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WO2019044698A1 - Dust core, method for producing said dust core, electrical/electronic component provided with said dust core, and electrical/electronic device equipped with said electrical/electronic component - Google Patents

Dust core, method for producing said dust core, electrical/electronic component provided with said dust core, and electrical/electronic device equipped with said electrical/electronic component Download PDF

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Publication number
WO2019044698A1
WO2019044698A1 PCT/JP2018/031351 JP2018031351W WO2019044698A1 WO 2019044698 A1 WO2019044698 A1 WO 2019044698A1 JP 2018031351 W JP2018031351 W JP 2018031351W WO 2019044698 A1 WO2019044698 A1 WO 2019044698A1
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WO
WIPO (PCT)
Prior art keywords
dust core
powder
soft magnetic
magnetic powder
core
Prior art date
Application number
PCT/JP2018/031351
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French (fr)
Japanese (ja)
Inventor
智史 丸山
政夫 松井
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アルプスアルパイン株式会社
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Filing date
Publication date
Application filed by アルプスアルパイン株式会社 filed Critical アルプスアルパイン株式会社
Publication of WO2019044698A1 publication Critical patent/WO2019044698A1/en

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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147Alloys characterised by their composition
    • H01F1/153Amorphous metallic alloys, e.g. glassy metals
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/24Magnetic cores
    • H01F27/255Magnetic cores made from particles
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00Cores, Yokes, or armatures
    • H01F3/08Cores, Yokes, or armatures made from powder
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets

Definitions

  • the present invention relates to a dust core, a method of manufacturing the dust core, an electric / electronic component provided with the dust core, and an electric / electronic device on which the electric / electronic component is mounted.
  • a dust core may be used as a magnetic member.
  • the dust core comprises a compact obtained by compacting a large number of soft magnetic powders and heat treating the resulting shaped product.
  • Patent Document 1 discloses a composite magnetic material for an inductor in which a soft magnetic metal powder is bonded with a nonmagnetic material, and the nonmagnetic material is a molding aid added to and mixed with the soft magnetic metal powder. After the heat treatment of the soft magnetic metal powder / molding aid molded body, the soft magnetic metal powder / impregnated resin impregnated in the molding aid molded body as a binder is impregnated with the impregnated resin under atmospheric pressure. There is disclosed a composite magnetic material characterized in that a thermosetting temperature is 180 ° C. or higher.
  • the use environment of the electric / electronic equipment provided with the electric / electronic parts having the above dust core is various, and the dust core is 100 ° C. because the outside air temperature is high, the dust core is located near the heat generation parts, It may be used in close environment.
  • the material constituting the dust core may be thermally denatured. If the modification of the material changes the magnetic properties of the dust core, especially the core loss, the calorific value from the dust core may increase, which may promote the heat denaturation of the dust core. It is feared that the change in the magnetic properties of the dust core based on the use under such a high temperature environment may affect the operation stability of the electric / electronic component having the dust core.
  • the present invention is a dust core having less change in magnetic properties and excellent mechanical properties even when used in a high temperature environment, a method for producing the dust core, an electric / electronic component comprising the dust core, and the electricity -It aims at providing the electric and electronic equipment in which electronic parts were mounted.
  • a dust core comprising a molded body containing a soft magnetic powder, and an outer coat of the molded body, wherein the outer coat is thermoplastic It is a dust core characterized by containing the thermoplastic resin containing at least one of a polyimide and a thermoplastic polyamide imide.
  • a dust core according to the present invention provided with an outer coat containing a thermoplastic resin containing at least one of a thermoplastic polyimide and a thermoplastic polyamideimide contains a conventionally used silicone resin (especially methylphenylsilicone resin). Magnetic properties, especially core loss, even when placed in a high-temperature environment (specifically, an environment of 250 ° C.) for a long time (specifically, 100 hours or longer) as compared to a dust core having an outer coating Is hard to change. Moreover, it is possible to maintain practical mechanical strength even when placed in a high temperature environment for a long time.
  • the outer coat preferably has an impregnated structure.
  • the soft magnetic powder may contain at least one powder of an iron-based material and a nickel-based material.
  • the soft magnetic powder may contain a powder of a crystalline magnetic material.
  • the soft magnetic powder may contain a powder of an amorphous magnetic material.
  • the soft magnetic powder may contain a powder of a nanocrystal magnetic material.
  • the soft magnetic powder may be a mixture of two or more selected from the crystalline magnetic material, the amorphous magnetic material, and the nanocrystal magnetic material.
  • the molded body comprises the soft magnetic powder and a binding component
  • the binding component comprises a thermal decomposition residue of a binder component including a resin material.
  • voids tend to be generated inside the compact.
  • a molded product having a large amount of voids inside tends to lack mechanical strength of the molded product.
  • the thermoplastic resin containing at least one of the thermoplastic polyimide and the thermoplastic polyamideimide can be positioned so as to fill the voids, the mechanical strength of the molded body is reinforced. Ru.
  • the outer coat is made of at least one of a highly heat resistant thermoplastic polyimide and a thermoplastic polyamide imide which is less thermally denatured, it is possible to improve the initial magnetic properties after the outer coat, and It is possible to suppress the deterioration of the magnetic properties under the high temperature environment accompanying the heat denaturation.
  • Another aspect of the present invention is a method for producing a dust core according to the present invention described above, which is a molded product obtained by a molding process including pressure molding of a mixture comprising the soft magnetic powder and the binder component.
  • a forming step a forming step obtained by the forming step is heated to obtain the forming body comprising the soft magnetic powder and a binding component comprising a thermal decomposition residue of the binder component, and a thermoplasticity
  • a liquid composition containing a thermoplastic resin containing at least one of a polyimide and a thermoplastic polyamideimide and a solvent is brought into contact with the molded product to form a coated film of the liquid composition in a region including the surface of the molded product,
  • It is a manufacturing method of the dusting core characterized by providing an exterior coat process which dries a coat and volatilizes a solvent and forms an exterior coat containing the thermoplastic resin. According to the above method, it is possible to efficiently produce a dust core containing a binding component comprising
  • Another aspect of the present invention is an electric / electronic component comprising a dust core according to the present invention, a coil, and a connection terminal connected to each end of the coil, wherein at least at least the dust core A part is an electric / electronic component characterized in being disposed so as to be located in an induced magnetic field generated by the current when a current is supplied to the coil through the connection terminal.
  • Another aspect of the present invention is an electric / electronic device comprising the electric / electronic component according to the above-mentioned present invention.
  • the dust core according to the present invention even when it is left for a long time (specifically, 100 hours or more) in a high temperature environment (specifically, an environment of 250 ° C.), the magnetic characteristics, particularly core loss, changes. Hateful. Moreover, it is possible to maintain practical mechanical strength even when placed in a high temperature environment for a long time. Therefore, the dust core according to the present invention is hard to change the magnetic characteristics even when used under high temperature environment, and is excellent in mechanical characteristics. Further, according to the present invention, there are provided an electric / electronic component comprising the above dust core and an electric / electronic device on which the electric / electronic component is mounted.
  • FIG. 1 A schematic view of the inside of a molded product before a heat treatment step after a forming step for producing a dust core according to an embodiment of the present invention
  • FIG. 1 A schematic view of the inside of a molded body before an outer coating step after a heat treatment step for producing a powder
  • FIG. 1 A schematic view of the inside of a molded body before an outer coating step after a heat treatment step for producing a powder
  • FIG. 1 It is a schematic diagram of the inside of. It is a figure which shows notionally the spray dryer apparatus used in one example of the method of manufacturing granulated powder, and its operation
  • the dust core 1 according to the embodiment of the present invention shown in FIG. 1 has a ring-like appearance, and includes a molded body containing soft magnetic powder and an outer coat of the molded body.
  • the dust core 1 according to an embodiment of the present invention contains a thermoplastic resin whose exterior coat contains at least one of a thermoplastic polyimide and a thermoplastic polyamideimide.
  • binding is performed to bind the soft magnetic powder to another material (which may be the same or different) contained in the dust core 1 Contains ingredients.
  • the appearance of the dust core 1 is not limited to the ring shape, and there are, for example, EE type, EI type, EER type, PQ type, I type, or one in which a coil is sealed inside a dust core.
  • the soft magnetic powder contained in the molded body of the dust core 1 is an iron-based material containing iron and a nickel-based material containing nickel It may contain at least one powder of
  • the soft magnetic powder contained in the compact of the dust core 1 according to an embodiment of the present invention may contain a powder of a crystalline magnetic material.
  • crystalline magnetic material means a material whose structure is crystalline and which is ferromagnetic, particularly soft magnetic.
  • the soft magnetic powder contained in the compact of the dust core 1 according to an embodiment of the present invention may be made of a powder of a crystalline magnetic material.
  • Specific examples of crystalline magnetic materials include Fe-Si-Cr alloys, Fe-Ni alloys, Ni-Fe alloys, Fe-Co alloys, Fe-V alloys, Fe-Al alloys, Fe-Si And Fe-Si-Al alloys, carbonyl iron and pure iron.
  • the soft magnetic powder contained in the compact of the dust core 1 according to an embodiment of the present invention may contain a powder of an amorphous magnetic material.
  • amorphous magnetic material means a material that is a ferromagnetic material, in particular a soft magnetic material, in which the volume of the amorphous part in the tissue is more than 50% of the whole.
  • the soft magnetic powder contained in the compact of the dust core 1 according to an embodiment of the present invention may be made of powder of an amorphous magnetic material.
  • Specific examples of the amorphous magnetic material include Fe-Si-B alloys, Fe-PC alloys and Co-Fe-Si-B alloys.
  • the above amorphous magnetic material may be composed of one kind of material or may be composed of plural kinds of materials.
  • the magnetic material constituting the powder of the amorphous magnetic material is preferably one or two or more materials selected from the group consisting of the above-mentioned materials, and among these, Fe—PC based alloys are preferred. It is preferable to contain, and it is more preferable to consist of a Fe-PC type
  • the composition formula is represented by Fe 100 at%-abcxy xt Ni a Sn b Cr c P x C y B z Si t , 0 at% ⁇ a ⁇ 10 at% 0 at% ⁇ b ⁇ 3 at%, 0 at% ⁇ c ⁇ 6 at%, 6.8 at% ⁇ x ⁇ 13.0 at%, 2.2 at% ⁇ y ⁇ 13.0 at%, 0 at% ⁇ z ⁇ 9.0 at% And Fe-based amorphous alloys in which 0 at% ⁇ t ⁇ 7 at% are included.
  • Ni, Sn, Cr, B and Si are optional additional elements.
  • the addition amount a of Ni is preferably 0 at% or more and 7 at% or less, and more preferably 4 at% or more and 6.5 at% or less.
  • the addition amount b of Sn is preferably 0 at% or more and 2 at% or less, and more preferably 0 at% or more and 1 at% or less.
  • the addition amount c of Cr is preferably 0 at% or more and 2.5 at% or less, and more preferably 1.5 at% or more and 2.5 at% or less.
  • the addition amount z of B is preferably 0 at% or more and 8.0 at% or less, and more preferably 0 at% or more and 2 at% or less.
  • the addition amount t of Si is preferably 0 at% or more and 6 at% or less, and more preferably 0 at% or more and 2 at% or less.
  • the soft magnetic powder contained in the compact of the dust core 1 according to an embodiment of the present invention may contain a powder of a nanocrystalline magnetic material.
  • nanocrystalline magnetic material has a nanocrystalline structure in which crystal grains having an average crystal grain size of several nm to several tens of nm are uniformly deposited in at least 50% of the structure.
  • a ferromagnetic material in particular a soft magnetic material.
  • the structure other than the nanocrystalline particles may be amorphous or all may be a nanocrystalline structure.
  • the soft magnetic powder contained in the compact of the dust core 1 according to an embodiment of the present invention may be made of a powder of a nanocrystalline magnetic material.
  • Fe-Cu-M (here, M is one or more metal elements selected from Nb, Zr, Ti, V, Mo, Hf, Ta, W) as a specific example of the nanocrystal magnetic material-Si -B-based alloy, Fe-M-B-based alloy, Fe-Cu-M-B-based alloy, etc. may be mentioned.
  • the soft magnetic powder contained in the compact of the dust core 1 may be composed of one type of powder or may be a mixture of a plurality of types. Specific examples of this mixture include a mixture of two or more of a crystalline magnetic material, an amorphous magnetic material, and a nanocrystalline magnetic material. More specifically, for example, the soft magnetic powder contained in the compact of the dust core 1 according to one embodiment of the present invention is a mixture of a powder of crystalline magnetic material and a powder of amorphous magnetic material. It may be a powder of an amorphous magnetic material, and part of it may be a powder of a nanocrystalline magnetic material.
  • the shape of the soft magnetic powder contained in the dust core 1 is not limited.
  • the shape of the soft magnetic powder may be spherical or non-spherical.
  • non-spherical shape it may be a shape having shape anisotropy such as scaly shape, elliptical spherical shape, droplet shape, needle shape, or even an irregular shape having no particular shape anisotropy.
  • amorphous soft magnetic powder a plurality of spherical soft magnetic powders may be bonded in contact with each other or may be bonded so as to be partially embedded in another soft magnetic powder. Such amorphous soft magnetic powder is likely to be observed when the soft magnetic powder is a powder of carbonyl iron.
  • the shape of the soft magnetic powder may be a shape obtained at the stage of manufacturing the soft magnetic powder, or may be a shape obtained by subjecting the manufactured soft magnetic powder to secondary processing.
  • Examples of the shape of the former include a sphere, an oval sphere, a droplet, a needle, and the like, and examples of the shape of the latter include a scale.
  • the particle size of the soft magnetic powder contained in the dust core 1 is not limited. If this particle size is defined by the median diameter D50 (the particle size when the volume cumulative value in the volume distribution of the particle size of the soft magnetic powder measured by laser diffraction scattering method is 50%), it is usually 1 ⁇ m to 45 ⁇ m. It is considered a range. From the viewpoint of enhancing the handleability, and the viewpoint of enhancing the packing density of the soft magnetic powder in the compact of the dust core 1, the median diameter D50 of the soft magnetic powder is preferably 2 ⁇ m to 30 ⁇ m, and preferably 3 ⁇ m to 15 ⁇ m. It is more preferable to do, and it is especially preferable to set it as 4 micrometers or more and 13 micrometers or less.
  • the median diameter D50 of the soft magnetic powder is preferably 2 ⁇ m to 30 ⁇ m, and preferably 3 ⁇ m to 15 ⁇ m. It is more preferable to do, and it is especially preferable to set it as 4 micrometers or more and 13 micrometers or less
  • the composition of the binding component is not limited as long as it is a material that contributes to fixing the soft magnetic powder contained in the dust core 1 according to an embodiment of the present invention.
  • Organic materials such as thermal decomposition residues of resin materials and resin materials (these are generically referred to as "components based on resin materials” in the present specification), inorganic materials, etc. as materials constituting the binding component Is illustrated.
  • the resin material include acrylic resin, silicone resin, epoxy resin, phenol resin, urea resin, and melamine resin.
  • the binding component made of an inorganic material is exemplified by a glass-based material such as water glass.
  • the binding component may be composed of one type of material or may be composed of a plurality of materials.
  • the binding component may be a mixture of an organic material and an inorganic material.
  • an insulating material is used as the binding component. Thereby, it becomes possible to improve the insulation as the dust core 1.
  • the molded article of the dust core 1 is manufactured by a manufacturing method including a molding process including pressure molding of a mixture containing a soft magnetic powder and a binder component as a specific example. It is.
  • the “binder component” is a component that provides a binding component, and the binder component may be a binding component or a material different from the binding component.
  • the binding component included in the compact of the dust core 1 is composed of the thermal decomposition residue of the binder component containing the resin material Can be mentioned.
  • the thermal decomposition residue a part of the binder component is decomposed and volatilized.
  • FIG. Fig.2 (a) is a schematic diagram of the inside of the shaping
  • FIG.2 (b) is a It is after the heat treatment process for producing the dust core according to one embodiment
  • FIG. 2 (c) is the dust core after the outer coating process for producing the dust core according to one embodiment of the present invention.
  • a material (outer coat material) CRM that constitutes an outer coat containing a thermoplastic resin containing at least one of a thermoplastic polyimide and a thermoplastic polyamideimide can be positioned so as to fill at least a part of the void PR. Therefore, in the dust core 1, the volume of the space PR is reduced, and the soft magnetic powder MM is bound and fixed by the thermal decomposition residue TDM and the outer coating material CRM, thereby reinforcing the mechanical strength.
  • the exterior coating material CRM uses a thermoplastic resin containing at least one of a thermoplastic polyimide and a thermoplastic polyamideimide which does not need to be thermally cured after coating, the stress due to the thermal curing after the exterior coating is a dust core 1 Not granted. For this reason, the magnetic characteristics of the dust core 1 obtained by the exterior coating step are maintained or improved.
  • the exterior coating material CRM uses a thermoplastic resin containing at least one of thermoplastic polyamideimides which is less thermally denatured, the heat of the exterior coating material CRM is obtained even if the dust core 1 is placed in a high temperature environment. Deterioration of the magnetic property of dust core 1 originating in denaturation is suppressed.
  • the dust core 1 includes an exterior coating.
  • the outer coat is a layer provided to cover at least a part of the molded body 1B for the purpose of improving the mechanical strength of the molded body 1B and the like. Since the molded body 1B is formed by press-molding a mixture containing the soft magnetic powder MM, the surface thereof may have asperities derived from the soft magnetic powder. In the case where the mixture contains the binder component BM, and the molded body 1B contains the thermal decomposition residue TDM of the binder component BM, as described above, the molded body may have the void PR. In such a case, as shown in FIG.
