JPH08236332A - High-frequency dust core and its manufacture - Google Patents
High-frequency dust core and its manufactureInfo
- Publication number
- JPH08236332A JPH08236332A JP7033590A JP3359095A JPH08236332A JP H08236332 A JPH08236332 A JP H08236332A JP 7033590 A JP7033590 A JP 7033590A JP 3359095 A JP3359095 A JP 3359095A JP H08236332 A JPH08236332 A JP H08236332A
- Authority
- JP
- Japan
- Prior art keywords
- powder
- frequency
- iron powder
- dust core
- iron
- 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.)
- Withdrawn
Links
- 239000000428 dust Substances 0.000 title claims abstract description 29
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 15
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 88
- 239000000843 powder Substances 0.000 claims abstract description 43
- 238000000137 annealing Methods 0.000 claims abstract description 11
- 150000004767 nitrides Chemical class 0.000 claims abstract description 10
- 239000000203 mixture Substances 0.000 claims abstract description 9
- 238000000465 moulding Methods 0.000 claims abstract description 8
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 4
- 229920005989 resin Polymers 0.000 claims description 18
- 239000011347 resin Substances 0.000 claims description 18
- 238000005121 nitriding Methods 0.000 claims description 14
- 150000003949 imides Chemical class 0.000 claims description 13
- 238000002156 mixing Methods 0.000 claims description 6
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 claims description 4
- 239000003822 epoxy resin Substances 0.000 claims description 4
- 239000011737 fluorine Substances 0.000 claims description 4
- 229910052731 fluorine Inorganic materials 0.000 claims description 4
- 229920000647 polyepoxide Polymers 0.000 claims description 4
- 238000009413 insulation Methods 0.000 abstract description 18
- 230000004907 flux Effects 0.000 abstract description 16
- 229920006395 saturated elastomer Polymers 0.000 abstract description 3
- 238000010410 dusting Methods 0.000 abstract 1
- 239000007787 solid Substances 0.000 abstract 1
- 239000011162 core material Substances 0.000 description 54
- 239000007788 liquid Substances 0.000 description 17
- 229910052742 iron Inorganic materials 0.000 description 14
- 230000035699 permeability Effects 0.000 description 11
- 230000000694 effects Effects 0.000 description 6
- 238000000034 method Methods 0.000 description 6
- 239000006247 magnetic powder Substances 0.000 description 5
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 229910000702 sendust Inorganic materials 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 229910000889 permalloy Inorganic materials 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- 229910021529 ammonia Inorganic materials 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 238000000354 decomposition reaction Methods 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000007580 dry-mixing Methods 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 235000019353 potassium silicate Nutrition 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 2
- 229910000859 α-Fe Inorganic materials 0.000 description 2
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 1
- 239000004327 boric acid Substances 0.000 description 1
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 1
- 235000013539 calcium stearate Nutrition 0.000 description 1
- 239000008116 calcium stearate Substances 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 229910001337 iron nitride Inorganic materials 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- 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
Landscapes
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Soft Magnetic Materials (AREA)
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は、高周波用圧粉磁心及び
その製造方法に関し、詳細には、鉄粉を主要原料として
用いて圧粉、接合、固化してなる高周波用圧粉磁心に関
し、例えば、電源装置用チョークコイル等の電磁気部品
として好適に使用できる高周波用圧粉磁心及びその製造
方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a high-frequency powder magnetic core and a method for manufacturing the same, and more particularly to a high-frequency powder magnetic core obtained by compacting, bonding and solidifying iron powder as a main raw material. For example, the present invention relates to a high frequency powder magnetic core that can be suitably used as an electromagnetic component such as a choke coil for a power supply device, and a method for manufacturing the same.
【０００２】[0002]
【従来の技術】近年、電子機器等に搭載されている各種
電力変換装置は、駆動周波数をより高周波化することに
よって小型化、高効率化を図っている。かかる技術動向
に対応して、電力変換装置の部品であるチョークコイル
やノイズフィルターも、損失、透磁率の面でより高周波
域での使用に耐え得ることが要求されている。2. Description of the Related Art In recent years, various power converters mounted on electronic equipment have been made smaller and more efficient by increasing the driving frequency. In response to such technological trends, it is required that the choke coil and the noise filter, which are the components of the power conversion device, can withstand use in a higher frequency region in terms of loss and magnetic permeability.
【０００３】かかるチョークコイルやノイズフィルター
等の磁性部品を構成するところの高周波用圧粉磁心とし
ては、従来、フェライトコアが使用されていたが、飽和
磁束密度が低いという欠点がある。これに対し、軟磁性
粉末にエポキシ樹脂やフッソ樹脂等のバインダーを被覆
をした圧粉磁心材料があり、これを圧粉、接合、固化し
てなる高周波用圧粉磁心はフェライトコアよりも飽和磁
束密度が高いという利点がある（例えば特開昭59-50138
号公報参照）。ここで、軟磁性粉末としては、純鉄、セ
ンダスト、パーマロイ等が用いられる。Ferrite cores have hitherto been used as high-frequency powder magnetic cores for forming magnetic parts such as choke coils and noise filters, but they have a drawback of low saturation magnetic flux density. On the other hand, there is a dust core material in which soft magnetic powder is coated with a binder such as epoxy resin or fluorine resin, and a high-frequency dust core formed by compacting, bonding, and solidifying the saturated magnetic flux is more saturated than the ferrite core. There is an advantage that the density is high (for example, JP-A-59-50138).
