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WO2001013386A1 - Noyau magnetique et procede de fabrication - Google Patents

Noyau magnetique et procede de fabrication Download PDF

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Publication number
WO2001013386A1
WO2001013386A1 PCT/JP2000/005448 JP0005448W WO0113386A1 WO 2001013386 A1 WO2001013386 A1 WO 2001013386A1 JP 0005448 W JP0005448 W JP 0005448W WO 0113386 A1 WO0113386 A1 WO 0113386A1
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WO
WIPO (PCT)
Prior art keywords
resin
heat
magnetic
magnetic core
curing
Prior art date
Application number
PCT/JP2000/005448
Other languages
English (en)
Japanese (ja)
Inventor
Hiroshi Watanabe
Nobuhiro Maruko
Kouichi Kanayama
Mitsunobu Yoshida
Shigeki Mochizuki
Shoji Tamai
Masayoshi Itoh
Original Assignee
Mitsui Chemicals, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP29304999A external-priority patent/JP2001118715A/ja
Priority claimed from JP2000061906A external-priority patent/JP2001250727A/ja
Priority claimed from JP2000122116A external-priority patent/JP2001307936A/ja
Application filed by Mitsui Chemicals, Inc. filed Critical Mitsui Chemicals, Inc.
Publication of WO2001013386A1 publication Critical patent/WO2001013386A1/fr

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0213—Manufacturing of magnetic circuits made from strip(s) or ribbon(s)

Definitions

  • the present invention relates to a magnetic core and a method for manufacturing the same.
  • Magnetic components such as gap yoke coils and transformers with various shapes are used in many electric and electronic devices such as switching power supplies and transformers. These magnetic components are formed by winding a ribbon made of a magnetic material in an annular shape or by laminating a magnetic core in which the shape is fixed by resin impregnation and a wire wound in a coil shape.
  • FIG. 9 shows a flow of manufacturing a magnetic core using an amorphous ribbon material.
  • the magnetic ribbon is wound up to a required size from the magnetic ribbon raw roll (process A), heat-treated in a desired shape in advance (process B), and then impregnated and cured with a resin (process C, D)) (Step E) ⁇ For parts with a gap, impregnate and cure with resin (Step (:, D), cut a part of the core (Step F), and insert a spacer.
  • Step G A gap-formed magnetic core is manufactured (Step H) More specifically, when a toroidal gap choke as shown in FIG.
  • the magnetic ribbon is wound into a toroidal shape.
  • the core is usually hardened by impregnation with resin (process C, D) and then cut (process F) in order to eliminate deformation of the core shape and burrs during cutting (process C, D).
  • the magnetic Optimal for expressing a fee of properties Heat treatment is performed (Step C).
  • the heat treatment temperature varies depending on the material. For example, the temperature of the amorphous alloy material is the lowest, and is usually performed at about 300 ° C. to 500 ° C.
  • the reason for performing such heat treatment and resin impregnation is as follows.
  • This distortion includes microscopic distortion such as dislocations and defects that enter the magnetic material itself during manufacturing, and macroscopic distortion for adjusting the core shape, and the magnetic properties are not good before heat treatment.
  • the core will be given extra strain by the subsequent resin impregnation hardening process and cutting process. Become.
  • the core after heat treatment has low mechanical strength, so the impregnation hardening step involves partially deforming the core material, cracking, chipping, etc. This included factors that reduced yield and reduced product production effects.
  • the present inventors have reduced the magnetic properties of the magnetic core in the manufacturing process of the core including the heat treatment step, the impregnation hardening step, the cutting step, etc.
  • the manufacturing process of the magnetic core was reviewed as described above.
  • the use of a heat-resistant resin makes it possible to perform a heat treatment after or at the same time as a step in which the magnetic core is distorted, such as an impregnation hardening step or a cutting step,
  • the macroscopic distortion of the magnetic core and the microscopic distortion of the material were alleviated at the same time, leading to improved magnetic properties, improved product yield, and improved production efficiency.
  • a magnetic core comprising a magnetic material and a heat-resistant resin for bonding the magnetic materials to each other.
  • a resin that cures to become a heat-resistant resin is attached to a magnetic material, and then the resin that cures to become a heat-resistant resin is hardened to become a heat-resistant resin. It is formed by removing the distortion of the magnetic material at the same time as the resin is formed and at or after Z.
  • the magnetic core of the present invention is formed by applying, impregnating or coating a heat-resistant resin on a plate-shaped, wound or laminated magnetic material.
  • the magnetic material is a Fe-based amorphous material, a Co-based amorphous material, a Fe-based nanocrystalline material, a Co-based nanocrystalline material, a FeSi-based gay. It is a material selected from the group consisting of raw steel, FeNi permalloy material, FeSiAl sendust material, and FeSiNi sendpam material.
  • the weight loss from room temperature in thermogravimetric measurement of heat-resistant resin is more than 300 ° C in air.
  • the heat-resistant resin is gay-containing resin, polyimide resin, ketone resin, polyamide resin, liquid crystal polymer, nitrile resin, thioether resin, arylate resin, sulfone resin, imimi resin. At least one of amide resin and amide imide resin.
  • the heat-resistant resin includes an epoxy resin, a phenolic resin, a polyurethane resin, a silicone resin, a polyacetal resin, a polyponate resin, a urea / melamine resin, a fluorine resin, a polyester resin, At least one selected from the group consisting of polyethylene resin, ABS resin, polystyrene resin, polypropylene resin, polyvinyl chloride resin, ionomer resin, and poly-4-methylpentene resin. Resin is mixed.
  • the heat resistant resin comprises a gay-containing resin, and more preferably, the silicone-containing resin cures a resin having at least one Si—H-based bond and a C 3 C bond.
  • the formed resin is a gay-containing resin, and more preferably, the silicone-containing resin cures a resin having at least one Si—H-based bond and a C 3 C bond.
