JP2003282317A - Alloy powder surface treatment method and dust core - Google Patents
Alloy powder surface treatment method and dust coreInfo
- Publication number
- JP2003282317A JP2003282317A JP2002082680A JP2002082680A JP2003282317A JP 2003282317 A JP2003282317 A JP 2003282317A JP 2002082680 A JP2002082680 A JP 2002082680A JP 2002082680 A JP2002082680 A JP 2002082680A JP 2003282317 A JP2003282317 A JP 2003282317A
- Authority
- JP
- Japan
- Prior art keywords
- alloy powder
- soft magnetic
- magnetic alloy
- core
- surface treatment
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000000843 powder Substances 0.000 title claims abstract description 62
- 238000000034 method Methods 0.000 title claims abstract description 13
- 239000000428 dust Substances 0.000 title claims abstract description 10
- 238000004381 surface treatment Methods 0.000 title claims description 22
- 229910045601 alloy Inorganic materials 0.000 title description 14
- 239000000956 alloy Substances 0.000 title description 14
- 229910001004 magnetic alloy Inorganic materials 0.000 claims abstract description 35
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 30
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 15
- -1 alkyl silicate Chemical compound 0.000 claims abstract description 14
- 239000000203 mixture Substances 0.000 claims abstract description 12
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 8
- 239000010419 fine particle Substances 0.000 claims abstract description 6
- 239000003960 organic solvent Substances 0.000 claims abstract description 5
- 238000000465 moulding Methods 0.000 claims description 6
- 238000006460 hydrolysis reaction Methods 0.000 claims description 5
- BOTDANWDWHJENH-UHFFFAOYSA-N Tetraethyl orthosilicate Chemical compound CCO[Si](OCC)(OCC)OCC BOTDANWDWHJENH-UHFFFAOYSA-N 0.000 claims description 4
- 239000012298 atmosphere Substances 0.000 claims description 3
- 230000007062 hydrolysis Effects 0.000 claims description 3
- 239000007788 liquid Substances 0.000 claims description 2
- 239000006247 magnetic powder Substances 0.000 claims description 2
- 238000000748 compression moulding Methods 0.000 abstract description 2
- 230000003247 decreasing effect Effects 0.000 abstract 1
- 229920002050 silicone resin Polymers 0.000 description 14
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 6
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 6
- 239000000463 material Substances 0.000 description 6
- 238000005259 measurement Methods 0.000 description 6
- 238000010438 heat treatment Methods 0.000 description 5
- 230000035699 permeability Effects 0.000 description 5
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 4
- 239000011230 binding agent Substances 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 229910000976 Electrical steel Inorganic materials 0.000 description 2
- 229910018619 Si-Fe Inorganic materials 0.000 description 2
- 229910008289 Si—Fe Inorganic materials 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000005415 magnetization Effects 0.000 description 2
- 229910000889 permalloy Inorganic materials 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229910000702 sendust Inorganic materials 0.000 description 2
- 238000009692 water atomization Methods 0.000 description 2
- 238000004804 winding Methods 0.000 description 2
- 229910000859 α-Fe Inorganic materials 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910017082 Fe-Si Inorganic materials 0.000 description 1
- 229910017133 Fe—Si Inorganic materials 0.000 description 1
- 229910001030 Iron–nickel alloy Inorganic materials 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000003301 hydrolyzing effect Effects 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000011259 mixed solution Substances 0.000 description 1
- 239000012299 nitrogen atmosphere Substances 0.000 description 1
- 239000000700 radioactive tracer Substances 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 238000003980 solgel method Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
Landscapes
- Powder Metallurgy (AREA)
- Soft Magnetic Materials (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、たとえばスイッチ
ング電源に好適な、圧粉磁芯とそれに用いる軟磁性合金
粉末に関するものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a dust core and a soft magnetic alloy powder used therein, which is suitable for a switching power supply, for example.
【０００２】[0002]
【従来の技術】近年、省エネルギー、ＣＯ2問題の高ま
りから、一般家電及び産業用機器において省エネルギー
対策が急速に進んでいる。一般的に、消費電力が大きく
省エネルギー効果が高いものとして、エアコン、冷蔵庫
等のモーターを使用しているもの、及び照明器具などが
挙げられる。 2. Description of the Related Art In recent years, energy saving and CO 2 problems have been increasing, and energy saving measures have been rapidly advanced in general household appliances and industrial equipment. In general, examples of the ones that consume a large amount of power and have a high energy saving effect include those that use motors such as air conditioners and refrigerators, and lighting equipment.
