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WO2019235574A1 - Poudre destinée à un noyau magnétique, et noyau magnétique et élément de bobine mettant en œuvre ladite poudre - Google Patents

Poudre destinée à un noyau magnétique, et noyau magnétique et élément de bobine mettant en œuvre ladite poudre Download PDF

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Publication number
WO2019235574A1
WO2019235574A1 PCT/JP2019/022543 JP2019022543W WO2019235574A1 WO 2019235574 A1 WO2019235574 A1 WO 2019235574A1 JP 2019022543 W JP2019022543 W JP 2019022543W WO 2019235574 A1 WO2019235574 A1 WO 2019235574A1
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Prior art keywords
powder
magnetic core
magnetic material
magnetic
amorphous
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English (en)
Japanese (ja)
Inventor
加藤　哲朗
千綿　伸彦
元基 太田
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Proterial Ltd
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Hitachi Metals Ltd
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Priority to JP2019549606A priority Critical patent/JP6693603B1/ja
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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
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C45/00—Amorphous alloys
    • C22C45/02—Amorphous alloys with iron as the major constituent
    • 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
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals

Definitions

  • the present invention relates to a powder for a magnetic core suitable for a transformer, a choke coil, a reactor or the like used for a switching power supply or the like, and a magnetic core and a coil component using the powder.
  • Switching power supplies are used in EVs (electric vehicles), HEVs (hybrid vehicles), PHEVs (plug-in hybrid vehicles), mobile communication devices (cell phones, smartphones, etc.), personal computers, servers, etc., DC-DC converters, etc.
  • EVs electric vehicles
  • HEVs hybrid vehicles
  • PHEVs plug-in hybrid vehicles
  • mobile communication devices cell phones, smartphones, etc.
  • personal computers, servers, etc. DC-DC converters, etc.
  • DC-DC converters DC-DC converters
  • Coil components are required to operate at a high excitation magnetic flux density in a high frequency range of 100 kHz or higher for higher frequency and higher current of the power supply circuit.
  • the magnetic core has an amorphous Fe-based alloy, pure iron, Alternatively, powders of metallic soft magnetic materials that are crystalline Fe-based alloys such as Fe—Si and Fe—Si—Cr are often used.
  • the powder of the soft magnetic material a granular powder obtained by an atomizing method, which hardly causes shape anisotropy of magnetic characteristics when formed into a magnetic core and has good flowability of the powder in forming the magnetic core, is preferably used.
  • JP-A-2017-108098 also improves the DC superposition characteristics by making the average particle size of amorphous alloy powder and crystalline alloy powder different, and adjusting the particle size distribution of each powder appropriately. Is described.
  • a nanocrystalline Fe-based alloy is known as a metal-based soft magnetic material, which is a soft magnetic material having a fine bccFeSi crystal in the structure, a small coercive force, and a low magnetostriction.
  • Such nanocrystalline Fe-based alloys are supplied exclusively in the form of ribbons (long ribbons), but recently, for example, JP 2002-60914, JP 2004-349585 and JP Since alloy powders produced by the atomization method as described in 2016-25352 are also available, it has begun to be considered to be mixed with amorphous alloy powders.
  • the coil component is required to maintain the initial value of the inductance under the condition of being excited by an alternating current superimposed with a direct current up to a high current value and to suppress the decrease thereof, that is, to have excellent direct current superposition characteristics.
  • a nanocrystalline Fe-based alloy has a structure in which fine crystal grains (for example, a particle size of about 10 nm) of randomly oriented ferromagnetic phase FeSi crystals are dispersed in an amorphous phase, and apparent crystal magnetism The anisotropy is close to zero and has a high sensitivity to an external magnetic field.
  • a magnetic core in which such a nanocrystalline Fe-based alloy is mixed with an amorphous alloy powder can reduce loss, but on the other hand, the maximum current value that can be used as a coil component is small, and DC superposition characteristics are improved. It has been demanded.
  • the present invention has been made in view of the above problems, and an object of the present invention is to provide a magnetic core powder that can improve DC superposition characteristics when used as a magnetic core, and a magnetic core and a coil component using the same.
  • One aspect of the present invention is that Fe-Cu-Si-B-Cr-Sn-C based crystalline magnetic material granular powder and Fe-Si-B based and / or Fe-PC based amorphous magnetic material
  • the peak intensity I P1 of the (110) diffraction peak P1 of the FeSi crystal of the bcc structure near the diffraction angle 2 ⁇ 45 °
  • This is a powder for a magnetic core having a peak intensity ratio (I P1 / I P2 ) of the main halo diffraction peak P2 of the amorphous phase to the peak intensity I P2 of more than 1.5 and not more than 6.5.
