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WO2024176656A1 - Procédé de fabrication de noyau à poudre de fer - Google Patents

Procédé de fabrication de noyau à poudre de fer Download PDF

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Publication number
WO2024176656A1
WO2024176656A1 PCT/JP2024/000959 JP2024000959W WO2024176656A1 WO 2024176656 A1 WO2024176656 A1 WO 2024176656A1 JP 2024000959 W JP2024000959 W JP 2024000959W WO 2024176656 A1 WO2024176656 A1 WO 2024176656A1
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WO
WIPO (PCT)
Prior art keywords
powder
magnetic
metal
resin
metal soap
Prior art date
Application number
PCT/JP2024/000959
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English (en)
Japanese (ja)
Inventor
透 岩渕
和希 野口
一志 堀内
Original Assignee
パナソニックＩｐマネジメント株式会社
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Publication of WO2024176656A1 publication Critical patent/WO2024176656A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • B22F1/102—Metallic powder coated with organic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/14—Treatment of metallic powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/14—Treatment of metallic powder
    • B22F1/142—Thermal or thermo-mechanical treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/14—Treatment of metallic powder
    • B22F1/148—Agglomerating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
    • H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
    • H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
    • H01F1/26—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated by macromolecular organic substances
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets

Definitions

  • This disclosure relates to a method for producing powder magnetic cores.
  • oxide magnetic materials such as ferrite and metal magnetic materials have been used as magnetic materials for the magnetic cores of inductors and transformers.
  • Magnetic cores using these magnetic materials include, for example, dust cores made by compressing and molding metal magnetic powder.
  • dust cores have a high saturation magnetic flux density and are advantageous for miniaturizing components such as inductors and transformers.
  • dust cores can be molded using a mold, allowing for a high degree of freedom in the shape of the magnetic core, and even complex shapes can be manufactured with a simple process with high precision, so their usefulness has attracted attention.
  • Patent Document 1 discloses a method for manufacturing a powder magnetic core in which a magnetic powder is mixed with a coupling agent and subjected to a first heat treatment, and then a resin is added and pressure-molded to form a powder magnetic core, which is then subjected to a second heat treatment.
  • the present disclosure therefore aims to provide a method for manufacturing powder magnetic cores that can improve insulation.
  • the method for producing a powder magnetic core includes a first step of mixing a metal magnetic powder composed of a plurality of metal magnetic particles, a resin, and a metal soap to obtain a granulated powder, a second step of pressurizing the obtained granulated powder to obtain a molded body, and a third step of annealing the obtained molded body, in which the metal soap mixed in the first step is liquid at 25°C and contains elemental Si.
  • This disclosure makes it possible to improve the insulation properties of powder magnetic cores.
  • FIG. 1A is a schematic perspective view illustrating a configuration of a coil component according to an embodiment.
  • FIG. 1B is an exploded perspective view illustrating a configuration of a coil component according to an embodiment.
  • FIG. 2 is a cross-sectional view showing the configuration of a magnetic material according to an embodiment.
  • FIG. 3 is a flowchart showing a method for manufacturing a powder magnetic core according to an embodiment.
  • FIG. 4 is a flowchart showing a process for producing granulated powder according to the embodiment.
  • FIG. 5 is a diagram showing the relationship between breakdown voltage and magnetic permeability in samples of powder magnetic cores.
  • FIG. 6 is a diagram showing the relationship between breakdown voltage and magnetic permeability in samples of powder magnetic cores.
  • each figure is a schematic diagram and is not necessarily an exact illustration. Therefore, for example, the scales of each figure do not necessarily match.
  • the same reference numerals are used for substantially the same configuration, and duplicate explanations are omitted or simplified.
  • FIG. 1A is a schematic perspective view showing the configuration of coil component 1 according to this embodiment.
  • FIG. 1B is an exploded perspective view showing the configuration of coil component 1 according to this embodiment.
  • FIG. 2 is a cross-sectional view showing the configuration of powder magnetic core 12 according to this embodiment.
  • the coil component 1 is composed of a magnetic core (dust core) formed of a powder magnetic core 12, and a coil portion disposed inside the magnetic core.