【０００３】これら製品の省エネルギー化を進めるため
に、高効率モーターの採用、電気回路の高効率化等が進
められている。電気回路で効率が大きく問題となるの
は、５０／６０Ｈｚの交流入力を直流化する電源部であ
り、その効率改善のため、スイッチング電源の普及が近
年、急速に進んでいる。In order to save energy in these products, adoption of high-efficiency motors, high-efficiency electric circuits, and the like have been promoted. It is a power supply section that converts an AC input of 50/60 Hz into a direct current, which causes a big problem in efficiency in an electric circuit. In order to improve the efficiency, a switching power supply has been rapidly spread in recent years.
【０００４】しかしながら、スイッチング電源を採用す
ると、電流波形の歪により高調波電流の発生が問題とな
ってくる。この対策として、様々な回路方式が提案され
ており、例えばチョークインプット方式、一石コンバー
ター方式、アクティブフィルター方式などが挙げられる
が、いずれの方式においても電流の導通角を広げるため
にリアクトルが使用される。However, when a switching power supply is used, the generation of harmonic current becomes a problem due to the distortion of the current waveform. As a countermeasure against this, various circuit systems have been proposed, such as a choke input system, an Ichiseki converter system, and an active filter system. In any system, a reactor is used to widen the conduction angle of current. .
【０００５】このリアクトルに求められる特性は、イン
ダクタンス値の他に、高変換効率、可聴域の唸りがな
い、温度上昇が小さい、小型軽量、及び低コストなど多
岐にわたっている。これら特性を達成する方法は、個別
には種々あるが、同時に解決できる最も有効な手段とし
てスイッチング周波数を上げることが考えられる。In addition to the inductance value, the characteristics required for this reactor are wide-ranging, such as high conversion efficiency, no growl in the audible range, small temperature rise, small size and light weight, and low cost. There are various methods for achieving these characteristics, but it is conceivable to increase the switching frequency as the most effective means that can be solved at the same time.
【０００６】その場合、使用されるリアクトル材が重要
であり、高周波まで低損失、しかも定格電流で高透磁率
の材質が必要とされる。実際、小容量の電源では、高周
波用フェライト材の商品化が高周波電源の設計に大きく
貢献していることは周知の事実である。一方、大容量の
電源では、上記特性に加え直流重畳特性が重要であり、
飽和磁化の低いフェライト材は使用できない。In this case, the reactor material used is important, and a material having a low loss up to a high frequency and a high magnetic permeability at a rated current is required. In fact, for small-capacity power supplies, it is a well-known fact that the commercialization of high-frequency ferrite materials has greatly contributed to the design of high-frequency power supplies. On the other hand, in a large capacity power supply, the DC superposition characteristics are important in addition to the above characteristics.
Ferrite materials with low saturation magnetization cannot be used.
【０００７】従って、他のリアクトル材を使用しなけれ
ばならないが、一般的な珪素鋼鉄は高周波でのコアロス
が大きいため使用できず、また高珪素鋼鉄でも、周波数
が２０ｋＨｚを超えると、急激にコアロスの増大と透磁
率の著しい劣化が発生するため、使用周波数が２０ｋＨ
ｚ以下に限定される。Therefore, other reactor materials must be used, but general silicon steel cannot be used because the core loss at high frequency is large, and even high silicon steel rapidly loses core loss when the frequency exceeds 20 kHz. Increase and the magnetic permeability significantly deteriorate, so the operating frequency is 20 kHz.
It is limited to z or less.
【０００８】また、アモルファス合金は、高価なボロン
を使用すること、及び特殊な製造装置が必要なことか
ら、どうしても高コストになること、さらに磁歪が大き
いため可聴域の唸りの発生が避けられず、とても最適な
材料とは言えない。これに対して、圧粉磁芯は、初透磁
率が低いという欠点があるが、周波数特性は良好であ
り、一方で初透磁率を下げることにより直流重畳特性が
向上できること、コアロスも比較的低いことが知られて
いる。[0008] Amorphous alloys are inevitably expensive due to the use of expensive boron and the need for special manufacturing equipment. In addition, the magnetostriction is large and the audible growl is inevitable. , Not the best material. On the other hand, the dust core has a drawback that the initial permeability is low, but the frequency characteristic is good, while the DC superimposition characteristic can be improved by lowering the initial permeability, and the core loss is relatively low. It is known.