(See the official gazette). Here, as the soft magnetic powder, pure iron, sendust, permalloy, or the like is used.
【０００４】[0004]
【発明が解決しようとする課題】ところが、前記従来の
高周波用圧粉磁心においては、下記の如き種々の問題点
がある。 軟磁性粉末として純鉄を用いた高周波用圧粉磁心に
おいては、飽和磁束密度は高いが、個々の粒子（純鉄）
の比抵抗が小さいため、高周波域では渦電流損失が顕著
となり、発熱量が大きく、100kHz以上では使用に耐えな
い。 軟磁性粉末としてセンダストを用いた高周波用圧粉
磁心においては、センダストがSi及びAlを含んでいるた
めに比抵抗が大きく、100kHz以上でも渦電流損失は小さ
いが、飽和磁束密度が低いという欠点がある。さらに、
粒子（センダスト）の硬度が高いために高周波用圧粉磁
心に成型（圧粉、接合、固化）する際の所要圧力が純鉄
の約４倍程度と大きく、又、そのために成型体（圧粉磁
心）の寸法の制約を受け易いという欠点もある。 軟磁性粉末としてパーマロイを用いた高周波用圧粉
磁心においては、パーマロイがNiを含んでいるために比
抵抗が大きく、100kHz以上でも渦電流損失は小さいが、
飽和磁束密度が低いという欠点がある。又、高価なNiを
含んでいるためにコスト的に高くつくという欠点もあ
る。However, the conventional high-frequency powder magnetic core has various problems as described below. In high-frequency dust cores that use pure iron as the soft magnetic powder, the saturation magnetic flux density is high, but individual particles (pure iron)
Since the specific resistance of is small, eddy current loss becomes significant in the high frequency range, the amount of heat generated is large, and it cannot withstand use above 100 kHz. In a high-frequency dust core using sendust as the soft magnetic powder, the sendust contains Si and Al, so that the specific resistance is large, and the eddy current loss is small even at 100 kHz or more, but the saturation magnetic flux density is low. is there. further,
Since the hardness of the particles (sendust) is high, the required pressure for molding (compacting, bonding, solidifying) into a high-frequency dust core is about four times that of pure iron, and for that reason, the compact (compact powder) There is also a drawback that it is easy to be restricted by the size of the magnetic core. In a high-frequency dust core using permalloy as the soft magnetic powder, the permalloy contains Ni, so the specific resistance is large, and the eddy current loss is small even at 100 kHz or more,
There is a drawback that the saturation magnetic flux density is low. In addition, since it contains expensive Ni, it has the drawback of being expensive.
【０００５】本発明は、このような事情に着目してなさ
れたものであって、その目的は前記従来の高周波用圧粉
磁心の有する問題点を解消し、高い飽和磁束密度という
特性、高周波性能（高周波域でも低い渦電流損という特
性）とを同時に有する高周波用圧粉磁心及びその製造方
法を提供しようとするものである。The present invention has been made in view of such circumstances, and its purpose is to solve the problems of the above-mentioned conventional high-frequency powder magnetic core, and to achieve high saturation magnetic flux density characteristics and high-frequency performance. An object of the present invention is to provide a powder magnetic core for high frequency and a method for manufacturing the same, which has (a characteristic of low eddy current loss even in the high frequency region).
【０００６】[0006]
【課題を解決するための手段】上記目的を達成するため
に、本発明に係る高周波用圧粉磁心及びその製造方法は
次のような構成としている。即ち、請求項１記載の高周
波用圧粉磁心は、窒化層を表面に有する鉄粉を圧粉、接
合、固化してなる高周波用圧粉磁心であって、前記鉄粉
が、Ｐ、Mg、Ｂを含むガラス状絶縁層で被覆されている
ことを特徴とする高周波用圧粉磁心である。In order to achieve the above object, a high-frequency dust core and a method for manufacturing the same according to the present invention have the following configurations. That is, the high-frequency dust core according to claim 1 is a high-frequency dust core obtained by compacting, bonding, and solidifying iron powder having a nitride layer on its surface, wherein the iron powder is P, Mg, It is a dust core for high frequencies characterized by being coated with a glassy insulating layer containing B.