  • the outer coating material CRM may be present not only on the surface of the molded body 1B, but also on a region which has entered the surface to a certain extent. That is, in the dust core 1 according to one embodiment of the present invention, the exterior coat preferably has an impregnated structure with respect to the molded body 1B.
  • the exterior coat with which the dust core 1 according to an embodiment of the present invention is provided contains a thermoplastic resin containing at least one of a thermoplastic polyimide and a thermoplastic polyamideimide.
  • a thermoplastic resin abbreviated as "thermoplastic resin” in the following description
  • the concentration of the thermoplastic resin in the liquid composition is not limited, but the ease of preparation (the ease of dissolution of the thermoplastic resin), the handleability (viscosity), and the thickness of the coating formed on the molded body 1B are suitable.
  • the concentration of the thermoplastic resin in the liquid composition is preferably 1% by mass or more and 40% by mass or less, and more preferably 5% by mass or more and 20% by mass or less.
  • the type of solvent is arbitrary as long as it can dissolve the thermoplastic resin.
  • a mixed solvent of an aprotic polar solvent such as N-methylpyrrolidone, methyl ethyl ketone or butyl acetate and an aromatic solvent such as xylene or toluene may be preferable.
  • the liquid composition may contain a resin or filler other than the thermoplastic resin as long as the object of the present invention can be achieved. In the following description, the case where the liquid composition contains only a thermoplastic polyimide or a thermoplastic polyamideimide as a thermoplastic resin as a solid content will be described as a specific example.
  • the prepared liquid composition is brought into contact with the above-mentioned molded body 1B to form a coating film of the liquid composition in a region including the surface of the molded body 1B.
  • the contact method is optional. Most simply, the molded body 1B may be immersed in the liquid composition for a predetermined time (for example, 5 minutes to 30 minutes). Alternatively, the liquid composition may be sprayed onto the molded body 1B. The atmosphere at the time of bringing the liquid composition and the molded body 1B into contact with each other may be reduced in pressure. The coating amount of the liquid composition and the thickness of the coating film formed by contact are arbitrary. As described above, since the formed body 1B has the space PR, the liquid composition can be easily impregnated into the inside of the formed body 1B by contacting in a reduced pressure atmosphere or reducing the viscosity of the liquid composition.
  • the coating film formed on the molded body 1B is dried to evaporate the solvent.
  • the drying temperature and time are appropriately set according to the type of solvent. By way of non-limiting illustration, it is from 60 ° C. to 170 ° C. for about 20 minutes to 5 hours. It may be preferable to carry out stepwise heating.
  • the exterior coat provided in the dust core 1 contains a thermoplastic resin and, in a preferable embodiment, is made of a thermoplastic resin. Even if it is, it is hard to produce change of a magnetic characteristic. Specifically, it is possible to make the increase rate of the core loss at 10% or less when left under the above environment for 200 hours. In addition, it is possible to set the reduction rate of the relative magnetic permeability to 6% or less (set the change rate to -6% or more) when the above-described environment is left for 200 hours.
  • the exterior coat provided in the dust core 1 contains a thermoplastic resin and, in a preferable embodiment, is made of a thermoplastic resin. Even if it is, it is hard to produce the fall of mechanical strength. Specifically, it is possible to set the initial radial crushing strength to 15 MPa or more, and to set the radial crushing strength to 15 MPa or more even when being placed in the above environment for 200 hours.
  • the method of producing the powder core 1 according to the embodiment of the present invention is not particularly limited, the powder core 1 can be made more efficient if the production method described below is adopted. Manufacturing is realized.
  • the method for producing the dust core 1 according to an embodiment of the present invention may include a forming step and an outer coating step described below, and may further include a heat treatment step.
  • a mixture containing soft magnetic powder and a binder component is prepared.
  • the formed product 1A can be obtained by the forming process including the pressure forming of the mixture.
  • the pressure condition is not limited, and is appropriately determined based on the composition of the binder component and the like.
  • the binder component is made of a thermosetting resin
  • the pressing force is high, heating is not a necessary condition, and it becomes pressing for a short time.
  • the mixture is granulated powder and compression molding is to be described in some detail. Since the granulated powder is excellent in handleability, it is possible to improve the workability of the compression molding process, which has a short molding time and excellent productivity.
  • the granulated powder contains a soft magnetic powder and a binder component.
  • the content of the binder component in the granulated powder is not particularly limited. When the content is excessively low, the binder component hardly holds the soft magnetic powder. Further, when the content of the binder component is excessively low, in the green compact core 1 obtained through the heat treatment step, the binding component consisting of the thermal decomposition residue of the binder component is composed of a plurality of soft magnetic powders It is difficult to insulate from On the other hand, when the content of the binder component is excessively high, the content of the binding component contained in the dust core 1 obtained through the heat treatment step tends to be high.
  • the magnetic properties of the dust core 1 are likely to be deteriorated due to the influence of the stress that the soft magnetic powder receives from the binding component.
  • the content of the binder component is excessively high, the space filling factor of the soft magnetic powder of the dust core 1 is lowered, and the magnetic properties of the dust core 1 are easily deteriorated. So, it is preferable to make content of the binder component in granulated powder into the quantity which will be 0.5 mass% or more and 5.0 mass% or less with respect to the whole granulated powder.
  • the content of the binder component in the granulated powder is 0.5% by mass or more with respect to the whole granulated powder.
  • the amount is preferably 5% by mass or less, and more preferably 0.6% by mass or more and 3.0% by mass or less.
  • Granulated powder may contain materials other than the above-mentioned soft magnetic powder and binder component.
  • a lubricant a silane coupling agent, an insulating filler and the like are exemplified.
  • the lubricant When the lubricant is contained, its type is not particularly limited. It may be an organic lubricant or an inorganic lubricant. Specific examples of organic lubricants include metal soaps such as zinc stearate and aluminum stearate. It is considered that such an organic lubricant evaporates in the heat treatment step and hardly remains in the dust core 1.
  • the method for producing granulated powder is not particularly limited.
  • the ingredients to give the above-mentioned granulated powder may be mixed as it is, and the obtained kneaded product may be ground by a known method to obtain granulated powder, or the above components may be mixed with a solvent (solvent, dispersion medium, Granulated powder may be obtained by preparing a slurry formed by adding water, for example, and drying and grinding this slurry. After crushing, sieving or classification may be performed to control the particle size distribution of the granulated powder.
  • a rotor 201 is provided in the spray dryer apparatus 200, and the slurry S is injected toward the rotor 201 from the top of the apparatus.
  • the rotor 201 is rotated at a predetermined rotation speed, and the slurry S is sprayed in the form of droplets by centrifugal force in a chamber inside the spray drier apparatus 200.
  • hot air is introduced into a chamber inside the spray dryer apparatus 200, whereby the dispersion medium (water) contained in the droplet slurry S is volatilized while maintaining the droplet shape.
  • granulated powder P is formed from slurry S.
  • the granulated powder P is recovered from the lower part of the spray drier apparatus 200.
  • Parameters such as the rotation speed of the rotor 201, the temperature of the hot air introduced into the spray dryer 200, the temperature of the lower portion of the chamber, etc. may be set as appropriate. Specific examples of setting ranges of these parameters include 4,000 to 6,000 rpm as the number of revolutions of the rotor 201, 130 to 170 ° C. as the temperature of hot air introduced into the spray dryer 200, and 80 to 90 ° C. as the temperature at the lower portion of the chamber. . Further, the atmosphere in the chamber and the pressure thereof may be set appropriately. As an example, the inside of the chamber is an air (air) atmosphere, and the pressure may be 2 mm H 2 O (about 0.02 kPa) in terms of differential pressure with respect to the atmospheric pressure. The particle size distribution of the obtained granulated powder P may be further controlled by sieving or the like.
  • the pressure condition in compression molding is not particularly limited. It may be set appropriately in consideration of the composition of the granulated powder, the shape of the formed product 1A, and the like. If the pressing force during compression molding of the granulated powder is excessively low, the mechanical strength of the molded product 1A is reduced. For this reason, the handling property of the formed product 1A is reduced, and the mechanical strength of the dust core 1 obtained from the formed product 1A is easily reduced. In addition, the magnetic properties of the dust core 1 may be degraded or the insulation may be degraded. On the other hand, when the pressing force at the time of compression molding of the granulated powder is excessively high, it becomes difficult to prepare a molding die that can withstand the pressure.
  • the pressure may be preferably 0.3 GPa or more and 2 GPa or less, or more preferably 0.5 GPa or more and 2 GPa or less, and particularly preferably 0.5 GPa or more and 1.8 GPa or less There is.
  • pressurization may be performed while heating, or pressurization may be performed at normal temperature.
  • the formed product 1A obtained in the forming step may be the formed body 1B provided in the dust core 1 according to the present embodiment, and the formed product 1A will be described next.
  • a heat treatment step may be performed to obtain a molded body 1B.
  • the heat treatment step by adjusting the distance between the soft magnetic powders by heating the shaped product 1A obtained in the above shaping step, the adjustment of the magnetic properties by correcting the distance between the soft magnetic powders and the distortion imparted to the soft magnetic powders in the shaping step The magnetic characteristics are adjusted by relaxation to obtain a compact 1B.
  • the purpose of the heat treatment step is to adjust the magnetic properties of the compact 1B as described above, and the heat treatment conditions such as the heat treatment temperature are set so that the magnetic properties of the compact 1B become the best.
  • the heating temperature of the formed product 1A is changed, and other conditions such as the temperature rising rate and the holding time at the heating temperature are constant.
  • the evaluation standard of the magnetic property of the molded body 1B at the time of setting the heat treatment conditions is not particularly limited.
  • the core loss of the molded object 1B can be mentioned as a specific example of an evaluation item.
  • the heating temperature of the formed product 1A may be set so as to minimize the core loss of the formed body 1B.
  • the measurement conditions of the core loss are appropriately set, and one example is a condition of a frequency of 100 kHz and a maximum magnetic flux density of 100 mT.
  • the atmosphere in the heat treatment is not particularly limited.
  • an oxidizing atmosphere the possibility of the thermal decomposition of the binder component proceeding excessively and the possibility of the oxidation of the soft magnetic powder proceeding increasing, so an inert atmosphere such as nitrogen, argon, etc., reduction of hydrogen etc. It is preferable to carry out the heat treatment in a reactive atmosphere.
  • the molded product 1B comprising the molded product 1A obtained by the above-mentioned molding step or the molded product 1B obtained by the above-mentioned heat treatment step for the molded product 1A Apply an exterior coat containing a plastic resin. Since an example of the manufacturing method is as described above, the description is omitted here.
  • An electric / electronic component according to an embodiment of the present invention includes the dust core according to the above-described embodiment of the present invention.
  • the electric / electronic component according to an embodiment of the present invention includes a dust core, a coil, and a connection terminal connected to each end of the coil.
  • at least a part of the dust core is disposed so as to be located in an induced magnetic field generated by the current when the current is supplied to the coil through the connection terminal.
  • the toroidal coil 10 shown by FIG. 3 is mentioned as an example of such an electrical and electronic component.
  • the toroidal coil 10 includes a coil 2 a formed by winding the coated conductive wire 2 around the ring-shaped dust core 1.
  • the ends 2d and 2e of the coil 2a can be defined in the portion of the conductive wire located between the coil 2a consisting of the wound coated conductive wire 2 and the ends 2b and 2c of the coated conductive wire 2.
  • the member constituting the coil and the member constituting the connection terminal may be constituted by the same member.
  • the present invention is not limited to the ring-shaped dust core 1 as described above, for example, an EE-type, EI-type, EER-type, EER-type, PQ-type or I-type dust core provided with coil winding or a coil What was enclosed inside the powder core etc. are mentioned.
  • the electric / electronic component according to the embodiment of the present invention includes the dust core according to the above-described embodiment of the present invention, the electric / electronic component is long in a high temperature environment (specifically, an environment of 250 ° C.) Even when it is left for a time (specifically, 100 hours or more), deterioration of the characteristics of the electric / electronic component due to the change of the magnetic characteristics of the dust core does not easily occur.
  • the dust core can maintain practical mechanical strength even when it is placed in the above environment for a long time, the manufacturing process of the electric and electronic parts using the dust core, such electric and electronic parts Thermal stress due to external mechanical load such as collision with other parts or sudden temperature change during process of mounting or incorporating as a part of equipment and using the obtained electric / electronic equipment Even if a problem occurs, it is unlikely to cause a problem that the electrical and electronic parts are broken.
  • a reactor In addition to the above-mentioned toroidal coil 10, a reactor, a transformer, a choke coil, etc. are illustrated as electric and electronic parts concerning one embodiment of the present invention.
  • the electric / electronic device includes the electric / electronic component including the dust core according to the above-described embodiment of the present invention. Specifically, those on which the above-mentioned electric and electronic components are mounted and those in which the above-mentioned electric and electronic components are incorporated are exemplified. As a further specific example of such electric and electronic equipment, a switching power supply unit provided with a voltage buck-boost circuit, a smoothing circuit, a DC-DC converter, an AC-DC converter, etc., a power control unit used for solar power generation etc. Can be mentioned.
  • the electric / electronic component according to the embodiment of the present invention includes the electric / electronic component including the dust core according to the embodiment of the present invention, so that the high temperature environment (specifically, an environment of 250 ° C.) Even when it is left for a long time (specifically, 100 hours or more), it is hard to cause an operation failure due to the deterioration or breakage of the magnetic properties of the dust core. Therefore, the electric / electronic component according to one embodiment of the present invention is excellent in reliability.
  • Example 1 (1) Preparation of Fe-based amorphous alloy powder Fe 74.3 at% Cr 1.56 at% P 8.78 at% C 2.62 at% B 7.57 at% Si 4.19 at% using a water atomizing method
  • the powder of the amorphous magnetic material obtained by weighing to a composition was produced as a soft magnetic powder.
  • the particle size distribution of the obtained soft magnetic powder was measured by volume distribution using a microtrack particle size distribution measuring apparatus ("MT3300EX" manufactured by Nikkiso Co., Ltd.).
  • the median diameter (D50) which is the particle size at which 50% is obtained in the particle diameter distribution when the volume cumulative value in the volume distribution is 50%, is 11 ⁇ m.
  • the obtained slurry was spray-dried with a spray dryer apparatus ("D350AT-24HOP" manufactured by Pris Co., Ltd.) to obtain granulated powder.
  • the particle size distribution of the obtained granulated powder was measured by volume distribution using a laser diffraction scattering particle size distribution measuring apparatus ("LS 13 320" manufactured by Beckman Coulter, Inc.).
  • the median diameter (D50) which is a particle size which will be 50% in the particle size volume distribution in case the volume accumulation value in the volume distribution of the particle size of the granulated powder measured is 85 micrometers.
  • the obtained formed product 1A is placed in a furnace in a nitrogen stream atmosphere, and the furnace temperature is 300 ° C., which is the optimum core heat treatment temperature at a heating rate of 10 ° C./min from room temperature (23 ° C.) It was heated to ⁇ 500 ° C., held at this temperature for 1 hour, and then heat-treated to cool to room temperature in a furnace to obtain a compact 1 B.
  • thermoplastic polyimide (“Q-VR-X1444" manufactured by PI Technology Inc.) is dissolved in N-methylpyrrolidone (NMP) and the concentration of the thermoplastic polyimide is 10% by mass Prepared.
  • the above-mentioned molded body 1B was immersed in the obtained liquid composition for 15 minutes. Thereafter, the molded product 1B is taken out of the liquid composition, dried at 80 ° C. for 30 minutes, then at 150 ° C. for 1 hour, and at 250 ° C. for 1 hour, and the coating film of the liquid composition is formed on the surface of the molded body 1B. To obtain a dust core 1 having an outer coat on the molded body 1B.
  • Example 2 In preparing the liquid composition, a thermoplastic polyamideimide ("HR-11NN” manufactured by Toyobo Co., Ltd.) is dissolved in NMP to prepare a liquid composition having a concentration of the thermoplastic polyamideimide of 10% by mass. Dust core 1 was obtained in the same manner as Example 1 except for the above.
  • Example 3 In the same manner as Example 1, a molded body 1B was obtained. A different type of thermoplastic polyamideimide ("HL-1210" manufactured by Hitachi Chemical Co., Ltd.) was dissolved in bis (2-methoxyethyl) ether to prepare a liquid composition having a concentration of thermoplastic polyamideimide of 10% by mass. Dust core 1 was obtained in the same manner as Example 1 except for the above.
  • Example 4 In the same manner as Example 1, a molded body 1B was obtained. A phenol-modified alkyd resin ("H550" manufactured by Meiden Chemical Co., Ltd.) was dissolved in xylene to prepare a liquid composition in which the concentration of the phenol-modified alkyd resin was 10% by mass. The above-mentioned molded body 1B was immersed in the obtained liquid composition for 15 minutes. Thereafter, the molded product 1B is taken out from the liquid composition, and heated at 45 ° C. for 1 hour, and then heated at 155 ° C. for 1 hour to obtain a dust core 1 having an outer coat on the molded product 1B.
  • H550 manufactured by Meiden Chemical Co., Ltd.