  • the coil component 1 is, for example, an inductor.
  • the coil component 1 is described as one example of the use of the powder magnetic core 12, but the powder magnetic core 12 can simply be used as a magnetic material, and the use example is not limited to the coil component 1 according to this embodiment.
  • the coil component 1 includes two powder magnetic cores 12, a conductor 13, and two coil supports 14.
  • the powder magnetic core 12 comprises a base 12a and a cylindrical core portion 12b formed on one side of the base 12a. Furthermore, two opposing sides of the four sides that make up the base 12a are formed with wall portions 12c that stand upright from the edge of the base 12a. The core portion 12b and the wall portion 12c are at the same height from the one side of the base 12a.
  • Each of the two powder magnetic cores 12 is a powder magnetic core formed by pressure-molding a magnetic material into a predetermined shape.
  • the two powder magnetic cores 12 are arranged so that their respective cores 12b and wall portions 12c abut against each other (i.e., one core portion 12b abuts against the other core portion 12b, and one wall portion 12c abuts against the other wall portion 12c).
  • the conductor 13 is arranged so as to surround the periphery of the core portion 12b.
  • the conductor 13 is incorporated into the powder magnetic core 12 via the coil support 14.
  • the two coil supports 14 each have an annular base 14a and a cylindrical portion 14b.
  • the core portion 12b of the powder magnetic core 12 is disposed inside the cylindrical portion 14b, and the conductor 13 is disposed on the outer periphery of the cylindrical portion 14b.
  • the dust core 12 includes a metal magnetic powder 17 composed of a plurality of metal magnetic particles, and an insulating material 18.
  • the metal magnetic powder 17 is pressure-molded, and the insulating material 18 is formed in a film shape on the surface of each metal magnetic particle of the metal magnetic powder 17.
  • the insulating material 18 covering the surfaces of adjacent metal magnetic particles of the metal magnetic powder 17 is bonded to each other. In other words, the insulating material 18 is disposed between each metal magnetic particle of the metal magnetic powder 17 and each adjacent metal magnetic particle, and each metal magnetic particle of the metal magnetic powder 17 and each adjacent metal magnetic particle are insulated from each other.
  • Metal magnetic powder 17 is made of Fe-Si-Al, Fe-Si, Fe-Si-Cr, or Fe-Si-Cr-B. Metal magnetic powder 17 has a higher saturation magnetic flux density than magnetic powders such as ferrite, making it useful for use under high currents.
  • the composition elements are Si at 8% by weight or more and 12% by weight or less, Al at 4% by weight or more and 6% by weight or less, and the remaining composition elements are Fe and unavoidable impurities.
  • unavoidable impurities include Mn, Ni, P, S, C, etc.
  • the composition elements when using Fe-Si-based metal magnetic powder, the composition elements include Si with a content of 1% by weight or more and 8% by weight or less, and the remaining composition elements include Fe and unavoidable impurities. Note that the unavoidable impurities are the same as those described above.
  • the composition elements are Si at 1% by weight or more and 8% by weight or less, Cr at 2% by weight or more and 8% by weight or less, and the remaining composition elements are Fe and unavoidable impurities. Note that the unavoidable impurities are the same as those described above.
  • composition elements are Si at 1% to 8% by weight, Cr at 2% to 8% by weight, B at 1% to 8% by weight, and the remaining composition elements are Fe and unavoidable impurities.
  • the unavoidable impurities are the same as those described above.
  • the role of Si in the composition elements of the above-mentioned metal magnetic powder 17 is to reduce the magnetic anisotropy and magnetostriction constant, increase the electrical resistance, and reduce eddy current loss.
  • Si content in the composition elements 1% by weight or more, it is possible to obtain an improvement effect on the soft magnetic properties, and by making it 8% by weight or less, it is possible to suppress the decrease in saturation magnetization and suppress the decrease in the DC superposition properties.
  • Cr in the metal magnetic powder 17, it is possible to impart the effect of improving weather resistance.
  • Cr content in the composition elements 2% by weight or more it is possible to obtain the effect of improving weather resistance, and by making it 8% by weight or less, it is possible to suppress the deterioration of the soft magnetic properties.