  • the median diameter d50C of the granular powder of the Fe—Cu—Si—B—Cr—Sn—C based crystalline magnetic material is 15.0 ⁇ m or less, and the Fe—Si—B based and / or Fe
  • the median diameter d50A of the granular powder of the amorphous magnetic material of the -PC based amorphous magnetic material is preferably more than 15.0 ⁇ m. More preferably, the median diameter d50C of the crystalline magnetic material powder is 8.0 ⁇ m or less, and the median diameter d50A of the amorphous magnetic material powder is more than 20 ⁇ m.
  • the median diameter d50 is preferably 20.0 ⁇ m or less.
  • the composition of the Fe-Cu-Si-B-Cr-Sn-C crystalline magnetic material is Fe 100-abcdefg Cu a Si b B c Cr d Sn e C f Mg ( However, in atomic%, 0.8 ⁇ a ⁇ 1.8, 3.0 ⁇ b ⁇ 9.0, 11.0 ⁇ c ⁇ 17.0, 0 ⁇ d ⁇ 2.0, 0 ⁇ e ⁇ 1.5, 0 ⁇ f ⁇ 0.4, 0 ⁇ g ⁇ 1.0, 77.5 ⁇ 100 -abcdefg is satisfied, and M is preferably at least one element selected from Nb, Ti, Zr, Hf, V, Ta and Mo.
  • Another aspect of the present invention is a magnetic core using the above-described magnetic core powder.
  • Still another aspect of the present invention is a coil component using the magnetic core according to another aspect described above.
  • the present invention when used as a magnetic core, it is possible to provide a magnetic material powder capable of improving the DC superimposition characteristics, and a magnetic core and a coil component using the powder.
  • FIG. 3 is a schematic diagram for explaining the peak intensity ratio (I P1 / I P2 ), showing an X-ray diffraction spectrum of a mixed powder of a crystalline magnetic material powder and an amorphous magnetic material powder. It is a perspective view which shows the magnetic core which concerns on one Embodiment of this invention. It is a top view which shows the coil components which concern on one Embodiment of this invention. It is a graph which shows the particle size distribution of the granular powder (sample No. 1) of the crystalline magnetic material of the Fe-Cu-Si-B-Cr-Sn-C system used in the Example. It is a graph which shows the particle size distribution of the granular powder (sample No.
  • a powder for a magnetic core according to an embodiment of the present invention, a magnetic core using the powder, and a coil component will be specifically described.
  • the present invention is not limited to these. Note that in some or all of the drawings, portions that are not necessary for the description are omitted, and some portions are illustrated in an enlarged or reduced manner for ease of description. Further, the dimensions and shapes shown in the description, the relative positional relationships of the constituent members, and the like are not limited to these unless otherwise specified. Further, in the description, the same name and reference numeral indicate the same or the same members, and the detailed description may be omitted even if illustrated.
  • the magnetic core powder according to the present invention comprises Fe-Cu-Si-B-Cr-Sn-C based crystalline magnetic material granular powder and Fe-Si-B based and / or Fe-PC based amorphous powder. It is a mixed powder containing a granular powder of a magnetic material.
  • the granular powder means a substantially spherical powder obtained by, for example, an atomizing method, and the shape is preferably spherical, but it is a non-spherical shape having shape anisotropy such as an elliptical shape or a droplet shape.
  • the ratio of the major axis Dl to the minor axis Ds is preferably 1.3 or less.
  • each powder can be easily identified by the X-ray diffraction spectrum by the X-ray diffraction method.
  • the diffraction peak angle includes errors such as fluctuations in the JCPDS card data due to element solid solution, etc.
  • the diffraction peak angle (2 ⁇ ) that is very close to each JCPDS card is defined as “near”. doing.
  • the (110) diffraction peak of the bSi structure FeSi crystal was in the range of 44 ° to 46 °.
  • the granular powder of crystalline magnetic material of Fe-Cu-Si-B-Cr-Sn-C system is a nanocrystalline Fe-based alloy.
  • a nanocrystal generally has an average crystal grain size of 100 nm or less, but typically an average crystal grain crystallized from an amorphous phase starting from a Cu cluster (a region rich in Cu).