  • Example 5 In the same manner as Example 1, a molded body 1B was obtained. An equivalent blend of polyamide imide ("V-8000 BM” manufactured by DIC) and bisphenol A epoxy resin ("850-S” manufactured by DIC) is diluted using cyclohexanone as a solvent, and the solid content concentration is 12% by mass A liquid composition was prepared. The above-mentioned molded body 1B was immersed in the obtained liquid composition for 15 minutes. Thereafter, the molded product 1B was taken out of the liquid composition and dried at 100 ° C. for 1 hour to form a coating film of the liquid composition on the surface of the molded product 1B. The compact 1B provided with the coating film was heated at 200 ° C. for 1 hour to obtain a dust core 1 having an outer coat on the compact 1B.
  • V-8000 BM manufactured by DIC
  • bisphenol A epoxy resin 850-S manufactured by DIC
  • Example 6 When preparing a liquid composition, methyl phenyl silicone ("KR-271" manufactured by Shin-Etsu Chemical Co., Ltd.) is diluted with xylene as a solvent instead of polyamideimide and bisphenol A epoxy resin, and the concentration of methyl phenyl silicone is reduced. A dust core was obtained in the same manner as in Example 5, except that a liquid composition having a content of 20% by mass was prepared.
  • KR-271 manufactured by Shin-Etsu Chemical Co., Ltd.
  • Example 7 A liquid composition having a concentration of methylphenylsilicone of 10% by mass by diluting methylphenylsilicone ("KR-300" manufactured by Shin-Etsu Chemical Co., Ltd.) different in kind using xylene as a solvent when preparing the liquid composition A dust core was obtained in the same manner as in Example 6, except that was prepared.
  • Example 8 In the same manner as Example 1, a molded body 1B was obtained. Phenyl silicone ("ASP-2010" manufactured by Shin-Etsu Chemical Co., Ltd.) was diluted with xylene to prepare a liquid composition having a solid content concentration of 20% by mass. The above-mentioned molded body 1B was immersed in the obtained liquid composition for 15 minutes. Thereafter, the molded product 1B was taken out of the liquid composition and dried at 100 ° C. for 2 hours to form a coating film of the liquid composition on the surface of the molded product 1B. The compact 1B provided with the coating film was heated at 150 ° C. for 5 hours to obtain a dust core 1 having an outer coat on the compact 1B.
  • Phenyl silicone (“ASP-2010" manufactured by Shin-Etsu Chemical Co., Ltd.) was diluted with xylene to prepare a liquid composition having a solid content concentration of 20% by mass.
  • the above-mentioned molded body 1B was immersed in the obtained liquid composition for 15
  • Example 9 When preparing a liquid composition, a modified silicone ("SCR-1012" manufactured by Shin-Etsu Chemical Co., Ltd.) is diluted using xylene as a solvent to prepare a liquid composition having a concentration of methyl phenyl silicone of 10% by mass. A dust core was obtained in the same manner as in Example 8 except for the above.
  • Example 10 In the same manner as Example 1, a molded body 1B was obtained.
  • a thermosetting polyimide (“UPIA-AT” manufactured by Ube Industries, Ltd.) was diluted with NMP to prepare a liquid composition having a solid content concentration of 10% by mass.
  • the above-mentioned molded body 1B was immersed in the obtained liquid composition for 15 minutes. Thereafter, the molded product 1B was taken out of the liquid composition, dried at 80 ° C. for 30 minutes, and then dried at 150 ° C. for 1 hour, to form a coating film of the liquid composition on the surface of the molded product 1B.
  • the compact 1B provided with the coating film was heated at 350 ° C. in a nitrogen atmosphere for 1 hour to obtain a dust core 1 having an outer coat on the compact 1B.
  • Example 11 When preparing a liquid composition, a liquid composition having a thermosetting polyimide concentration of 10% by mass by diluting different kinds of thermosetting polyimides ("U imide CR" manufactured by Unitika, Inc.) using NMP as a solvent Dust core 1 was obtained in the same manner as in Example 10 except that the product was prepared.
  • Test Example 1 Measurement of Relative Permeability and Rate of Change
  • the powder core 1 manufactured according to the examples and reference examples was wound with a copper wire to obtain a toroidal core.
  • the relative permeability at a frequency of 100 kHz was measured for the toroidal core using an impedance analyzer ("4192A" manufactured by HP). This relative permeability is referred to as “initial relative permeability ⁇ 0 ”.
  • the dust core 1 produced according to the example and the comparative example was allowed to stand in an environment of 250 ° C. for 200 hours, and the relative permeability was measured in the manner described above for the dust core 1 after standing. This relative permeability is referred to as “after heating relative permeability ⁇ 1 ”.
  • the rate of change in relative permeability R ⁇ (unit:%) was determined by the following equation.
  • R ⁇ ( ⁇ 1 - ⁇ 0 ) / ⁇ 0 ⁇ 100
  • the initial relative permeability ⁇ 0 and the post-heating relative permeability ⁇ 1 and the change rate R ⁇ of the relative permeability are shown in Table 1.
  • Table 1 shows the resin species and the concentration (unit: mass%) of the liquid composition used in the examples.
  • Test Example 2 Measurement of Core Loss and Rate of Change Thereof
  • a toroidal coil 10 was obtained by winding a copper wire on a dust core 1 produced according to the examples and reference examples.
  • the core loss (PCV) of the toroidal coil 10 was measured under the conditions of a frequency of 100 kHz and a maximum magnetic flux density of 100 mT using a BH analyzer ("SY-8218" manufactured by Iwasaki Communication Co., Ltd.). This core loss is called “initial core loss W 0 " (unit: kW / m 3 ).
  • the dust cores 1 produced according to the examples and comparative examples were allowed to stand in an environment of 250 ° C. for 200 hours, and core loss was measured for the dust cores 1 after standing as described above.
  • the core loss change rate RW (W 1- W 0 ) / W 0 ⁇ 100 The initial core loss W 0 and after heating core loss W 1 and core loss change rate RW shown in Table 1.
  • the green compact core 1 prepared according to the examples and reference examples is measured by a test method according to JIS Z 2507: 2000, and the initial radial crushing strength S 0 (unit: MPa Asked for).
  • the dust core 1 separately prepared according to the example and the comparative example is allowed to stand in an environment of 250 ° C. for 200 hours, and the dust core 1 after standing is measured by the test method according to JIS Z 2507: 2000, After heating, the radial crushing strength S 1 (unit: MPa) was determined.
  • the rate of change in radial crushing strength RS (unit:%) was determined by the following equation.
  • RS (S 1 -S 0 ) / S 0 ⁇ 100
  • the initial radial crushing strength S 0, the post-heating radial crushing strength S 1, and the rate of change RS of the radial crushing strength are shown in Table 1.
  • the dust core 1 according to the inventive example has a change rate of relative permeability of ⁇ even after being placed under an environment of 250 ° C. for 200 hours.
  • the core loss change rate was ⁇ 10% or less
  • the radial crushing strength was 15 MPa or more even after heating.
  • the reduction rate of relative permeability is 6% or less
  • the increase rate of core loss is 10% or less
  • at least one of the initial radial crushing strength and the post-heating radial crushing strength could not have particularly excellent properties with respect to both the magnetic properties and the mechanical strength, for at least one of 15 MPa or more.
  • the electronic component using the dust core of the present invention can be suitably used as a booster circuit of a hybrid car or the like, a reactor used for power generation or transformation equipment, a transformer, a choke coil or the like.
  • SYMBOLS 1 Powdered powder core 1A: Molded product 1B: Molded body MM: Soft magnetic powder BM: Binder component TDM: Thermal decomposition residue PR: Air gap CRM: Exterior coating material 10: Toroidal coil 2: Coated conductive wire 2a: Coil 2b, 2c: End 2d of the coated conductive wire 2, 2e: End 200 of the coil 2a: Spray dryer device 201: Rotor S: Slurry P: Granulated powder

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Abstract

This dust core 1, which is provided with a molded body 1B containing a soft magnetic powder MM and an exterior coat of the molded body 1B, and wherein the exterior coat contains at least one of a thermoplastic polyimide and a thermoplastic polyamide-imide, has excellent mechanical characteristics and is not susceptible to changes in the magnetic characteristics even if used in a high temperature environment. The exterior coat may have an impregnation structure. The present invention also provides: a method for producing this dust core; an electrical/electronic component which is provided with this dust core; and an electrical/electronic device which is equipped with this electrical/electronic component.

Description

圧粉コア、該圧粉コアの製造方法、該圧粉コアを備える電気・電子部品、および該電気・電子部品が実装された電気・電子機器Dust core, method of manufacturing the dust core, electric / electronic component provided with the dust core, and electric / electronic device on which the electric / electronic component is mounted
 本発明は、圧粉コア、該圧粉コアの製造方法、該圧粉コアを備える電気・電子部品、および該電気・電子部品が実装された電気・電子機器に関する。 The present invention relates to a dust core, a method of manufacturing the dust core, an electric / electronic component provided with the dust core, and an electric / electronic device on which the electric / electronic component is mounted.
 データセンターのサーバー内の電源回路、ハイブリッド自動車等の昇圧回路、発電、変電設備等の電気・電子機器には、リアクトル、トランス、チョークコイル等の電気・電子部品が用いられている。こうした電気・電子部品には、磁性部材として圧粉コアが使用される場合がある。かかる圧粉コアは、多数の軟磁性粉末を圧粉成形し、得られた成形製造物を熱処理して得られる成形体を備える。 Electrical and electronic components such as reactors, transformers, and choke coils are used in power circuits in servers of data centers, booster circuits for hybrid vehicles and the like, and electric and electronic devices such as power generation and transformation facilities. In such electric and electronic components, a dust core may be used as a magnetic member. The dust core comprises a compact obtained by compacting a large number of soft magnetic powders and heat treating the resulting shaped product.
 圧粉コアは上記のとおり軟磁性粉末の成形体を備えるため、機械的強度を高める観点から外装コートを備える場合がある。この点に関し、特許文献1には、軟磁性金属粉末を非磁性材料で結合したインダクタ用複合磁性材料であって、前記非磁性材料は、前記軟磁性金属粉末に添加混合された成形助剤と、前記軟磁性金属粉末・成形助剤成形体を熱処理した後に結合材として該軟磁性金属粉末・成形助剤成形体に含浸された含浸樹脂とを有し、前記含浸樹脂は大気圧下での熱硬化温度が180℃以上であることを特徴とする複合磁性材料が開示されている。 Since the dust core is provided with the soft magnetic powder compact as described above, the dust core may be provided with an outer coat from the viewpoint of enhancing the mechanical strength. In this regard, Patent Document 1 discloses a composite magnetic material for an inductor in which a soft magnetic metal powder is bonded with a nonmagnetic material, and the nonmagnetic material is a molding aid added to and mixed with the soft magnetic metal powder. After the heat treatment of the soft magnetic metal powder / molding aid molded body, the soft magnetic metal powder / impregnated resin impregnated in the molding aid molded body as a binder is impregnated with the impregnated resin under atmospheric pressure. There is disclosed a composite magnetic material characterized in that a thermosetting temperature is 180 ° C. or higher.
実用新案登録第3145832号公報Utility model registration 3145832 gazette
 上記の圧粉コアを有する電気・電子部品を備える電気・電子機器の使用環境は様々であって、外気温が高い、発熱部品の近傍に位置する、などの理由により、圧粉コアが100℃近い環境で使用される場合がある。このような高温の環境で使用されると、圧粉コアを構成する材料が熱変性することがある。材料の変性が圧粉コアの磁気特性、特にコアロスを変化させると、圧粉コアからの発熱量が増加して、圧粉コアの熱変性を助長してしまうこともある。このような高温環境下で使用されたことに基づく圧粉コアの磁気特性の変化は、圧粉コアを有する電気・電子部品の動作安定性に影響を与えることが懸念される。したがって、上記の高温環境下で使用されても、磁気特性が変化しにくい圧粉コアが求められている。また、上記の高温環境下で使用された場合に、圧粉コアの機械的強度が適切な範囲内に維持されることも求められている。 The use environment of the electric / electronic equipment provided with the electric / electronic parts having the above dust core is various, and the dust core is 100 ° C. because the outside air temperature is high, the dust core is located near the heat generation parts, It may be used in close environment. When used in such a high temperature environment, the material constituting the dust core may be thermally denatured. If the modification of the material changes the magnetic properties of the dust core, especially the core loss, the calorific value from the dust core may increase, which may promote the heat denaturation of the dust core. It is feared that the change in the magnetic properties of the dust core based on the use under such a high temperature environment may affect the operation stability of the electric / electronic component having the dust core. Therefore, there is a need for a dust core that is less likely to change in magnetic properties even when used under the above-described high temperature environment. There is also a need to maintain the mechanical strength of the dust core within an appropriate range when used under the above-mentioned high temperature environment.
 本発明は、高温環境下で使用されても磁気特性が変化しにくく、機械特性にも優れる圧粉コア、該圧粉コアの製造方法、該圧粉コアを備える電気・電子部品、および該電気・電子部品が実装された電気・電子機器を提供することを目的とする。 The present invention is a dust core having less change in magnetic properties and excellent mechanical properties even when used in a high temperature environment, a method for producing the dust core, an electric / electronic component comprising the dust core, and the electricity -It aims at providing the electric and electronic equipment in which electronic parts were mounted.
 上記課題を解決するために提供される本発明の一態様は、軟磁性粉末を含む成形体と、前記成形体の外装コートと、を備える圧粉コアであって、前記外装コートは、熱可塑性ポリイミドおよび熱可塑性ポリアミドイミドの少なくとも一方を含む熱可塑性樹脂を含有することを特徴とする圧粉コアである。 One aspect of the present invention provided to solve the above problems is a dust core comprising a molded body containing a soft magnetic powder, and an outer coat of the molded body, wherein the outer coat is thermoplastic It is a dust core characterized by containing the thermoplastic resin containing at least one of a polyimide and a thermoplastic polyamide imide.
 熱可塑性ポリイミドおよび熱可塑性ポリアミドイミドの少なくとも一方を含む熱可塑性樹脂を含有する外装コートを備える本発明に係る圧粉コアは、従来使用されていたシリコーン系の樹脂(特にメチルフェニルシリコーン樹脂)を含有する外装コートを備える圧粉コアに比べて、高温環境(具体的には250℃の環境)に長時間(具体的には100時間以上)置かれた場合であっても、磁気特性、特にコアロスが変化しにくい。しかも、高温環境下に長時間置かれた場合であっても、実用的な機械的強度を維持することが可能である。外装コートは含浸構造を有していることが好ましい。 A dust core according to the present invention provided with an outer coat containing a thermoplastic resin containing at least one of a thermoplastic polyimide and a thermoplastic polyamideimide contains a conventionally used silicone resin (especially methylphenylsilicone resin). Magnetic properties, especially core loss, even when placed in a high-temperature environment (specifically, an environment of 250 ° C.) for a long time (specifically, 100 hours or longer) as compared to a dust core having an outer coating Is hard to change. Moreover, it is possible to maintain practical mechanical strength even when placed in a high temperature environment for a long time. The outer coat preferably has an impregnated structure.
 上記の本発明に係る圧粉コアにおいて、前記軟磁性粉末は、鉄系材料およびニッケル系材料の少なくとも一方の粉末を含有していてもよい。 In the dust core according to the present invention, the soft magnetic powder may contain at least one powder of an iron-based material and a nickel-based material.
 上記の本発明に係る圧粉コアにおいて、前記軟磁性粉末は、結晶質磁性材料の粉末を含有してもよい。上記の本発明に係る圧粉コアにおいて、前記軟磁性粉末は、非晶質磁性材料の粉末を含有してもよい。上記の本発明に係る圧粉コアにおいて、前記軟磁性粉末は、ナノ結晶磁性材料の粉末を含有してもよい。また、前記軟磁性粉末は、前記結晶質磁性材料、前記非晶質磁性材料、前記ナノ結晶磁性材料より選ばれる2種以上を混合したものであっても良い。 In the dust core according to the present invention, the soft magnetic powder may contain a powder of a crystalline magnetic material. In the dust core according to the present invention, the soft magnetic powder may contain a powder of an amorphous magnetic material. In the dust core according to the present invention, the soft magnetic powder may contain a powder of a nanocrystal magnetic material. The soft magnetic powder may be a mixture of two or more selected from the crystalline magnetic material, the amorphous magnetic material, and the nanocrystal magnetic material.
 上記の本発明に係る圧粉コアにおいて、前記成形体は、前記軟磁性粉末と結着成分とを備え、前記結着成分は、樹脂系材料を含むバインダー成分の熱分解残渣からなるものであってもよい。本発明に係る圧粉コアが備える成形体が上記の熱分解残渣を備える場合には、成形体内部に空隙が生じやすい。一般に内部に空隙の多い成形体は成形体の機械的強度が不足しやすい。本発明に係る圧粉コアは、この空隙を埋めるように熱可塑性ポリイミドおよび熱可塑性ポリアミドイミドの少なくとも一方を含む熱可塑性樹脂が位置することができるため、成形体の機械的強度の補強が成される。また、外装コートが熱変性の少ない耐熱性の高い熱可塑性ポリイミドおよび熱可塑性ポリアミドイミドの少なくとも一方から成ることで、外装コート後の初期の磁気特性の向上を図ることができるとともに、外装コート材の熱変性に伴う高温環境下における磁気特性劣化が抑えられる。 In the dust core according to the present invention, the molded body comprises the soft magnetic powder and a binding component, and the binding component comprises a thermal decomposition residue of a binder component including a resin material. May be In the case where the compact provided in the dust core according to the present invention includes the above-described thermal decomposition residue, voids tend to be generated inside the compact. In general, a molded product having a large amount of voids inside tends to lack mechanical strength of the molded product. In the dust core according to the present invention, since the thermoplastic resin containing at least one of the thermoplastic polyimide and the thermoplastic polyamideimide can be positioned so as to fill the voids, the mechanical strength of the molded body is reinforced. Ru. In addition, since the outer coat is made of at least one of a highly heat resistant thermoplastic polyimide and a thermoplastic polyamide imide which is less thermally denatured, it is possible to improve the initial magnetic properties after the outer coat, and It is possible to suppress the deterioration of the magnetic properties under the high temperature environment accompanying the heat denaturation.
