the shape of a dust core according to an embodiment of the present invention.

Fig. 2 is a conceptual diagram of a spray dryer device used in an example of a method for producing a granulated powder and an operation thereof.

Fig. 3 is a conceptual perspective view showing the shape of a toroidal core, which is an electronic/electrical component of a dust core according to an embodiment of the present invention.

Fig. 4 is a partially perspective perspective view showing the overall configuration of an inductance component including an electronic/electrical component of a dust core according to another embodiment of the present invention.

[Fig. 5] A state in which the inductance component shown in Fig. 4 is mounted on a mounting substrate Part of the front view.

Fig. 6 is a graph showing the results of measurement of the frequency dependence of the iron loss Pcv in the examples.

Fig. 7 is a graph showing the dependence of the constant k _h on the first mixing ratio.

Fig. 8 is a graph showing the dependence of the constant k _e on the first mixing ratio.

[Fig. 9] A graph showing the dependence of the rate of change of iron loss on the first mixing ratio in 100 kHz and 2 MHz.

[Fig. 10] A graph showing the dependence of the insulation resistance on the first mixing ratio according to Tables 2 and 4.

[Fig. 11] A graph of the dependence of the iron loss Pcv on the first mixing ratio at a frequency of 100 kHz.

[Fig. 12] A graph showing the dependence of the iron loss Pcv on the first mixing ratio at a frequency of 1 MHz.

[Fig. 13] A graph showing the dependence of the iron loss Pcv on the first mixing ratio at a frequency of 2 MHz.

[Fig. 14] A graph showing the dependence of the iron loss Pcv on the first mixing ratio at a frequency of 3 MHz.

The applied current value (Isat) mixing the first time before [15] superimposed current is applied (initial) of the amount of change △ L inductance L L of the ratio of the value of the inductance L ₀ (△ L / L ₀₎ becomes 30% A graph of the dependence of the ratio.

Hereinafter, embodiments of the present invention will be described in detail.

Powder core

Fig. 1 shows a dust core 1 according to an embodiment of the present invention, which has a ring shape and contains a powder of a crystalline magnetic material and a powder of an amorphous magnetic material. The dust core 1 of the present embodiment is produced by a production method including a molding process including a press molding of a mixture containing the powders. In a non-limiting example, the dust core 1 of the present embodiment includes a binder component that bonds the powder of the crystalline magnetic material and the powder of the amorphous magnetic material to other materials contained in the dust core 1 (Can be the same material, or a different material). Hereinafter, the components will be described.

(1) Powder of crystalline magnetic material

A crystalline magnetic material for providing a powder of a crystalline magnetic material contained in the dust core 1 according to the embodiment of the present invention, as long as the crystal quality is satisfied (by the usual X-ray diffraction measurement, the type of material can be defined. The diffraction spectrum with a clear peak to the extent, and the ferromagnetic body, the specific kind is not limited. 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 and pure iron. The above crystalline magnetic material may be composed of one type of material or a plurality of types of materials. A crystalline magnetic material which provides a powder of a crystalline magnetic material, preferably one selected from the group consisting of the above materials Two or more kinds of materials, among them, preferably contain carbonyl iron and are preferably composed of carbonyl iron.

The shape of the powder of the crystalline magnetic material contained in the dust 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 a non-spherical shape, it may have a shape having an anisotropy such as a scaly shape, an elliptical shape, a droplet shape, or a needle shape, or may be an amorphous shape having no special shape anisotropy. In the case of an amorphous powder, a plurality of spherical powders may be bonded to each other or partially embedded in other powders. Such an amorphous powder is easily observed in carbonyl iron.

The shape of the powder may be a shape obtained at the stage of producing the powder, or may be a shape obtained by subjecting the produced powder to secondary processing. The shape of the former is, for example, a spherical shape, an elliptical shape, a droplet shape, a needle shape, or the like, and the shape of the latter is, for example, a scale.

The particle size of the powder of the crystalline magnetic material contained in the dust core 1 according to the embodiment of the present invention is not limited. The particle diameter is defined by a median diameter D50 (particle diameter when the volume cumulative value of the particle diameter of the soft magnetic powder measured by the laser diffraction scattering method is 50%), and is usually set to 1 μm to 20 μm. The scope. From the viewpoint of improving the handling property, the powder of the crystalline magnetic material has a median diameter D50 (also referred to as "in this specification" in terms of improving the packing density of the powder of the crystalline magnetic material in the dust core. 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.

Crystalline magnetic in the dust core 1 of one embodiment of the present invention The content of the powder of the material is set in accordance with the relationship between the content of the amorphous magnetic material in the dust core 1 so that the dust core 1 satisfies the condition of the iron loss Pcv described later.

It is preferably composed of a material in which at least a part of the powder of the crystalline magnetic material is subjected to insulation treatment, and more preferably a material which is subjected to insulation treatment by powder of the crystalline magnetic material. When the powder of the crystalline magnetic material is applied to the insulation treatment, it contributes to the improvement of the insulation resistance of the powder core. Further, not only the high frequency band but also the low frequency band tends to reduce the iron loss Pcv.

The type of the insulating treatment of the powder of the crystalline magnetic material is not limited. For example, it may be a phosphoric acid treatment, a phosphate treatment, an oxidation treatment, or the like.

When the powder of the crystalline magnetic material is composed of a material subjected to the insulating treatment, the content of the powder of the crystalline magnetic material is the sum of the content of the powder of the crystalline magnetic material and the content of the powder of the amorphous magnetic material. The mass ratio (unit: mass%, also referred to as "first mixing ratio" in the present specification) is preferably 5% by mass or more and 40% by mass or less. When the first mixing ratio is within the above range, the iron loss Pcv tends to be lowered in the high frequency band and the low frequency band. The first mixing ratio is more preferably 5% by mass or more and 35% by mass or less, and more preferably 5% by mass or more and 30% by mass or less, and particularly preferably 5% by mass or more and 25% by mass or less. It is set to 10% by mass or more and 20% by mass or less.