  • the diameter is, for example, FeSi crystal grains having a diameter of 30 nm or less, and the granular powder has a structure in which nanocrystals are randomly oriented and dispersed in an amorphous phase.
  • the crystal grain size is smaller than the magnetic correlation length (approximately the domain wall width, several tens of nm).
  • the average crystal grain size is preferably 30 nm or less, more preferably 20 nm or less.
  • the average crystal grain size can be determined from the measurement result by the X-ray diffraction method.
  • Fe-Cu-Si-B-Cr-Sn-C crystalline magnetic materials have high saturation magnetic flux density and should be used in magnetic cores with Fe-Si-B and / or Fe-PC amorphous magnetic materials Therefore, it contributes to improving the DC superposition characteristics.
  • the X-ray diffraction spectrum of is a combination of the X-ray diffraction spectra of the respective powders.
  • the peak intensity ratio (I P1 / I P2 ) is more than 1.5 and not more than 6.5. The larger the peak intensity ratio (I P1 / I P2 ), the larger the proportion of the granular magnetic material powder in the mixed powder.
  • the peak intensity ratio (I P1 / I P2 ) of the mixed powder of crystalline magnetic material powder and amorphous magnetic material powder obtained by X-ray diffraction measurement
  • the horizontal axis is the diffraction angle 2 ⁇ (deg.)
  • the vertical axis is the diffraction intensity (au).
  • the X-ray diffraction spectrum of the mixed powder has a diffraction peak P1 in a region Cx of a FeSi crystal having a bcc structure and a diffraction peak P2 in a halo region Hx showing amorphous properties.
  • the X-ray diffraction spectrum of each powder is synthesized.
  • the peak intensity ratio (I P1 / I P2 ) When the peak intensity ratio (I P1 / I P2 ) is 1.5 or less, the magnetic permeability is low, the magnetic core loss is slightly reduced, and the DC superposition characteristics of the coil component may not be improved. Further, if the peak intensity ratio (I P1 / I P2 ) exceeds 6.5, the magnetic permeability may be lowered. When the peak intensity ratio (I P1 / I P2 ) is more than 1.5 and not more than 6.5, the DC superposition characteristics can be improved, the permeability can be improved, and the core loss can be reduced.
  • the median diameter d50C which is the average particle diameter of the granular powder of the Fe-Cu-Si-B-Cr-Sn-C crystalline magnetic material, and non-Fe-Si-B and / or Fe-PC It is preferable to vary the median diameter d50A, which is the average particle diameter of the granular powder of the crystalline magnetic material.
  • the median diameter is a particle size at which the cumulative particle size distribution from the small particle size side becomes 50% in the volume-based particle size distribution.
  • the granular powder having a larger average particle size has a greater influence on the magnetic properties. Therefore, whether the crystalline magnetic material or the amorphous magnetic material is a granular powder having a large average particle size is determined by considering the DC superposition characteristics when the coil component is used, and the saturation magnetic flux density and magnetic core when the magnetic core is used. What is necessary is just to select so that the characteristics which give priority to magnetic characteristics, such as a loss and initial permeability, may be obtained.
  • the median diameter d50b is preferably more than 15.0 ⁇ m and not more than 60.0 ⁇ m. As the particle diameter of the powder becomes larger, it becomes more difficult to obtain spherical particles, and since the required cooling rate increases and the manufacturing conditions become severe, the median diameter d50b is preferably 40.0 ⁇ m or less, more preferably 35.0 ⁇ m or less.
  • the median diameter d50b is preferably 20.0 ⁇ m or more, more preferably 25.0 ⁇ m or more It is.
  • a median diameter d50s that fills the voids formed between the large-diameter granular powders may be selected, and is preferably 2.0 ⁇ m or more and 15.0 ⁇ m or less.
  • the median diameter d50s is preferably 10.0 ⁇ m or less, more preferably 8.0 ⁇ m or less.
  • the median diameter d50b of the relatively large diameter granular powder is 1.1 times or more the median diameter d50s of the relatively small diameter granular powder. More preferably, it is 1.2 times or more.
  • the median diameter d50m of the mixed powder of large-sized granular powder and small-sized granular powder is preferably 30.0 ⁇ m or less, more preferably 20.0 ⁇ m or less, and even more preferably 19.0 ⁇ m or less.
  • the median diameter d50m is preferably 8.0 ⁇ m or more, more preferably 9.0 ⁇ m or more, and more preferably 10.0 ⁇ m or more.