  • the method for producing the metal magnetic powder 17 in this embodiment is not particularly limited, and various atomization methods and various pulverization methods can be used.
  • the median diameter D50 of these metal magnetic powders 17 is, for example, 5.0 ⁇ m or more and 35 ⁇ m or less. In order to alleviate electric field concentration between particles, the median diameter D50 of the metal magnetic powder 17 is made small to ensure insulation. Furthermore, by setting the median diameter D50 as described above, a high filling rate and ease of handling can be ensured. Furthermore, by setting the median diameter D50 of the metal magnetic powder 17 to 35 ⁇ m or less, core loss can be reduced in the high frequency range, and eddy current loss in particular can be reduced.
  • the median diameter D50 of the metal magnetic powder 17 is the particle diameter when the particle diameter is counted from the smallest particle diameter using a particle size distribution meter measured by the laser diffraction scattering method, and the cumulative value reaches 50% of the total.
  • the insulating material 18 is formed so as to cover the surface of the metal magnetic powder 17, and the metal magnetic particles of adjacent metal magnetic powder 17 are insulated from each other by the insulating material 18.
  • the insulating material 18 contains the Si element derived from the metal soap.
  • the insulating material 18 contains, for example, a reactant of the metal soap containing the Si element as a component containing the Si element.
  • the insulating material 18 may also contain, for example, a residue after degreasing of the resin used in manufacturing the dust core 12 described below.
  • FIG. 3 is a flowchart showing the method for manufacturing a powder magnetic core according to this embodiment.
  • step S10 is an example of the first step.
  • step S10 for example, after obtaining a mixture of the metal magnetic powder 17 and the metal soap, the mixture is mixed with resin to obtain a granulated powder.
  • FIG. 4 is a flow chart showing the process for producing granulated powder according to this embodiment.
  • step S10 granulated powder is obtained by carrying out the process (steps) shown in FIG. 4.
  • step S11 in producing the granulated powder, first, the metal magnetic powder 17 and the metal soap are mixed (step S11). This results in a mixture of the metal magnetic powder 17 and the metal soap.
  • the mixture does not substantially contain resin.
  • the mixing in step S11 is performed at room temperature, for example, at about 25°C, without any particular temperature control such as heating or cooling. Note that if the ambient temperature is low, the mixture may be heated to a temperature of about 40°C or less before mixing in order to maintain the metal soap in a liquid state.
  • the metal soap contains silicon. Specifically, the metal soap is fatty acid silicon.
  • the mixed metal soap is liquid at 25°C (room temperature). That is, the melting point of the metal soap is less than 25°C. Therefore, in step S11, the metal magnetic powder 17 is mixed with the liquid metal soap.
  • the liquid metal soap has a branch in the hydrocarbon chain of the fatty acid, for example, to lower the melting point.
  • the metal soap is produced, for example, by a direct method or a double decomposition method.
  • the direct method is a method in which a fatty acid is directly reacted with a metal oxide or metal hydroxide.
  • the double decomposition method is a method in which a basic compound is reacted with a fatty acid in an aqueous solution to produce a basic compound of the fatty acid, and then a metal salt containing a metal or metalloid is reacted with the basic compound.
  • the surfaces of the metal magnetic particles of the metal magnetic powder 17 and the hydrophilic parts of the metal soap are more likely to interact with each other, allowing the metal soap to function effectively.
  • the metal soap is in liquid form, it has high dispersibility, making it easier for the metal soap to act uniformly on the surfaces of the metal magnetic particles of the metal magnetic powder 17.
  • a solvent may be further added to facilitate mixing of the metal magnetic powder 17 and the metal soap. If a solvent is added, after mixing, the mixture is heated at a temperature of, for example, 65°C or higher and 150°C or lower to evaporate the solvent and remove it from the mixture.
  • the solvent include toluene, xylene, ethanol, isopropyl alcohol, acetone, and methyl ethyl ketone.
  • step S12 the mixture of metal magnetic powder 17 and metal soap obtained in step S11 is subjected to heat treatment (step S12).
  • This heat treatment forms a strong coating derived from the metal soap on the surface of the metal magnetic particles of metal magnetic powder 17.