(2) Powder of amorphous magnetic material

An amorphous magnetic material for providing a powder of an amorphous magnetic material contained in the dust core 1 according to the embodiment of the present invention is provided as long as it satisfies amorphous (determined by general X-ray diffraction) The diffraction spectrum having a clear peak to the extent of the material type and the ferromagnetic body, particularly the soft magnetic material, may be used, and the specific type is not limited. Specific examples of the amorphous magnetic material include Fe-Si-B alloy, Fe-P-C alloy, and Co-Fe-Si-B alloy. The amorphous magnetic material may be composed of one type of material or a plurality of types of materials. The magnetic material constituting the powder of the amorphous magnetic material is preferably one or more selected from the group consisting of the above materials, and among them, a Fe-PC-based alloy is preferable, and the Fe-PC system is preferable. The alloy composition is even better.

A specific example of the Fe-PC-based alloy, which has a composition formula of, for example, Fe _100-abcxyzt Ni _a Sn _b Cr _c P _x C _y B _z Si _t , 0 atom% ≦a ≦ 10 atom%, 0 atom% ≦b≦ 3 atom%, 0 atom% ≦c≦6 atom%, 6.8 atom% ≦x≦10.8 atom%, 2.2 atom% ≦y≦9.8 atom%, 0 atom% ≦z≦4.2 atom%, 0 atom%≦t≦ 7 atom% Fe-based amorphous alloy. In the above composition formula, Ni, Sn, Cr, B, and Si are arbitrary added elements.

The addition amount a of Ni is preferably 0 atom% or more and 6 atom% or less, more preferably 0 atom% or more and 4 atom% or less. The addition amount b of Sn is preferably 0 atom% or more and 2 atom% or less, more preferably 1 atom% or more and 2 atom% or less. The addition amount c of Cr is preferably 0 atom% or more and 2 atom% or less, more preferably 1 atom% or more and 2 atom% or less. The addition amount of P is also possible to be set to 8.8 atoms. More than % is better. It is also preferable that the amount of addition y of C is 5.8 atom% or more and 8.8 atom% or less. The addition amount z of B is preferably 0 atom% or more and 3 atom% or less, more preferably 0 atom% or more and 2 atom% or less. The addition amount t of Si is preferably 0 atom% or more and 6 atom% or less, more preferably 0 atom% or more and 2 atom% or less.

The shape of the powder of the amorphous magnetic material contained in the dust 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 will be omitted. In the relationship of the manufacturing method, the amorphous magnetic material is more likely to be in the form of a spherical shape or an ellipsoidal shape. Further, since the amorphous magnetic material is generally harder than the crystalline magnetic material, the crystalline magnetic material is non-spherical and is easily deformed during press molding, which may be preferable.

The shape of the powder of the amorphous magnetic material contained in the dust core 1 according to the embodiment of the present invention may be a shape obtained at the stage of producing a powder or a shape obtained by subjecting the produced powder to secondary processing. The shape of the former is, for example, a spherical shape, an elliptical shape, a needle shape, or the like, and the shape of the latter is, for example, scaly.

The particle diameter of the powder of the amorphous magnetic material contained in the dust core 1 according to the embodiment of the present invention is not limited. The particle diameter is usually set in the range of 1 μm to 20 μm when defined by the median diameter D50. From the viewpoint of improving the handleability, the powder of the amorphous magnetic material has a median diameter D50 (also referred to as "second median diameter d2" in the present specification), and is preferably 1 μm or more, more preferably It is set to 2 μm or more, and particularly preferably set to 3 μm or more.

To improve the powder of the amorphous and crystalline magnetic material in the powder core 1 The powder of the amorphous magnetic material has a median diameter D50 of preferably 15 μm or less, more preferably 12 μm or less, and particularly preferably 6 μm or less. Moreover, when the high insulation resistance of the dust core 1 and the low iron loss Pcv are desired, it is preferable that the powder of the amorphous magnetic material has a median diameter D50 of 6 μm or less. From the viewpoint of achieving good DC superposition characteristics of the dust core 1 and low iron loss Pcv in the high frequency band, it is preferable that the powder of the amorphous magnetic material has a median diameter D50 of 5 μm or less. .

The relationship between the first median diameter d1 and the second median diameter d2 is not limited. In general, since the amorphous magnetic material is harder than the crystalline magnetic material, it is preferable that the first median diameter d1 is relatively small, and the void portion generated when the powder of the amorphous magnetic material is filled is easily Powder filling of crystalline magnetic material. In this case, d1/d2 is preferably set to 0.8 or less, and more preferably set to 0.5 or less.

The content of the powder of the amorphous magnetic material in the dust core 1 according to the embodiment of the present invention is based on the method in which the dust core 1 satisfies the condition of the iron loss Pcv described later, and is based on the powder core 1 The relationship between the content of the crystalline magnetic material is set.

(3) Iron loss Pcv versus frequency dependence

In the dust core 1 according to the embodiment of the present invention, the dependence of the iron loss Pcv (unit: kW/m ³ ) on the frequency f (unit: kHz) satisfies the following relationship. In other words, the dependence of the iron loss Pcv on the frequency f measured under the condition that the effective maximum magnetic flux density B _m is 15 mT is expressed by the following formula (1) using two constants k _h and k _e . k _h is 1.5 × 10 ^-3 kW / m ³ / kHz / (mT) ^1.6 or less, and the other constant k _e is 3.0 × 10 ^-7 kW / m ³ / (kHz) ² / (mT) ² or less.