  • the heat-resistant resin includes a resin having an imido group, and more preferably, the resin having an imido group is a polyimide resin.
  • the resin having an imido group is a polyimide resin.
  • a method for manufacturing a magnetic core is provided.
  • the weight loss from room temperature in thermogravimetric measurement of heat-resistant resin Is more than 300 ° C in air.
  • the straightening of the magnetic material includes heating to 300 ° C. or higher.
  • the heat-resistant resin includes a silicon-containing resin.
  • the heat-resistant resin includes a resin having an imido group.
  • the adhesion of the heat resistant resin to the magnetic material is impregnation, impregnation, application, coating or spraying.
  • a method for manufacturing a magnetic core comprising: impregnating and hardening a resin to become a heat-resistant resin, then cutting a part of the wound or laminated magnetic material, and then subjecting the magnetic material to heat treatment.
  • a method for producing a magnetic core wherein a heat treatment of a magnetic material is performed at the same time as the curing treatment of the resin that becomes a heat-resistant resin after curing and after the Z or curing treatment.
  • a method for manufacturing a magnetic core is provided. Next, the present invention will be described in detail.
  • Examples of the magnetic material suitably used in the present invention include FeSi-based gay steel, FeNi-based permalloy material, FeSiAl-based sendust material, FeSiNi-based sendampal material, and the like.
  • examples of the Fe-based amorphous material include Fe-half-metallic amorphous materials such as Fe-Si-B-based, Fe-B-based, and Fe-PC-based, and Fe-based amorphous materials.
  • Fe—transition metal amorphous materials such as Zr, Fe—Hf, and Fe—Ti
  • Co—Si— Amorphous metals such as B-based and Co-B-based can be exemplified.
  • Fe-based nanocrystalline materials include Fe-Si-B-Cu-Nb, Fe-B-Cu-Nb, Fe-Zr-B, and Fe-Zr.
  • Nanocrystalline materials such as C0-11—: 6 and (0—c3— (:) can be exemplified as Co-based nanocrystalline materials.
  • the heat treatment temperature is relatively lower than other materials.
  • Amorphous materials such as Fe-based and Co-based materials, and Fe-based and Co-based nanocrystalline materials are more preferable.
  • the heat treatment temperature varies depending on the magnetic material, and amorphous materials such as Fe and Co have the lowest heat treatment temperature. In this temperature range, the optimum magnetic properties are usually exhibited at 300 to 500 ° C.
  • For Fe-based and Co-based nanocrystalline materials there is an optimal heat treatment temperature in the range of 400 ° C to 700 ° C. Other crystalline and oxide materials require higher heat treatment temperatures.
  • As the heat-resistant resin used for the magnetic core it is preferable to select a heat-resistant resin that does not decompose at or above the heat treatment temperature at which the magnetic properties of the magnetic material appear.
  • the temperature at which the weight loss from room temperature is 5% when the temperature rise rate is 10 ° C / min and the sample amount is 10 mg in thermogravimetry (TGA) (T d 5) is preferably 300 ° C. or higher in the air, and is preferably a resin containing a gayne, a polyimide, a ketone, a polyamide, a liquid crystal polymer or a nitrile resin.
  • It preferably contains at least one of a polyester resin, a polyester resin, an arylate resin, a sulfone resin, an imid resin, and an amide imid resin.
  • a polyester resin preferably contains at least one of a polyester resin, a polyester resin, an arylate resin, a sulfone resin, an imid resin, and an amide imid resin.
  • Td5 in air is preferably 350 ° C or higher, more preferably 400 ° C or higher, and the heat-resistant temperature of 400 ° C or higher.
  • a polyimide resin a silicon-containing resin, and a ketone resin.
  • amorphous materials such as Fe-based and Co-based, Fe-based and Co-based It can be used not only for crystalline materials, but also for carbon steel, permalloy, sempum, sendust, etc.
  • a gay-containing resin is preferably used as the resin having a heat-resistant temperature of 600 ° C. or higher.
  • the heat-resistant resin of the present invention includes a silicon-containing resin, a polyimide resin, a ketone resin, a polyamide resin, a liquid crystal polymer, a nitrile resin, a thioether resin, a polyester resin, an arylate resin, At least one of a Hong resin, an imido resin, and an amide imid resin, for example, an epoxy resin, a phenol resin, a polyurethane resin, a silicone resin, a polyacetyl resin, and a polycarbonate resin , Urea-melamine resin, fluorine resin, polyester resin, polyethylene resin, ABS resin, polystyrene resin, polypropylene resin, polyvinyl chloride resin, ionomer resin, poly-4-methylpentene -A resin in which at least one of the first resins is mixed. It is preferable that Td5 of the resin obtained by mixing them is 300 ° C. or higher in the air.
  • the heat-resistant resin of the present invention may contain an inorganic or organic filler in order to adjust the viscosity of the resin.
  • a silicon-containing resin preferably, a silicon-containing resin, a polyimide resin, a ketone resin, a polyamide resin, a liquid crystal polymer, a nitrile resin, a polyester resin, a polyester resin, At least one cured product of arylate-based resin, sulfone-based resin, imid-based resin, and amide-imido-based resin is used.
  • inorganic substances (i) glass (sodium silicate), mica (alumino-silicate) Naturally stable inorganic substances represented by acid salts, alkali salts of potassium silicate, gay carbide, calcium sulfate hemihydrate, potassium carbonate, magnesium carbonate, calcium carbonate, barium sulfate, etc.
  • Composite oxide ceramics aluminum nitride, aluminum oxynitride sintered body, boron nitride, boron magnesium nitride, boron nitride composite, nitrides such as silicon nitride, lanthanum nitride nitride, sialon, boron carbide, silicon carbide
  • Ceramic materials exemplified by borides such as aluminum, boron carbide, aluminum carbide, aluminum carbide, titanium carbide and the like, titanium diboride, calcium hexaboride, lanthanum hexaboride and the like It is preferable to use ceramics, talc, aerosol, etc., which have a heat resistance of 300 ° C or more, such as ceramics, talc, and aerosol formed of a simple substance or a composite.