【０００７】請求項２記載の高周波用圧粉磁心は、前記
ガラス状絶縁層が、Ｐ、Mg、Ｂの酸化物よりなる請求項
１記載の高周波用圧粉磁心である。請求項３記載の高周
波用圧粉磁心は、前記鉄粉のガラス状絶縁層の上に更に
エポキシ樹脂、イミド樹脂、フッソ樹脂の１種又は２種
以上が被覆されている請求項１又は２記載の高周波用圧
粉磁心である。The high-frequency dust core according to claim 2 is the high-frequency dust core according to claim 1, wherein the glass-like insulating layer is made of an oxide of P, Mg, or B. The high-frequency dust core according to claim 3, wherein the glass-like insulating layer of iron powder is further coated with one or more of epoxy resin, imide resin, and fluorine resin. It is a high frequency powder magnetic core.
【０００８】請求項４記載の高周波用圧粉磁心の製造方
法は、鉄粉の表面を窒化させた後、これをＰ、Mg、Ｂを
含むガラス状絶縁剤と混合し、この混合体を粉末成型プ
レスにより圧縮して固化成型し、しかる後、歪み取り焼
鈍を施すことを特徴とする高周波用圧粉磁心の製造方法
である。According to a fourth aspect of the present invention, there is provided a method for producing a dust core for high frequencies, wherein after nitriding the surface of iron powder, this is mixed with a glassy insulating agent containing P, Mg and B, and this mixture is powdered. This is a method for producing a dust core for high frequency, which comprises compressing with a molding press to solidify, and then subjecting to strain relief annealing.
【０００９】[0009]
【作用】本発明に係る高周波用圧粉磁心は、前記の如
く、窒化層を表面に有する鉄粉を圧粉、接合、固化して
なる高周波用圧粉磁心であって、前記鉄粉が、Ｐ、Mg、
Ｂを含むガラス状絶縁層で被覆されている。The high-frequency dust core according to the present invention is, as described above, a high-frequency dust core obtained by compacting, bonding, and solidifying iron powder having a nitride layer on its surface. P, Mg,
It is covered with a glassy insulating layer containing B.
【００１０】上記窒化層は粒子（基材の鉄粉）の電気抵
抗を高め、更に上記ガラス状絶縁層は粒子（基材の鉄
粉）間の絶縁性能を向上させる働きを有している。その
ため、高周波性能を高め、高周波域でも鉄損の原因であ
る渦電流損を低減することができる。The nitride layer has the function of increasing the electrical resistance of the particles (iron powder of the base material), and the glassy insulating layer has the function of improving the insulating performance between the particles (iron powder of the base material). Therefore, high frequency performance can be improved and eddy current loss, which is a cause of iron loss, can be reduced even in a high frequency range.
【００１１】又、上記Ｐ、Mg、Ｂを含むガラス状絶縁層
は、耐熱性に優れているので、高周波用圧粉磁心形状に
圧粉成型（圧粉、接合、固化）した後の歪み取り焼鈍の
際、歪み取りを充分に果たし得る焼鈍温度に加熱でき、
そのため充分に歪み取りでき、それにより鉄損を小さく
でき、透磁率及び飽和磁束密度を向上し得る。Further, since the glassy insulating layer containing P, Mg and B is excellent in heat resistance, strain relief after compacting (compacting, bonding, solidifying) into a compacted magnetic core for high frequency is performed. At the time of annealing, it can be heated to the annealing temperature that can sufficiently perform strain relief,
Therefore, the strain can be sufficiently removed, thereby reducing the iron loss, and improving the magnetic permeability and the saturation magnetic flux density.
【００１２】従って、本発明に係る高周波用圧粉磁心
は、高い飽和磁束密度という特性、高周波性能（高周波
域でも低い渦電流損という特性）とを同時に有し得る。Therefore, the high frequency dust core according to the present invention can simultaneously have the characteristics of high saturation magnetic flux density and high frequency performance (the characteristics of low eddy current loss even in the high frequency range).
【００１３】前記Ｐ、Mg、Ｂを含むガラス状絶縁層とし
ては、これら元素の酸化物が代表的である（請求項２記
載の高周波用圧粉磁心）。As the glassy insulating layer containing P, Mg and B, oxides of these elements are typical (powder magnetic core for high frequency according to claim 2).
【００１４】前記鉄粉のガラス状絶縁層の上に更にエポ
キシ樹脂、イミド樹脂、フッソ樹脂の１種又は２種以上
が被覆されていると、高周波用圧粉磁心の機械的強度を
向上できる（請求項３記載の高周波用圧粉磁心）。If the glass-like insulating layer of iron powder is further coated with one or more of epoxy resin, imide resin, and fluorine resin, the mechanical strength of the high-frequency powder magnetic core can be improved ( The powder magnetic core for high frequencies according to claim 3.