  • the heating method is not particularly limited, but the heating is performed, for example, using a heating furnace such as an electric furnace. Note that, if the mixture is heated in step S11 to remove the solvent, the heat treatment may be performed immediately after the solvent is removed.
  • the heat treatment in step S12 is performed, for example, at a temperature of 200°C or higher and 800°C or lower. This allows the heat treatment to be performed at a temperature higher than the resin hardening temperature and at a temperature at which sintering of the metal magnetic powder 17 is unlikely to occur, so that a coating derived from the metal soap can be effectively formed. From the viewpoint of enhancing the function of the coating derived from the metal soap, the temperature condition of the heat treatment may be 400°C or higher and 600°C or lower.
  • the time of the heat treatment (the time to treat at the target temperature) is, for example, 20 minutes or higher and 120 minutes or lower.
  • step S12 the mixture is heat-treated in a non-oxidizing atmosphere such as nitrogen gas. This prevents the mixture from being altered by oxidation.
  • the mixture is heat-treated before being mixed with the resin.
  • step S13 resin is further added to the mixture that has been heat-treated in step S12, and the mixture and resin are mixed (step S13). This results in a granular granulated powder that is a mixture of the metal magnetic powder 17, resin, and metal soap.
  • the mixing in step S13 is performed at room temperature, for example, around 25°C, without any temperature control such as heating or cooling.
  • the resin to be mixed in step S13 is, for example, dissolved in a solvent beforehand. Note that the resin to be mixed in step S13 does not have to be dissolved in a solvent.
  • the solvent for example, the solvents exemplified for use in step S11 above can be used.
  • the resin is, for example, a thermosetting resin.
  • thermosetting resins include epoxy resin, phenol resin, silicone resin, and polyimide resin.
  • the resin may be a thermoplastic resin. Two or more types of resins may be mixed in step S13.
  • step S13 the mixture that was heat-treated in step S12 is mixed with resin, and then the mixture is heated, for example, at a temperature of 65°C or higher and 150°C or lower to evaporate the solvent, and the mixture after the solvent has evaporated is pulverized to obtain a granular granulated powder (composite magnetic material) with good moldability. Furthermore, this granulated powder may be classified to obtain granulated powder with particle sizes aligned within a specified range. This can further improve moldability.
  • steps S11 and S13 is carried out using, for example, a mortar, a mixer, a ball mill, a V-type mixer, or a cross rotary.
  • step S11 or step S13 other materials such as a coupling agent may be further added and mixed as necessary.
  • the other materials may also include insulating particles.
  • the metal magnetic powder 17, the resin, and the metal soap are mixed to obtain a granular granulated powder in which the metal magnetic powder 17, the resin, and the metal soap are mixed.
  • the resin in the granulated powder functions as a binder that binds the metal magnetic powder 17 in the pressure molding of the granulated powder described below.
  • the mixing ratio of the metal soap to the metal magnetic powder 17 (i.e., the ratio of the amount of metal soap added to the amount of metal magnetic powder 17 added) is, for example, 2.0 wt% or less. This effectively improves the insulation of the powder core 12.
  • the mixing ratio of the metal soap may be 0.01 wt% or more and 2.0 wt% or less, or 0.025 wt% or more and 2.0 wt% or less.
  • the mixing ratio of the metal soap may be 0.025 wt% or more and 0.5 wt% or less. Note that wt% means weight percent.
  • the mixing ratio of the resin to the metal magnetic powder 17 (i.e., the ratio of the amount of resin added to the amount of metal magnetic powder 17 added) is, for example, 1 wt % or more and 10 wt % or less.
  • granulated powder may be obtained by mixing the mixture of metal magnetic powder 17 that has not been subjected to heat treatment and metal soap with resin in step S13.
  • the mixing of the metal magnetic powder 17, the resin, and the metal soap was performed in separate steps S11 and S13, but this is not limited to the above.
  • the mixing procedure of the metal magnetic powder 17, the resin, and the metal soap may be different from that described above.
  • the metal magnetic powder 17, the resin, and the metal soap may be mixed at once.
  • a combination of materials different from the above may be mixed in two or more steps.