 本発明の他の一態様は、上記の本発明に係る圧粉コアの製造方法であって、前記軟磁性粉末と前記バインダー成分とを備える混合物の加圧成形を含む成形処理により成形製造物を得る成形工程、前記成形工程により得られた成形製造物を加熱して、前記軟磁性粉末と前記バインダー成分の熱分解残渣からなる結着成分とを備える前記成形体を得る熱処理工程、および熱可塑性ポリイミドおよび熱可塑性ポリアミドイミドの少なくとも一方を含む熱可塑性樹脂および溶剤を含む液状組成物を前記成形体と接触させ、前記成形体の表面を含む領域に前記液状組成物の塗膜を形成し、前記塗膜を乾燥させて溶剤を揮発させ、前記熱可塑性樹脂を含む外装コートを形成する外装コート工程を備えることを特徴とする圧粉コアの製造方法である。上記の方法によれば、バインダー成分の熱分解残渣からなる結着成分を含有する圧粉コアを効率的に製造することが可能である。 Another aspect of the present invention is a method for producing a dust core according to the present invention described above, which is a molded product obtained by a molding process including pressure molding of a mixture comprising the soft magnetic powder and the binder component. A forming step, a forming step obtained by the forming step is heated to obtain the forming body comprising the soft magnetic powder and a binding component comprising a thermal decomposition residue of the binder component, and a thermoplasticity, A liquid composition containing a thermoplastic resin containing at least one of a polyimide and a thermoplastic polyamideimide and a solvent is brought into contact with the molded product to form a coated film of the liquid composition in a region including the surface of the molded product, It is a manufacturing method of the dusting core characterized by providing an exterior coat process which dries a coat and volatilizes a solvent and forms an exterior coat containing the thermoplastic resin. According to the above method, it is possible to efficiently produce a dust core containing a binding component comprising thermal decomposition residue of a binder component.
 本発明の別の一態様は、上記の本発明に係る圧粉コア、コイルおよび前記コイルのそれぞれの端部に接続された接続端子を備える電気・電子部品であって、前記圧粉コアの少なくとも一部は、前記接続端子を介して前記コイルに電流を流したときに前記電流により生じた誘導磁界内に位置するように配置されていることを特徴とする電気・電子部品である。 Another aspect of the present invention is an electric / electronic component comprising a dust core according to the present invention, a coil, and a connection terminal connected to each end of the coil, wherein at least at least the dust core A part is an electric / electronic component characterized in being disposed so as to be located in an induced magnetic field generated by the current when a current is supplied to the coil through the connection terminal.
 本発明のまた別の一態様は、上記の本発明に係る電気・電子部品を備えることを特徴とする電気・電子機器である。 Another aspect of the present invention is an electric / electronic device comprising the electric / electronic component according to the above-mentioned present invention.
 本発明に係る圧粉コアは、高温環境(具体的には250℃の環境)に長時間(具体的には100時間以上)置かれた場合であっても、磁気特性、特にコアロスが変化しにくい。しかも、高温環境下に長時間置かれた場合であっても、実用的な機械的強度を維持することが可能である。したがって、本発明に係る圧粉コアは、高温環境下で使用されても磁気特性が変化しにくく、機械特性にも優れる。また、本発明によれば、上記の圧粉コアを備える電気・電子部品、および該電気・電子部品が実装された電気・電子機器が提供される。 In the dust core according to the present invention, even when it is left for a long time (specifically, 100 hours or more) in a high temperature environment (specifically, an environment of 250 ° C.), the magnetic characteristics, particularly core loss, changes. Hateful. Moreover, it is possible to maintain practical mechanical strength even when placed in a high temperature environment for a long time. Therefore, the dust core according to the present invention is hard to change the magnetic characteristics even when used under high temperature environment, and is excellent in mechanical characteristics. Further, according to the present invention, there are provided an electric / electronic component comprising the above dust core and an electric / electronic device on which the electric / electronic component is mounted.
本発明の一実施形態に係る圧粉コアの形状を概念的に示す斜視図である。It is a perspective view which shows notionally the shape of the dust core which concerns on one Embodiment of this invention. (a)本発明の一実施形態に係る圧粉コアを製造するための成形工程後、熱処理工程前の成形製造物の内部の模式図、(b)本発明の一実施形態に係る圧粉コアを製造するための熱処理工程後、外装コート工程前の成形体の内部の模式図、および(c)本発明の一実施形態に係る圧粉コアを製造するための外装コート工程後の圧粉コアの内部の模式図である。(A) A schematic view of the inside of a molded product before a heat treatment step after a forming step for producing a dust core according to an embodiment of the present invention, (b) a dust core according to an embodiment of the present invention A schematic view of the inside of a molded body before an outer coating step after a heat treatment step for producing a powder, and (c) a dust core after an outer coating step for manufacturing a powder core according to an embodiment of the present invention It is a schematic diagram of the inside of. 造粒粉を製造する方法の一例において使用されるスプレードライヤー装置およびその動作を概念的に示す図である。It is a figure which shows notionally the spray dryer apparatus used in one example of the method of manufacturing granulated powder, and its operation | movement. 本発明の一実施形態に係る圧粉コアを備える電子部品であるトロイダルコアの形状を概念的に示す斜視図である。It is a perspective view which shows notionally the shape of the toroidal core which is an electronic component provided with the dust core which concerns on one Embodiment of this invention.
 以下、本発明の実施形態について詳しく説明する。
1.圧粉コア
 図1に示す本発明の一実施形態に係る圧粉コア1は、その外観がリング状であって、軟磁性粉末を含む成形体と、成形体の外装コートと、を備える。本発明の一実施形態に係る圧粉コア1は、外装コートが熱可塑性ポリイミドおよび熱可塑性ポリアミドイミドの少なくとも一方を含む熱可塑性樹脂を含有する。限定されない一例として、軟磁性粉末を、圧粉コア1に含有される他の材料(同種の材料である場合もあれば、異種の材料である場合もある。)に対して結着させる結着成分を含有する。なお、圧粉コア1の外観はリング状に限定されず、例えばEE型、EI型、EER型、PQ型、I型、あるいはコイルを圧粉コアの内部に封入したもの等がある。
Hereinafter, embodiments of the present invention will be described in detail.
1. Dust core The dust core 1 according to the embodiment of the present invention shown in FIG. 1 has a ring-like appearance, and includes a molded body containing soft magnetic powder and an outer coat of the molded body. The dust core 1 according to an embodiment of the present invention contains a thermoplastic resin whose exterior coat contains at least one of a thermoplastic polyimide and a thermoplastic polyamideimide. As one non-limiting example, binding is performed to bind the soft magnetic powder to another material (which may be the same or different) contained in the dust core 1 Contains ingredients. The appearance of the dust core 1 is not limited to the ring shape, and there are, for example, EE type, EI type, EER type, PQ type, I type, or one in which a coil is sealed inside a dust core.
(1)成形体
(1-1)軟磁性粉末
 本発明の一実施形態に係る圧粉コア1の成形体が含む軟磁性粉末は、鉄を含有する鉄系材料およびニッケルを含有するニッケル系材料の少なくとも一方の粉末を含有していてもよい。
(1) Molded body (1-1) Soft magnetic powder The soft magnetic powder contained in the molded body of the dust core 1 according to one embodiment of the present invention is an iron-based material containing iron and a nickel-based material containing nickel It may contain at least one powder of
 本発明の一実施形態に係る圧粉コア1の成形体が含む軟磁性粉末は、結晶質磁性材料の粉末を含有してもよい。本明細書において、「結晶質磁性材料」とは、その組織が結晶質からなるものであって、強磁性体、特に軟磁性体である材料を意味する。本発明の一実施形態に係る圧粉コア1の成形体が含む軟磁性粉末は、結晶質磁性材料の粉末からなるものであってもよい。結晶質磁性材料の具体例として、Fe-Si-Cr系合金、Fe-Ni系合金、Ni-Fe系合金、Fe-Co系合金、Fe-V系合金、Fe-Al系合金、Fe-Si系合金、Fe-Si-Al系合金、カルボニル鉄および純鉄が挙げられる。 The soft magnetic powder contained in the compact of the dust core 1 according to an embodiment of the present invention may contain a powder of a crystalline magnetic material. In the present specification, "crystalline magnetic material" means a material whose structure is crystalline and which is ferromagnetic, particularly soft magnetic. The soft magnetic powder contained in the compact of the dust core 1 according to an embodiment of the present invention may be made of a powder of a crystalline magnetic material. Specific examples of crystalline magnetic materials include Fe-Si-Cr alloys, Fe-Ni alloys, Ni-Fe alloys, Fe-Co alloys, Fe-V alloys, Fe-Al alloys, Fe-Si And Fe-Si-Al alloys, carbonyl iron and pure iron.
 本発明の一実施形態に係る圧粉コア1の成形体が含む軟磁性粉末は、非晶質磁性材料の粉末を含有してもよい。本明細書において、「非晶質磁性材料」とは、組織中の非晶質の部分の体積が全体の50%超であって、強磁性体、特に軟磁性体である材料を意味する。本発明の一実施形態に係る圧粉コア1の成形体が含む軟磁性粉末は、非晶質磁性材料の粉末からなるものであってもよい。非晶質磁性材料の具体例として、Fe-Si-B系合金、Fe-P-C系合金およびCo-Fe-Si-B系合金が挙げられる。上記の非晶質磁性材料は1種類の材料から構成されていてもよいし複数種類の材料から構成されていてもよい。非晶質磁性材料の粉末を構成する磁性材料は、上記の材料からなる群から選ばれた1種または2種以上の材料であることが好ましく、これらの中でも、Fe-P-C系合金を含有することが好ましく、Fe-P-C系合金からなることがより好ましい。 The soft magnetic powder contained in the compact of the dust core 1 according to an embodiment of the present invention may contain a powder of an amorphous magnetic material. As used herein, "amorphous magnetic material" means a material that is a ferromagnetic material, in particular a soft magnetic material, in which the volume of the amorphous part in the tissue is more than 50% of the whole. The soft magnetic powder contained in the compact of the dust core 1 according to an embodiment of the present invention may be made of powder of an amorphous magnetic material. Specific examples of the amorphous magnetic material include Fe-Si-B alloys, Fe-PC alloys and Co-Fe-Si-B alloys. The above amorphous magnetic material may be composed of one kind of material or may be composed of plural kinds of materials. The magnetic material constituting the powder of the amorphous magnetic material is preferably one or two or more materials selected from the group consisting of the above-mentioned materials, and among these, Fe—PC based alloys are preferred. It is preferable to contain, and it is more preferable to consist of a Fe-PC type | system | group alloy.
 なお、上記非晶質磁性材料のFe-P-C系合金の具体例として、組成式が、Fe100at%-a-b-c-x-y-z-tNiaSnbCrcxyzSitで示され、0at%≦a≦10at%
、0at%≦b≦3at%、0at%≦c≦6at%、6.8at%≦x≦13.0at%、2.2at%≦y≦13.0at%、0at%≦z≦9.0at%、0at%≦t≦7at%であるFe基非晶質合金が挙げられる。上記の組成式において、Ni,Sn,Cr,BおよびSiは任意添加元素である。
In addition, as a specific example of the Fe- PC based alloy of the above-mentioned amorphous magnetic material, the composition formula is represented by Fe 100 at%-abcxy xt Ni a Sn b Cr c P x C y B z Si t , 0 at% ≦ a ≦ 10 at%
0 at% ≦ b ≦ 3 at%, 0 at% ≦ c ≦ 6 at%, 6.8 at% ≦ x ≦ 13.0 at%, 2.2 at% ≦ y ≦ 13.0 at%, 0 at% ≦ z ≦ 9.0 at% And Fe-based amorphous alloys in which 0 at% ≦ t ≦ 7 at% are included. In the above composition formula, Ni, Sn, Cr, B and Si are optional additional elements.
 Niの添加量aは、0at%以上7at%以下とすることが好ましく、4at%以上6.5at%以下とすることがより好ましい。Snの添加量bは、0at%以上2at%以下とすることが好ましく、0at%以上1at%以下とすることがより好ましい。Crの添加量cは、0at%以上2.5at%以下とすることが好ましく、1.5at%以上2.5at%以下とすることがより好ましい。Pの添加量xは、8.8at%以上とすることが好ましい場合もある。Cの添加量yは、2.2at%以上9.8at%以下とすることが好ましい場合もある。Bの添加量zは、0at%以上8.0at%以下とすることが好ましく、0at%以上2at%以下とすることがより好ましい。Siの添加量tは、0at%以上6at%以下とすることが好ましく、0at%以上2at%以下とすることがより好ましい。 The addition amount a of Ni is preferably 0 at% or more and 7 at% or less, and more preferably 4 at% or more and 6.5 at% or less. The addition amount b of Sn is preferably 0 at% or more and 2 at% or less, and more preferably 0 at% or more and 1 at% or less. The addition amount c of Cr is preferably 0 at% or more and 2.5 at% or less, and more preferably 1.5 at% or more and 2.5 at% or less. In some cases, it is preferable to set the addition amount x of P to 8.8 at% or more. In some cases, it is preferable to set the addition amount y of C to 2.2 at% or more and 9.8 at% or less. The addition amount z of B is preferably 0 at% or more and 8.0 at% or less, and more preferably 0 at% or more and 2 at% or less. The addition amount t of Si is preferably 0 at% or more and 6 at% or less, and more preferably 0 at% or more and 2 at% or less.
 本発明の一実施形態に係る圧粉コア1の成形体が含む軟磁性粉末は、ナノ結晶磁性材料の粉末を含有してもよい。本明細書において、「ナノ結晶磁性材料」とは、平均結晶粒径が数nm~数十nmの結晶粒が組織の少なくとも50%を超える部分に均一に析出してなるナノ結晶組織を有し、強磁性体、特に軟磁性体である材料を意味する。ナノ結晶磁性材料は、ナノ結晶粒以外の組織が非晶質であってもよいし、全てがナノ結晶組織であってもよい。本発明の一実施形態に係る圧粉コア1の成形体が含む軟磁性粉末は、ナノ結晶磁性材料の粉末からなるものであってもよい。ナノ結晶磁性材料の具体例としてFe-Cu-M(ここで、Mは、Nb、Zr、Ti、V、Mo、Hf、Ta、Wより選ばれる1種または2種以上の金属元素)-Si-B系合金、Fe-M-B系合金、Fe-Cu-M-B系合金等が挙げられる。 The soft magnetic powder contained in the compact of the dust core 1 according to an embodiment of the present invention may contain a powder of a nanocrystalline magnetic material. In the present specification, "nanocrystalline magnetic material" has a nanocrystalline structure in which crystal grains having an average crystal grain size of several nm to several tens of nm are uniformly deposited in at least 50% of the structure. , A ferromagnetic material, in particular a soft magnetic material. In the nanocrystalline magnetic material, the structure other than the nanocrystalline particles may be amorphous or all may be a nanocrystalline structure. The soft magnetic powder contained in the compact of the dust core 1 according to an embodiment of the present invention may be made of a powder of a nanocrystalline magnetic material. Fe-Cu-M (here, M is one or more metal elements selected from Nb, Zr, Ti, V, Mo, Hf, Ta, W) as a specific example of the nanocrystal magnetic material-Si -B-based alloy, Fe-M-B-based alloy, Fe-Cu-M-B-based alloy, etc. may be mentioned.
 本発明の一実施形態に係る圧粉コア1の成形体が含む軟磁性粉末は、1種類の粉末から構成されていてもよいし、複数種類の混合体であってもよい。この混合体の具体例として、結晶質磁性材料、非晶質磁性材料、ナノ結晶磁性材料のうちの2種以上を混合したものが挙げられる。さらに具体的には、例えば、本発明の一実施形態に係る圧粉コア1の成形体が含む軟磁性粉末は、結晶質磁性材料の粉末と非晶質磁性材料の粉末との混合体であってもよいし、非晶質磁性材料の粉末であって、その一部がナノ結晶磁性材料の粉末であってもよい。 The soft magnetic powder contained in the compact of the dust core 1 according to an embodiment of the present invention may be composed of one type of powder or may be a mixture of a plurality of types. Specific examples of this mixture include a mixture of two or more of a crystalline magnetic material, an amorphous magnetic material, and a nanocrystalline magnetic material. More specifically, for example, the soft magnetic powder contained in the compact of the dust core 1 according to one embodiment of the present invention is a mixture of a powder of crystalline magnetic material and a powder of amorphous magnetic material. It may be a powder of an amorphous magnetic material, and part of it may be a powder of a nanocrystalline magnetic material.