Pcv=k _h ×f×B _m ^1.6 +k _e ×f ² ×B _m ² (1)

Further, in the present specification, the constants k _h and k _e are calculated based on the iron loss Pcv in the range of 1 MHz to 3 MHz with respect to the frequency f dependency.

When the set constants k _h and k _e are within the above range, the degree of increase in the iron loss Pcv due to the increase in the frequency f is stable, and even if the frequency is 1 MHz or higher, the iron loss Pcv does not easily increase. The constant k _{h is} preferably set to 1.0 × 10 ^-3 kW / m ³ / kHz / (mT) ^1.6 or less, from the viewpoint that the iron loss Pcv is more stable in terms of frequency f dependency. It is 0.8 × 10 ^-3 kW / m ³ / kHz / (mT) ^1.6 or less. Further, from the above viewpoints, the constant k _{e is} preferably set to 2.8 × 10 ^-7 kW/m ³ /(kHz) ² /(mT) ² or less, more preferably 2.7 × 10 ^-7 kW / m ³ /(kHz) ² /(mT) ² or less.

The lower limit of the constants k _h and k _e is not limited from the viewpoint that the iron loss Pcv has a more stable frequency f dependency. Usually, the constant k _h is 1.0 × 10 ^-4 kW / m ³ / kHz / (mT) ^1.6 or more, and the constant k _e is 1.0 × 10 ^-7 kW / m ³ / (kHz) ² / (mT) ² or more.

In the dust core 1 according to the embodiment of the present invention, the influence of the content of the powder of the crystalline magnetic material and the content of the powder of the amorphous magnetic material on the constants k _h and k _e is as follows.

The basic tendency is that 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) is higher, 2 Any one of the constants k _h and k _e also becomes high. Therefore, the higher the first mixing ratio, the tendency for the iron loss Pcv to become higher.

The relationship between the change in the first mixing ratio and the change in the constants k _h and k _{e was} confirmed in detail, and it was found that the relationship was nonlinear, and the tendency was that the lower the first mixing ratio, the more remarkable. That is, when the first mixing ratio is about 40% by mass or less, even if the first mixing ratio is increased, the degree of increase of either of the two constants k _h and k _e is small. According to the above formula (1), the lower the two constants k _h and k _{e , the} higher the maximum magnetic flux density B _m and the higher the frequency f, the higher the iron loss Pcv does not easily increase. Therefore, in order to suppress the increase in the iron loss Pcv (hereinafter also referred to as "iron loss suppression function"), the suppression function can be more effectively exhibited by the first mixing ratio. In view of the iron loss-reducing function, the first mixing ratio is preferably 35 mass% or less, more preferably 30 mass% or less, and particularly preferably 20 mass% or less. In addition, when the DC superposition characteristic is to be improved, the first mixing ratio is preferably 5% by mass or more, more preferably 10% by mass or more, and particularly preferably 15% by mass or more. The first mixing ratio is preferably 5% by mass or more and 40% by mass, and more preferably 15% by mass or more, from the viewpoint of improving the iron loss suppressing function and the DC overlapping property. 30% by mass.

When the first mixing ratio becomes high, the basic tendency is that the iron loss Pcv increases, and the tendency to increase has the following frequency dependence. That is, according to the iron loss Pcv when the first mixing ratio is 0% by mass (when only the powder of the amorphous magnetic material), the iron loss Pc _v at any first mixing ratio is normalized to obtain the iron loss. The rate of change, the rate of change in iron loss becomes larger as the first mixing ratio becomes higher, but the degree of increase in the rate of change in iron loss is moderated as the frequency is higher. As shown in the later-described embodiment, the increase in the iron loss change rate in 2 MHz is dependent on the first mixing ratio, and the increase in the iron loss change rate at 100 kHz is about one-half the dependence on the first mixing ratio. Therefore, the electronic/electrical component including the dust core 1 according to the embodiment of the present invention is less likely to cause the influence of the iron loss Pcv when it is used in a high frequency band.

(4) Adhesive components

The binder component can be fixed by the powder of the crystalline magnetic material and the powder of the amorphous magnetic material contained in the dust core 1 of the present embodiment (the powder is also referred to as "magnetic powder" in the present specification). The material is only required, and its composition is not limited. The material constituting the adhesive component may be, for example, an organic material such as a resin material or a thermal decomposition residue of a resin material (referred to as "reagent-based component" in the present specification), an inorganic material, or the like. The resin material may be, for example, an acrylic resin, an anthrone resin, an epoxy resin, a phenol resin, a urea resin, a melamine resin or the like. The bonding component made of an inorganic material may be, for example, a glass-based material such as water glass. The bonding component may be composed of one type of material or a plurality of materials. The bonding component may be a mixture of an organic material and an inorganic material.

Bonding components, usually using insulating materials. In this way, the insulation of the dust core 1 can be improved.

2. Method for manufacturing powdered iron core

The method for producing the dust core 1 according to the embodiment of the present invention is not particularly limited, and the dust core 1 can be more efficiently produced by the manufacturing method described below.

The method for producing the dust core 1 according to the embodiment of the present invention includes the molding process described below, and may further include a heat treatment process.

(1) Forming engineering

First, a mixture is prepared which contains a magnetic powder and a component which provides a binder component to the dust core 1 . The component that provides the bonding component (also referred to as "adhesive component" in this specification) may refer to the bonding component itself, and may also refer to a material different from the bonding component. In the specific example of the latter, for example, the binder component is a resin material, and the binder component is a thermal decomposition residue thereof.

The shaped article can be obtained by a forming process of press forming containing the mixture. The pressurization conditions are not limited and may be appropriately determined depending on the composition of the binder component and the like. For example, when the binder component is composed of a thermosetting resin, it is preferably heated while being pressurized, and a resin hardening reaction is carried out in the mold. Further, the pressing force at the time of compression molding is high, but heating is not a necessary condition, and it becomes a pressurization for a short time.