【０００９】一般的に直流重畳特性を改善する方法とし
て、磁芯の飽和磁化を高くすること、磁路の一部に空隙
を設けることなどが考えられる。また、コアロス特性や
周波数特性を改善する方法としては、渦電流半径を小さ
くすること、比抵抗を上昇させることなどが考えられ
る。そして、今後、省エネルギー、ＣＯ２抑制は、必須
の課題であり、大容量スイッチン電源において、さらに
高周波数化、低ロス化は不可避と考えられ、それに適合
可能なリアクトルが強く求められている。Generally, as a method of improving the DC superposition characteristic, it is considered to increase the saturation magnetization of the magnetic core, to provide a void in a part of the magnetic path, or the like. Further, as a method for improving the core loss characteristic and the frequency characteristic, it is conceivable to reduce the eddy current radius and increase the specific resistance. In the future, energy saving and CO 2 suppression are indispensable issues, and it is considered that higher frequency and lower loss are inevitable in a large-capacity switched power source, and there is a strong demand for a reactor that can be adapted to it.
【００１０】[0010]
【発明が解決しようとする課題】従って、本発明の技術
的な課題は、電源回路の効率を向上させるために、ロス
特性、周波数特性に優れ、しかも定格電流における透磁
率が高い圧粉磁芯用合金粉末、及びこの合金粉末からな
る圧紛磁芯、さらにはこの圧紛磁芯を使用したリアクト
ルを提供することにある。SUMMARY OF THE INVENTION Therefore, a technical object of the present invention is to improve the efficiency of a power supply circuit by providing a dust core having excellent loss characteristics and frequency characteristics and having a high magnetic permeability at the rated current. It is intended to provide an alloy powder for use, a powder core made of the alloy powder, and a reactor using the powder core.
【００１１】[0011]
【課題を解決するための手段】本発明は、前記課題を達
成すべく、圧紛磁芯の特性向上について検討を重ねた結
果、Ｓｉ−Ｆｅ系合金、またはパーマロイ系合金などか
らなり、かつ粒径が実質的に１５０μｍ以下である軟磁
性合金粉末の表面に、アルキルシリケートを加水分解し
て得られるシリカ膜または、シリカの微粒子を付着させ
ることで、圧紛磁芯の特性が改善されることが見出され
た結果なされたものである。In order to achieve the above-mentioned object, the present invention has been made as a result of repeated studies for improving the characteristics of a powder core, and as a result, it is made of a Si-Fe alloy or a permalloy alloy, The characteristics of the powder magnetic core are improved by attaching a silica film obtained by hydrolyzing an alkyl silicate or silica fine particles to the surface of a soft magnetic alloy powder having a diameter of substantially 150 μm or less. It was made as a result of the discovery.
【００１２】即ち、本発明は、表面に、アルキルシリケ
ートの加水分解によって得られるシリカ膜またはシリカ
の微粒子が付着してなることを特徴とする軟磁性合金粉
末である。That is, the present invention is a soft magnetic alloy powder characterized in that a silica film or silica fine particles obtained by hydrolysis of an alkyl silicate is attached to the surface.
【００１３】また、本発明は、前記の軟磁性合金粉末に
おいて、前記アルキルシリケートは、ＳｉnＯn-1（ＯＣ
2Ｈ5）2n+2なる組成式で示されるエチルシリケートであ
ることを特徴とする軟磁性合金粉末である。In the soft magnetic alloy powder according to the present invention, the alkyl silicate is Si n O n-1 (OC
2 H 5 ) 2n + 2 is a soft magnetic alloy powder characterized by being ethyl silicate represented by a composition formula.
【００１４】また、本発明は、軟磁性合金粉末に、有機
溶媒及び水の少なくともいずれかと、アルキルシリケー
トを含む液を混合した後、不活性雰囲気中の加熱を行う
ことを特徴とする請求項１もしくは請求項２のいずれか
に記載の軟磁性合金粉末の表面処理方法である。Further, according to the present invention, the soft magnetic alloy powder is mixed with at least one of an organic solvent and water and a liquid containing an alkyl silicate, and then heated in an inert atmosphere. Alternatively, the surface treatment method of the soft magnetic alloy powder according to claim 2.
【００１５】また、本発明は、前記の軟磁性合金粉末を
成形してなることを特徴とする圧粉磁芯である。Further, the present invention is a dust core formed by molding the above soft magnetic alloy powder.
【００１６】また、本発明は、比抵抗が５Ω・ｃｍ以上
であることを特徴とする前記の圧粉磁芯である。Further, the present invention is the above dust core, which has a specific resistance of 5 Ω · cm or more.
【００１７】[0017]
【作用】本発明による軟磁性合金粉末では、表面にシリ
カ膜、あるいはシリカの微粒子を付着させることで、絶
縁層が形成され、この軟磁性合金粉末とバインダーと混
合し、適当な金型で圧縮成形、熱処理することにより、
比抵抗が５Ω・ｃｍ以上の圧粉磁芯が得られ、これに巻
線を施すことにより、回路効率に優れた圧粉磁芯を提供
することが可能となる。In the soft magnetic alloy powder according to the present invention, an insulating layer is formed by adhering a silica film or silica fine particles on the surface, and the soft magnetic alloy powder and the binder are mixed and compressed with an appropriate mold. By molding and heat treatment,
A powder magnetic core having a specific resistance of 5 Ω · cm or more can be obtained, and by winding the powder magnetic core, a powder magnetic core having excellent circuit efficiency can be provided.