  • silicon dioxide, aluminum oxide, and zirconium dioxide. Diantimony and titanium oxide are more preferred.
  • a resin containing a resin having an imido group it is more preferable to use a resin containing a polyimide resin.
  • the resin containing the resin having an imido group may be a form in which one or more resins having an imido group are present alone in the magnetic core, or may be a resin in which one or more imid groups are present.
  • the resin having a group may be mixed with another resin such as an epoxy resin.
  • resins suitably mixed with a resin having an imido group include a polyamide resin, a phenol resin, a polysulfone (PSF) resin, a polyethersulfone (PES) resin, a polyphenylene sulfide (PPS) resin, Polyarylate (PAR) resin, polyetherimide (PEI) resin, polyetherethylketone (PEEK) resin, liquid crystal polymer (LCP) resin, polybenzimidazole (PBI) resin, polymethylpentene (TPX) resin Poly1
  • a preferable example is 4-cyclohexanedimethylene terephthalate (PCT) resin.
  • the resin containing the resin having an imido group may contain the above-mentioned filler.
  • the heat resistance of the resin containing the resin having an imido group after the magnetic core was manufactured was determined by measuring the temperature at a rate of 10 ° C / min and measuring Is 1 Omg
  • Td5 is preferably at least 300 ° C, more preferably at least 350 ° C, and even more preferably at least 400 ° C.
  • Td 5 is preferably 300 ° C or more, It is preferably at least 350 ° C, more preferably at least 400 ° C.
  • the polyimide resin used in the present invention has the chemical formula (1) oo
  • Aromatic polyimide having a repeating structural unit represented by the following formula (1):
  • Ar is the Ar substituent group
  • R is a group of R substituents
  • polyamide acid (chemical formula (2)) which is a precursor of polyimide.
  • the polyamide acid adhering to the magnetic material is heated to be imidized, and the chemical formula (1)
  • the amide acid used is represented by the chemical formula (3) having amino groups at both ends of the substituent Ar.
  • the diamine used is not particularly limited, and a conventionally known aromatic diamine can be used.
  • Chemical formula (3) is not particularly limited, and a conventionally known aromatic diamine can be used.
  • aromatic diamine represented by NH: Ar-NH2 (3) include the following. Specific examples of these aromatic diamines can be used alone or in combination of two or more.
  • the aromatic tetracarboxylic dianhydride to be used is not particularly limited.
  • polyimide having various glass transition temperatures and various T d5 can be obtained. Can be obtained.
  • aromatic tetracarboxylic dianhydride examples include, for example, pyromellitic dianhydride, 3, 3 ', 4, 4'-benzophenone tetracarboxylic dianhydride, 2, 3', 3,4, -Benzophenonetetracarboxylic dianhydride, 3,3 ', 4,4'-Biphenyltetracarboxylic dianhydride, 2,3', 3,4'-Biphenyltetracarboxylic acid Dianhydride, 2,2-bis (3,4-dicarboxyphenyl) propane dianhydride, bis (3,4-dicarboxyphenyl) ether dianhydride, bis (3,4-dicarboxyphenyl) ) Sulfone dianhydride, 1,1-bis (3,4-dicarboxyphenyl) dianhydride, bis (2,3— Dicarboxyphenyl) methane dianhydride, bis (3,4-dicarboxyphenyl)
  • the polyimide used in the present invention has a molecular weight by shifting the molar ratio of diamine and aromatic tetracarboxylic dianhydride used in preparing a polyamic acid before imidization from a theoretical equivalent. Can be adjusted.
  • the excess amino group or acid anhydride group is deactivated by reacting it with an aromatic dicarbonic anhydride or aromatic monoamine having a theoretical equivalent or more of the excess amino group or acid anhydride group. You may.
  • the method for producing the polyamic acid represented by the formula (1) is not particularly limited to these methods, and can be a method in which a ring-opening polyaddition reaction between an aromatic diamine compound and a tetracarboxylic dianhydride can be used.
  • Solvents used in such reactions include, for example, N, N-dimethylformamide, N, N-dimethylacetamide, N, N-ethylformamide, N, N-getylacetamide, N , N-Dimethoxyacetamide, N-methyl-1-pyrrolidone, 1,3-Dimethyl-12-imidazolidinone, N-Methylcaprolactam, 1,2-Dimethoxetane, Bis (2-methoxicetyl) ether, 1,2-bis (2-methoxetoxy) ethane, bis [2- (2-methoxyethoxy) ethyl] ether, tetrahydrofuran, 1,3-dioxane, 1,4-dioxane, pyrroline, picoline, dimethylsulfoxide , Dimethyl sulfone, tetramethylurea, hexamethylphosphoramide, phenol,
  • the polyimide used in the present invention not only the above-mentioned chain type polyimide resin but also a soluble polyimide resin is preferably used. can do.
  • the soluble polyimide resin may be dissolved in a solvent, adjusted to an appropriate viscosity, adhered to a magnetic material, and heated to evaporate the solvent to cure.
  • the addition-type polyimide resin is produced by coating a magnetic core in a state of a monomer or prepolymer solution or a dispersed slurry, and curing and polymerizing the core by a thermal reaction.
  • a maleimide terminal a nadic terminal, an acetylene terminal, a benzocyclobutene terminal, or the like is used.
  • a polyimide using a bismaleide compound and a diamine compound has the general formula (5)
  • X is a direct bond, a divalent hydrocarbon group having 1 to 10 carbon atoms, a hexafluorinated isopropylidene group, a carbonyl group, a thio group, a sulfinyl group, Represents a group selected from the group consisting of a honyl group and an oxide.