Hereinafter, the mixture is granulated powder and subjected to compression molding. The granulated powder has advantages in handling characteristics, and the short forming time can improve the workability of a compression molding process with good productivity.

(1-1) Granulated powder

The granulated powder contains magnetic powder and a binder component. 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, the binder component composed of the thermal decomposition residue of the binder component in the dust core 1 obtained by the heat treatment process makes it difficult to insulate the plurality of magnetic powders from each other. In addition, when the content of the above-mentioned binder component is too high, the content of the binder component contained in the dust core 1 obtained by the heat treatment process tends to be high. When the content of the binder component in the dust core 1 becomes high, the magnetic characteristics of the powder core 1 are easily reduced. 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 and 3.5 mass based on the total amount of the granulated powder, from the viewpoint of stabilizing the possibility of reducing the magnetic characteristics of the powdered iron core 1 . The amount of % or less is more preferably 1.2% by mass or more and 3.0% by mass or less.

The granulated powder may contain materials other than the above magnetic powder and binder components. Such a material may be, for example, a lubricant, a decane coupling agent, an insulating filler or the like. When the lubricant is contained, the kind thereof is not particularly limited. It may be an organic lubricant or an inorganic lubricant. A specific example of the organic-based lubricant may be a metal soap such as zinc stearate or aluminum stearate. Such an organic lubricant can be vaporized in a heat treatment process and hardly remains in the dust core 1 .

The method for producing the granulated powder is not particularly limited. The mixture of the above granulated powder may be directly mixed and the mixture obtained by a conventional method may be obtained. The granulated powder is obtained by pulverizing the material or the like, or a dispersion medium (water is used as an example) is added to the above-mentioned components to prepare a slurry, and the slurry is dried to obtain a granulated powder by pulverization. After pulverization, screening or grading is performed to control the particle size distribution of the granulated powder.

An example of the method of obtaining the granulated powder from the above slurry may be a method using a spray dryer. As shown in Fig. 2, a rotor 201 is provided in the spray dryer unit 200, and the slurry S is injected into the rotor 201 from the upper portion of the apparatus. The rotator 201 is rotated by a specific number of rotations, and the slurry S is sprayed in a droplet shape by centrifugal force in a chamber inside the apparatus 200. Further, hot air is introduced into the chamber inside the apparatus 200, and the dispersion medium (water) contained in the droplet-shaped slurry S is maintained in a droplet shape and volatilized. 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 apparatus 200. The parameters such as the number of rotations 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. For a specific example of the setting range of the parameters, for example, the number of rotations of the rotor 201 can be set to 4000 to 6000 rpm, and the temperature of the hot air introduced into the spray dryer device 200 can be set to 130 to 170 ° C to lower the temperature of the lower portion of the chamber. Set to 80~90°C. Moreover, the atmosphere and the pressure inside the chamber can also be appropriately set. For example, for example, the chamber may be an air atmosphere, and the pressure is set to ₂ mm H ₂ O (about 0.02 kPa) based on the pressure difference from the atmospheric pressure. The particle size distribution of the obtained granulated powder P can be further controlled by screening or the like.

(1-2) Pressurization conditions

The pressing conditions in the compression molding are not particularly limited. Can consider granulated powder The composition, the shape of the molded article, and the like are 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, the shape of the molded article is rationally reduced, and problems such as a decrease in the mechanical strength of the dust core 1 obtained from the molded article are likely to occur. Further, the magnetic characteristics of the dust core 1 may be reduced, and the insulation may be reduced. Further, when the pressing force at the time of compression molding of the granulated powder is too high, it is difficult to produce a molding die resistant to the pressure. In terms of stabilizing and mitigating the adverse effects of the compression and pressurization engineering on the mechanical properties or magnetic properties of the powdered iron core 1, the industrial pressure is easy to mass-produce, and the pressing force during compression molding of the granulated powder is preferably set to 0.3. GPa or more is 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.

The compression molding can be pressurized while heating, or pressurized at room temperature.

(2) Heat treatment engineering

The molded article obtained by the forming process may be the dust core 1 of the present embodiment, or a heat-treated project may be performed on the molded article to obtain the dust core 1 as described below.

In the heat treatment process, the molded article obtained by the above-mentioned forming process is heated, the distance between the magnetic powders is corrected, the magnetic properties are adjusted, and the deformation of the magnetic powder in the forming process is relaxed to adjust the magnetic properties, and the pressure is obtained. Powder iron core 1.

The purpose of the heat treatment project is to adjust the magnetic characteristics of the dust core 1 as described above, so the heat treatment temperature and the like are set as the powder iron. The magnetic gas characteristics of the core 1 are the best. An example of the method of setting the heat treatment conditions may be, for example, changing the heating temperature of the molded article, and maintaining other conditions such as the temperature increase rate and the holding time of the heating temperature.

The evaluation criteria of the magnetic gas characteristics of the dust core 1 at the time of setting the heat treatment conditions are not particularly limited. A specific example of the evaluation item may be the iron loss Pcv of the dust core 1. At this time, the heating temperature of the molded article is set so that the iron loss Pcv of the dust core 1 can be minimized. The measurement conditions of the iron loss Pcv are appropriately set, and may be, for example, a condition of a frequency of 100 kHz and a maximum magnetic flux density of 100 mT.

The atmosphere at the time of heat treatment is not particularly limited. In the 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 preferred to carry out heat treatment in an inert atmosphere such as nitrogen or argon or a reductive atmosphere such as hydrogen.

3. Electronic / electrical components

An electronic/electrical component according to an embodiment of the present invention includes the dust core 1 according to the embodiment of the present invention, a coil, and a connection terminal connected to each end of the coil. Here, at least a part of the dust core 1 is disposed such that a current flows into the coil through the connection terminal and is located in an induced magnetic field generated by the current.