【００１８】本発明に用いられる軟磁性合金粉末として
は、鋳造法によって作製したインゴットを機械的に粉砕
したもの、アトマイズ法によって作製したものの、どち
らも使用可能である。組成についても、あらゆる軟磁性
粉末に応用が可能で、Ｓｉ−Ｆｅ系合金、センダスト系
合金、パーマロイ系合金、アモルファス合金等の軟磁性
合金粉末に応用が可能である。As the soft magnetic alloy powder used in the present invention, both an ingot prepared by a casting method and an atomized method which are mechanically crushed can be used. The composition can be applied to all soft magnetic powders, including soft magnetic alloy powders such as Si-Fe alloys, sendust alloys, permalloy alloys, and amorphous alloys.
【００１９】[0019]
【発明の実施の形態】本発明の軟磁性合金粉末、及び圧
紛磁芯を得るには、まず、前記合金粉末にアルキルシリ
ケート、エタノール、水、酢酸や塩酸などを加え、撹拌
を行う。これによって、アルキルシリケートが加水分解
反応を起こす。一定時間撹拌を行ったところで、軟磁性
合金粉末を取り出し、乾燥させると粉末表面にシリカ膜
または、微粒子シリカが被覆される。なお、酢酸や塩酸
はアルキルシリケートの加水分解反応の触媒であり、加
えなくともよい。BEST MODE FOR CARRYING OUT THE INVENTION In order to obtain the soft magnetic alloy powder and the powder magnetic core of the present invention, first, alkyl silicate, ethanol, water, acetic acid, hydrochloric acid, etc. are added to the alloy powder and stirred. As a result, the alkyl silicate undergoes a hydrolysis reaction. After stirring for a certain period of time, the soft magnetic alloy powder is taken out and dried to coat the surface of the powder with a silica film or fine particle silica. Note that acetic acid and hydrochloric acid are catalysts for the hydrolysis reaction of alkyl silicates and need not be added.
【００２０】次に、この絶縁層を形成した軟磁性合金粉
末に、バインダーとして樹脂を混合した後、たとえばト
ロイダル形状の金型を使用して圧縮成形する。次に、そ
の成形体に対し、適当な温度で歪とり熱処理を行う。次
に、定格電流に応じた線径の銅線を使用し、所望のイン
ダクタンス値が得られるターン数の巻線を施す。Next, the soft magnetic alloy powder having the insulating layer formed thereon is mixed with a resin as a binder, and then compression molded using, for example, a toroidal mold. Then, the molded body is subjected to strain relief heat treatment at an appropriate temperature. Next, a copper wire having a wire diameter corresponding to the rated current is used, and a winding having the number of turns capable of obtaining a desired inductance value is provided.
【００２１】前記の工程によって作製されたリアクトル
用の圧紛磁芯は、比抵抗が５Ω・ｃｍ以上となり、その
結果、周波数特性、コアロス特性が向上し好適な特性が
得られる。The powder core for a reactor produced by the above steps has a specific resistance of 5 Ω · cm or more, and as a result, frequency characteristics and core loss characteristics are improved and suitable characteristics are obtained.
【００２２】[0022]
【実施例】次に、本発明の実施例を、具体的な例を挙げ
説明する。EXAMPLES Next, examples of the present invention will be described with reference to specific examples.
【００２３】（実施例１）Ｓｉが４.０重量％、Ｏが０.
５重量％、残部がＦｅなる組成の軟磁性合金粉末、Ｓｉ
が５.０重量％、Ｏが０.５重量％、残部がＦｅなる組成
の軟磁性合金粉末、Ｓｉが６.５重量％、Ｏが０.５重量
％、残部がＦｅなる組成の軟磁性合金粉末を、それぞれ
水アトマイズ法で作製した。(Example 1) Si was 4.0% by weight and O was 0.1%.
Soft magnetic alloy powder having a composition of 5 wt% and the balance being Fe, Si
Is 5.0 wt%, O is 0.5 wt%, the balance is Fe soft magnetic alloy powder, Si is 6.5 wt%, O is 0.5 wt%, and the soft magnetic composition is Fe. The alloy powder was produced by the water atomizing method.