  • ⁇ ′ is selected from the group consisting of a direct bond, a divalent hydrocarbon group having 1 to 10 carbon atoms, a hexafluorinated isopropylidene group, a carbonyl group, a thio group, a sulfinyl group, a sulfonyl group, and an oxide.
  • ⁇ ′ ′ is selected from the group consisting of a direct bond, a divalent hydrocarbon group having 1 to 10 carbon atoms, a hexafluorinated isopropylidene group, a carbonyl group, a thio group, a sulfinyl group, a sulfonyl group, and an oxide.
  • a polyimide having a repeating unit structure represented by the following formula can be produced.
  • a prepolymer solution is attached to a magnetic material, and then heated and cured by an addition reaction to obtain a polymer.
  • the subsequent steps are the same as the above-described chain type polyimide resins £ Further, among the above heat-resistant resins, it is more preferable to use a resin containing a silicon-containing resin.
  • the resin containing a gay-containing resin refers to one kind of a silicon-containing resin alone, a mixture of two or more kinds of a gay-containing resin, and a mixture of one or more kinds of a silicon-containing resin and another resin. Or a mixture of any of these with the above filler.
  • Other resins to be mixed with one or more silicon-containing resins preferably include resins such as epoxy, polyimide, polyamide, polyester 0, polyester, polysulfide, and polysulfone.
  • the preferable ratio of the silicon-containing resin is 0.1 part by weight or more, more preferably 1 part by weight or more, and further preferably It is at least 10 parts by weight.
  • a solvent may be used as necessary during the impregnation.
  • the heat resistance after the magnetic core of the resin containing the silicon-containing resin is manufactured is as follows.In thermogravimetric measurement in air, the rate of temperature rise is 10 min, and the sample size is 10 mg. Further, Td5 is preferably at least 300 ° C, more preferably at least 350 ° C, even more preferably at least 400 ° C.
  • the silicon-containing resin used in the present invention substantially contains gayin in the molecule, and specifically includes polycarbosilane, polysiloxane, and polysilazane.
  • the silicon-containing resin used in the present invention is preferably formed by curing a resin having at least one Si—H bond and at least one C 3 C bond in the molecule.
  • the gay-containing resin used in the present invention is represented by the general formula (8)
  • R 1 and R 2 are each independently a hydrogen atom, an alkyl group having 1 to 30 carbon atoms which may have a substituent,
  • a alkynylene group, a divalent aromatic group linked to at least one C ⁇ C-C and having a substituent Good divalent aromatic groups, linked with at least one single C ⁇ C- with aromatic groups are linked Ri by the direct bond or a bridge member
  • R l and R 2 independently represent a hydrogen atom, an alkyl group having 1 to 30 carbon atoms, an alkenyl group having 1 to 30 carbon atoms, an alkynyl group having 1 to 30 carbon atoms, or Aromatic groups such as diyl groups and naphthyl groups.These groups are halogen atoms, hydroxyl groups, amino groups, carboxyl groups, etc. May be included.
  • R 3 is —C ⁇ C—, linked to at least one C ⁇ C——CH 2 _, alkylene group having 2 to 30 carbon atoms linked to at least one C ⁇ C, at least 1 One C ⁇ C 1 -alkenylene group having 2 to 30 carbon atoms linked to one C, at least one —C ⁇ C— linked alkynylene group having 2 to 30 carbon atoms, at least one C ⁇ Divalent aromatic group such as phenylene group and naphthylene group linked to C—, and aromatic group linked directly or by a bridging member and linked to at least one —C 3 C—
  • Is formed by curing a polymer having a repeating unit represented by A high heat resistance can be obtained from a gay-containing resin formed by thermosetting.
  • the weight average molecular weight of these resins which become heat-resistant silicon-containing resins after curing is preferably from 200 to 1, 000, 0000, and more preferably. Or 300 to 500,000, even more preferably 300 to 100,000.
  • Preferable examples of the resin which becomes a heat-resistant resin containing hardened silicon after curing include silylene edylene, methylsilyleneethynylene phenylsilyleneethynylene, silyleneethynylene-1,3-phenyleneethylene (chemical formula (9))
  • Methylsilyleneethynylene-1,4-phenylenethynylene methylsilyleneethylenetin 1,2-phenylenethynylene, dimethylsilyleneethynylene-1,3-phenylenethynylene, dimethylsilyleneethynylene 1,1,4-phenylenethynylene , Dimethylsilylene ethynylene-1,2-phenylene ethynylene, dimethylsilylene ethynylene-1,3- phenylene ethynylene, phenylsilylene ethynylene-1,3, phenylene ethynylene (chemical formula (1 1) )
  • Phenylsilylene lenethynylene 1,4-phenylene oxy 1,4-phenylene ethynylene (chemical formula (15))
  • Phenylsilylene oxy (phenylsilylene) ethynylene 1 3'-phenylene ethynylene (chemical formula (17))
  • Phenylsilylene 1 4-phenylenetinylene, phenylsilylene 1,2 -phenylenetinylene, diphenylsilylene 1,3 -phenylenetinylene, methylsilylene 1,1,3 -phenylenetin Len (Chemical formula (28))
  • Methylsilylene-1,4-phenyleneethynylene methylsilylene-1,2, -phenylenetinylene, dimethylsilylene-1,3,3-phenylenelenethynylene, getylsilylene-1,3,3-phenyleneethynylene, phenylsilylene 1,3-butydinylene, diphenylsilylene-1,3-butynediyne, phenylsilylene methyleneethynylene methylene, diphenylsilylene lemethyleneethynylene methylene, phenylsilylene methyleneethyleneylene methylene, etc.
  • Can be The form of these polymers is solid or liquid at room temperature.