  • the shape of the compact is, for example, the shape of the powder magnetic core 12 shown in FIG. 1B. Note that the shape of the compact is not limited to this, and may be, for example, a shape in which the core portion 12b of the powder magnetic core 12 is configured as a separate body.
  • step S30 the molded body obtained in step S20 is degreased.
  • the molded body is heated in the atmosphere at a temperature condition of 200°C or more and 450°C or less. This removes at least a portion of the resin contained in the molded body.
  • the degreasing may be performed under a predetermined oxygen partial pressure or in a non-oxidizing atmosphere.
  • step S40 is an example of the third step.
  • the annealing in step S40 may be performed consecutively to the degreasing in step S30.
  • the distortion caused by the compression during the pressure molding in step S20 is alleviated in the molded body.
  • the magnetic properties can be improved.
  • the molded body is heated to, for example, 400°C or more and 1000°C or less. Also, from the viewpoint of the distortion relaxation effect and maintaining the characteristics of the insulating material 18, the annealing may be performed at a temperature condition of 400°C or more and 600°C or less.
  • step S40 for example, annealing is performed in a non-oxidizing atmosphere such as nitrogen gas. This prevents deterioration of the molded body due to oxidation. Note that annealing may also be performed in the atmosphere or under a predetermined oxygen partial pressure.
  • the heating time during annealing (the time to process at the desired temperature) is, for example, 10 minutes or more and 120 minutes or less.
  • step S30 may be omitted, and annealing may be performed on the molded body that has not been degreased in step S40.
  • the obtained powder magnetic core 12 is assembled with the above-mentioned conductor 13 and coil support 14 to complete the coil component 1.
  • a coil is formed by winding the conductor 13 a predetermined number of times.
  • the powder magnetic core 12, the conductor 13, and the coil support 14 are assembled.
  • the conductor 13 is arranged so as to surround the periphery of the core portion 12b of the two powder magnetic cores 12.
  • the cylindrical portion 14b of each of the two coil supports 14 is arranged between the conductor 13 and each of the core portions 12b of the two powder magnetic cores 12.
  • each of the two coil supports 14 is arranged between the conductor 13 and each of the bases 12a of the two powder magnetic cores 12. At this time, the ends of the cylindrical portion 14b of the two coil supports 14 opposite to the side on which the annular base portion 14a is formed are arranged to abut against each other.
  • the two powder magnetic cores 12 are arranged so that their respective cores 12b and wall portions 12c abut against each other (i.e., one core portion 12b abuts against the other core portion 12b, and one wall portion 12c abuts against the other wall portion 12c).
  • the coil component 1 is assembled by incorporating the conductor 13 into the powder magnetic cores 12 via the coil support 14.
  • the powder magnetic core 12 becomes a magnetic core in which the core portion 12b penetrates the conductor 13 in the direction of the winding axis of the conductor 13.
  • the assembled coil component 1 may be molded with a resin material.
  • the manufacturing method of the dust core 12 includes a first step (step S10) of mixing the metal magnetic powder 17, resin, and metal soap to obtain a granulated powder, a second step (step S20) of pressurizing the obtained granulated powder to obtain a molded body, and a third step (step S40) of annealing the obtained molded body.
  • the metal soap mixed in the first step is liquid at 25°C and contains elemental Si.
  • the liquid metal soap containing Si element coats the surfaces of the metal magnetic particles of the metal magnetic powder 17.
  • the liquid metal soap containing Si element forms a strong coating on the surfaces of the metal magnetic particles of the metal magnetic powder 17, making it difficult for the metal magnetic particles to come into contact with each other, and improving the insulation of the powder core. Therefore, the manufacturing method of the powder core 12 according to this embodiment can improve the insulation of the powder core 12.
  • the metal soap improves the affinity between the metal magnetic powder 17 and the resin, the gaps between the metal magnetic particles of the metal magnetic powder 17 are more likely to be reduced during pressure molding, and the magnetic properties of the powder core 12 can be improved.
  • evaluation results of the powder magnetic core according to the embodiment will be described. Specifically, the powder magnetic core was produced as described below, and the produced powder magnetic core was evaluated. Note that the present embodiment is not limited to the following evaluation.
  • the metal magnetic powder, resin, and Si-based additives were prepared.