An example of such an electronic/electrical component may be the toroidal coil 10 shown in FIG. The toroidal coil 10 is provided with a coil 2a formed by winding a coated conductive wire 2 around an annular powder core (annular iron core) 1. The coil 2a composed of the wound coated conductive wire 2 and the end portion 2b covering the conductive wire 2, In the portion of the conductive line between 2c, the ends 2d, 2e of the coil 2a can be defined. As described above, in the electronic/electrical component of the present embodiment, the member constituting the coil and the member constituting the connection terminal can be constituted by the same member.

An electronic/electrical component according to an embodiment of the present invention includes a dust core having different shapes of the dust core 1 according to the embodiment of the present invention. A specific example of such an electronic/electrical component can be the inductor component 20 shown in FIG. Fig. 4 is a partially perspective perspective view showing the overall configuration of an inductance component 20 according to an embodiment of the present invention. The lower surface (mounting surface) of the inductance component 20 in Fig. 4 is shown in an upward posture. FIG. 5 is a partial front elevational view showing a state in which the inductance component 20 shown in FIG. 4 is mounted on the mounting substrate 100.

The inductor component 20 shown in FIG. 4 is configured to include a dust core 3, and an air core coil 5 as a coil embedded in the dust core 3, and is electrically connected to the air core coil 5 as a connection terminal by fusion bonding. A pair of terminal portions 4.

The air-core coil 5 is formed by winding an insulating film conductor into a spiral shape. The air-core coil 5 is configured to have a winding portion 5a and lead ends 5b and 5b which are led out by the winding portion 5a. The number of windings of the air-core coil 5 can be appropriately set according to the necessary inductance.

As shown in FIG. 4, in the dust core 3, a housing recess 30 that accommodates one of the terminal portions 4 is formed on the mounting surface 3a that faces the mounting substrate. The housing recess 30 is formed on both sides of the mounting surface 3a and is formed to open toward the side faces 3b and 3c of the dust core 3.

One part of the terminal portion 4 protruding from the side faces 3b, 3c of the dust core 3 The branch is bent toward the mounting surface 3a and housed inside the housing recess 30.

The terminal portion 4 is formed of a thin Cu-shaped base material. The terminal portion 4 is configured to be embedded in the interior of the dust core 3, electrically connected to the connection end portion 40 of the lead ends 5b, 5b of the air core coil 5, and to expose the outer surface of the dust core 3 by the above pressure The side faces 3b and 3c of the powder iron core 3 are sequentially bent toward the mounting surface 3a to form the first curved portion 42a and the second curved portion 42b. The connection end portion 40 is melted in the fusion portion of the air core coil 5. The first curved portion 42a and the second curved portion 42b are welded portions that are welded to the mounting substrate 100. The welded portion is a portion exposed by the dust core 3 in the terminal portion 4, and at least means a surface facing the outer side of the dust core 3.

The connection end portion 40 of the terminal portion 4 and the lead end portion 5b of the air core coil 5 are joined by resistance welding.

As shown in FIG. 5, the inductor component 20 is mounted on the mounting substrate 100.

The surface of the mounting substrate 100 is formed with a conductor pattern that is electrically connected to an external circuit, and one of the conductor patterns forms a pair of land 110 for mounting the inductive component 20.

As shown in FIG. 5, in the inductor component 20, the mounting surface 3a faces the mounting substrate 100 side, and the first bending portion 42a and the second bending portion 42b which are exposed to the outside by the dust core 3 are on the island portion 110 of the mounting substrate 100. They are joined together via the solder layer 120.

In the welding process, paste-like solder is applied to the island portion 110 by printing, and the second bending portion 42b is placed facing the island portion 110 to mount the inductor component 20, and the solder is melted by heating. As shown in Figure 4 As shown in FIG. 5, the second curved portion 42b faces the island portion 110 of the mounting substrate 100, the first curved portion 42a exposes the side faces 3b, 3c of the inductor component 20, and the fish-shaped solder layer 120 is fixed to the island portion 110. At the same time, it is sufficiently expanded and fixed to the surfaces of both the second curved portion 42b and the first curved portion 42a, which are welded portions.

4. Electronic / electrical machines

An electronic/electrical device according to an embodiment of the present invention is an electronic/electrical component including the dust core of the embodiment of the present invention. Such an electronic/electrical device may be, for example, a power switch circuit, a voltage step-up circuit, a power supply device including a smoothing circuit, or a small mobile communication device.

The power switch circuit, the voltage step-up circuit, the smoothing circuit, and the like are generally high-frequency with miniaturization, and the loss is increased. When the electronic/electrical component according to the embodiment of the present invention is the inductance component 20, it is possible to achieve both high frequency, excellent DC superposition characteristics, and low loss. Therefore, even electronic/electrical machines are progressing to miniaturization. When the speed is increased (high frequency), it is easy to realize the same high-efficiency circuit as the conventional one, and it is possible to increase the power consumption of the electronic/electrical machine.

The embodiments described above are intended to facilitate the understanding of the present invention and are not intended to limit the invention. Therefore, each of the elements disclosed in the above embodiments includes all design changes or equivalents that are within the technical scope of the present invention.

For example, the dust core of the embodiment of the present invention is a dust core including a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, and may have a feature of a powder content of the crystalline magnetic material. The mass ratio of the content of the powder of the amorphous magnetic material to the total amount of the powder of the amorphous magnetic material is 5% by mass or more and 40% by mass or less. The dust core having the above characteristics may further include the above-described characteristics of the above formula (1) (one of the constant k _h is 1.5 × 10 ^-3 kW / m ³ / kHz / (mT) ^1.6 or less, and the other constant k _e is 3.0 × 10 ^-7 kW / m ³ / (kHz) ² / (mT) ² or less).