 本発明の一実施形態に係る圧粉コア1が含有する軟磁性粉末の形状は限定されない。軟磁性粉末の形状は球状であってもよいし非球状であってもよい。非球状である場合には、鱗片状、楕円球状、液滴状、針状といった形状異方性を有する形状であってもよいし、特段の形状異方性を有しない不定形であってもよい。不定形の軟磁性粉末の例として、球状の軟磁性粉末の複数が、互いに接して結合していたり、他の軟磁性粉末に部分的に埋没するように結合していたりする場合が挙げられる。このような不定形の軟磁性粉末は、軟磁性粉末がカルボニル鉄の粉末である場合に観察されやすい。 The shape of the soft magnetic powder contained in the dust core 1 according to an embodiment of the present invention is not limited. The shape of the soft magnetic powder may be spherical or non-spherical. In the case of non-spherical shape, it may be a shape having shape anisotropy such as scaly shape, elliptical spherical shape, droplet shape, needle shape, or even an irregular shape having no particular shape anisotropy. Good. As an example of the amorphous soft magnetic powder, a plurality of spherical soft magnetic powders may be bonded in contact with each other or may be bonded so as to be partially embedded in another soft magnetic powder. Such amorphous soft magnetic powder is likely to be observed when the soft magnetic powder is a powder of carbonyl iron.
 軟磁性粉末の形状は、軟磁性粉末を製造する段階で得られた形状であってもよいし、製造された軟磁性粉末を二次加工することにより得られた形状であってもよい。前者の形状としては、球状、楕円球状、液滴状、針状などが例示され、後者の形状としては、鱗片状が例示される。 The shape of the soft magnetic powder may be a shape obtained at the stage of manufacturing the soft magnetic powder, or may be a shape obtained by subjecting the manufactured soft magnetic powder to secondary processing. Examples of the shape of the former include a sphere, an oval sphere, a droplet, a needle, and the like, and examples of the shape of the latter include a scale.
 本発明の一実施形態に係る圧粉コア1が含有する軟磁性粉末の粒径は限定されない。かかる粒径を、メジアン径D50(レーザ回折散乱法により測定された軟磁性粉末の粒径の体積分布における体積累積値が50%のときの粒径)により規定すれば、通常、1μmから45μmの範囲とされる。取り扱い性を高める観点、圧粉コア1の成形体における軟磁性粉末の充填密度を高める観点などから、軟磁性粉末のメジアン径D50は、2μm以上30μm以下とすることが好ましく、3μm以上15μm以下とすることがより好ましく、4μm以上13μm以下とすることが特に好ましい。 The particle size of the soft magnetic powder contained in the dust core 1 according to an embodiment of the present invention is not limited. If this particle size is defined by the median diameter D50 (the particle size when the volume cumulative value in the volume distribution of the particle size of the soft magnetic powder measured by laser diffraction scattering method is 50%), it is usually 1 μm to 45 μm. It is considered a range. From the viewpoint of enhancing the handleability, and the viewpoint of enhancing the packing density of the soft magnetic powder in the compact of the dust core 1, the median diameter D50 of the soft magnetic powder is preferably 2 μm to 30 μm, and preferably 3 μm to 15 μm. It is more preferable to do, and it is especially preferable to set it as 4 micrometers or more and 13 micrometers or less.
(1-2)結着成分
 結着成分は、本発明の一実施形態に係る圧粉コア1に含有される軟磁性粉末を固定することに寄与する材料である限り、その組成は限定されない。結着成分を構成する材料として、樹脂材料および樹脂材料の熱分解残渣(本明細書において、これらを「樹脂材料に基づく成分」と総称する。)等の有機系の材料、無機系の材料などが例示される。樹脂材料として、アクリル樹脂、シリコーン樹脂、エポキシ樹脂、フェノール樹脂、尿素樹脂、メラミン樹脂などが例示される。無機系の材料からなる結着成分は水ガラスなどガラス系材料が例示される。結着成分は一種類の材料から構成されていてもよいし、複数の材料から構成されていてもよい。結着成分は有機系の材料と無機系の材料との混合体であってもよい。
(1-2) Binding Component The composition of the binding component is not limited as long as it is a material that contributes to fixing the soft magnetic powder contained in the dust core 1 according to an embodiment of the present invention. Organic materials such as thermal decomposition residues of resin materials and resin materials (these are generically referred to as "components based on resin materials" in the present specification), inorganic materials, etc. as materials constituting the binding component Is illustrated. Examples of the resin material include acrylic resin, silicone resin, epoxy resin, phenol resin, urea resin, and melamine resin. The binding component made of an inorganic material is exemplified by a glass-based material such as water glass. The binding component may be composed of one type of material or may be composed of a plurality of materials. The binding component may be a mixture of an organic material and an inorganic material.
 結着成分として、通常、絶縁性の材料が使用される。これにより、圧粉コア1としての絶縁性を高めることが可能となる。 Usually, an insulating material is used as the binding component. Thereby, it becomes possible to improve the insulation as the dust core 1.
 本発明の一実施形態に係る圧粉コア1の成形体は、具体的な一例として、軟磁性粉末とバインダー成分とを含む混合物の加圧成形を含む成形処理を備える製造方法により製造されたものである。本明細書において、「バインダー成分」とは結着成分を与える成分であって、バインダー成分は、結着成分からなる場合もあれば、結着成分と異なる材料である場合もある。 The molded article of the dust core 1 according to an embodiment of the present invention is manufactured by a manufacturing method including a molding process including pressure molding of a mixture containing a soft magnetic powder and a binder component as a specific example. It is. In the present specification, the “binder component” is a component that provides a binding component, and the binder component may be a binding component or a material different from the binding component.
 バインダー成分が結着成分と異なる場合の具体例として、本発明の一実施形態に係る圧粉コア1の成形体が備える結着成分が、樹脂系材料を含むバインダー成分の熱分解残渣からなる場合が挙げられる。この熱分解残渣の生成にあたり、バインダー成分の一部は分解・揮発する。このため、圧粉コア1が備える成形体が上記の熱分解残渣を備える場合には、成形体内に、具体的には、成形体における最近位に位置する軟磁性粉末同士の間に空隙が生じる場合がある。 As a specific example in the case where the binder component is different from the binding component, the binding component included in the compact of the dust core 1 according to an embodiment of the present invention is composed of the thermal decomposition residue of the binder component containing the resin material Can be mentioned. In forming the thermal decomposition residue, a part of the binder component is decomposed and volatilized. For this reason, when the compact provided in the dust core 1 is provided with the above-described thermal decomposition residue, a void is generated in the compact, specifically, between soft magnetic powders positioned closest to each other in the compact. There is a case.
 この点を図2を用いて説明する。図2(a)は本発明の一実施形態に係る圧粉コアを製造するための成形工程後、熱処理工程前の成形製造物の内部の模式図であり、図2(b)は本発明の一実施形態に係る圧粉コアを製造するための熱処理工程後であり、図2(c)は本発明の一実施形態に係る圧粉コアを製造するための外装コート工程後の圧粉コアの内部の模式図である。図2(a)に示されるように、成形工程を経て得られた成形製造物1Aにおいて、軟磁性粉末MMは樹脂系材料を含むバインダー成分BMによって結着・固定されている。この成形製造物1Aに対して熱処理工程を行うと、図2(b)に示されるように、バインダー成分BMの分解・揮発によって熱分解残渣TDMが生成し、成形体1Bの軟磁性粉末MMは熱分解残渣TDMによって結着・固定される。このため、成形体1Bでは、成形製造物1Aに比べて、空隙PRの体積が増加する。 This point will be described with reference to FIG. Fig.2 (a) is a schematic diagram of the inside of the shaping | molding product before a heat treatment process after the shaping | molding process for manufacturing the powder-powder core which concerns on one Embodiment of this invention, FIG.2 (b) is a It is after the heat treatment process for producing the dust core according to one embodiment, and FIG. 2 (c) is the dust core after the outer coating process for producing the dust core according to one embodiment of the present invention. It is a schematic diagram of an inside. As shown in FIG. 2A, in the molded product 1A obtained through the molding process, the soft magnetic powder MM is bound and fixed by the binder component BM containing a resin-based material. When this molded product 1A is subjected to a heat treatment step, as shown in FIG. 2 (b), a thermal decomposition residue TDM is generated by the decomposition and volatilization of the binder component BM, and the soft magnetic powder MM of the molded body 1B is It is bound and fixed by the thermal decomposition residue TDM. For this reason, in the molded body 1B, the volume of the space PR is increased as compared with the molded product 1A.
 このような場合であっても、成形体1Bに対して外装コート工程を含む工程を行うことにより製造される本発明に係る圧粉コア1では、図2(c)に示されるように、この空隙PRの少なくとも一部を埋めるように熱可塑性ポリイミドおよび熱可塑性ポリアミドイミドの少なくとも一方を含む熱可塑性樹脂を含有する外装コートを構成する材料(外装コート材)CRMが位置することができる。このため、圧粉コア1では、空隙PRの体積が少なくなるとともに軟磁性粉末MMは熱分解残渣TDMおよび外装コート材CRMによって結着・固定され、機械的強度の補強が成される。また、外装コート材CRMがコーティング後に熱硬化の必要が無い熱可塑性ポリイミドおよび熱可塑性ポリアミドイミドの少なくとも一方を含む熱可塑性樹脂を用いているため、外装コート後の熱硬化による応力が圧粉コア1に付与されない。このため、外装コート工程により得られた圧粉コア1の磁気特性が維持もしくは向上する。また、外装コート材CRMが熱変性の少ない、熱可塑性ポリアミドイミドの少なくとも一方を含む熱可塑性樹脂を用いているため、圧粉コア1が高温環境下に置かれても、外装コート材CRMの熱変性に由来する圧粉コア1の磁気特性の劣化が抑制される。 Even in such a case, in the dust core 1 according to the present invention manufactured by performing the step including the outer coating step on the molded body 1B, as shown in FIG. A material (outer coat material) CRM that constitutes an outer coat containing a thermoplastic resin containing at least one of a thermoplastic polyimide and a thermoplastic polyamideimide can be positioned so as to fill at least a part of the void PR. Therefore, in the dust core 1, the volume of the space PR is reduced, and the soft magnetic powder MM is bound and fixed by the thermal decomposition residue TDM and the outer coating material CRM, thereby reinforcing the mechanical strength. In addition, since the exterior coating material CRM uses a thermoplastic resin containing at least one of a thermoplastic polyimide and a thermoplastic polyamideimide which does not need to be thermally cured after coating, the stress due to the thermal curing after the exterior coating is a dust core 1 Not granted. For this reason, the magnetic characteristics of the dust core 1 obtained by the exterior coating step are maintained or improved. In addition, since the exterior coating material CRM uses a thermoplastic resin containing at least one of thermoplastic polyamideimides which is less thermally denatured, the heat of the exterior coating material CRM is obtained even if the dust core 1 is placed in a high temperature environment. Deterioration of the magnetic property of dust core 1 originating in denaturation is suppressed.
(2)外装コート
 本発明の一実施形態に係る圧粉コア1は、外装コートを備える。外装コートは、成形体1Bの機械的強度の向上などを目的として、成形体1Bの少なくとも一部を覆うように設けられる層である。成形体1Bは、軟磁性粉末MMを含む混合物を加圧成形することを含んで形成されるものであるから、その表面は、軟磁性粉末に由来する凹凸を有している場合がある。また、混合物がバインダー成分BMを含む場合であって、成形体1Bがバインダー成分BMの熱分解残渣TDMを含む場合には、上記のように、成形体は空隙PRを有することがある。こうした場合には、図2(c)に示されるように、外装コート材CRMは、成形体1Bの表面のみならず、表面からある程度内部に入った領域まで存在していてもよい。すなわち、本発明の一実施形態に係る圧粉コア1において、外装コートは成形体1Bに対して含浸構造を有していることが好ましい。
(2) Exterior Coating The dust core 1 according to the embodiment of the present invention includes an exterior coating. The outer coat is a layer provided to cover at least a part of the molded body 1B for the purpose of improving the mechanical strength of the molded body 1B and the like. Since the molded body 1B is formed by press-molding a mixture containing the soft magnetic powder MM, the surface thereof may have asperities derived from the soft magnetic powder. In the case where the mixture contains the binder component BM, and the molded body 1B contains the thermal decomposition residue TDM of the binder component BM, as described above, the molded body may have the void PR. In such a case, as shown in FIG. 2 (c), the outer coating material CRM may be present not only on the surface of the molded body 1B, but also on a region which has entered the surface to a certain extent. That is, in the dust core 1 according to one embodiment of the present invention, the exterior coat preferably has an impregnated structure with respect to the molded body 1B.
 本発明の一実施形態に係る圧粉コア1が備える外装コートは、熱可塑性ポリイミドおよび熱可塑性ポリアミドイミドの少なくとも一方を含む熱可塑性樹脂を含有する。かかる外装コートの限定されない製造方法の一例は次のとおりである。まず、熱可塑性ポリイミドおよび熱可塑性ポリアミドイミドの少なくとも一方を含む熱可塑性樹脂(以下の説明では、「熱可塑性樹脂」と略記する。)および溶剤を含む液状組成物を調製する。液状組成物における熱可塑性樹脂の濃度は限定されないが、調製のしやすさ(熱可塑性樹脂の溶解しやすさ)、取り扱い性(粘度)および成形体1Bに形成される塗膜厚さを適切な範囲にすることを考慮すると、液状組成物における熱可塑性樹脂の濃度は、1質量%以上40質量%以下とすることが好ましく、5質量%以上20質量%以下とすることがより好ましい。溶剤の種類は、熱可塑性樹脂を溶解できる限り、任意である。N-メチルピロリドン、メチルエチルケトン、酢酸ブチル等の非プロトン性極性溶剤とキシレン、トルエン等の芳香族系溶剤との混合溶剤が好ましい場合がある。液状組成物は、本発明の目的を達成できる限り、熱可塑性樹脂以外の樹脂やフィラーを含有していてもよい。以下の説明では、液状組成物が固形分として熱可塑性樹脂として熱可塑性ポリイミドまたは熱可塑性ポリアミドイミドのみを含有する場合を具体例とする。 The exterior coat with which the dust core 1 according to an embodiment of the present invention is provided contains a thermoplastic resin containing at least one of a thermoplastic polyimide and a thermoplastic polyamideimide. An example of a non-limiting method for producing such an outer coat is as follows. First, a liquid composition containing a thermoplastic resin (abbreviated as "thermoplastic resin" in the following description) containing at least one of a thermoplastic polyimide and a thermoplastic polyamideimide and a solvent is prepared. The concentration of the thermoplastic resin in the liquid composition is not limited, but the ease of preparation (the ease of dissolution of the thermoplastic resin), the handleability (viscosity), and the thickness of the coating formed on the molded body 1B are suitable. Considering the range, the concentration of the thermoplastic resin in the liquid composition is preferably 1% by mass or more and 40% by mass or less, and more preferably 5% by mass or more and 20% by mass or less. The type of solvent is arbitrary as long as it can dissolve the thermoplastic resin. In some cases, a mixed solvent of an aprotic polar solvent such as N-methylpyrrolidone, methyl ethyl ketone or butyl acetate and an aromatic solvent such as xylene or toluene may be preferable. The liquid composition may contain a resin or filler other than the thermoplastic resin as long as the object of the present invention can be achieved. In the following description, the case where the liquid composition contains only a thermoplastic polyimide or a thermoplastic polyamideimide as a thermoplastic resin as a solid content will be described as a specific example.
 次に、調製した液状組成物と上記の成形体1Bと接触させ、成形体1Bの表面を含む領域に液状組成物の塗膜を形成する。接触方法は任意である。最も簡易的には、液状組成物中に所定時間(例えば5分間から30分間)成形体1Bを浸漬させればよい。あるいは、液状組成物を成形体1Bに噴霧してもよい。液状組成物と成形体1Bとを接触させる際の雰囲気を減圧にしてもよい。液状組成物の塗布量や接触によって形成される塗膜の厚さは任意である。上記のように成形体1Bは空隙PRを有するため、減圧雰囲気において接触させたり、液状組成物の粘度を低下させたりすることにより、液状組成物が成形体1Bの内部に含浸しやすくなる。 Next, the prepared liquid composition is brought into contact with the above-mentioned molded body 1B to form a coating film of the liquid composition in a region including the surface of the molded body 1B. The contact method is optional. Most simply, the molded body 1B may be immersed in the liquid composition for a predetermined time (for example, 5 minutes to 30 minutes). Alternatively, the liquid composition may be sprayed onto the molded body 1B. The atmosphere at the time of bringing the liquid composition and the molded body 1B into contact with each other may be reduced in pressure. The coating amount of the liquid composition and the thickness of the coating film formed by contact are arbitrary. As described above, since the formed body 1B has the space PR, the liquid composition can be easily impregnated into the inside of the formed body 1B by contacting in a reduced pressure atmosphere or reducing the viscosity of the liquid composition.
 続いて、成形体1Bに形成された塗膜を乾燥させて溶剤を揮発させる。乾燥温度および時間は溶剤の種類に応じて適宜設定される。限定されない例示を行えば、60℃~170℃で、20分から5時間程度である。段階的な加熱を行うことが好ましい場合がある。 Subsequently, the coating film formed on the molded body 1B is dried to evaporate the solvent. The drying temperature and time are appropriately set according to the type of solvent. By way of non-limiting illustration, it is from 60 ° C. to 170 ° C. for about 20 minutes to 5 hours. It may be preferable to carry out stepwise heating.