  • the metallic magnetic powder used was the metallic magnetic powder shown in Tables 1 and 2 below (Fe-Si-Cr metallic magnetic powder or Fe-Si metallic magnetic powder).
  • the resin used was a modified silicone resin with methyl and phenyl groups on the side chains that had been dissolved in a solvent (isopropyl alcohol) in advance (concentration: 50%).
  • the amount of resin added relative to the amount of metal magnetic powder added was the amount (wt%) shown in Tables 1 and 2. Note that the amount of resin added is the amount added by weight excluding the solvent.
  • the Si-based additives used were metal soaps containing Si element (hereinafter also referred to as "Si-containing metal soaps") or silane-based coupling agents.
  • the Si-containing metal soaps used were fatty acid silicons that were liquid at 25°C and had a branched hydrocarbon chain.
  • the silane-based coupling agents used were those that were liquid at 25°C.
  • the amount of Si-based additive added relative to the amount of metal magnetic powder added was the amount (wt%) shown in Tables 1 and 2.
  • the metal magnetic powder, liquid Si-based additive, and toluene were mixed. After that, the mixture of the metal magnetic powder and the Si-based additive, from which the toluene had been removed by heating at 90°C for 90 minutes, was heat-treated for 30 minutes under the temperature conditions shown in Table 2. The heat treatment was carried out under nitrogen gas. Note that for the samples shown in Table 1, only the toluene was removed and no heat treatment was carried out. Next, resin was added to the mixture and mixed, and the mixture was heated to remove the solvent and then pulverized to produce a granulated powder. In other words, the granulated powder was produced by the method described above using Figure 4.
  • the produced granulated powder was subjected to pressure molding at room temperature with a pressure of 8 tons/ cm2 , and then the resin was cured to produce a ring core with an outer diameter of 14.4 mm, an inner diameter of 10.3 mm, and a thickness of 4.4 mm for evaluating magnetic permeability.
  • the obtained ring core was degreased by heating at 280°C in air for 6.5 hours, and then annealed by heating to the temperatures shown in Tables 1 and 2 under nitrogen gas and holding for 30 minutes to produce a ring-shaped powder core sample.
  • the produced granulated powder was subjected to pressure molding at room temperature with a pressure of 8 ton/ cm2 , and then the resin was cured to produce a plate-shaped molded body having a length of 12 mm, a width of 12 mm, and a thickness of 0.70 mm for evaluation of the breakdown voltage.
  • the obtained plate-shaped molded body was degreased by heating at 280°C for 6.5 hours in air, and then annealed by heating to the temperatures shown in Tables 1 and 2 under nitrogen gas and holding for 30 minutes to produce a plate-shaped powder core sample.
  • the resin was cured after pressure molding, but it is also possible to obtain a molded body without curing the resin, and then cure the resin by heating before degreasing or during degreasing.
  • Magnetic permeability ⁇ i Magnetic permeability ⁇ i below
  • a high magnetic permeability ⁇ i indicates good magnetic properties of the powder core.
  • ⁇ i (L ⁇ le)/( ⁇ 0 ⁇ Ae ⁇ n 2 )...(1)
  • le is the effective magnetic path length
  • ⁇ 0 is the magnetic permeability of a vacuum
  • Ae is the cross-sectional area
  • n is the number of turns of the measuring coil.
  • Oersted (Oe) is the unit of magnetic field strength.
  • 1 Oe (1/4 ⁇ )10 3 A/m, where ⁇ is the constant of the circumference of a circle.
  • Table 1 shows the type of metal magnetic powder, the amount of resin added, the type and amount of Si-based additive, the annealing temperature, the magnetic permeability, and the breakdown voltage of each of the samples of the powder magnetic core used in the evaluation.
  • Figure 5 shows the relationship between the breakdown voltage and the magnetic permeability of the samples shown in Table 1. That is, Figure 5 is a graph of the data in Table 1. In Figure 5, the vertical axis represents the magnetic permeability, and the horizontal axis represents the breakdown voltage. Therefore, in Figure 5, it can be seen that the samples plotted in the upper right corner are samples that have both magnetic properties and insulating properties.