  • the method for producing the resin represented by the general formula (8) includes a method of performing dehydrogenation copolymerization of a ethynyl compound and a silane compound using a basic oxide, a metal hydride, and a metal compound as a catalyst (Japanese Patent Publication). Japanese Patent Application Laid-Open No. 7-90085, Japanese Patent Laid-Open Publication No. 11-158 8187) and dehydrogenation polymerization of ethynylsilane compounds using basic oxides as catalysts. (Japanese Patent Laid-Open Publication No.
  • Hei 9-1433271 a method in which an organic magnesium reagent is reacted with dichlorosilanes (Japanese Patent Laid-Open Publication No. Hei 7-110209) ), Dehydrogenation copolymerization of a ethynyl compound and a silane compound using cuprous chloride and a tertiary amine as catalysts (Hua Qin Liu and John F. Harrod, The Canadian Journal of Chemistry, Vol. 68, 1100) -1105 (1990)) can be used, but the method is not particularly limited to these methods.
  • FIG. 1 is a process diagram for explaining a magnetic core and a method of manufacturing the same according to first and second embodiments of the present invention.
  • FIG. 2 is a diagram showing the results of thermogravimetric measurement (TGA) of the resin containing manganese after the heat treatment used in the first embodiment of the present invention.
  • FIG. 3 is a process diagram for explaining a transformer magnetic core and a method of manufacturing the same according to a third embodiment of the present invention.
  • FIGS. 4A, 4B, 4C, and 4D are schematic perspective views illustrating a winding-type core.
  • FIGS. 5A, 5B, 5C, and 5D are schematic perspective views illustrating a laminated core.
  • FIG. 6 is a process diagram for explaining a magnetic core and a method of manufacturing the same according to a fourth embodiment of the present invention.
  • FIGS. 7A, 7B and 7C are schematic diagrams of the coated magnetic metal sheet.
  • Figures 8A, 8B and 8C are schematic diagrams of a partially coated magnetic metal sheet.
  • FIG. 9 is a process chart for explaining a conventional magnetic core and a method for manufacturing the same.
  • the magnetic core according to the present embodiment is preferably heat-treated after impregnated and hardened as shown in FIG. 1 or cut after impregnated and hardened to develop magnetic properties, contrary to the conventional process shown in FIG. It is manufactured by That is, a magnetic ribbon is wound into a required size from a raw roll of the magnetic ribbon into a toroidal shape (process A), and then impregnated with a resin (process B) and cured (process C). After that, a heat treatment for developing magnetic properties is performed (Step F), and a product of the magnetic core is manufactured (Step H). In the case of a magnetic core formed with a gap, a resin is impregnated.
  • Step B After curing (Step C), a part of the core is cut (Step D), a spacer is inserted (Step E), and heat treatment is performed to develop magnetic properties. (Step F), a gap-forming magnetic core is manufactured
  • a resin containing a resin that becomes a gayne-containing resin after curing is impregnated and cured to form a heat-resistant resin containing a gayne-containing resin.
  • heat treatment can be performed to develop magnetic properties.
  • Table 1 shows the resin remaining amount (after the impregnation curing and after the heat treatment) of the magnetic cores produced by impregnating and curing the resin that becomes the silicon-containing resin after curing and the epoxy impregnated resin, respectively. %) And the core impregnation hardening strength.
  • the residual amount of resin (%) refers to the ratio of the amount of resin in the core after the impregnation and curing to the amount of resin remaining in each heat treatment.
  • the polystyrene-equivalent molecular weight by gel permeation chromatography of the resin that becomes a gayne-containing resin after this curing is 1700 in weight average molecular weight ( Mw ), 770 in number average molecular weight (Mn), and 194 in viscosity at 30. P a • s.
  • the viscosity was measured with a B-type viscometer.
  • Figure 2 shows the results of thermogravimetric measurement (TGA) of the heat-treated gay-containing resin. This is the weight change when a 10 mg sample was heated in air at a heating rate of 10 ° CZmin. The temperature at which the weight decreases by 5% (Td 5) is found to be about 600 ° C in this case.
  • Table 1 shows the results of heat treatment for 2 hours in the air, and the amount of resin in the core after impregnation and curing, and the amount of resin remaining in each heat treatment.
  • the epoxy resin is decomposed, and the core is hardened by the resin. The effect of fixing is lost.
  • the resin did not substantially decompose even after the heat treatment, and the core impregnation hardening strength remained strong.
  • the heat treatment of the magnetic core having the resin containing the gayne-containing resin requires 300 ° C. or more.
  • the atmosphere for the heat treatment may be a conventional heat treatment condition, and may be performed in the air, in hydrogen, in steam, or in an inert atmosphere such as argon or nitrogen.
  • the impregnation curing may be any method as long as the core can be impregnated with the resin.
  • a method in which the resin is impregnated with a vacuum or its own weight and then the resin is cured as in the conventional method can be adopted.
  • the core is impregnated with resin, if the viscosity of the resin is too high, the resin will be impregnated unevenly and the mechanical strength of the core will vary after impregnation and hardening, resulting in a significant decrease in the yield as a product. Resulting in.
  • the viscosity is too high, it is difficult to impregnate the magnetic core, so that the impregnation time is extremely long and the cost is not effective.
  • the viscosity of the resin at the time of impregnation is preferably from 0.01 to 500 Pa * s at 25 ° C, and more preferably from 0.05 to 5, as measured by a B-type viscometer. L 0 0 Pa ⁇ s is more preferred.
  • a resin containing a silicon-containing resin that decomposes very little even at a temperature of 300 ° C. or more is used.
  • the magnetic properties can be developed, the magnetic properties can be greatly improved, the cost of the impregnation hardening step can be reduced, and the production efficiency can be significantly improved.
  • the optimal heat treatment temperature of the magnetic core obtained by a new process of impregnating and curing the resin that will become the silicon-containing resin after curing
  • the relative permeability value (2100) at (400 ° C) is the value obtained when the epoxy resin is impregnated and cured on the magnetic core that has been subjected to the optimal heat treatment, which is the conventional process (comparative example). It was found that the conditions of impregnation and hardening of the core manufactured in the process of (Example) and the conditions of impregnation and hardening of the core manufactured in the conventional process of (Comparative Example) were respectively increased. The conditions, shown below, are considered optimal for each resin.