 本発明の一実施形態に係る圧粉コア1が備える外装コートは、熱可塑性樹脂を含み、好ましい一形態では熱可塑性樹脂からなるため、圧粉コア1が250℃の環境下に置かれた場合であっても、磁気特性の変化が生じにくい。具体的には、上記の環境下に200時間置かれた場合のコアロスの上昇率を10%以下とすることが可能である。また、上記の環境下に200時間置かれた場合の比透磁率の低下率を6%以下とすること(変化率を-6%以上とすること)が可能である。 When the dust core 1 is placed in an environment of 250 ° C., the exterior coat provided in the dust core 1 according to an embodiment of the present invention contains a thermoplastic resin and, in a preferable embodiment, is made of a thermoplastic resin. Even if it is, it is hard to produce change of a magnetic characteristic. Specifically, it is possible to make the increase rate of the core loss at 10% or less when left under the above environment for 200 hours. In addition, it is possible to set the reduction rate of the relative magnetic permeability to 6% or less (set the change rate to -6% or more) when the above-described environment is left for 200 hours.
 本発明の一実施形態に係る圧粉コア1が備える外装コートは、熱可塑性樹脂を含み、好ましい一形態では熱可塑性樹脂からなるため、圧粉コア1が250℃の環境下に置かれた場合であっても、機械的強度の低下が生じにくい。具体的には、初期の圧環強度を15MPa以上とするとともに、上記の環境下に200時間置かれた場合であっても圧環強度を15MPa以上とすることが可能である。 When the dust core 1 is placed in an environment of 250 ° C., the exterior coat provided in the dust core 1 according to an embodiment of the present invention contains a thermoplastic resin and, in a preferable embodiment, is made of a thermoplastic resin. Even if it is, it is hard to produce the fall of mechanical strength. Specifically, it is possible to set the initial radial crushing strength to 15 MPa or more, and to set the radial crushing strength to 15 MPa or more even when being placed in the above environment for 200 hours.
(3)圧粉コアの製造方法
 上記の本発明の一実施形態に係る圧粉コア1の製造方法は特に限定されないが、次に説明する製造方法を採用すれば、圧粉コア1をより効率的に製造することが実現される。
(3) Method of Producing Powder Core Although the method of producing the powder core 1 according to the embodiment of the present invention is not particularly limited, the powder core 1 can be made more efficient if the production method described below is adopted. Manufacturing is realized.
 本発明の一実施形態に係る圧粉コア1の製造方法は、次に説明する、成形工程および外装コート工程を備え、さらに熱処理工程を備えていてもよい。 The method for producing the dust core 1 according to an embodiment of the present invention may include a forming step and an outer coating step described below, and may further include a heat treatment step.
(3-1)成形工程
 まず、軟磁性粉末およびバインダー成分を含む混合物を用意する。この混合物の加圧成形を含む成形処理により成形製造物1Aを得ることができる。加圧条件は限定されず、バインダー成分の組成などに基づき適宜決定される。例えば、バインダー成分が熱硬化性の樹脂からなる場合には、加圧とともに加熱して、金型内で樹脂の硬化反応を進行させることが好ましい。一方、圧縮成形の場合には、加圧力が高いものの、加熱は必要条件とならず、短時間の加圧となる。
(3-1) Forming Step First, a mixture containing soft magnetic powder and a binder component is prepared. The formed product 1A can be obtained by the forming process including the pressure forming of the mixture. The pressure condition is not limited, and is appropriately determined based on the composition of the binder component and the like. For example, in the case where the binder component is made of a thermosetting resin, it is preferable to heat with pressure to advance the curing reaction of the resin in the mold. On the other hand, in the case of compression molding, although the pressing force is high, heating is not a necessary condition, and it becomes pressing for a short time.
 以下、混合物が造粒粉であって、圧縮成形を行う場合について、やや詳しく説明する。造粒粉は取り扱い性に優れるため、成形時間が短く生産性に優れる圧縮成形工程の作業性を向上させることができる。 Hereinafter, the case where the mixture is granulated powder and compression molding is to be described in some detail. Since the granulated powder is excellent in handleability, it is possible to improve the workability of the compression molding process, which has a short molding time and excellent productivity.
(3-1-1)造粒粉
 造粒粉は、軟磁性粉末およびバインダー成分を含有する。造粒粉におけるバインダー成分の含有量は特に限定されない。かかる含有量が過度に低い場合には、バインダー成分が軟磁性粉末を保持しにくくなる。また、バインダー成分の含有量が過度に低い場合には、熱処理工程を経て得られた圧粉コア1中で、バインダー成分の熱分解残渣からなる結着成分が、複数の軟磁性粉末を互いに他から絶縁しにくくなる。一方、上記のバインダー成分の含有量が過度に高い場合には、熱処理工程を経て得られた圧粉コア1に含有される結着成分の含有量が高くなりやすい。圧粉コア1中の結着成分の含有量が高くなると、軟磁性粉末が結着成分から受ける応力の影響により圧粉コア1の磁気特性が低下しやすくなる。また、バインダー成分の含有量が過度に高い場合には、圧粉コア1の軟磁性粉末の空間充填率が低下し、圧粉コア1の磁気特性が低下しやすくなる。それゆえ、造粒粉中のバインダー成分の含有量は、造粒粉全体に対して、0.5質量%以上5.0質量%以下となる量にすることが好ましい。圧粉コア1の磁気特性が低下する可能性をより安定的に低減させる観点から、造粒粉中のバインダー成分の含有量は、造粒粉全体に対して、0.5質量%以上3.5質量%以下となる量にすることが好ましく、0.6質量%以上3.0質量%以下となる量にすることがより好ましい。
(3-1-1) Granulated Powder The granulated powder contains a soft magnetic powder and a binder component. The content of the binder component in the granulated powder is not particularly limited. When the content is excessively low, the binder component hardly holds the soft magnetic powder. Further, when the content of the binder component is excessively low, in the green compact core 1 obtained through the heat treatment step, the binding component consisting of the thermal decomposition residue of the binder component is composed of a plurality of soft magnetic powders It is difficult to insulate from On the other hand, when the content of the binder component is excessively high, the content of the binding component contained in the dust core 1 obtained through the heat treatment step tends to be high. When the content of the binding component in the dust core 1 becomes high, the magnetic properties of the dust core 1 are likely to be deteriorated due to the influence of the stress that the soft magnetic powder receives from the binding component. In addition, when the content of the binder component is excessively high, the space filling factor of the soft magnetic powder of the dust core 1 is lowered, and the magnetic properties of the dust core 1 are easily deteriorated. So, it is preferable to make content of the binder component in granulated powder into the quantity which will be 0.5 mass% or more and 5.0 mass% or less with respect to the whole granulated powder. From the viewpoint of more stably reducing the possibility of lowering the magnetic properties of the dust core 1, the content of the binder component in the granulated powder is 0.5% by mass or more with respect to the whole granulated powder. The amount is preferably 5% by mass or less, and more preferably 0.6% by mass or more and 3.0% by mass or less.
 造粒粉は、上記の軟磁性粉末およびバインダー成分以外の材料を含有してもよい。そのような材料として、潤滑剤、シランカップリング剤、絶縁性のフィラーなどが例示される。潤滑剤を含有させる場合において、その種類は特に限定されない。有機系の潤滑剤であってもよいし、無機系の潤滑剤であってもよい。有機系の潤滑剤の具体例として、ステアリン酸亜鉛、ステアリン酸アルミニウムなどの金属石鹸が挙げられる。こうした有機系の潤滑剤は、熱処理工程において気化し、圧粉コア1にはほとんど残留していないと考えられる。 Granulated powder may contain materials other than the above-mentioned soft magnetic powder and binder component. As such a material, a lubricant, a silane coupling agent, an insulating filler and the like are exemplified. When the lubricant is contained, its type is not particularly limited. It may be an organic lubricant or an inorganic lubricant. Specific examples of organic lubricants include metal soaps such as zinc stearate and aluminum stearate. It is considered that such an organic lubricant evaporates in the heat treatment step and hardly remains in the dust core 1.
 造粒粉の製造方法は特に限定されない。上記の造粒粉を与える成分をそのまま混錬し、得られた混練物を公知の方法で粉砕するなどして造粒粉を得てもよいし、上記の成分に溶剤(溶媒・分散媒、水が一例として挙げられる。)を添加してなるスラリーを調製し、このスラリーを乾燥させて粉砕することにより造粒粉を得てもよい。粉砕後にふるい分けや分級を行って、造粒粉の粒度分布を制御してもよい。 The method for producing granulated powder is not particularly limited. The ingredients to give the above-mentioned granulated powder may be mixed as it is, and the obtained kneaded product may be ground by a known method to obtain granulated powder, or the above components may be mixed with a solvent (solvent, dispersion medium, Granulated powder may be obtained by preparing a slurry formed by adding water, for example, and drying and grinding this slurry. After crushing, sieving or classification may be performed to control the particle size distribution of the granulated powder.
 上記のスラリーから造粒粉を得る方法の一例として、スプレードライヤーを用いる方法が挙げられる。図2に示されるように、スプレードライヤー装置200内には回転子201が設けられ、装置上部からスラリーSを回転子201に向けて注入する。回転子201は所定の回転数により回転しており、スプレードライヤー装置200内部のチャンバーにてスラリーSを遠心力により小滴状として噴霧する。さらにスプレードライヤー装置200内部のチャンバーに熱風を導入し、これにより小滴状のスラリーSに含有される分散媒(水)を、小滴形状を維持したまま揮発させる。その結果、スラリーSから造粒粉Pが形成される。この造粒粉Pをスプレードライヤー装置200の下部から回収する。 As an example of a method of obtaining granulated powder from said slurry, the method of using a spray dryer is mentioned. As shown in FIG. 2, a rotor 201 is provided in the spray dryer apparatus 200, and the slurry S is injected toward the rotor 201 from the top of the apparatus. The rotor 201 is rotated at a predetermined rotation speed, and the slurry S is sprayed in the form of droplets by centrifugal force in a chamber inside the spray drier apparatus 200. Furthermore, hot air is introduced into a chamber inside the spray dryer apparatus 200, whereby the dispersion medium (water) contained in the droplet slurry S is volatilized while maintaining the droplet shape. As a result, granulated powder P is formed from slurry S. The granulated powder P is recovered from the lower part of the spray drier apparatus 200.
 回転子201の回転数、スプレードライヤー装置200内に導入する熱風温度、チャンバー下部の温度など各パラメータは適宜設定すればよい。これらのパラメータの設定範囲の具体例として、回転子201の回転数として4000~6000rpm、スプレードライヤー装置200内に導入する熱風温度として130~170℃、チャンバー下部の温度として80~90℃が挙げられる。またチャンバー内の雰囲気およびその圧力も適宜設定すればよい。一例として、チャンバー内をエアー(空気)雰囲気として、その圧力を大気圧との差圧で2mmHO(約0.02kPa)とすることが挙げられる。得られた造粒粉Pの粒度分布をふるい分けなどによりさらに制御してもよい。 Parameters such as the rotation speed of the rotor 201, the temperature of the hot air introduced into the spray dryer 200, the temperature of the lower portion of the chamber, etc. may be set as appropriate. Specific examples of setting ranges of these parameters include 4,000 to 6,000 rpm as the number of revolutions of the rotor 201, 130 to 170 ° C. as the temperature of hot air introduced into the spray dryer 200, and 80 to 90 ° C. as the temperature at the lower portion of the chamber. . Further, the atmosphere in the chamber and the pressure thereof may be set appropriately. As an example, the inside of the chamber is an air (air) atmosphere, and the pressure may be 2 mm H 2 O (about 0.02 kPa) in terms of differential pressure with respect to the atmospheric pressure. The particle size distribution of the obtained granulated powder P may be further controlled by sieving or the like.
(3-1-2)加圧条件
 圧縮成形における加圧条件は特に限定されない。造粒粉の組成、成形製造物1Aの形状などを考慮して適宜設定すればよい。造粒粉を圧縮成形する際の加圧力が過度に低い場合には、成形製造物1Aの機械的強度が低下する。このため、成形製造物1Aの取り扱い性が低下する、成形製造物1Aから得られた圧粉コア1の機械的強度が低下する、といった問題が生じやすくなる。また、圧粉コア1の磁気特性が低下したり絶縁性が低下したりする場合もある。一方、造粒粉を圧縮成形する際の加圧力が過度に高い場合には、その圧力に耐えうる成形金型を作成するのが困難になってくる。
(3-1-2) Pressure condition The pressure condition in compression molding is not particularly limited. It may be set appropriately in consideration of the composition of the granulated powder, the shape of the formed product 1A, and the like. If the pressing force during compression molding of the granulated powder is excessively low, the mechanical strength of the molded product 1A is reduced. For this reason, the handling property of the formed product 1A is reduced, and the mechanical strength of the dust core 1 obtained from the formed product 1A is easily reduced. In addition, the magnetic properties of the dust core 1 may be degraded or the insulation may be degraded. On the other hand, when the pressing force at the time of compression molding of the granulated powder is excessively high, it becomes difficult to prepare a molding die that can withstand the pressure.
 圧縮加圧工程が圧粉コア1の機械特性や磁気特性に悪影響を与える可能性をより安定的に低減させ、工業的に大量生産を容易に行う観点から、造粒粉を圧縮成形する際の加圧力は、0.3GPa以上2GPa以下とすることが好ましい場合があり、0.5GPa以上2GPa以下とすることがより好ましい場合があり、0.5GPa以上1.8GPa以下とすることが特に好ましい場合がある。 From the viewpoint of more stably reducing the possibility that the compression / pressing step adversely affects the mechanical properties and magnetic properties of the dust core 1 and facilitating industrial mass production, when compacting granulated powder The pressure may be preferably 0.3 GPa or more and 2 GPa or less, or more preferably 0.5 GPa or more and 2 GPa or less, and particularly preferably 0.5 GPa or more and 1.8 GPa or less There is.
 圧縮成形では、加熱しながら加圧を行ってもよいし、常温で加圧を行ってもよい。 In compression molding, pressurization may be performed while heating, or pressurization may be performed at normal temperature.
(3-2)熱処理工程
 成形工程により得られた成形製造物1Aが本実施形態に係る圧粉コア1が備える成形体1Bであってもよいし、次に説明するように成形製造物1Aに対して熱処理工程を実施して成形体1Bを得てもよい。
(3-2) Heat Treatment Step The formed product 1A obtained in the forming step may be the formed body 1B provided in the dust core 1 according to the present embodiment, and the formed product 1A will be described next. Alternatively, a heat treatment step may be performed to obtain a molded body 1B.
 熱処理工程では、上記の成形工程により得られた成形製造物1Aを加熱することにより、軟磁性粉末間の距離を修正することによる磁気特性の調整および成形工程において軟磁性粉末に付与された歪を緩和させて磁気特性の調整を行って、成形体1Bを得る。 In the heat treatment step, by adjusting the distance between the soft magnetic powders by heating the shaped product 1A obtained in the above shaping step, the adjustment of the magnetic properties by correcting the distance between the soft magnetic powders and the distortion imparted to the soft magnetic powders in the shaping step The magnetic characteristics are adjusted by relaxation to obtain a compact 1B.
 熱処理工程は上記のように成形体1Bの磁気特性の調整が目的であるから、熱処理温度などの熱処理条件は、成形体1Bの磁気特性が最も良好となるように設定される。熱処理条件を設定する方法の一例として、成形製造物1Aの加熱温度を変化させ、昇温速度および加熱温度での保持時間など他の条件は一定とすることが挙げられる。 The purpose of the heat treatment step is to adjust the magnetic properties of the compact 1B as described above, and the heat treatment conditions such as the heat treatment temperature are set so that the magnetic properties of the compact 1B become the best. As an example of the method of setting the heat treatment conditions, the heating temperature of the formed product 1A is changed, and other conditions such as the temperature rising rate and the holding time at the heating temperature are constant.
 熱処理条件を設定する際の成形体1Bの磁気特性の評価基準は特に限定されない。評価項目の具体例として成形体1Bのコアロスを挙げることができる。この場合には、成形体1Bのコアロスが最低となるように成形製造物1Aの加熱温度を設定すればよい。コアロスの測定条件は適宜設定され、一例として、周波数100kHz、最大磁束密度100mTとする条件が挙げられる。 The evaluation standard of the magnetic property of the molded body 1B at the time of setting the heat treatment conditions is not particularly limited. The core loss of the molded object 1B can be mentioned as a specific example of an evaluation item. In this case, the heating temperature of the formed product 1A may be set so as to minimize the core loss of the formed body 1B. The measurement conditions of the core loss are appropriately set, and one example is a condition of a frequency of 100 kHz and a maximum magnetic flux density of 100 mT.
 熱処理の際の雰囲気は特に限定されない。酸化性雰囲気の場合には、バインダー成分の熱分解が過度に進行する可能性や、軟磁性粉末の酸化が進行する可能性が高まるため、窒素、アルゴンなどの不活性雰囲気や、水素などの還元性雰囲気で熱処理を行うことが好ましい。 The atmosphere in the heat treatment is not particularly limited. In the case of an oxidizing atmosphere, the possibility of the thermal decomposition of the binder component proceeding excessively and the possibility of the oxidation of the soft magnetic powder proceeding increasing, so an inert atmosphere such as nitrogen, argon, etc., reduction of hydrogen etc. It is preferable to carry out the heat treatment in a reactive atmosphere.