  • sample A1 is a sample made using 0.05 wt% of a silane coupling agent as the Si-based additive.
  • Samples B1 to B4 are samples made using Si-containing metal soap as the Si-based additive, with the amounts of Si-containing metal soap added being varied. As mentioned above, in the samples shown in Table 1, no heat treatment was performed in the production of the granulated powder.
  • sample A1 which uses a silane-based coupling agent as the Si-based additive
  • samples B1 to B4 which use Si-containing metal soap as the Si-based additive
  • Si-containing metal soap is more likely to be present on the surface of metal magnetic particles, such as by forming a coating on the surface of metal magnetic particles, than silane-based coupling agents, so it is thought that the breakdown voltage is high in powder magnetic cores using Si-containing metal soap.
  • samples B1 to B3 in which the amount of Si-containing metal soap added is 0.25 wt% or less, have higher magnetic permeability than sample A1, which uses a silane-based coupling agent. Because Si-containing metal soap has a long hydrocarbon chain, it has a higher affinity with resin than silane-based coupling agents, making it easier to reduce the gap between metal magnetic particles during molding. For this reason, it is believed that the magnetic permeability has been improved in powder magnetic cores that use Si-containing metal soap.
  • the magnetic permeability tends to decrease as the amount of Si-containing metal soap added increases. This is thought to be because the effect of the Si-containing metal soap is to increase the affinity between the metal magnetic powder and the resin, making it easier to narrow the gaps between the metal magnetic particles during molding, while when a large amount is added, the amount of components derived from the Si-containing metal soap increases, making it easier for the gaps between the metal magnetic particles to widen.
  • Table 2 shows the type of metal magnetic powder, the amount of resin added, the type and amount of Si-based additive, the heat treatment temperature, the annealing temperature, the magnetic permeability, and the breakdown voltage of each of the samples of the powder magnetic core used in the evaluation.
  • Figure 6 shows the relationship between the breakdown voltage and the magnetic permeability of the samples shown in Table 2. That is, Figure 6 is a graph of the data in Table 2. In Figure 6, the vertical axis represents the magnetic permeability, and the horizontal axis represents the breakdown voltage. Therefore, in Figure 6, it can be seen that the samples plotted in the upper right corner are samples that have both magnetic properties and insulating properties.
  • Table 2 also shows the evaluation results of some of the samples of the powder magnetic cores shown in Table 1. The same samples in Table 2 as those in Table 1 are given the same identification symbols.
  • sample A2 is a sample that uses 0.05 wt% of a silane coupling agent as a Si-based additive and is heat-treated and annealed at 500°C.
  • Samples B5 to B9 are samples that use 0.05 wt% of a Si-containing metal soap as a Si-based additive and are produced by changing the heat treatment temperature and annealing temperature.
  • the compositions of the metal magnetic powder are different between samples A1 and B2 that were not heat-treated in the production of the granulated powder and samples A2 and B5 to B9 that were heat-treated in the production of the granulated powder.
  • samples B5 to B9 using Si-containing metal soap have both higher breakdown voltage and magnetic permeability than sample A2 using a silane-based coupling agent.
  • the use of Si-containing metal soap improves both the insulating and magnetic properties compared to the use of a silane-based coupling agent. This is thought to be because the Si-containing metal soap, which has a long hydrocarbon chain, is stronger on the surface of the metal magnetic particles than the silane-based coupling agent, and is more likely to form a coating with high affinity with resin through heat treatment.
  • samples B5 to B9, which were heat-treated and annealed at temperatures between 400°C and 600°C all have insulating and magnetic properties equal to or greater than those of sample A2 using a silane-based coupling agent.
  • the magnetic permeability can be further increased, making it possible to produce a powder magnetic core that combines magnetic properties with insulating properties.
  • electrical components using the above-mentioned powder magnetic cores are also included in the present disclosure.
  • electrical components include inductance components such as high-frequency reactors, inductors, and transformers.
  • power supply devices equipped with the above-mentioned electrical components are also included in the present disclosure.
  • the method for producing a powder magnetic core according to the first aspect of the present disclosure includes a first step of mixing a metal magnetic powder composed of a plurality of metal magnetic particles, a resin, and a metal soap to obtain a granulated powder, a second step of pressurizing the obtained granulated powder to obtain a molded body, and a third step of annealing the obtained molded body, in which the metal soap mixed in the first step is liquid at 25°C and contains elemental Si.