  • Impregnation conditions Vacuum impregnation (temperature 85 ° C) 40 minutes, impregnation liquid viscosity (up to 5 Pas)
  • Curing conditions Vacuum, Curing temperature (100 ° C for 1 hour, 150 ° C for 2 hours Hold while curing)
  • Impregnation conditions Vacuum impregnation (temperature 23 ° C) for 20 minutes, impregnation liquid viscosity ( ⁇ 0.2 Pas)
  • Curing conditions Vacuum, curing temperature (held at 120 ° C for 2 hours, then cured at 150 ° C for 4 hours)
  • the magnetic core according to the present embodiment is preferably, as shown in FIG. 1, after the impregnation after the impregnation or after the impregnation after the impregnation, as opposed to the conventional process shown in FIG. It is manufactured by cutting and then heat-treating to develop magnetic properties. That is, a magnetic ribbon is wound into a toroidal shape of a required size from a magnetic ribbon roll (process A), then impregnated with a resin (process B), and imidized (process C). . Thereafter, a heat treatment is performed to develop magnetic properties (Step F), and a product of a magnetic core is manufactured (Step H).
  • the resin is impregnated with resin (Step B) and imidized (Step C), and then a part of the core is cut (Step D). Then, a heat treatment is performed to develop magnetic properties (Step F), and a gap-formed magnetic core is manufactured (Step G).
  • the impregnation is carried out using a polyamic acid solution and then imidization, so that the impregnation is performed as shown in FIG. 1, contrary to the conventional process shown in FIG.
  • heat treatment can be performed to develop magnetic properties.
  • the heat treatment of the magnetic core having a resin containing a polyimide resin is preferably performed at 300 ° C. or higher.
  • the atmosphere for the heat treatment may be a conventional heat treatment condition, and may be performed in the air, in hydrogen, in steam, or in an inert atmosphere such as argon or nitrogen.
  • any method can be used as long as the core can be impregnated with the resin.
  • the resin is impregnated by vacuum or by its own weight and then imidized. Take the method.
  • the core is impregnated with resin, if the viscosity of the resin is too high, the resin will be impregnated unevenly, and the mechanical strength of the core will vary after impregnation and imidization, resulting in lower product yield. It will be greatly reduced.
  • the viscosity is too high, it is difficult to impregnate the magnetic core, so that the impregnation time is extremely long and the cost is not effective.
  • the viscosity of the resin at the time of impregnation is preferably from 0.1 to l OOP a at 25 ° C., and more preferably from 0.03 to 50 P a ′, when measured with an E-type viscometer. s is more preferred.
  • a polyimide resin is used, which decomposes the resin very little even at a temperature of 300 ° C.
  • the core is impregnated and imidized first, and then the core is heat-treated to exhibit magnetic characteristics.
  • the magnetic properties are greatly improved, the cost of the impregnation and imidization process can be reduced, and the production efficiency can be significantly improved.
  • Metg 1 as: 2605S-2 (trade name), Fe78Si9B13 (at%) (Outer diameter: 14 mm, inner diameter: 8 mm, height: 5 mm) using a magnetic core impregnated with a polyamic acid solution and imidized at 250 ° C.
  • Characteristic Table 3 shows the change in the relative heat permeability (relative magnetic permeability: 10 kHz) with the value obtained by impregnating and curing the epoxy resin according to the conventional process shown in FIG. 9 (comparative example).
  • the epoxy resin a commercially available one-component thermosetting epoxy resin was used.
  • Polyamide acid has the chemical formula (30)
  • the residual amount of resin refers to the ratio of the amount of resin in the core after impregnation and imidization to the amount of resin remaining after heat treatment.
  • the imidization by heat treatment was performed in air.
  • the value of relative magnetic permeability (21) at the optimum heat treatment temperature (400 ° C) of the magnetic core obtained in the step of impregnating with the polyamic acid solution in this example and imidizing by a thermal reaction and then performing heat treatment 50) is more than twice the value (990) obtained when the epoxy resin is impregnated and cured on the magnetic core that has been subjected to the optimal heat treatment, which is the conventional process (Comparative Example). .
  • Impregnation conditions Vacuum impregnation (room temperature) 30 minutes, impregnation liquid viscosity (30 OmPas)
  • Imidation conditions Air, temperature (350 ° C for 2 hours)
  • Impregnation conditions Vacuum impregnation (temperature 23 ° C) 20 minutes, impregnation liquid viscosity ( ⁇ 0.2 Pa ⁇ s) Curing conditions: Vacuum, curing temperature (120 ° C for 2 hours, 150 ° C 4 after holding for 2 hours) Hold for time and cure) According to this embodiment, it is possible to improve the magnetic characteristics of the magnetic core, improve the yield of the product, and improve the production efficiency.
  • a resin that becomes a heat-resistant resin after hardening is applied and cured, and then heat-treated to manufacture a magnetic core for a transformer. That is, a lipon made of a metallic magnetic material in a state of high mechanical strength before heat treatment is wound or laminated into a required size and shape to produce a wound core or a laminated core (process A), and then cured.
  • the resin that will later become heat-resistant resin is applied to the take-up core or laminated core (Step B).
  • the resin that becomes heat-resistant resin after curing is applied to at least the wound or laminated end face a of the take-up core or laminated core.
  • Step C to produce a magnetic core for transformer.
  • a magnetic core for a transformer with almost no deformation, cracking, chipping, etc. of the core after heat treatment can be efficiently manufactured in a short time, and the product yield can be improved to improve production efficiency. It has improved.
  • a winding method a method of winding and manufacturing a single or a plurality of magnetic ribbons (spools) (for example, see Japanese Patent No. 2587140) is preferably used.