(3-3)外装コート工程
 上記の成形工程により得られた成形製造物1Aからなる成形体1B、または成形製造物1Aに対して上記の熱処理工程により得られた成形体1Bに対して、熱可塑性樹脂を含む外装コートを施す。その製造方法の一例は前述のとおりであるからここでは記載を省略する。
(3-3) Exterior Coating Step The molded product 1B comprising the molded product 1A obtained by the above-mentioned molding step or the molded product 1B obtained by the above-mentioned heat treatment step for the molded product 1A Apply an exterior coat containing a plastic resin. Since an example of the manufacturing method is as described above, the description is omitted here.
2.電気・電子部品
 本発明の一実施形態に係る電気・電子部品は、上記の本発明の一実施形態に係る圧粉コアを備える。具体的には、本発明の一実施形態に係る電気・電子部品は、圧粉コア、コイルおよびこのコイルのそれぞれの端部に接続された接続端子を備える。ここで、圧粉コアの少なくとも一部は、接続端子を介してコイルに電流を流したときにこの電流により生じた誘導磁界内に位置するように配置されている。
2. Electric / Electronic Component An electric / electronic component according to an embodiment of the present invention includes the dust core according to the above-described embodiment of the present invention. Specifically, the electric / electronic component according to an embodiment of the present invention includes a dust core, a coil, and a connection terminal connected to each end of the coil. Here, at least a part of the dust core is disposed so as to be located in an induced magnetic field generated by the current when the current is supplied to the coil through the connection terminal.
 このような電気・電子部品の一例として、図3に示されるトロイダルコイル10が挙げられる。トロイダルコイル10は、リング状の圧粉コア1に、被覆導電線2を巻回することによって形成されたコイル2aを備える。巻回された被覆導電線2からなるコイル2aと被覆導電線2の端部2b,2cとの間に位置する導電線の部分において、コイル2aの端部2d,2eを定義することができる。このように、本実施形態に係る電気・電子部品は、コイルを構成する部材と接続端子を構成する部材とが同一の部材から構成されていてもよい。また、上記のようなリング状の圧粉コア1に限定されず、例えばEE型、EI型、EER型、PQ型、I型の圧粉コアにコイル巻線を施したもの、あるいはコイルを圧粉コアの内部に封入したもの等が挙げられる。 The toroidal coil 10 shown by FIG. 3 is mentioned as an example of such an electrical and electronic component. The toroidal coil 10 includes a coil 2 a formed by winding the coated conductive wire 2 around the ring-shaped dust core 1. The ends 2d and 2e of the coil 2a can be defined in the portion of the conductive wire located between the coil 2a consisting of the wound coated conductive wire 2 and the ends 2b and 2c of the coated conductive wire 2. Thus, in the electric / electronic component according to the present embodiment, the member constituting the coil and the member constituting the connection terminal may be constituted by the same member. Further, the present invention is not limited to the ring-shaped dust core 1 as described above, for example, an EE-type, EI-type, EER-type, EER-type, PQ-type or I-type dust core provided with coil winding or a coil What was enclosed inside the powder core etc. are mentioned.
 本発明の一実施形態に係る電気・電子部品は、上記の本発明の一実施形態に係る圧粉コアを備えるため、電気・電子部品が高温環境(具体的には250℃の環境)に長時間(具体的には100時間以上)置かれた場合であっても、圧粉コアの磁気特性の変化に基づく電気・電子部品の特性の劣化が生じにくい。また、上記の環境に長時間置かれても圧粉コアが実用的な機械的強度を維持できるため、圧粉コアを用いた電気・電子部品の製造過程、かかる電気・電子部品を電気・電子機器の一部として実装したり組み込んだりする過程、得られた電気・電子機器の使用時において、他の部品との衝突等の外部からの機械的負荷や、急激な温度変化に起因する熱応力などが生じても、電気・電子部品が破損する不具合が生じにくい。 Since the electric / electronic component according to the embodiment of the present invention includes the dust core according to the above-described embodiment of the present invention, the electric / electronic component is long in a high temperature environment (specifically, an environment of 250 ° C.) Even when it is left for a time (specifically, 100 hours or more), deterioration of the characteristics of the electric / electronic component due to the change of the magnetic characteristics of the dust core does not easily occur. In addition, since the dust core can maintain practical mechanical strength even when it is placed in the above environment for a long time, the manufacturing process of the electric and electronic parts using the dust core, such electric and electronic parts Thermal stress due to external mechanical load such as collision with other parts or sudden temperature change during process of mounting or incorporating as a part of equipment and using the obtained electric / electronic equipment Even if a problem occurs, it is unlikely to cause a problem that the electrical and electronic parts are broken.
 本発明の一実施形態に係る電気・電子部品として、上記のトロイダルコイル10のほか、リアクトル、トランス、チョークコイルなどが例示される。 In addition to the above-mentioned toroidal coil 10, a reactor, a transformer, a choke coil, etc. are illustrated as electric and electronic parts concerning one embodiment of the present invention.
3.電気・電子機器
 本発明の一実施形態に係る電気・電子機器は、上記の本発明の一実施形態に係る圧粉コアを備える電気・電子部品を備える。具体的には、上記の電気・電子部品が実装されたものや、上記の電気・電子部品が組み込まれたものが例示される。そのような電気・電子機器のさらなる具体例として、電圧昇降圧回路、平滑回路、DC-DCコンバータ、AC-DCコンバータ等を備えたスイッチング電源装置や太陽光発電等に使用されるパワーコントロールユニット等が挙げられる。
3. Electric / Electronic Device The electric / electronic device according to the embodiment of the present invention includes the electric / electronic component including the dust core according to the above-described embodiment of the present invention. Specifically, those on which the above-mentioned electric and electronic components are mounted and those in which the above-mentioned electric and electronic components are incorporated are exemplified. As a further specific example of such electric and electronic equipment, a switching power supply unit provided with a voltage buck-boost circuit, a smoothing circuit, a DC-DC converter, an AC-DC converter, etc., a power control unit used for solar power generation etc. Can be mentioned.
 こうした本発明の一実施形態に係る電気・電子部品は、上記の本発明の一実施形態に係る圧粉コアを備える電気・電子部品を備えるため、高温環境(具体的には250℃の環境)に長時間(具体的には100時間以上)置かれた場合であっても、圧粉コアの磁気特性の低下や破損に起因する動作不良を生じにくい。したがって、本発明の一実施形態に係る電気・電子部品は、信頼性に優れる。 The electric / electronic component according to the embodiment of the present invention includes the electric / electronic component including the dust core according to the embodiment of the present invention, so that the high temperature environment (specifically, an environment of 250 ° C.) Even when it is left for a long time (specifically, 100 hours or more), it is hard to cause an operation failure due to the deterioration or breakage of the magnetic properties of the dust core. Therefore, the electric / electronic component according to one embodiment of the present invention is excellent in reliability.
 以上説明した実施形態は、本発明の理解を容易にするために記載されたものであって、本発明を限定するために記載されたものではない。したがって、上記実施形態に開示された各要素は、本発明の技術的範囲に属する全ての設計変更や均等物をも含む趣旨である。 The embodiments described above are described to facilitate the understanding of the present invention, and are not described to limit the present invention. Therefore, each element disclosed in the above embodiment is intended to include all design changes and equivalents that fall within the technical scope of the present invention.
 以下、実施例等により本発明をさらに具体的に説明するが、本発明の範囲はこれらの実施例等に限定されるものではない。 Hereinafter, the present invention will be more specifically described by way of examples and the like, but the scope of the present invention is not limited to these examples and the like.
(実施例1)
(1)Fe基非晶質合金粉末の作製
 水アトマイズ法を用いて、Fe74.3at%Cr1.56at%8.78at%2.62at%7.57at%Si4.19at%なる組成になるように秤量して得られた非晶質磁性材料の粉末を軟磁性粉末として作製した。得られた軟磁性粉末の粒度分布は、マイクロトラック粒度分布測定装置(日機装社製「MT3300EX」)を用いて体積分布で測定した。その結果、体積分布における体積累積値が50%のときの粒径体積分布において50%となる粒度であるメジアン径(D50)は11μmであった。
Example 1
(1) Preparation of Fe-based amorphous alloy powder Fe 74.3 at% Cr 1.56 at% P 8.78 at% C 2.62 at% B 7.57 at% Si 4.19 at% using a water atomizing method The powder of the amorphous magnetic material obtained by weighing to a composition was produced as a soft magnetic powder. The particle size distribution of the obtained soft magnetic powder was measured by volume distribution using a microtrack particle size distribution measuring apparatus ("MT3300EX" manufactured by Nikkiso Co., Ltd.). As a result, the median diameter (D50), which is the particle size at which 50% is obtained in the particle diameter distribution when the volume cumulative value in the volume distribution is 50%, is 11 μm.
(2)造粒粉の作製
 上記の軟磁性粉末を98.1質量部、アクリル系樹脂からなる絶縁性結着材を0.8質量部、シランカップリング剤0.6質量%およびステアリン酸亜鉛からなる潤滑剤0.6質量部を含み、水を溶剤とするスラリーを用意した。
(2) Preparation of Granulated Powder 98.1 parts by mass of the above soft magnetic powder, 0.8 parts by mass of an insulating binder comprising an acrylic resin, 0.6% by mass of a silane coupling agent and zinc stearate A slurry containing 0.6 parts by mass of the lubricant consisting of water as a solvent was prepared.
 得られたスラリーをスプレードライヤー装置(プリス社製「D350AT-24HOP」)にて噴霧乾燥し造粒粉を得た。得られた造粒粉の粒度分布はレーザ回折散乱法粒度分布測定装置(ベックマン・コールター社製「LS 13 320」)を用いて体積分布により測定した。その結果、測定された造粒粉の粒径の体積分布における体積累積値が50%のときの粒径体積分布において50%となる粒度であるメジアン径(D50)は85μmであった。 The obtained slurry was spray-dried with a spray dryer apparatus ("D350AT-24HOP" manufactured by Pris Co., Ltd.) to obtain granulated powder. The particle size distribution of the obtained granulated powder was measured by volume distribution using a laser diffraction scattering particle size distribution measuring apparatus ("LS 13 320" manufactured by Beckman Coulter, Inc.). As a result, the median diameter (D50) which is a particle size which will be 50% in the particle size volume distribution in case the volume accumulation value in the volume distribution of the particle size of the granulated powder measured is 85 micrometers.
(3)圧縮成形
 得られた造粒粉を金型に充填し、面圧0.5~2GPaで加圧成形して、外径20mm×内径12.8mm×厚さ6.8mmのリング形状を有する成形製造物1Aを得た。
(3) Compression molding The obtained granulated powder is filled in a mold and pressure molded with a surface pressure of 0.5 to 2 GPa to form a ring having an outer diameter of 20 mm, an inner diameter of 12.8 mm and a thickness of 6.8 mm. The molded product 1A which it has was obtained.
(4)熱処理
 得られた成形製造物1Aを、窒素気流雰囲気の炉内に載置し、炉内温度を、室温(23℃)から昇温速度10℃/分で最適コア熱処理温度である300~500℃まで加熱し、この温度にて1時間保持し、その後、炉内で室温まで冷却する熱処理を行い、成形体1Bを得た。
(4) Heat treatment The obtained formed product 1A is placed in a furnace in a nitrogen stream atmosphere, and the furnace temperature is 300 ° C., which is the optimum core heat treatment temperature at a heating rate of 10 ° C./min from room temperature (23 ° C.) It was heated to ̃500 ° C., held at this temperature for 1 hour, and then heat-treated to cool to room temperature in a furnace to obtain a compact 1 B.
(5)外装コート
 熱可塑性ポリイミド(ピーアイ技研社製「Q-VR-X1444」)を、N-メチルピロリドン(NMP)にて溶解し、熱可塑性ポリイミドの濃度が10質量%である液状組成物を調製した。
(5) Outer coat A liquid composition in which a thermoplastic polyimide ("Q-VR-X1444" manufactured by PI Technology Inc.) is dissolved in N-methylpyrrolidone (NMP) and the concentration of the thermoplastic polyimide is 10% by mass Prepared.
 得られた液状組成物中に、上記の成形体1Bを15分間浸漬させた。その後、成形体1Bを液状組成物中から取り出し、80℃にて30分間、その後150℃にて1時間、250℃にて1時間で乾燥させ、成形体1Bの表面に液状組成物の塗膜を形成し、成形体1B上に外装コートを備える圧粉コア1を得た。 The above-mentioned molded body 1B was immersed in the obtained liquid composition for 15 minutes. Thereafter, the molded product 1B is taken out of the liquid composition, dried at 80 ° C. for 30 minutes, then at 150 ° C. for 1 hour, and at 250 ° C. for 1 hour, and the coating film of the liquid composition is formed on the surface of the molded body 1B. To obtain a dust core 1 having an outer coat on the molded body 1B.
(実施例2)
 液状組成物を調製する際に、熱可塑性ポリアミドイミド(東洋紡社製「HR-11NN」)を、NMPにて溶解し、熱可塑性ポリアミドイミドの濃度が10質量%である液状組成物を調製したこと以外は、実施例1と同様にして、圧粉コア1を得た。
(Example 2)
In preparing the liquid composition, a thermoplastic polyamideimide ("HR-11NN" manufactured by Toyobo Co., Ltd.) is dissolved in NMP to prepare a liquid composition having a concentration of the thermoplastic polyamideimide of 10% by mass. Dust core 1 was obtained in the same manner as Example 1 except for the above.
(実施例3)
 実施例1と同様にして、成形体1Bを得た。種類の異なる熱可塑性ポリアミドイミド(日立化成社製「HL-1210」)をビス(2-メトキシエチル)エーテルにて溶解し、熱可塑性ポリアミドイミドの濃度が10質量%である液状組成物を調製したこと以外は、実施例1と同様にして、圧粉コア1を得た。
(Example 3)
In the same manner as Example 1, a molded body 1B was obtained. A different type of thermoplastic polyamideimide ("HL-1210" manufactured by Hitachi Chemical Co., Ltd.) was dissolved in bis (2-methoxyethyl) ether to prepare a liquid composition having a concentration of thermoplastic polyamideimide of 10% by mass. Dust core 1 was obtained in the same manner as Example 1 except for the above.
(実施例4)
 実施例1と同様にして、成形体1Bを得た。フェノール変性アルキド樹脂(明電ケミカル社製「H550」)をキシレンにて溶解し、フェノール変性アルキド樹脂の濃度が10質量%である液状組成物を調製した。得られた液状組成物中に、上記の成形体1Bを15分間浸漬させた。その後、成形体1Bを液状組成物中から取り出し、45℃にて1時間、その後155℃にて1時間加熱して、成形体1B上に外装コートを備える圧粉コア1を得た。
(Example 4)
In the same manner as Example 1, a molded body 1B was obtained. A phenol-modified alkyd resin ("H550" manufactured by Meiden Chemical Co., Ltd.) was dissolved in xylene to prepare a liquid composition in which the concentration of the phenol-modified alkyd resin was 10% by mass. The above-mentioned molded body 1B was immersed in the obtained liquid composition for 15 minutes. Thereafter, the molded product 1B is taken out from the liquid composition, and heated at 45 ° C. for 1 hour, and then heated at 155 ° C. for 1 hour to obtain a dust core 1 having an outer coat on the molded product 1B.
(実施例5)
 実施例1と同様にして、成形体1Bを得た。ポリアミドイミド(DIC社製「V-8000BM」)とビスフェノールA型エポキシ樹脂(DIC社製「850-S」)とを当量配合したものを、シクロヘキサノンを溶剤として希釈し、固形分濃度が12質量%である液状組成物を調製した。得られた液状組成物中に、上記の成形体1Bを15分間浸漬させた。その後、成形体1Bを液状組成物中から取り出し、100℃にて1時間乾燥させて、成形体1Bの表面に液状組成物の塗膜を形成した。この塗膜を備えた成形体1Bを200℃で1時間加熱して、成形体1B上に外装コートを備える圧粉コア1を得た。
(Example 5)
In the same manner as Example 1, a molded body 1B was obtained. An equivalent blend of polyamide imide ("V-8000 BM" manufactured by DIC) and bisphenol A epoxy resin ("850-S" manufactured by DIC) is diluted using cyclohexanone as a solvent, and the solid content concentration is 12% by mass A liquid composition was prepared. The above-mentioned molded body 1B was immersed in the obtained liquid composition for 15 minutes. Thereafter, the molded product 1B was taken out of the liquid composition and dried at 100 ° C. for 1 hour to form a coating film of the liquid composition on the surface of the molded product 1B. The compact 1B provided with the coating film was heated at 200 ° C. for 1 hour to obtain a dust core 1 having an outer coat on the compact 1B.
(実施例6)
 液状組成物を調製する際に、ポリアミドイミドおよびビスフェノールA型エポキシ樹脂に代えて、メチルフェニルシリコーン(信越化学社製「KR-271」)を、キシレンを溶剤として希釈して、メチルフェニルシリコーンの濃度が20質量%である液状組成物を調製したこと以外は、実施例5と同様にして、圧粉コアを得た。
(Example 6)
When preparing a liquid composition, methyl phenyl silicone ("KR-271" manufactured by Shin-Etsu Chemical Co., Ltd.) is diluted with xylene as a solvent instead of polyamideimide and bisphenol A epoxy resin, and the concentration of methyl phenyl silicone is reduced. A dust core was obtained in the same manner as in Example 5, except that a liquid composition having a content of 20% by mass was prepared.