【００２４】次に、前記軟磁性合金粉末を、それぞれ粒
径１５０μｍ以下に分級し、これらを２００ｇ秤量し、
エチルシリケート［Ｓｉ（ＯＣ2Ｈ5）4］を５０ｇ、エ
タノールを５０ｇ混合した溶液の中に投入し、１分間撹
枠した。次に、純水を１０ｇ混合した後、密閉容器中で
５分間撹枠した。その後、軟磁性合金粉末を取り出し、
Ｎ2雰囲気下で３００℃、６０分間熱処理を行って表面
処理を施した。Next, each of the soft magnetic alloy powders was classified into particles having a particle size of 150 μm or less, and 200 g of each was weighed.
50 g of ethyl silicate [Si (OC 2 H 5 ) 4 ] and 50 g of ethanol were put into a mixed solution and stirred for 1 minute. Next, after mixing 10 g of pure water, the mixture was stirred in a closed container for 5 minutes. After that, take out the soft magnetic alloy powder,
Surface treatment was performed by performing heat treatment at 300 ° C. for 60 minutes in an N 2 atmosphere.
【００２５】次に、バインダーとしてシリコーン樹脂を
重量比で０.６％混合し、成形金型を用い、外径が２７
ｍｍ、内径が１４ｍｍ、高さが１８ｍｍのトロイダル形
状に成形した。次に、この成形体を不活性雰囲気中で７
００℃×１時間保持後、室温まで徐冷した。また、比較
のため、表面処理を施さない他は、前記と同様にして、
３種類の軟磁性合金粉末を用いた圧紛磁芯を作製した。
これら圧紛磁芯の比抵抗を２端子法で測定した。表１
は、これらの比抵抗の測定結果を示したものである。Next, 0.6% by weight of a silicone resin was mixed as a binder and a molding die was used.
mm, the inner diameter was 14 mm, and the height was 18 mm. Next, the molded body is placed in an inert atmosphere for 7 minutes.
After holding at 00 ° C. for 1 hour, it was gradually cooled to room temperature. Also, for comparison, the same as above except that no surface treatment is performed,
A powder magnetic core using three types of soft magnetic alloy powder was produced.
The specific resistance of these powder magnetic cores was measured by the two-terminal method. Table 1
Shows the measurement results of these specific resistances.
【００２６】次に、それぞれの磁芯に対して巻線を施
し、インピーダンスアナライザー（ヒューレッド・パッ
カー社製：４１９４Ａ）を用いて、μの周波数特性を測
定した。図１は、組成の異なる合金粉末を用いた圧紛磁
芯の、μの周波数特性の測定結果を示したものである。
また、交流ＢＨトレーサー（岩崎通信機製：ＳＹ−８２
３２）を用いて、５０ｋＨｚ、０.１Ｔにおけるコアロ
ス特性を測定した。これらの結果についても、表１にま
とめて示した。Next, each magnetic core was wound, and the frequency characteristic of μ was measured using an impedance analyzer (4194A manufactured by Hured Packer). FIG. 1 shows the measurement results of the frequency characteristics of μ of a powder magnetic core using alloy powders having different compositions.
In addition, AC BH tracer (manufactured by Iwasaki Tsushinki: SY-82
32) was used to measure core loss characteristics at 0.1 kHz at 50 kHz. These results are also summarized in Table 1.
【００２７】[0027]
【表１】 [Table 1]
【００２８】表１及び図１に示した結果から、表面処理
を施した軟磁性合金粉末を用いた試料では、すべての組
成において比抵抗が大きく上昇し、そのため周波数特性
が向上し、渦電流損失が抑えられ、コアロス特性が約２
０〜３０％程度低くなっていることが確認できる。つま
り、本発明のようなシリカ被膜の形成法、即ち、ゾルゲ
ル法を用いて表面に絶縁層を形成した試料では、比抵抗
が上昇し、その結果、周波数特性、コアロス特性が向上
し、好適な特性を発現することが分かった。From the results shown in Table 1 and FIG. 1, in the sample using the surface-treated soft magnetic alloy powder, the specific resistance greatly increased in all compositions, and therefore the frequency characteristic was improved and the eddy current loss was increased. Is suppressed and the core loss characteristic is about 2
It can be confirmed that it is lowered by about 0 to 30%. That is, in the method for forming a silica film as in the present invention, that is, in the sample in which the insulating layer is formed on the surface by using the sol-gel method, the specific resistance is increased, and as a result, the frequency characteristic and the core loss characteristic are improved, which is preferable. It has been found that the characteristics are expressed.