【００１５】本発明に係る高周波用圧粉磁心の製造方法
は、前述の如く、鉄粉の表面を窒化させた後、これを
Ｐ、Mg、Ｂを含むガラス状絶縁剤と混合し、この混合体
を粉末成型プレスにより圧縮して固化成型し、しかる
後、歪み取り焼鈍を施すようにしている。従って、窒化
層を表面に有する鉄粉を圧粉、接合、固化してなる高周
波用圧粉磁心であって、前記鉄粉が、Ｐ、Mg、Ｂを含む
ガラス状絶縁層で被覆されたもの（即ち、前記の如く優
れた作用効果を奏する本発明に係る高周波用圧粉磁心）
を得ることができる。As described above, the method for producing a high-frequency powder magnetic core according to the present invention comprises nitriding the surface of iron powder, and then mixing this with a glassy insulating agent containing P, Mg, and B, and mixing this. The body is compressed by a powder molding press to be solidified and molded, and then strain relief annealing is performed. Therefore, a high-frequency dust core formed by compacting, bonding, and solidifying iron powder having a nitride layer on the surface, wherein the iron powder is covered with a glassy insulating layer containing P, Mg, and B (That is, the high-frequency powder magnetic core according to the present invention that exhibits the above-described excellent effects)
Can be obtained.
【００１６】本発明において、前記基材の鉄粉として
は、還元鉄粉、アトマイズ鉄粉等があるが、磁気特性を
より向上させるには、鉄粉を双ロールやボールミルで偏
平加工し、これにより反磁界係数を低下させることが有
効である。更に、渦電流を微小域に閉じ込めるために上
記鉄粉粒度を微粉化することは、磁束密度を若干犠牲に
するが、交流透磁率の高周波特性の安定性、低鉄損を得
る上で有効である。In the present invention, as the iron powder of the base material, there are reduced iron powder, atomized iron powder and the like. In order to further improve the magnetic properties, the iron powder is flattened by a twin roll or a ball mill, It is effective to reduce the demagnetizing factor. Further, pulverizing the iron powder grain size in order to confine the eddy current in a minute region slightly sacrifices the magnetic flux density, but is effective in obtaining stability of high frequency characteristics of AC permeability and low iron loss. is there.
【００１７】鉄粉表面に窒化層を形成するための窒化処
理方法としてはガス窒化法が最も簡便であり、反応容器
又は焼鈍炉においてアンモニア分解ガス又は窒素、水素
混合ガス雰囲気のもとで500 ℃程度に加熱することによ
り窒化できる。The gas nitriding method is the simplest nitriding method for forming a nitriding layer on the surface of iron powder, and it is carried out at 500 ° C. in an atmosphere of ammonia decomposition gas or nitrogen / hydrogen mixed gas in a reaction vessel or annealing furnace. Nitriding can be performed by heating to a certain degree.
【００１８】圧粉成型後の歪み取り焼鈍の際の加熱温度
としては、高いほど歪み取りの効果はあるが、鉄粉表面
の窒化層（Fe4N) の分解温度(680℃) 以下で且つ該窒化
層の上層のガラス状絶縁層と窒化鉄粉とが反応を起こさ
ない温度以下にする必要がある。The higher the heating temperature for strain relief annealing after compacting, the higher the strain relief effect, but below the decomposition temperature (680 ° C.) of the nitride layer (Fe 4 N) on the iron powder surface and It is necessary to keep the temperature below the temperature at which the glassy insulating layer above the nitrided layer does not react with the iron nitride powder.
【００１９】本発明に係る高周波用圧粉磁心の断面の一
部を模式図で図１に示す。図１において、１は窒化層を
表面に有する鉄粉、２はその窒化層、３はガラス状絶縁
層を示すものであり、鉄粉１はガラス状絶縁層３を介し
て接合されている。FIG. 1 is a schematic view showing a part of the cross section of the high-frequency dust core according to the present invention. In FIG. 1, 1 is iron powder having a nitride layer on the surface, 2 is the nitride layer, and 3 is a glass-like insulating layer, and the iron powder 1 is bonded via the glass-like insulating layer 3.
【００２０】本発明の実施例に係る高周波用圧粉磁心の
製造工程を図１に示す。この図１に従って該高周波用圧
粉磁心の製造方法を説明する。先ず、高純度アトマイズ
鉄粉をボールミルまたは双ロールで偏平加工し、偏平度
（平均直径／厚さ）１〜６の偏平状鉄粉を得た（図示し
ていない）。次に、該偏平状鉄粉について水素とアンモ
ニアとの混合比が６対４のガス雰囲気のもとで500 ℃に
30分加熱する窒化処理を行い、鉄粉表面に窒化層を形成
させた〔図２-(a)〕。一方、水１リットル当り、燐酸:1
63ｇ、MgO:31ｇ、硼酸:30 ｇを含む混合液からなる絶縁
処理液を作成した。FIG. 1 shows a manufacturing process of a high frequency powder magnetic core according to an embodiment of the present invention. A method of manufacturing the high-frequency dust core will be described with reference to FIG. First, high-purity atomized iron powder was flattened with a ball mill or twin rolls to obtain flat iron powder having flatness (average diameter / thickness) 1 to 6 (not shown). Next, the flat iron powder was heated to 500 ° C under a gas atmosphere with a mixing ratio of hydrogen and ammonia of 6 to 4.
Nitriding treatment was performed by heating for 30 minutes to form a nitriding layer on the iron powder surface [Fig. 2- (a)]. On the other hand, phosphoric acid: 1 per liter of water
An insulation treatment liquid was prepared from a mixed liquid containing 63 g, MgO: 31 g, and boric acid: 30 g.