(実施例7)
 液状組成物を調製する際に、種類の異なるメチルフェニルシリコーン(信越化学社製「KR-300」)を、キシレンを溶剤として希釈して、メチルフェニルシリコーンの濃度が10質量%である液状組成物を調製したこと以外は、実施例6と同様にして、圧粉コアを得た。
(Example 7)
A liquid composition having a concentration of methylphenylsilicone of 10% by mass by diluting methylphenylsilicone ("KR-300" manufactured by Shin-Etsu Chemical Co., Ltd.) different in kind using xylene as a solvent when preparing the liquid composition A dust core was obtained in the same manner as in Example 6, except that was prepared.
(実施例8)
 実施例1と同様にして、成形体1Bを得た。フェニルシリコーン(信越化学社製「ASP-2010」)をキシレンにて希釈し、固形分濃度が20質量%である液状組成物を調製した。得られた液状組成物中に、上記の成形体1Bを15分間浸漬させた。その後、成形体1Bを液状組成物中から取り出し、100℃にて2時間乾燥させて、成形体1Bの表面に液状組成物の塗膜を形成した。この塗膜を備えた成形体1Bを150℃で5時間加熱して、成形体1B上に外装コートを備える圧粉コア1を得た。
(Example 8)
In the same manner as Example 1, a molded body 1B was obtained. Phenyl silicone ("ASP-2010" manufactured by Shin-Etsu Chemical Co., Ltd.) was diluted with xylene to prepare a liquid composition having a solid content concentration of 20% by mass. The above-mentioned molded body 1B was immersed in the obtained liquid composition for 15 minutes. Thereafter, the molded product 1B was taken out of the liquid composition and dried at 100 ° C. for 2 hours to form a coating film of the liquid composition on the surface of the molded product 1B. The compact 1B provided with the coating film was heated at 150 ° C. for 5 hours to obtain a dust core 1 having an outer coat on the compact 1B.
(実施例9)
 液状組成物を調製する際に、変性シリコーン(信越化学社製「SCR-1012」)を、キシレンを溶剤として希釈して、メチルフェニルシリコーンの濃度が10質量%である液状組成物を調製したこと以外は、実施例8と同様にして、圧粉コアを得た。
(Example 9)
When preparing a liquid composition, a modified silicone ("SCR-1012" manufactured by Shin-Etsu Chemical Co., Ltd.) is diluted using xylene as a solvent to prepare a liquid composition having a concentration of methyl phenyl silicone of 10% by mass. A dust core was obtained in the same manner as in Example 8 except for the above.
(実施例10)
 実施例1と同様にして、成形体1Bを得た。熱硬化性ポリイミド(宇部興産社製「UPIA-AT」)をNMPにて希釈し、固形分濃度が10質量%である液状組成物を調製した。得られた液状組成物中に、上記の成形体1Bを15分間浸漬させた。その後、成形体1Bを液状組成物中から取り出し、80℃にて30分間、その後150℃にて1時間乾燥させて、成形体1Bの表面に液状組成物の塗膜を形成した。この塗膜を備えた成形体1Bを窒素雰囲気中で350℃で1時間加熱して、成形体1B上に外装コートを備える圧粉コア1を得た。
(Example 10)
In the same manner as Example 1, a molded body 1B was obtained. A thermosetting polyimide ("UPIA-AT" manufactured by Ube Industries, Ltd.) was diluted with NMP to prepare a liquid composition having a solid content concentration of 10% by mass. The above-mentioned molded body 1B was immersed in the obtained liquid composition for 15 minutes. Thereafter, the molded product 1B was taken out of the liquid composition, dried at 80 ° C. for 30 minutes, and then dried at 150 ° C. for 1 hour, to form a coating film of the liquid composition on the surface of the molded product 1B. The compact 1B provided with the coating film was heated at 350 ° C. in a nitrogen atmosphere for 1 hour to obtain a dust core 1 having an outer coat on the compact 1B.
(実施例11)
 液状組成物を調製する際に、種類の異なる熱硬化性ポリイミド(ユニチカ社製「Uイミド CR」)を、NMPを溶剤として希釈して、熱硬化性ポリイミドの濃度が10質量%である液状組成物を調製したこと以外は、実施例10と同様にして、圧粉コア1を得た。
(Example 11)
When preparing a liquid composition, a liquid composition having a thermosetting polyimide concentration of 10% by mass by diluting different kinds of thermosetting polyimides ("U imide CR" manufactured by Unitika, Inc.) using NMP as a solvent Dust core 1 was obtained in the same manner as in Example 10 except that the product was prepared.
(参考例1)
 実施例1と同様にして得た成形体1Bからなる圧粉コア1を得た。すなわち、参考例1に係る圧粉コア1は、外装コートを有しないものであった。
(Reference Example 1)
A dust core 1 comprising a molded body 1B obtained in the same manner as in Example 1 was obtained. That is, the dust core 1 which concerns on the reference example 1 did not have an exterior coat.
(試験例1)比透磁率およびその変化率の測定
 実施例および参考例により作製した圧粉コア1に銅線の巻線を施してトロイダルコアを得た。このトロイダルコアについて、インピーダンスアナライザー(HP社製「4192A」)を用いて、周波数100kHzのときの比透磁率を測定した。この比透磁率を「初期比透磁率μ」という。
 実施例および比較例により作製した圧粉コア1を250℃の環境に200時間静置し、静置後の圧粉コア1について、上記の要領で比透磁率を測定した。この比透磁率を「加熱後比透磁率μ」という。
 下記式にて比透磁率の変化率Rμ(単位:%)を求めた。
  Rμ=(μ-μ)/μ×100
 初期比透磁率μおよび加熱後比透磁率μならびに比透磁率の変化率Rμを表1に示す。なお、表1には、実施例において用いた液状組成物の樹脂種および濃度(単位:質量%)を示した。
(Test Example 1) Measurement of Relative Permeability and Rate of Change The powder core 1 manufactured according to the examples and reference examples was wound with a copper wire to obtain a toroidal core. The relative permeability at a frequency of 100 kHz was measured for the toroidal core using an impedance analyzer ("4192A" manufactured by HP). This relative permeability is referred to as “initial relative permeability μ 0 ”.
The dust core 1 produced according to the example and the comparative example was allowed to stand in an environment of 250 ° C. for 200 hours, and the relative permeability was measured in the manner described above for the dust core 1 after standing. This relative permeability is referred to as “after heating relative permeability μ 1 ”.
The rate of change in relative permeability Rμ (unit:%) was determined by the following equation.
Rμ = (μ 10 ) / μ 0 × 100
The initial relative permeability μ 0 and the post-heating relative permeability μ 1 and the change rate R μ of the relative permeability are shown in Table 1. Table 1 shows the resin species and the concentration (unit: mass%) of the liquid composition used in the examples.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
(試験例2)コアロスおよびその変化率の測定
 実施例および参考例により作製した圧粉コア1に銅線の巻線を施してトロイダルコイル10を得た。このトロイダルコイル10について、BHアナライザー(岩崎通信機社製「SY-8218」)を用いて、周波数100kHz,最大磁束密度100mTの条件でコアロス(PCV)を測定した。このコアロスを「初期コアロスW」(単位:kW/m)という。
 実施例および比較例により作製した圧粉コア1を250℃の環境に200時間静置し、静置後の圧粉コア1について、上記の要領でコアロスを測定した。このコアロスを「加熱後コアロスW」(単位:kW/m)という。
 下記式にてコアロスの変化率RW(単位:%)を求めた。
  RW=(W-W)/W×100
 初期コアロスWおよび加熱後コアロスWならびにコアロスの変化率RWを表1に示した。
Test Example 2 Measurement of Core Loss and Rate of Change Thereof A toroidal coil 10 was obtained by winding a copper wire on a dust core 1 produced according to the examples and reference examples. The core loss (PCV) of the toroidal coil 10 was measured under the conditions of a frequency of 100 kHz and a maximum magnetic flux density of 100 mT using a BH analyzer ("SY-8218" manufactured by Iwasaki Communication Co., Ltd.). This core loss is called "initial core loss W 0 " (unit: kW / m 3 ).
The dust cores 1 produced according to the examples and comparative examples were allowed to stand in an environment of 250 ° C. for 200 hours, and core loss was measured for the dust cores 1 after standing as described above. This core loss is referred to as “after heating core loss W 1 ” (unit: kW / m 3 ).
The core loss change rate RW (unit:%) was determined by the following equation.
RW = (W 1- W 0 ) / W 0 × 100
The initial core loss W 0 and after heating core loss W 1 and core loss change rate RW shown in Table 1.
(試験例3)圧環強度およびその変化率の測定
 実施例および参考例により作製した圧粉コア1を、JIS Z2507:2000に準拠した試験方法により測定して、初期圧環強度S(単位:MPa)を求めた。
 実施例および比較例により別途作製した圧粉コア1を、250℃の環境に200時間静置し、静置後の圧粉コア1について、JIS Z2507:2000に準拠した試験方法により測定して、加熱後圧環強度S(単位:MPa)を求めた。
 下記式にて圧環強度の変化率RS(単位:%)を求めた。
  RS=(S-S)/S×100
 初期圧環強度Sおよび加熱後圧環強度Sならびに圧環強度の変化率RSを表1に示した。
(Test Example 3) Measurement of radial crushing strength and rate of change thereof The green compact core 1 prepared according to the examples and reference examples is measured by a test method according to JIS Z 2507: 2000, and the initial radial crushing strength S 0 (unit: MPa Asked for).
The dust core 1 separately prepared according to the example and the comparative example is allowed to stand in an environment of 250 ° C. for 200 hours, and the dust core 1 after standing is measured by the test method according to JIS Z 2507: 2000, After heating, the radial crushing strength S 1 (unit: MPa) was determined.
The rate of change in radial crushing strength RS (unit:%) was determined by the following equation.
RS = (S 1 -S 0 ) / S 0 × 100
The initial radial crushing strength S 0, the post-heating radial crushing strength S 1, and the rate of change RS of the radial crushing strength are shown in Table 1.
 表1に示されるように、本発明例(実施例1から実施例3)に係る圧粉コア1は、250℃の環境下に200時間置かれた後でも、比透磁率の変化率は-6%以上(低下率として6%以下)であり、コアロスの変化率は±10%以内であり、かつ圧環強度は加熱後においても15MPa以上であった。
 これに対し、比較例(実施例4から実施例11)および参考例(参考例1)に係る圧粉コア1は、比透磁率の低下率が6%以下、コアロスの増加率が10%以下、および初期圧環強度および加熱後圧環強度の双方が15MPa以上の少なくとも一つについて、磁気特性および機械的強度の双方について特に優れた特性を有することはできなかった。
As shown in Table 1, the dust core 1 according to the inventive example (Examples 1 to 3) has a change rate of relative permeability of − even after being placed under an environment of 250 ° C. for 200 hours. The core loss change rate was ± 10% or less, and the radial crushing strength was 15 MPa or more even after heating.
On the other hand, in the dust core 1 according to Comparative Example (Examples 4 to 11) and Reference Example (Reference Example 1), the reduction rate of relative permeability is 6% or less, and the increase rate of core loss is 10% or less And at least one of the initial radial crushing strength and the post-heating radial crushing strength could not have particularly excellent properties with respect to both the magnetic properties and the mechanical strength, for at least one of 15 MPa or more.
 本発明の圧粉コアを用いた電子部品は、ハイブリッド自動車等の昇圧回路や、発電、変電設備に用いられるリアクトル、トランスやチョークコイル等として好適に使用されうる。 The electronic component using the dust core of the present invention can be suitably used as a booster circuit of a hybrid car or the like, a reactor used for power generation or transformation equipment, a transformer, a choke coil or the like.
1…圧粉コア
1A…成形製造物
1B…成形体
MM…軟磁性粉末
BM…バインダー成分
TDM…熱分解残渣
PR…空隙
CRM…外装コート材
10…トロイダルコイル
2…被覆導電線
2a…コイル
2b,2c…被覆導電線2の端部
2d,2e…コイル2aの端部
200…スプレードライヤー装置
201…回転子
S…スラリー
P…造粒粉
DESCRIPTION OF SYMBOLS 1: Powdered powder core 1A: Molded product 1B: Molded body MM: Soft magnetic powder BM: Binder component TDM: Thermal decomposition residue PR: Air gap CRM: Exterior coating material 10: Toroidal coil 2: Coated conductive wire 2a: Coil 2b, 2c: End 2d of the coated conductive wire 2, 2e: End 200 of the coil 2a: Spray dryer device 201: Rotor S: Slurry P: Granulated powder

Claims (11)

  1.  軟磁性粉末を含む成形体と、前記成形体の外装コートと、を備える圧粉コアであって、
     前記外装コートは、熱可塑性ポリイミドおよび熱可塑性ポリアミドイミドの少なくとも一方を含む熱可塑性樹脂を含有すること
    を特徴とする圧粉コア。
    A dust core comprising a molded body containing soft magnetic powder, and an outer coat of the molded body,
    A dust core characterized in that the outer coat contains a thermoplastic resin containing at least one of a thermoplastic polyimide and a thermoplastic polyamideimide.
  2.  前記外装コートは含浸構造を有していることを特徴とする請求項1に記載の圧粉コア。 The dust core according to claim 1, wherein the outer coat has an impregnated structure.
  3.  前記軟磁性粉末は、鉄系材料およびニッケル系材料の少なくとも一方の粉末を含有する、請求項1または請求項2に記載の圧粉コア。 The dust core according to claim 1, wherein the soft magnetic powder contains a powder of at least one of an iron-based material and a nickel-based material.
  4.  前記軟磁性粉末は、結晶質磁性材料の粉末を含有する、請求項1から請求項3のいずれか一項に記載の圧粉コア。 The dust core according to any one of claims 1 to 3, wherein the soft magnetic powder contains a powder of a crystalline magnetic material.
  5.  前記軟磁性粉末は、非晶質磁性材料の粉末を含有する、請求項1から請求項4のいずれか一項に記載の圧粉コア。 The dust core according to any one of claims 1 to 4, wherein the soft magnetic powder contains a powder of an amorphous magnetic material.
  6.  前記軟磁性粉末はナノ結晶磁性材料の粉末を含有する、請求項1から請求項5のいずれか一項に記載の圧粉コア。 The dust core according to any one of claims 1 to 5, wherein the soft magnetic powder contains a powder of nanocrystalline magnetic material.
  7.  前記軟磁性粉末は、前記結晶質磁性材料、前記非晶質磁性材料、前記ナノ結晶磁性材料のうちの2種以上を混合したものである請求項1から請求項6のいずれか1項に記載の圧粉コア。 The soft magnetic powder according to any one of claims 1 to 6, wherein two or more of the crystalline magnetic material, the amorphous magnetic material, and the nanocrystalline magnetic material are mixed. Dust core.
  8.  前記成形体は、前記軟磁性粉末と結着成分とを備え、前記結着成分は、樹脂系材料を含むバインダー成分の熱分解残渣からなる、請求項1から請求項7のいずれか1項に記載の圧粉コア。 The said molded object is provided with the said soft-magnetic powder and a binding component, The said binding component consists of a thermal decomposition residue of the binder component containing resin-type material, The any one of Claims 1-7 Dust core as described.
  9.  請求項8に記載される圧粉コアの製造方法であって、
     前記軟磁性粉末と前記バインダー成分とを備える混合物の加圧成形を含む成形処理により成形製造物を得る成形工程、
     前記成形工程により得られた成形製造物を加熱して、前記軟磁性粉末と前記バインダー成分の熱分解残渣からなる結着成分とを備える前記成形体を得る熱処理工程、および
     熱可塑性ポリイミドおよび熱可塑性ポリアミドイミドの少なくとも一方を含む熱可塑性樹脂および溶剤を含む液状組成物を前記成形体と接触させ、前記成形体の表面を含む領域に前記液状組成物の塗膜を形成し、前記塗膜を乾燥させて溶剤を揮発させ、前記熱可塑性樹脂を含む外装コートを形成する外装コート工程を備えること
    を特徴とする圧粉コアの製造方法。
    A method of producing a dust core according to claim 8, wherein
    A forming step of obtaining a formed product by a forming process including pressure forming of a mixture comprising the soft magnetic powder and the binder component,
    A heat treatment step of heating the molded product obtained by the molding step to obtain the molded article comprising the soft magnetic powder and a binding component comprising a thermal decomposition residue of the binder component, and a thermoplastic polyimide and a thermoplastic resin A liquid composition containing a thermoplastic resin containing at least one of polyamideimide and a solvent is brought into contact with the molded product to form a coated film of the liquid composition in a region including the surface of the molded product, and the coated film is dried. A method for producing a dust core, comprising: an exterior coating step of volatilizing a solvent to form an exterior coating containing the thermoplastic resin.
  10.  請求項1から請求項8のいずれか1項に記載される圧粉コア、コイルおよび前記コイルのそれぞれの端部に接続された接続端子を備える電気・電子部品であって、
     前記圧粉コアの少なくとも一部は、前記接続端子を介して前記コイルに電流を流したときに前記電流により生じた誘導磁界内に位置するように配置されていること
    を特徴とする電気・電子部品。
    An electric / electronic component comprising the dust core according to any one of claims 1 to 8, a coil, and a connection terminal connected to each end of the coil,
    At least a part of the dust core is disposed so as to be located in an induced magnetic field generated by the current when the current is supplied to the coil through the connection terminal. parts.
  11.  請求項10に記載される電気・電子部品を備えることを特徴とする電気・電子機器。 An electric / electronic device comprising the electric / electronic component according to claim 10.
PCT/JP2018/031351 2017-08-29 2018-08-24 Dust core, method for producing said dust core, electrical/electronic component provided with said dust core, and electrical/electronic device equipped with said electrical/electronic component WO2019044698A1 (en)

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