【００２９】なお、ここでは、有機溶媒として、エタノ
ールを用いたが、アルキルシリケートを溶解し、揮発す
るものであれば、他の溶媒でも使用可能である。また、
加水分解のために水を添加したが、場合によっては空気
中の水や、有機溶媒に含まれる水酸基も同様の機能を発
現するので、水の添加は不要となる。Although ethanol was used as the organic solvent here, other solvents can be used as long as they dissolve and volatilize the alkyl silicate. Also,
Water was added for hydrolysis, but in some cases, water in air and hydroxyl groups contained in the organic solvent also exhibit the same function, so that the addition of water is unnecessary.
【００３０】（実施例２）次に、圧縮成形の際に混合す
るシリコーン系樹脂の混合量と特性の関係について、確
認するために、Ｎｉが５０重量％、Ｏが０.５重量％、
残部がＦｅなる組成の軟磁性合金粉末を、水アトマイズ
法で作製し、粒径１５０μｍ以下に分級後、エチルシリ
ケートを用いて、実施例１と同様に表面処理を施した。
次にバインダーとしてシリコーン系樹脂を重量比で０.
３，０.５，１.０，１.５％混合し、実施例１と同様
に、成形、熱処理を行い、圧紛磁芯を得た。(Example 2) Next, in order to confirm the relationship between the mixing amount of silicone resin mixed in compression molding and the characteristics, Ni was 50% by weight, O was 0.5% by weight, and
A soft magnetic alloy powder having a composition with the balance being Fe was produced by a water atomizing method, and after being classified to have a particle size of 150 μm or less, a surface treatment was performed in the same manner as in Example 1 using ethyl silicate.
Next, a silicone resin is used as a binder in a weight ratio of 0.1.
3, 0.5, 1.0, and 1.5% were mixed, and molding and heat treatment were performed in the same manner as in Example 1 to obtain a powder magnetic core.
【００３１】また、比較のため、表面処理を施していな
い軟磁性合金粉末についても、同様にシリコーン系樹脂
を重量比で０.３，０.５，１.０，１.５％混合し、成
形、熱処理を行い、圧紛磁芯を作製した。そして、これ
ら８種類の圧紛磁芯について、実施例１と同様に評価し
た。For comparison, the soft magnetic alloy powder which has not been surface-treated is also mixed with the silicone resin in a weight ratio of 0.3, 0.5, 1.0, and 1.5%. Molding and heat treatment were performed to produce a compressed magnetic core. Then, these eight types of compressed magnetic cores were evaluated in the same manner as in Example 1.
【００３２】図２は、シリコーン樹脂混合量の異なる圧
紛磁芯の、μの周波数特性の測定結果を示したものであ
る。また、表２は、それらの比抵抗とコアロスの測定結
果を、まとめて示したものである。FIG. 2 shows the measurement results of the frequency characteristics of μ of the powder magnetic cores having different amounts of silicone resin mixed. In addition, Table 2 collectively shows the measurement results of those specific resistances and core losses.
【００３３】[0033]
【表２】 [Table 2]
【００３４】これらの結果によると、シリカによる表面
処理を施した軟磁性合金粉末を用いた圧紛磁芯では、い
ずれの樹脂量においても、比抵抗が５Ω・ｃｍ以上増加
し、渦電流損失低減により、約１０％のコアロスの減少
が認められる。また、図２から、シリカによる表面処理
がμの周波数特性向上にも、一定の効果を発現している
ことが分かる。According to these results, in the powder magnetic core using the soft magnetic alloy powder surface-treated with silica, the specific resistance is increased by 5 Ω · cm or more and the eddy current loss is reduced regardless of the amount of resin. As a result, about 10% reduction in core loss is recognized. Further, it can be seen from FIG. 2 that the surface treatment with silica has a certain effect in improving the frequency characteristic of μ.
【００３５】[0035]
【発明の効果】以上に説明したように、本発明によれ
ば、アルキルシリケートを用いた軟磁性合金粉末の表面
処理により、圧紛磁芯の比抵抗が増加し、コアロスの低
減が可能となり、周波数特性も改善できる。また、実施
例では、Ｆｅ−Ｓｉ系、Ｆｅ−Ｎｉ系の軟磁性合金粉末
を用いた例を示したが、センダスト系、Ｆｅ系などの軟
磁性合金粉末を用いた場合においても、同様の効果を発
現し得る。As described above, according to the present invention, the surface treatment of the soft magnetic alloy powder using the alkyl silicate increases the specific resistance of the powder magnetic core, and the core loss can be reduced. The frequency characteristic can also be improved. Further, in the examples, the example using the Fe-Si-based and Fe-Ni-based soft magnetic alloy powders is shown, but the same effect is obtained when the Sendust-based or Fe-based soft magnetic alloy powders are used. Can be expressed.