【００２１】上記窒化処理後の鉄粉の中、60メッシュ以
下の鉄粉４を100 ｇ採取し、これに対し上記絶縁処理液
５を0.05〜30ml添加し、両者を混合して混合体６を得た
〔図２-(b)〕。次に、該混合体６について400 ℃以下で
約10分間乾燥させた後、解粒し絶縁処理粉末７を得た
〔図２-(c)〕。From the iron powder after the nitriding treatment, 100 g of iron powder 4 of 60 mesh or less was sampled, 0.05 to 30 ml of the insulating treatment liquid 5 was added thereto, and both were mixed to form a mixture 6. Obtained [Fig. 2- (b)]. Next, the mixture 6 was dried at 400 ° C. or lower for about 10 minutes and then pulverized to obtain an insulation-treated powder 7 (FIG. 2- (c)).
【００２２】そして、上記絶縁処理粉末７に必要に応じ
てステアリン酸カルシウム等の潤滑剤を0.6wt%程度添加
し、これを通常の粉末成型プレス８により圧縮して所定
の磁心形状に固化成型した〔図２-(d)〕。しかる後、こ
れを 400〜600 ℃で約１時間加熱して歪み取り焼鈍を施
した。この焼鈍により、鉄粉７に生じていた歪みが開放
される。If necessary, a lubricant such as calcium stearate is added to the insulation-treated powder 7 in an amount of about 0.6 wt%, and the powder is compressed by an ordinary powder molding press 8 to be solidified and molded into a predetermined magnetic core shape [ Fig. 2- (d)]. After that, this was heated at 400 to 600 ° C. for about 1 hour to be subjected to strain relief annealing. The strain generated in the iron powder 7 is released by this annealing.
【００２３】このようにして得られた本発明の実施例に
係る高周波用圧粉磁心は、窒化層を表面に有する鉄粉が
ガラス状絶縁層で被覆され、鉄粉同士がガラス状絶縁層
で分離されガラス状絶縁層を介して接合されているの
で、絶縁性に優れ、飽和磁束密度が高く、渦電流の発生
を防止できて高周波域でも渦電流損が小さい。In the thus obtained high frequency powder magnetic core according to the embodiment of the present invention, the iron powder having the nitride layer on the surface is covered with the glass-like insulating layer, and the iron powders are the glass-like insulating layers. Since they are separated and bonded via the glass-like insulating layer, they have excellent insulating properties, high saturation magnetic flux density, can prevent generation of eddy currents, and have small eddy current loss even in a high frequency range.
【００２４】そして、上記ガラス状絶縁層がＰ、Mg、Ｂ
を含んでいるので、従来の水ガラス或いは樹脂を用いた
場合に比較し、耐熱性に極めて優れ、そのため、鉄粉の
歪み（固化成型時に鉄粉に発生した歪み）を充分に開放
させるに必要な温度で歪み取り焼鈍することができる。
その結果、水ガラス等の無機バインダーを用いた場合の
如く保磁力減少の達成が困難であるという問題点も解消
でき、高周波域での鉄損値が小さくなり、使用可能な周
波数帯域を拡大できる。The glassy insulating layer is made of P, Mg, B.
Since it contains, it has excellent heat resistance compared to the case of using conventional water glass or resin, and therefore it is necessary to sufficiently release the distortion of iron powder (strain generated in iron powder during solidification molding). Strain relief annealing can be performed at various temperatures.
As a result, it is possible to solve the problem that it is difficult to achieve a decrease in coercive force as in the case of using an inorganic binder such as water glass, the iron loss value in the high frequency range becomes small, and the usable frequency band can be expanded. .
【００２５】又、本実施例では、鉄粉をボールミル等に
より偏平度１〜６に偏平加工したので、これにより反磁
界係数を低減でき、磁気特性を向上し得る効果がある。
更に、高周波電流は金属導体の表面に集中し易いが、本
実施例では60メッシュアンダー（以下）の鉄粉を用いた
ので、これにより鉄損値の向上が図れるだけでなく、周
波数特性を改善できる。Further, in this embodiment, the iron powder is flattened to a flatness of 1 to 6 by a ball mill or the like, so that the demagnetizing factor can be reduced and the magnetic characteristics can be improved.
Furthermore, high-frequency current tends to concentrate on the surface of the metal conductor, but since iron powder of 60 mesh under (below) is used in this embodiment, not only the iron loss value can be improved, but also the frequency characteristic is improved. it can.
【００２６】上記本発明の本実施例に係る高周波用圧粉
磁心について、その特性に及ぼす各種条件（鉄粉の偏平
加工時間、偏平加工後の鉄粉のアスペクト比、偏平加工
後の鉄粉への絶縁処理液の添加量、絶縁処理後の鉄粉へ
のイミド樹脂被覆の有無等）の影響を調べた。その結果
を以下説明する。Regarding the high-frequency dust core according to this embodiment of the present invention, various conditions affecting its characteristics (iron powder flattening time, flattened iron powder aspect ratio, flattened iron powder) The effect of the amount of the insulation treatment liquid added, the presence or absence of the imide resin coating on the iron powder after the insulation treatment, etc. was examined. The results will be described below.