  • the median diameter d50C of granular powder of crystalline magnetic material of Fe-Cu-Si-B-Cr-Sn-C system is the median diameter of granular powder of amorphous magnetic material of Fe-Si-B system or Fe-PC system
  • the median diameter d50C of the crystalline magnetic material powder is 15.0 ⁇ m or less
  • the median diameter d50A of the amorphous magnetic material powder is more than 15.0 ⁇ m.
  • the median diameter d50C of the crystalline magnetic material powder is 8.0 ⁇ m or less
  • the median diameter d50A of the amorphous magnetic material powder is more than 20 ⁇ m.
  • the median diameter d50m of the mixed powder is preferably 20.0 ⁇ m or less.
  • the gas atomization method is used to produce granular powders of Fe-Cu-Si-B-Cr-Sn-C crystalline magnetic materials and Fe-Si-B or Fe-PC amorphous magnetic materials. , Water atomization method, high-speed rotating water flow atomization method, etc. It can be produced by the atomizing method.
  • the gas atomizing method is suitable for obtaining a granular powder having a median diameter of 30 ⁇ m or more
  • the high-speed combustion flame atomizing method is suitable for obtaining a granular powder having a median diameter of 10 ⁇ m or less.
  • the high-speed combustion flame atomization method is not as common as other atomization methods, it is described in, for example, JP-A-2014-136807.
  • the molten metal is powdered by a high-speed combustion flame by a high-speed combustor, and is cooled by a rapid cooling mechanism having a plurality of cooling nozzles capable of injecting a cooling medium such as liquid nitrogen and liquefied carbon dioxide.
  • the granular powder of crystalline magnetic material based on Fe-Cu-Si-B-Cr-Sn-C is subjected to a heat treatment for nano-crystallization on the powder of amorphous structure obtained by any of the above atomization methods. It can be obtained by applying.
  • the furnace used for the heat treatment is a heating furnace capable of controlling the temperature up to about 600 ° C.
  • any furnace can be used without any particular problem.
  • it can be performed by a heating furnace such as a batch type electric furnace or a mesh belt type continuous electric furnace. It is preferable that the atmosphere can be adjusted if oxidation is prevented.
  • the temperature increase rate in the heat treatment is an average temperature increase rate until the target heat treatment temperature is reached.
  • the heat treatment temperature can be appropriately set based on the crystallization start temperature of the nanocrystalline alloy that becomes a granular structure.
  • the crystallization start temperature is measured using a differential scanning calorimeter (DSC) in the temperature range from room temperature (RT) to 600 ° C at a heating rate of 600 ° C / hr. Can be evaluated.
  • the heat treatment temperature is also the holding temperature when the temperature is held for a predetermined time after the temperature rise. Further, the heat treatment time includes a time for which the heat treatment temperature is maintained.
  • the heat treatment condition may be a setting that does not increase the crystal phase that deteriorates the soft magnetic characteristics such as Fe 2 B crystal.
  • the average heating rate in the temperature range of 300 ° C or higher in heat treatment is 0.001 to 1000 ° C / s, preferably in the range of 0.5 to 500 ° C / s for a continuous furnace, 0.006 to 0.08 ° C / s for a batch furnace. It is desirable to be in the range of s.
  • the rate of temperature rise is in the above range, excessive temperature rise due to self-heating caused by crystallization of the alloy is prevented, and overshooting with respect to the heat treatment temperature setting is suppressed, and the magnetic properties of the resulting powder are reduced. It is possible to prevent deterioration of characteristics.
  • the heat treatment temperature depends on the crystallization temperature, it is preferably 350 to 450 ° C., more preferably 390 to 430 ° C.
  • the heat treatment time is preferably 1 to 3 hours, more preferably 1 to 300 seconds for a continuous furnace, and 300 to 2 hours (7200 seconds) for a batch furnace.
  • the composition of Fe-Cu-Si-B-Cr-Sn-C based crystalline magnetic material is Fe 100-abcdefg Cu a Si b B c Cr d Sn e C f Mg (However, in atomic%, 0.8 ⁇ a ⁇ 1.8, 3.0 ⁇ b ⁇ 9.0, 11.0 ⁇ c ⁇ 17.0, 0 ⁇ d ⁇ 2.0, 0 ⁇ e ⁇ 1.5, 0 ⁇ f ⁇ 0.4, 0 ⁇ g ⁇ 1.0, 77.5 ⁇ 100-abcdefg, M is Nb , At least one element selected from Ti, Zr, Hf, V, Ta and Mo.).