【００３６】そして、本発明による圧紛磁芯は、たとえ
ば産業機器及び一般家庭用電気製品に搭載されるスイッ
チング電源、殊に、スイッチング周波数が１０ｋＨｚ以
上の電源に搭載される圧粉磁芯に好適であり、回路効率
向上による省エネルギーに寄与できる。The powder magnetic core according to the present invention is suitable for, for example, a switching power supply mounted in industrial equipment and general household electric appliances, particularly a powder magnetic core mounted in a power supply having a switching frequency of 10 kHz or more. Therefore, it is possible to contribute to energy saving by improving circuit efficiency.
【図１】組成の異なる合金粉末を用いた圧紛磁芯の、μ
の周波数特性の測定結果を示す図。FIG. 1 is a graph showing μ of a powder magnetic core using alloy powders having different compositions.
FIG. 6 is a diagram showing the measurement results of the frequency characteristics of FIG.
【図２】シリコーン樹脂混合量の異なる圧紛磁芯の、μ
の周波数特性の測定結果を示す図。[Fig. 2] μ of pressure cores with different amounts of silicone resin mixed
FIG. 6 is a diagram showing the measurement results of the frequency characteristics of FIG.
１１ ４.０重量％Ｓｉ−０.５重量％Ｏ−残部Ｆｅ、
表面処理有
１２ ５.０重量％Ｓｉ−０.５重量％Ｏ−残部Ｆｅ、
表面処理有
１３ ６.０重量％Ｓｉ−０.５重量％Ｏ−残部Ｆｅ、
表面処理有
１４ ４.０重量％Ｓｉ−０.５重量％Ｏ−残部Ｆｅ、
表面処理無
１５ ５.０重量％Ｓｉ−０.５重量％Ｏ−残部Ｆｅ、
表面処理無
１６ ６.０重量％Ｓｉ−０.５重量％Ｏ−残部Ｆｅ、
表面処理無
２１ シリコーン樹脂０.３重量％、表面処理有
２２ シリコーン樹脂０.５重量％、表面処理有
２３ シリコーン樹脂１.０重量％、表面処理有
２４ シリコーン樹脂１.５重量％、表面処理有
２５ シリコーン樹脂０.３重量％、表面処理無
２６ シリコーン樹脂０.５重量％、表面処理無
２７ シリコーン樹脂１.０重量％、表面処理無
２８ シリコーン樹脂１.５重量％、表面処理無11 4.0 wt% Si-0.5 wt% O-balance Fe,
With surface treatment 12 5.0 wt% Si-0.5 wt% O-balance Fe,
With surface treatment 13 6.0 wt% Si-0.5 wt% O-balance Fe,
With surface treatment 14 4.0 wt% Si-0.5 wt% O-balance Fe,
No surface treatment 15 5.0 wt% Si-0.5 wt% O-balance Fe,
No surface treatment 16 6.0 wt% Si-0.5 wt% O-balance Fe,
No surface treatment 21 Silicone resin 0.3% by weight, surface treatment available 22 Silicone resin 0.5% by weight, surface treatment available 23 Silicone resin 1.0% by weight, surface treatment available 24 Silicone resin 1.5% by weight, surface treatment Yes 25 Silicone resin 0.3 wt%, no surface treatment 26 Silicone resin 0.5 wt%, no surface treatment 27 Silicone resin 1.0 wt%, no surface treatment 28 Silicone resin 1.5 wt%, no surface treatment
───────────────────────────────────────────────────── フロントページの続き (72)発明者 保志 晴輝 宮城県仙台市太白区郡山６丁目７番１号 株式会社トーキン内 Ｆターム(参考） 4K018 AA26 AA30 BC28 BC35 KA44 5E041 BC01 CA03 HB14 ─────────────────────────────────────────────────── ─── Continued front page (72) Inventor Haruki Hoshi 6-7-1 Koriyama, Taihaku-ku, Sendai City, Miyagi Prefecture Tokin Co., Ltd. F term (reference) 4K018 AA26 AA30 BC28 BC35 KA44 5E041 BC01 CA03 HB14
Claims (5)
によって得られるシリカ膜またはシリカの微粒子が付着
してなることを特徴とする軟磁性合金粉末。1. A soft magnetic alloy powder characterized in that a silica film or silica fine particles obtained by hydrolysis of an alkyl silicate adheres to the surface.
前記アルキルシリケートは、ＳｉnＯn-1（ＯＣ2Ｈ5）
2n+2なる組成式で示されるエチルシリケートであること
を特徴とする軟磁性合金粉末。2. The soft magnetic powder according to claim 1, wherein
The alkyl silicate is Si n O n-1 (OC 2 H 5 ).
A soft magnetic alloy powder, which is ethyl silicate represented by a composition formula of 2n + 2 .