【００２７】図３に、偏平加工後の鉄粉:100ｇに対する
絶縁処理液の添加量をパラメータとして0.05〜10mlと変
化させた場合に、得られた高周波用圧粉磁心の交流初透
磁率の周波数特性を示す。図中、特性曲線(1):◎印は絶
縁処理液量を0.05mlとしたもの、特性曲線(2):●印は絶
縁処理液量を0.1ml 、特性曲線(3):▲印は絶縁処理液量
を0.3ml 、特性曲線(4):○印は絶縁処理液量を１ml、特
性曲線(5):△印は絶縁処理液量を３ml、特性曲線(6):□
印は絶縁処理液量を５ml、特性曲線(7):■印は絶縁処理
液量を10mlとした場合のものである。FIG. 3 shows the frequency of the initial AC permeability of the high-frequency powder magnetic core obtained when the amount of the insulating treatment liquid added to 100 g of the flattened iron powder: 100 g was changed as a parameter. Show the characteristics. In the figure, characteristic curve (1): ◎ indicates that the amount of insulation treatment liquid is 0.05 ml, characteristic curve (2): ● indicates the amount of insulation treatment liquid, characteristic curve (3): ▲ indicates insulation Treatment liquid volume is 0.3 ml, characteristic curve (4): ○ is insulation treatment fluid volume 1 ml, characteristic curve (5): △ is insulation treatment fluid volume 3 ml, characteristic curve (6): □
The mark indicates that the amount of the insulating treatment liquid is 5 ml, and the characteristic curve (7): ■ indicates that the amount of the insulating treatment liquid is 10 ml.
【００２８】絶縁処理液量が0.05mlの(1) 、0.1ml の
(2) では、高い周波数域での透磁率の低下が大きく、絶
縁効果は認められるが、安定性に劣る。絶縁処理液量が
10mlの(7) では、安定性は良いものの、透磁率のレベル
が低い。これに対して、絶縁処理液量が 0.3〜５mlの
(3) 〜(6) の場合は、周波数が高くなっても透磁率のレ
ベル及び安定性とも良好な値になっている。Insulation treatment liquid amount of 0.05 ml (1), 0.1 ml
In (2), the magnetic permeability in the high frequency range is greatly reduced, and the insulating effect is recognized, but the stability is poor. The amount of insulation treatment liquid
At 10 ml (7), the stability is good, but the level of permeability is low. On the other hand, if the amount of insulation treatment liquid is 0.3-5 ml,
In the cases of (3) to (6), the level of magnetic permeability and the stability are good even when the frequency is high.
【００２９】図４に、偏平加工後の鉄粉:100ｇに対する
絶縁処理液の添加量を１mlとして絶縁処理し、該絶縁処
理後の鉄粉へイミド樹脂を湿式混合又は乾式混合により
被覆した場合、かかるイミド樹脂被覆を施さない場合
に、得られた高周波用圧粉磁心の交流初透磁率の周波数
依存性を示す。図中、特性曲線(8):○印はイミド樹脂被
覆を施さない場合、特性曲線(9):△印は鉄粉99%(vol.%)
にイミド樹脂１％を湿式混合した後、解粒した場合、特
性曲線 (10):□印は鉄粉99%(vol.%)にイミド樹脂１％を
乾式混合した場合、特性曲線 (11):●印は鉄粉97%(vol.
%)にイミド樹脂３％を湿式混合した後、解粒した場合、
特性曲線 (12):■印は鉄粉95%(vol.%)にイミド樹脂５％
を湿式混合した後、解粒した場合のものである。FIG. 4 shows a case where the flattened iron powder: Insulation treatment is performed with an addition amount of the insulating treatment liquid to 100 g per 100 g, and the iron powder after the insulation treatment is coated with an imide resin by wet mixing or dry mixing. When the imide resin coating is not applied, the frequency dependence of the AC initial permeability of the obtained high-frequency powder magnetic core is shown. In the figure, characteristic curve (8): ○ is the case where the imide resin coating is not applied, characteristic curve (9): △ is iron powder 99% (vol.%)
Characteristic curve (10) when wet-mixing 1% imide resin and then disintegrating: Characteristic curve (11) when dry mixing 1% imide resin with 99% (vol.%) Iron powder : ● indicates iron powder 97% (vol.
%), When 3% of imide resin was wet-mixed and then disintegrated,
Characteristic curve (12): ■ indicates iron powder 95% (vol.%) And imide resin 5%
Is wet-mixed and then disintegrated.