[Examples]

Hereinafter, the present invention will be specifically described based on examples and the like, but the scope of the present invention is not limited to the examples and the like.

(Example 1) (1) Fabrication of Fe-based amorphous alloy powder

An amorphous magnetic material obtained by weighing a composition of Fe _{71 atom%} Ni _{6 atom%} Cr _{2 atom%} P _{11 atom%} C _{8 atom%} B _{2 atom%} by a water atomized method The powder is made into a magnetic powder. The first mixing ratio (the mass ratio of the content of the powder of the crystalline magnetic material to the content of the powder of the amorphous magnetic material, and the mass ratio of the content of the powder of the crystalline 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 volume distribution becomes 50% of the particle diameter, that is, the median diameter. The D50 is 5 μm.

(2) Production of granulated powder

The magnetic powder is 97.2 parts by mass, the insulating adhesive material composed of acrylic resin and phenol resin is 2 to 3 parts by mass, and the lubricant composed of zinc stearate is 0 to 0.5 parts by mass, and they are mixed as a solvent. Water is obtained to obtain a slurry.

The obtained slurry was granulated under the above conditions using the spray dryer device 200 shown in Fig. 2 to obtain a granulated powder.

(3) compression forming

The obtained granulated powder was filled in a mold, and press-molded at a surface pressure of 0.5 to 1.5 GPa to obtain a molded body having a ring shape of an outer diameter of 20 mm, an inner diameter of 12 mm, and a thickness of 3 mm.

(4) Heat treatment

The obtained molded body is placed in a furnace in a nitrogen gas atmosphere, and the furnace temperature is heated from room temperature (23 ° C) to a temperature of 10 ° C / min to an optimum core heat treatment temperature of 200 to 400 ° C. The temperature was maintained for 1 hour, and then heat-treated in a furnace to room temperature to obtain a toroidal core composed of a powdered iron core.

(Examples 2 and 3)

When the magnetic powder is prepared, the amorphous magnetic material used in Example 1 is used. The powder was mixed with a powder of a crystalline magnetic material (median diameter D50: 4.3 μm) composed of carbonyl iron to which insulation treatment was applied, except that the first mixing ratio was used in Example 2 as 10% by mass, in Example 3 A toroidal core was produced in the same manner as in Example 1 except that the magnetic powder was 20% by mass.

(Example 4)

When the magnetic powder is prepared, in place of the powder of the amorphous magnetic material used in the first embodiment, the carbonyl iron which is subjected to the insulation treatment used in Example 2 or the like, which is the total weight of the scale, that is, the first mixing ratio of the magnetic powder is used. A toroidal core was produced in the same manner as in Example 1 except that the amount was 100% by mass.

(Examples 5, 6 and 7)

When the magnetic powder is prepared, the powder of the amorphous magnetic material used in Example 1 is mixed with the powder of the crystalline magnetic material (median diameter D50: 4.3 μm) composed of the carbonyl iron to be subjected to the insulating treatment, except that the first is used. A toroidal core was produced in the same manner as in Example 1 except that the magnetic powder having a mixing ratio of the following values was used.

Example 5 5 mass%

Example 6 15% by mass

Example 7 30% by mass

(Examples 8 to 12)

When the magnetic powder is prepared, instead of the powder of the crystalline magnetic material used in Examples 2 to 4, the crystal composed of carbonyl iron which is not subjected to the insulating treatment is used instead. a powder of a magnetic material (median diameter D50: 4.3 μm), and the powder of the crystalline magnetic material is mixed with the powder of the amorphous magnetic material prepared in Example 1, except that the first mixing ratio is used as the following value A toroidal core was produced in the same manner as in Example 1 except for the magnetic powder.

Example 8 5 mass%

Example 9 10% by mass

Example 10 20% by mass

Example 11 30% by mass

(Embodiment 12)

When the magnetic powder is prepared, in place of the powder of the amorphous magnetic material used in Example 1, the carbonyl iron which is not subjected to the insulation treatment used in Example 8 or the like, which is the total weight of the scale, that is, the first mixing ratio of the magnetic powder is set. A toroidal core was produced in the same manner as in Example 1 except for 100% by mass.

(Example 13)

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 6 μm. A ring-shaped iron core was produced in the same manner as in Example 1 using the powder of the amorphous magnetic material.

(Examples 14 and 15)

A powder of an amorphous magnetic material having a median diameter D50 of 6 μm adjusted in Example 13 and a crystalline magnetic material of carbonyl iron to be insulated by the use of Example 2 or the like (median diameter D50: 4.3μm) The ring-shaped iron core was produced in the same manner as in Example 1 except that the magnetic powder having the first mixing ratio of the following values was used.

Example 14 10% by mass

Example 15 20% by weight

(Test Example 1) Measurement of iron loss Pcv

For the toroidal coils obtained by winding the toroidal cores of the first and second sides, which were wound 15 times on the primary side and 10 times on the secondary side, a BH analyzer (made by Iwasaki Communication Co., Ltd.) SY-8218"), the dependence of the iron loss Pcv (unit: kW/m ³ ) on the frequency (measurement frequency range: 100 kHz to 3 MHz) was measured under the condition that the effective maximum magnetic flux density B _{m was} 15 mT. One of the results is shown in Table 1. Two constants k _h and k _e were obtained as a result of the frequency dependence of the range of 1 to 3 MHz in each iron loss Pcv measured under the above conditions. The results are shown in Tables 2 to 4. Further, in Tables 2 to 4, the examples in which the first mixing ratio is low to the embodiment in which the first mixing ratio is high are shown in parallel. Further, as in the first embodiment, an embodiment in which a plurality of times are expressed for comparison is easy. The respective iron loss Pcv of 100 kHz, 1 MHz, 2 MHz, and 3 MHz shown in Tables 2 to 4 was measured under the conditions of effective maximum magnetic flux density B _{m of} 100 mT, 25 mT, 15 mT, and 15 mT, respectively.