  • the method for producing a powder magnetic core according to the second aspect of the present disclosure is the method for producing a powder magnetic core according to the first aspect, and in the first step, the mixing ratio of the metal soap to the metal magnetic powder is 2.0 wt % or less.
  • the method for producing a powder magnetic core according to the third aspect of the present disclosure is the method for producing a powder magnetic core according to the first or second aspect, in which in the first step, the metal magnetic powder and the metal soap are mixed to obtain a mixture, and then the mixture is mixed with the resin to obtain the granulated powder.
  • the method for producing a powder magnetic core according to the fourth aspect of the present disclosure is the method for producing a powder magnetic core according to the third aspect, and in the first step, after obtaining the mixture, the mixture is heat-treated at a temperature of 200°C or higher and 800°C or lower before mixing the mixture with the resin.
  • the method for producing a powder magnetic core according to the fifth aspect of the present disclosure is the method for producing a powder magnetic core according to the fourth aspect, in which the temperature condition of the heat treatment is 400°C or higher and 600°C or lower.
  • the method for producing a powder magnetic core according to the sixth aspect of the present disclosure is the method for producing a powder magnetic core according to the fourth or fifth aspect, in which, in the first step, the heat treatment is performed in a non-oxidizing atmosphere.
  • the method for producing a powder magnetic core according to the seventh aspect of the present disclosure is a method for producing a powder magnetic core according to any one of the first to sixth aspects, in which in the third step, the annealing is performed under temperature conditions of 400°C or higher and 600°C or lower.
  • the method for producing a powder magnetic core according to the eighth aspect of the present disclosure is a method for producing a powder magnetic core according to any one of the first to seventh aspects, in which in the third step, the annealing is performed in a non-oxidizing atmosphere.
  • the powder magnetic cores disclosed herein can be used as materials for high-frequency inductors and transformer cores, etc.

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Abstract

L'invention concerne un procédé de fabrication de noyau à poudre de fer permettant d'améliorer des propriétés d'isolation. Ce procédé de fabrication de noyau à poudre de fer comprend : une première étape (étape S10) pour mélanger une poudre magnétique métallique composée d'une pluralité de particules magnétiques métalliques, une résine et un savon métallique pour obtenir une poudre granulée granulaire ; une deuxième étape (étape S20) pour mouler sous pression la poudre granulée obtenue pour obtenir un corps moulé ; et une troisième étape (étape S40) pour recuire le corps moulé obtenu. Le savon métallique mélangé dans la première étape est liquide à 25 °C et contient un élément Si.
PCT/JP2024/000959 2023-02-22 2024-01-16 Procédé de fabrication de noyau à poudre de fer WO2024176656A1 (fr)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2008117839A (ja) * 2006-11-01 2008-05-22 Oya Giken:Kk 磁芯部材およびその製造方法
JP2014086672A (ja) * 2012-10-26 2014-05-12 Tamura Seisakusho Co Ltd 圧粉磁心及びその製造方法、磁心用粉末及びその製造方法
WO2020145047A1 (fr) * 2019-01-08 2020-07-16 パナソニックＩｐマネジメント株式会社 Procédé de fabrication de matériau magnétique, procédé de fabrication de noyau magnétique en poudre, procédé de fabrication d'élément de bobine, noyau magnétique en poudre, élément de bobine et poudre granulée

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2008117839A (ja) * 2006-11-01 2008-05-22 Oya Giken:Kk 磁芯部材およびその製造方法
JP2014086672A (ja) * 2012-10-26 2014-05-12 Tamura Seisakusho Co Ltd 圧粉磁心及びその製造方法、磁心用粉末及びその製造方法
WO2020145047A1 (fr) * 2019-01-08 2020-07-16 パナソニックＩｐマネジメント株式会社 Procédé de fabrication de matériau magnétique, procédé de fabrication de noyau magnétique en poudre, procédé de fabrication d'élément de bobine, noyau magnétique en poudre, élément de bobine et poudre granulée

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