【００３０】イミド樹脂被覆を施していない(8) に対し
て、イミド樹脂量が増えるほど透磁率のレベルは下がる
ものの、安定性は向上している。又、湿式混合した(9)
と乾式混合した(10)とを比較すると、湿式混合した方が
安定度が高いことがわかる。In contrast to (8) not coated with imide resin, the level of magnetic permeability decreases as the amount of imide resin increases, but the stability is improved. Wet mixed (9)
Comparing with the dry-mixed (10), it can be seen that the wet-mix has higher stability.
【００３１】図５に、鉄粉の偏平加工時間と偏平加工後
の鉄粉のアスペクト比(D/t) との関係を示す。このアス
ペクト比は、図に示す如く平均直径（D1＋D2）／厚みt
である。図中、(13)は D/t比:1.5、(14)は D/t比:3.5、
(15)は D/t比:5.0、(16)は D/t比:6.0、(17)は D/t比:
3.25 、(18)は D/t比:2.5である、FIG. 5 shows the relationship between the flattening time of iron powder and the aspect ratio (D / t) of the iron powder after flattening. As shown in the figure, this aspect ratio is the average diameter (D 1 + D 2 ) / thickness t
Is. In the figure, (13) is D / t ratio: 1.5, (14) is D / t ratio: 3.5,
(15) D / t ratio: 5.0, (16) D / t ratio: 6.0, (17) D / t ratio:
3.25, (18) has a D / t ratio of 2.5,
【００３２】上記偏平加工後の鉄粉(13)〜(18)について
前記と同様の窒化処理を行った後、この鉄粉について圧
粉成型後、印加磁場100 Oeでの磁束密度を測定した。そ
の結果、磁束密度は、(13)の場合のもので8500Ｇ、(14)
の場合のもので9500Ｇ、(15)の場合のもので 11500Ｇ、
(16)の場合のもので 11500Ｇ、(17)の場合のもので9500
Ｇ、(18)の場合のもので8000Ｇであった。このことか
ら、アスペクト比(D/t)を１〜６の範囲にすることによ
り、磁気特性が向上することがわかる。中でも、(14)〜
(16)の場合は磁束密度が特に向上しており、偏平化によ
る効果が認められる。The iron powders (13) to (18) after the flattening were subjected to the same nitriding treatment as described above, and the iron powders were compacted, and the magnetic flux density under an applied magnetic field of 100 Oe was measured. As a result, the magnetic flux density in the case of (13) is 8500G, (14)
9500G for the case of 11500G for (15),
11500G for (16), 9500 for (17)
In the case of G and (18), it was 8000G. From this, it is understood that the magnetic characteristics are improved by setting the aspect ratio (D / t) in the range of 1 to 6. Among them, (14) ~
In the case of (16), the magnetic flux density is particularly improved, and the effect of flattening is recognized.
【００３３】[0033]
【発明の効果】本発明に係る高周波用圧粉磁心は、高周
波域でも渦電流損が低くて鉄損が小さく、又、飽和磁束
密度が高く、従って、高周波域での鉄損を小さくできる
と共に、高い飽和磁束密度を得ることができ、引いて
は、電源装置用チョークコイル等の電磁気部品を構成す
る高周波用圧粉磁心として好適に使用できるという効果
を奏する。又、本発明に係る高周波用圧粉磁心の製造方
法は、上記の如き優れた特性を有する高周波用圧粉磁心
を得ることができるという効果を奏する。The powder core for high frequencies according to the present invention has a low eddy current loss and a small iron loss even in a high frequency region, and a high saturation magnetic flux density. Therefore, the iron loss in a high frequency region can be reduced. It is possible to obtain a high saturation magnetic flux density, and, by extension, it can be suitably used as a high frequency powder magnetic core that constitutes an electromagnetic component such as a choke coil for a power supply device. Further, the method for producing a high-frequency powder magnetic core according to the present invention has an effect that a high-frequency powder magnetic core having the above-described excellent characteristics can be obtained.
【図１】 本発明に係る高周波用圧粉磁心についての断
面の一部を示す模式図である。FIG. 1 is a schematic view showing a part of a cross section of a high-frequency powder magnetic core according to the present invention.
【図２】 本発明に係る高周波用圧粉磁心の製造方法の
概要を説明する模式図であって、図２-(a)は鉄粉の窒化
処理状況、図２-(b)は該窒化処理後の鉄粉と絶縁処理液
とを混合して混合体となす状況、図２-(c)は該混合体を
乾燥し、そして解粒する状況、図２-(d)は該解粒後のも
のを磁心形状に固化成型する状況を示すものである。FIG. 2 is a schematic diagram for explaining an outline of a method for producing a high-frequency powder magnetic core according to the present invention, wherein FIG. 2- (a) is a nitriding treatment state of iron powder, and FIG. The situation in which the iron powder after the treatment and the insulation treatment liquid are mixed to form a mixture, Fig. 2- (c) is the situation in which the mixture is dried and granulated, and Fig. 2- (d) is the granule. It shows a situation in which the latter one is solidified and molded into a magnetic core shape.
【図３】 実施例に係る高周波用圧粉磁心についての周
波数と交流初透磁率との関係を示す図である。FIG. 3 is a diagram showing a relationship between a frequency and an AC initial magnetic permeability of a high-frequency powder magnetic core according to an example.