なくともいずれかと、アルキルシリケートを含む液を混
合した後、不活性雰囲気中の加熱を行うことを特徴とす
る請求項１もしくは請求項２のいずれかに記載の軟磁性
合金粉末の表面処理方法。3. The soft magnetic alloy powder is mixed with at least one of an organic solvent and water and a liquid containing an alkyl silicate, and then heated in an inert atmosphere. 5. A surface treatment method for soft magnetic alloy powder according to any one of 1.
記載の軟磁性合金粉末を成形してなることを特徴とする
圧粉磁芯。4. A dust core formed by molding the soft magnetic alloy powder according to claim 1 or 2.
徴とする請求項４に記載の圧粉磁芯。5. The dust core according to claim 4, which has a specific resistance of 5 Ω · cm or more.
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|---|---|---|---|
| JP2002082680A JP2003282317A (en) | 2002-03-25 | 2002-03-25 | Alloy powder surface treatment method and dust core |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002082680A JP2003282317A (en) | 2002-03-25 | 2002-03-25 | Alloy powder surface treatment method and dust core |
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|---|---|
| JP2003282317A true JP2003282317A (en) | 2003-10-03 |
Family
ID=29230779
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Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2005281805A (en) * | 2004-03-30 | 2005-10-13 | Sumitomo Electric Ind Ltd | Method for producing soft magnetic material, soft magnetic powder and dust core |
| JP2007123703A (en) * | 2005-10-31 | 2007-05-17 | Mitsubishi Materials Pmg Corp | SOFT MAGNETIC POWDER COATED WITH Si OXIDE FILM |
| JP2007254768A (en) * | 2006-03-20 | 2007-10-04 | Aisin Seiki Co Ltd | Soft magnetic powder material, its production method, soft magnetic compact and its production method |
| JP2008041691A (en) * | 2006-08-01 | 2008-02-21 | Nec Tokin Corp | Compound magnetic material and its manufacturing method |
| JP2008060506A (en) * | 2006-09-04 | 2008-03-13 | Nec Tokin Corp | Inductor and method of manufacturing the same |
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| JP2015181208A (en) * | 2015-07-17 | 2015-10-15 | 住友電気工業株式会社 | reactor |
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| CN116013678A (en) * | 2023-03-02 | 2023-04-25 | 深圳信义磁性材料有限公司 | Preparation method of low-loss ferrosilicon magnetic powder core material |
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2002
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7674342B2 (en) | 2004-03-30 | 2010-03-09 | Sumitomo Electric Industries, Ltd. | Method of producing soft magnetic material, soft magnetic powder, and dust core |
| JP2005281805A (en) * | 2004-03-30 | 2005-10-13 | Sumitomo Electric Ind Ltd | Method for producing soft magnetic material, soft magnetic powder and dust core |
| JP4507663B2 (en) * | 2004-03-30 | 2010-07-21 | 住友電気工業株式会社 | Method for producing soft magnetic material, soft magnetic powder and dust core |
| JP2007123703A (en) * | 2005-10-31 | 2007-05-17 | Mitsubishi Materials Pmg Corp | SOFT MAGNETIC POWDER COATED WITH Si OXIDE FILM |
| JP2007254768A (en) * | 2006-03-20 | 2007-10-04 | Aisin Seiki Co Ltd | Soft magnetic powder material, its production method, soft magnetic compact and its production method |
| JP2008041691A (en) * | 2006-08-01 | 2008-02-21 | Nec Tokin Corp | Compound magnetic material and its manufacturing method |
| JP4646238B2 (en) * | 2006-08-01 | 2011-03-09 | Ｎｅｃトーキン株式会社 | Composite magnetic material and method for producing composite magnetic material |
| JP2008060506A (en) * | 2006-09-04 | 2008-03-13 | Nec Tokin Corp | Inductor and method of manufacturing the same |
| JP2013254970A (en) * | 2013-07-25 | 2013-12-19 | Sumitomo Electric Ind Ltd | Reactor |
| JP2015181208A (en) * | 2015-07-17 | 2015-10-15 | 住友電気工業株式会社 | reactor |
| US20180261385A1 (en) * | 2017-03-09 | 2018-09-13 | Tdk Corporation | Dust core |
| US11915847B2 (en) * | 2017-03-09 | 2024-02-27 | Tdk Corporation | Dust core |
| CN116013678A (en) * | 2023-03-02 | 2023-04-25 | 深圳信义磁性材料有限公司 | Preparation method of low-loss ferrosilicon magnetic powder core material |
| CN116013678B (en) * | 2023-03-02 | 2023-10-17 | 深圳信义磁性材料有限公司 | Preparation method of low-loss ferrosilicon magnetic powder core material |
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