(Test Example 2) Measurement of magnetic permeability

The toroidal coil obtained by winding the toroidal core of the embodiment in 40 times on the primary side and winding the copper wire 10 times on the secondary side, respectively, is used. The impedance analyzer ("4192A" manufactured by HP Co., Ltd.) superposed the initial magnetic permeability μ and the direct current at 100 kHz, and measured the relative magnetic permeability μ5500 when the DC applied magnetic field was 5500 A/m. The results are shown in Tables 2 to 4.

(Test Example 3) Measurement of DC superposition characteristics

A toroidal coil formed by a toroidal core made of the embodiment was used, and a direct current was superposed on the toroidal coil in accordance with JIS C2560-2. Isat value of the applied current by the inductance L with respect to the time before (early) applying the superimposed current value of the inductance L L of the ratio of the amount of change △ L ₀ (△ L / L ₀₎ becomes 30% (unit: A), The DC overlap characteristics are evaluated. The results are shown in Tables 2 to 4.

(Test Example 4) Measurement of insulation resistance

The insulation resistance (unit: Ω) of the toroidal core produced according to the example was measured by the surface 2-terminal method. The results are shown in Tables 2 and 4.

Figures 6 to 15 show the above results by curves. Specifically, Fig. 6 is a graph showing the measurement results of the frequency dependence of the iron loss Pcv in the embodiment. Figure 7 is a graph showing the dependence of the constant k _h on the first mixing ratio. Figure 8 is a graph showing the dependence of the constant k _e on the first mixing ratio. Fig. 9 is a graph showing the rate of change in iron loss at 100 kHz and 2 MHz (the value of the iron loss Pcv at the first mixing ratio of 0% by mass to normalize the iron loss Pcv in the first first mixing ratio) to the first mixing ratio. A graph of dependencies. In addition, the rate of change in iron loss in FIG. 9 is obtained by winding the toroidal core 40 times on the primary side, winding the copper wire 10 times on the secondary side, and measuring B _m = 100 mT for 100 kHz, for 2 MHz. The measurement was performed with B _m = 15 mT. Figure 10 is a graph of the dependence of the insulation resistance on the first mixing ratio. 11 to 14 are graphs showing the dependence of the iron loss Pcv on the first mixing ratio when the frequencies are 100 kHz (Fig. 11), 1 MHz (Fig. 12), 2 MHz (Fig. 13), and 3 MHz (Fig. 14), respectively. Further, B _m at the time of measurement is 100 mT at 100 kHz, 25 mT at 1 MHz, and 15 mT at 2 MHz as shown in the respective graphs. 15 shows the inductance L of (△ L / L ₀₎ becomes 30%, is applied to the first mixed current value (Isat) of value L (initial) variation of the inductance L L of △ ₀ the ratio of a superimposed current is applied to the front A graph of the dependence of the ratio.

The following items can be understood based on Tables 1 to 4 and Figures 6 to 15.

(A) A dust core containing a magnetic powder prepared to satisfy the above formula (1) has excellent magnetic properties (iron loss Pcv, initial conductance) in a wide frequency band, particularly in a high frequency band of 1 MHz or more. Magnetic rate, DC overlap characteristics).

(B) It can be seen from FIG. 7 and FIG. 8 that when the first mixing ratio is 30% by weight or less, it can be maintained at a low value of k _e , k _h , and 20% by weight or less. Therefore, when the first mixing ratio is 30% by weight or less, preferably 20% by weight or less, the effect of suppressing an increase in the iron loss Pcv in the high frequency band can be confirmed. On the other hand, when the first mixing ratio is more than 30% by weight, k _e and k _h tend to rise, and as a result, the iron loss Pcv in the high frequency band is greatly increased. Moreover, as shown in FIG. 15, it is understood that the applied current value Isat increases when the first mixing ratio is more than 10% by weight, and becomes larger when it is 15% by weight or more.

(C) The basic tendency of the iron loss Pcv to increase when the first mixing ratio of the magnetic powder becomes high exists, but the higher the frequency, the harder the iron loss Pcv is hard to increase even when the first mixing ratio is increased. This tendency can be confirmed by Figure 9. According to Fig. 9, at 100 kHz, the iron loss change rate becomes 2.5 when the first mixing ratio is 10%, and the iron loss change rate is 3.6 when the first mixing ratio is 20%. In contrast, at 2 MHz, even if the first mixing ratio is The increase in the 20% iron loss rate is only around 1.4. Therefore, when the electronic/electrical component having the dust core of the present embodiment is used in a high-frequency circuit, the effect becomes more remarkable. Moreover, electronic circuits in small and lightweight electronic/electrical devices have a tendency to increase in frequency, and are also suitable for DC-DC converters for mobile use.

(D) As shown in FIG. 10, when using a magnetic powder containing a powder of a crystalline magnetic material to which an insulating treatment is applied, when using a magnetic powder containing a powder of a crystalline magnetic material which is not subjected to the insulating treatment, the powdered iron is used. The insulation resistance of the core tends to become higher.

(E) As shown in FIG. 11, when using a magnetic powder containing a powder of a crystalline magnetic material to which an insulating treatment is applied, when using a magnetic powder containing a powder of a crystalline magnetic material which is not subjected to the insulating treatment, in a low frequency band There is less iron loss Pcv. This point is also understood by the frequency dependence of the constant k _h shown in FIG.