【図４】 実施例に係る高周波用圧粉磁心高周波用圧粉
磁心についての周波数と交流初透磁率との関係を示す図
である。FIG. 4 is a diagram showing a relationship between a frequency and an AC initial magnetic permeability of a high frequency powder magnetic core according to an example.
【図５】 実施例に係る鉄粉についての偏平加工時間と
偏平加工後の鉄粉のアスペクト比(D/t) との関係を示す
図である。FIG. 5 is a diagram showing the relationship between the flattening time and the aspect ratio (D / t) of the iron powder after the flattening for the iron powder according to the example.
１--鉄粉、２--窒化層、３--ガラス状絶縁層、４--窒化
処理後の鉄粉、５--絶縁処理液、６--鉄粉と絶縁処理液
との混合体、７--圧粉磁心原料の鉄粉、８--粉末成型プ
レス。1--iron powder, 2--nitriding layer, 3--glass insulating layer, 4--iron powder after nitriding, 5--insulating treatment liquid, 6--mixture of iron powder and insulating treatment liquid , 7-powder core raw material iron powder, 8--powder molding press.
Claims (4)
合、固化してなる高周波用圧粉磁心であって、前記鉄粉
が、Ｐ、Mg、Ｂを含むガラス状絶縁層で被覆されている
ことを特徴とする高周波用圧粉磁心。1. A high-frequency powder magnetic core obtained by compacting, bonding and solidifying iron powder having a nitride layer on its surface, wherein the iron powder is covered with a glassy insulating layer containing P, Mg and B. The high-frequency dust core characterized in that
化物よりなる請求項１記載の高周波用圧粉磁心。2. The high frequency powder magnetic core according to claim 1, wherein the glassy insulating layer is made of an oxide of P, Mg or B.
ポキシ樹脂、イミド樹脂、フッソ樹脂の１種又は２種以
上が被覆されている請求項１又は２記載の高周波用圧粉
磁心。3. The dust core for high frequencies according to claim 1, wherein the glass-like insulating layer of iron powder is further coated with one or more of epoxy resin, imide resin, and fluorine resin.
Mg、Ｂを含むガラス状絶縁剤と混合し、この混合体を粉
末成型プレスにより圧縮して固化成型し、しかる後、歪
み取り焼鈍を施すことを特徴とする高周波用圧粉磁心の
製造方法。4. After nitriding the surface of the iron powder, P,
A method for producing a dust core for high frequencies, which comprises mixing with a glassy insulating agent containing Mg and B, compressing the mixture by a powder molding press to solidify, and then subjecting it to strain relief annealing.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP7033590A JPH08236332A (en) | 1995-02-22 | 1995-02-22 | High-frequency dust core and its manufacture |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP7033590A JPH08236332A (en) | 1995-02-22 | 1995-02-22 | High-frequency dust core and its manufacture |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH08236332A true JPH08236332A (en) | 1996-09-13 |
Family
ID=12390724
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP7033590A Withdrawn JPH08236332A (en) | 1995-02-22 | 1995-02-22 | High-frequency dust core and its manufacture |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH08236332A (en) |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2009105368A (en) * | 2007-10-19 | 2009-05-14 | Taida Electronic Ind Co Ltd | Inductor and its core |
| JP2009296015A (en) * | 2009-09-18 | 2009-12-17 | Sumitomo Electric Ind Ltd | In-vehicle power conversion device |
| JP2010028131A (en) * | 2003-12-29 | 2010-02-04 | Hoganas Ab | Powder composition, soft magnetic constituent member, and manufacturing method of soft magnetic complex constituent member |
| JP2013107208A (en) * | 2011-11-17 | 2013-06-06 | Aisin Chemical Co Ltd | Microwave resin welded body and welding method by the same |
| CN114724834A (en) * | 2022-03-08 | 2022-07-08 | 天通（六安）新材料有限公司 | An insulation coating process of ultra-fine alloy powder for 5G high frequency |
| CN119703047A (en) * | 2024-11-29 | 2025-03-28 | 南京航空航天大学 | Glass powder/FeSiAl composite material with low-frequency wave absorbing performance and preparation method thereof |
-
1995
- 1995-02-22 JP JP7033590A patent/JPH08236332A/en not_active Withdrawn
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2010028131A (en) * | 2003-12-29 | 2010-02-04 | Hoganas Ab | Powder composition, soft magnetic constituent member, and manufacturing method of soft magnetic complex constituent member |
| JP2009105368A (en) * | 2007-10-19 | 2009-05-14 | Taida Electronic Ind Co Ltd | Inductor and its core |
| JP2009296015A (en) * | 2009-09-18 | 2009-12-17 | Sumitomo Electric Ind Ltd | In-vehicle power conversion device |
| JP2013107208A (en) * | 2011-11-17 | 2013-06-06 | Aisin Chemical Co Ltd | Microwave resin welded body and welding method by the same |
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