  • the shape after winding there are various shapes such as a circular wound core and an elliptical wound core shown in FIGS. 4A to 4D.
  • the laminated core is made by punching and cutting magnetic material.
  • the outer frame may be tied with an iron plate or the like in order to maintain the shape during heat treatment.
  • the resin is cured and then heat-treated, or the curing of the resin and the heat treatment of the magnetic material are simultaneously performed.
  • a resin that is a heat-resistant resin that can withstand the same heat treatment temperature as the material it is necessary to apply a resin that is a heat-resistant resin that can withstand the same heat treatment temperature as the material.
  • the residual amount of resin (%) refers to the ratio of the amount of resin in the core after coating and curing to the amount of resin remaining in each heat treatment.
  • the epoxy resin a commercially available one-part thermosetting epoxy resin (viscosity of 150 Pa ⁇ s at 25 ° C.) was used.
  • Table 4 shows the ratio of the amount of resin in the core after application and curing to the amount of resin remaining in each heat treatment.Epoxy resin, etc., decomposes at 350 ° C or higher, and the core is cured by the resin. The effect of fixing is lost. On the other hand, in the silicon-containing resin, even at the heat treatment temperature of the magnetic material, the resin hardly decomposed, and the strength of the core remained unchanged.
  • the heat treatment of the magnetic core having a heat-resistant resin is preferably performed at 300 ° C. or higher.
  • the atmosphere for the heat treatment may be a conventional heat treatment condition, and may be performed in the air, in water vapor, in hydrogen, or in an inert atmosphere such as argon or nitrogen.
  • the coating and curing may be any method as long as the resin can be applied to the core. For example, a conventional method of applying a resin using a brush or the like and then curing the resin is employed.
  • Metallic glaze 260 5 S-2 (trade name), Fe 78 Si 9 B 13 (at)
  • a polyamic acid solution was applied using a magnetic core wound up to 10 Omm, height 25.4 mm) and imidized in the air.
  • the strain in the transformer magnetic core is relaxed and In addition to improving air quality, it is possible to improve product yield and production efficiency.
  • the present embodiment is suitably applied to a magnetic core for a transformer used in a magnetic transformer for electric power transport or the like.
  • FIG. 6 shows an example of a method for manufacturing a magnetic core according to the present embodiment.
  • a coating film of a resin which becomes a heat-resistant resin by being cured on a metal magnetic thin plate from a raw material of the metallic magnetic thin plate by using a coating device such as a roll roller is formed and dried.
  • the magnetic metal sheet coated with a resin that cures and becomes heat-resistant resin is wound or laminated and shaped into a predetermined shape (Step B-1) to develop the magnetic properties of the metal magnetic material.
  • a heat treatment is performed (step B-2) to produce a magnetic core (step B-3), or after cutting (step B-4), a magnetic core is produced (step B-5).
  • the resin that is hardened to become a heat-resistant resin is thermoset to form a heat-resistant resin.
  • the heat treatment temperature of metallic magnetic materials is at least as high as 300 ° C or more, so the resin to be coated should be a resin that has sufficient heat resistance to withstand the heat treatment temperature of magnetic materials.
  • a resin such as polyethylene cannot withstand a heat treatment temperature of 300 ° C. or more and is carbonized, so that insulation between metal magnetic thin plates cannot be performed after heat treatment.
  • a resin coated with a heat-resistant resin that can withstand the heat treatment temperature of the magnetic material retains the insulation and bonding strength of the resin even after the heat treatment, so it has high impact resistance and excellent magnetic properties.
  • a magnetic core can be provided.
  • the resin 12 that is cured to become a heat-resistant resin as shown in FIGS. On one side only (see Figure 7A), on both sides (see Figure 7B), or on the end face (see Figure 7C).
  • the coating it is preferable that the coating be performed uniformly on the surface to be coated.However, in order to obtain the mechanical strength as a magnetic core, e.g., to achieve excellent impact resistance, it is necessary to obtain adhesion between the magnetic thin plates. All that is required is that it be partially coated (see Figures 8A-8C).
  • the viscosity of the varnish of the resin in the coating step in the present example is less than 0.005 Pa ⁇ s as measured with an E-type viscometer. And a sufficient amount of coating film cannot be obtained on a thin plate, resulting in an extremely thin coating film. Also, in this case, if the coating speed is extremely slowed down to increase the film thickness, multiple coatings will be necessary, which will reduce the production efficiency and is not practical. On the other hand, if the varnish viscosity is 200 Pa ⁇ s or more, it is extremely difficult to control the film thickness for forming a thin coating film on a magnetic thin plate because of the high viscosity.
  • the varnish viscosity of the resin used at the time of coating preferably ranges from 0.005 to 200 Pa's at 25 ° C. Further, in 25, 0.01 to 100? & '5 is preferable, and more preferably, it is in the range of 0.05 to 50 Pa * s.
  • the varnish coating method is a method using a coating method such as a roll coating method, a gravure coating method, an air mixing method, a blade coating method, a knife coating method, a rod coating method, a rod coating method, Kisco method, Beadco method, Castco method, Mouth-Tari screen method, Immersion coating method in which a varnish is coated while immersing a magnetic thin plate, Varnish is dropped on a magnetic thin plate from an orifice It can be done by the slot orifice overnight method or the like.
  • a coating method such as a roll coating method, a gravure coating method, an air mixing method, a blade coating method, a knife coating method, a rod coating method, a rod coating method, Kisco method, Beadco method, Castco method, Mouth-Tari screen method, Immersion coating method in which a varnish is coated while immersing a magnetic thin plate, Varnish is dropped on a magnetic thin plate from an orifice It can be done by the slot orifice overnight method or
  • varnish is sprayed using the principle of spraying
  • a method that can coat resin on a magnetic thin plate such as a spray coating method that sprays a magnetic thin plate onto a magnetic thin plate, a spin coating method, an electrodeposition coating method, or a physical vapor deposition method, a sputtering method, or an ion plating method. Any method may be used.