(F) It is understood from the frequency dependency of the constant k _e shown in Fig. 8 that when a magnetic powder containing a powder of a crystalline magnetic material subjected to an insulating treatment is used, and a powder containing a crystalline magnetic material not subjected to an insulating treatment is used, The same result can be obtained with magnetic powder. According to the results, it is conceivable that when a magnetic powder containing a powder of a crystalline magnetic material subjected to an insulating treatment is used, and a magnetic powder containing a powder of a crystalline magnetic material not subjected to an insulating treatment is used, iron loss in both high frequency bands is used. Pcv is the same. However, as shown in FIGS. 12 to 14, the magnetic powder containing the powder of the crystalline magnetic material subjected to the insulating treatment is used in a high frequency band as compared with the case of using a magnetic powder containing a powder of a crystalline magnetic material which is not subjected to the insulating treatment. There is less Pcv in the iron loss.

(G) The amorphous magnetic material contained in the magnetic powder is compared with the case where the powder of the amorphous magnetic material containing the magnetic powder contains a median diameter D50 of 6 μm. When the powder median diameter D50 of the material is 5 μm, the iron loss Pcv tends to be low in the high frequency band ( FIGS. 12 to 14 ). The higher the tendency, the more pronounced the high frequency. In addition, when a powder of an amorphous magnetic material having a median diameter D50 of 5 μm is used, the DC superposition property tends to be good when compared with a powder of an amorphous magnetic material having a median diameter D50 of 6 μm ( FIG. 15 ). . On the other hand, when the magnetic powder contains the crystalline magnetic material to which the insulating treatment is applied, and the powder of the amorphous magnetic material contained in the magnetic powder, the median diameter of the powder When the D50 is 5 μm, the insulation resistance of the amorphous magnetic material contained in the magnetic powder tends to be high when the median diameter D50 is 6 μm ( FIG. 10 ). Therefore, according to the present embodiment, it is confirmed that the powder median diameter D50 of the amorphous magnetic material contained in the magnetic powder is controlled to be effective in accordance with the characteristics required for the dust core.

(H) From the above results, it is understood that the iron loss Pcv in the high frequency band can be reduced by using the magnetic powder composed of the powder of the amorphous magnetic material and the powder of the crystalline magnetic material regardless of the insulation treatment. Further, when the crystalline magnetic material is used as the magnetic powder composed of the material subjected to the insulating treatment, it is confirmed that the iron loss Pcv in the low frequency band is small. In addition, it was confirmed that the magnetic particle characteristics or electrical characteristics of the dust core can be adjusted by controlling the powder median diameter D50 of the amorphous magnetic material contained in the magnetic powder.

[Industrial availability]

The electronic/electrical component using the dust core of the present invention is suitable for use in a booster circuit such as a hybrid electric vehicle or a reactor for generating electricity or a substation, a transformer, a choke coil, or the like.

1‧‧‧Powder core (ring core)

Claims (15)

A powdered iron core comprising a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, characterized in that: using two constants k _h and k _e , the following formula (1) is used for effective maximum magnetic When the iron loss Pcv (unit: kW/m ³ ) measured under the condition that the density B _m is 15 mT is expressed in terms of frequency f (unit: kHz), Pcv = k _h × f × B _m ^1.6 + k _e × f ² × B _m ² (1) The above constant k _h is 1.5 × 10 ^-3 kW / m ³ / kHz / (mT) ^1.6 or less, and the above constant k _e is 3.0 × 10 ^-7 kW / m ³ / (kHz ) ² / (mT) ² or less. The powdered iron core according to the first aspect of the invention, wherein the content of the powder of the crystalline magnetic material is the sum of the content of the powder of the crystalline magnetic material and the content of the powder of the amorphous magnetic material The mass ratio of the amount is 5% by mass or more and 40% by mass or less. The powdered iron core according to claim 1 or 2, wherein the crystalline magnetic material comprises: an Fe-Si-Cr alloy, an Fe-Ni alloy, an Fe-Co alloy, an Fe-V alloy, One or two or more materials selected from the group consisting of Fe-Al alloys, Fe-Si alloys, Fe-Si-Al alloys, carbonyl iron, and pure iron. The dust core of claim 3, wherein the crystalline magnetic material is composed of carbonyl iron. The dust core of claim 1 or 2, wherein the amorphous magnetic material comprises: Fe-Si-B alloy, Fe-P- One or two or more materials selected from the group consisting of a C-based alloy and a Co-Fe-Si-B-based alloy. The dust core of claim 5, wherein the amorphous magnetic material is composed of an Fe-P-C alloy. A powdered iron core according to claim 1 or 2, wherein the powder of the crystalline magnetic material is composed of a material which is subjected to an insulation treatment. The dust core of claim 1 or 2, wherein the amorphous magnetic material has a powder median diameter D50 of 6 μm or less. The powdered iron core according to claim 1 or 2, wherein the powdered component contains a binder component, and the powder of the crystalline magnetic material and the powder of the amorphous magnetic material are bonded to the powder core Other materials. For example, in the dust core of claim 9, wherein the above-mentioned adhesive component contains a resin-based component. A method for producing a shaped article for use in the production of a powdered iron core according to claim 10, characterized in that it is provided with a forming process comprising press forming of a mixture to obtain the above-mentioned forming A molding process for a product comprising a powder of a crystalline magnetic material and a powder of an amorphous magnetic material and a binder component composed of a resin material. A method for producing a dust core, which is characterized in that a molded article produced by the production method of claim 11 of the patent application is obtained as a powder core. A method for producing a powdered iron core, comprising: a heat treatment process of obtaining a dust core by heating a shaped article produced by the method of manufacturing according to claim 11 of the patent application. An electronic/electrical component comprising: a powdered iron core according to claim 1 or 2, a coil, and a connection terminal connected to each end of the coil, wherein at least a part of the powdered iron core is located in the induction A mode in the magnetic field is generated by the current generated when a current flows into the coil through the connection terminal. An electronic/electrical device is an electronic/electrical device to which an electronic/electrical component as claimed in claim 14 is attached, and the electronic/electrical component is connected to the substrate via the connection terminal.