  • the thickness of the coating is larger than the average thickness t of the magnetic thin plate
  • the volume of the coating resin is larger than the volume of the magnetic material in the volume of the magnetic core. It is not practical because the performance and size of the magnetic core increase. For this reason, the thickness of the coating resin is preferably smaller than the average plate thickness t, and 50% or less of t is practical. Among them, 30% or less of t is more preferable.
  • Metg 1 as: 2605 S-2 (trade name), Fe 7 8 Si 9 B 13 (at) with a thickness of about 25 m
  • a polyamic acid varnish was coated and dried on the belt, and an amorphous metal ribbon was formed on the amorphous metal ribbon by insulation coating with a polyimide resin of about 4 microns.
  • a toroidal core (outer diameter 20 mm, inner diameter 12 mm, height 10 mm) is prepared from this amorphous metal ribbon and heat-treated at 420 ° C for 2 hours in a nitrogen atmosphere.
  • a magnetic core was manufactured. In order to examine the impact resistance of the core after the heat treatment, the core was dropped three consecutive times onto a 10 mm thick veneer plywood from a height of 1 m. (JISC04004).
  • the chemical formula (34) As polyamic acid, the chemical formula (34) And a liquid diluted with N-methyl-2-pyrrolidine as a solvent. The viscosity of the liquid used was measured with an E-type viscometer and found to be 30 OmPa ⁇ s at 25 ° C.
  • the polyimide resin after imidization has the chemical formula (35)
  • a colloidal solution in which silica fine particles were dispersed in a toluene organic solvent was coated on an amorphous metal ribbon, and a dried amorphous ribbon was produced.
  • a toroidal core (20 mm in outer diameter, 12 mm in inner diameter, and 10 mm in height) was prepared and heat-treated at 420 ° C for 2 hours in a nitrogen atmosphere to prepare a magnetic core, and this impact resistance test was performed.
  • Table 5 shows the results. Table 5 Impact test of magnetic cores made by coating heat-resistant resin
  • the magnetic core coated on the amorphous metal ribbon manufactured by the manufacturing method of this example has extremely high impact resistance.
  • the deformation of the product (core) and chipping due to impact, etc. are extremely small, greatly contributing to the improvement of production and yield in terms of reducing production management costs and ensuring stable quality.
  • heat-resistant resins such as a gay-containing resin, a polyimide, a polyamide, a ketone-based polymer, and a liquid crystal polymer, in which the decomposition of the resin is extremely small even at a temperature of 300 ° C. or more, are performed.
  • a magnetic core with extremely excellent mechanical strength such as impact resistance and continuity can be produced with high production efficiency. be able to.
  • a magnetic core in the method of manufacturing a magnetic core, is manufactured from a thin plate coated with a resin that cures to become a heat-resistant resin, and is subjected to a heat treatment to receive an impact such as dropping.
  • a resin that cures to become a heat-resistant resin it is possible to efficiently produce a magnetic core with almost no occurrence of partial deformation, cracking, chipping, etc. in the core material, thereby improving product yield and improving production efficiency.
  • a choke coil In this example, a choke coil, a high-frequency transformer, a low-frequency transformer, a reactor, It is suitably applied to magnetic cores used in loose transformers, step-up transformers, noise filters, sensors, transformer transformers, magnetic heads, electromagnetic shields, and the like.
  • Industrial applicability is suitably applied to magnetic cores used in loose transformers, step-up transformers, noise filters, sensors, transformer transformers, magnetic heads, electromagnetic shields, and the like.
  • the present invention can be suitably applied to a magnetic core manufactured using a magnetic material and a resin and a method of manufacturing the same.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un noyau magnétique, consistant (A) à enrouler ou à laminer une matière magnétique, (B) à imprégner la matière d'une résine capable de résister à la chaleur lorsqu'elle a durci, (C) à faire durcir la résine, et (F) à procéder à un traitement thermique. Un autre procédé consiste (A) à enrouler et à laminer la matière magnétique, (B) à imprégner la matière d'une résine capable de résister à la chaleur lorsqu'elle a durci, (C) à faire durcir la résine, (D, E) à couper et à travailler une partie de la matière magnétique, et (F) à procéder à un traitement thermique.
PCT/JP2000/005448 1999-08-16 2000-08-14 Noyau magnetique et procede de fabrication WO2001013386A1 (fr)

Applications Claiming Priority (10)

Application Number Priority Date Filing Date Title
JP22995499 1999-08-16
JP11/229954 1999-08-16
JP11/293049 1999-10-14
JP29304999A JP2001118715A (ja) 1999-10-14 1999-10-14 磁気コア
JP2000/56470 2000-03-01
JP2000056470 2000-03-01
JP2000061906A JP2001250727A (ja) 2000-03-07 2000-03-07 磁気コア
JP2000/61906 2000-03-07
JP2000/122116 2000-04-24
JP2000122116A JP2001307936A (ja) 2000-04-24 2000-04-24 磁気コアの製造方法

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WO2001013386A1 true WO2001013386A1 (fr) 2001-02-22

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6165418A (ja) * 1984-09-07 1986-04-04 Toshiba Corp 磁心の製造法
JPS6182412A (ja) * 1984-09-29 1986-04-26 Toshiba Corp 巻鉄心の製造方法
JPH05190360A (ja) * 1992-01-10 1993-07-30 Totoku Electric Co Ltd 高周波変圧器

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6165418A (ja) * 1984-09-07 1986-04-04 Toshiba Corp 磁心の製造法
JPS6182412A (ja) * 1984-09-29 1986-04-26 Toshiba Corp 巻鉄心の製造方法
JPH05190360A (ja) * 1992-01-10 1993-07-30 Totoku Electric Co Ltd 高周波変圧器

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