  • Cu is an element that contributes to the formation of FeSi crystals with a refined structure after nanocrystallization.
  • the Cu content is preferably 0.8% or more and 1.8% or less in atomic%. If the Cu content is less than the above range, the effect of addition cannot be obtained, and conversely if the Cu content is high, the saturation magnetic flux density decreases. If the Cu content is excessive, in order to crystallize in the cooling process proceeds too, the residual amorphous phase depleted having an inhibitory effect of grain growth, coarsening and magnetic anisotropy of the crystal grains is high Fe 2 B precipitates and the soft magnetic properties deteriorate.
  • the Cu content is more preferably 1.1% or more, and most preferably 1.2% or more so as to give sufficient number density of Cu clusters. Further, the Cu content is more preferably 1.6% or less.
  • Si has the effect of promoting the amorphization of the nanocrystalline alloy and is the main component of the FeSi crystal. It is a solid solution in Fe and contributes to the reduction of magnetostriction and magnetic anisotropy.
  • the Si content is preferably more than 3.0% and not more than 9.0% in atomic%. Further, in the cooling process, the presence of B together has an effect of strengthening the amorphous forming ability, and it has the effect of suppressing the coarsening even if the crystal grain precipitation is suppressed or precipitated in the cooling process. When the Si content is less than the above range, the effect of addition cannot be obtained. On the other hand, when the Si content is too high, the saturation magnetic flux density is lowered.
  • the lower limit of the Si content is more preferably 3.5%.
  • the Si content is more preferably 8.0% or less, and most preferably 7.0% or less.
  • the B has the effect of promoting the amorphization of the alloy during rapid cooling.
  • the B content is preferably 11.0% or more and 17.0% or less in atomic%. If the B content is less than the above range, a very high cooling rate is required for the formation of the amorphous phase, and relatively coarse crystal grains on the order of micrometers are likely to precipitate, and good soft magnetic properties cannot be obtained. There is a case. Further, when the B content is large, the volume fraction of the residual amorphous phase is increased in the nanocrystalline phase after the heat treatment, which leads to deterioration of magnetic characteristics such as saturation magnetization. Since the Fe content can be increased as the total content of Si and B is smaller, the total content of B and Si is preferably 20.0% or less in order to obtain a high saturation magnetic flux density, and 18.0% The following is more preferable.
  • Element M is an optional element and is at least one element selected from Nb, Ti, Zr, Hf, V, Ta and Mo.
  • Element M is effective in making the grain size of the refined FeSi crystal uniform, and the content of element M is preferably 1.0% or less (including 0) in atomic%, and preferably 0.8% or less. More preferred.
  • the Cr is an element effective for improving the corrosion resistance of the alloy, and is preferably 2.0% or less (not including 0) in atomic%.
  • the Cr content is preferably 0.1% or more, and more preferably 0.3% or more, in order to obtain the effect of preventing the inside from being oxidized.
  • the upper limit of the Cr content is more preferably 1.5%. 1.3% is most preferable.
  • Sn is an element effective for assisting the formation of Cu clusters, and is preferably 1.5% or less (not including 0) in atomic%.
  • Sn atoms that can diffuse even at low temperatures first gather in the process of heat treatment of the amorphous phase after atomization, or the amorphous phase of the nanocrystalline alloy, and Cu atoms around it Gather to form a cluster to reduce the potential energy.
  • the upper limit of the Sn content does not exceed the Cu content.
  • the Sn content is more preferably 0.5% or less (excluding 0).
  • the lower limit is preferably 0.01%, more preferably 0.05%.
  • C acts to stabilize the viscosity of the molten metal, and its preferable amount is 0.4% or less (not including 0) in atomic%.
  • the lower limit is preferably 0.1%, and the upper limit is preferably 0.3%.
  • the inevitable impurities are, for example, S, O, N, etc., and their contents are preferably 200 ppm or less for S, 5000 ppm or less for O, and 1000 ppm or less for N, respectively.
  • Fe is a main element constituting a nanocrystalline alloy and affects magnetic properties such as saturation magnetization. Although depending on the balance with other non-ferrous metals, it is preferable to contain 77.5% or more of Fe in atomic%, whereby a nanocrystalline alloy having a large saturation magnetization can be obtained.
  • the Fe content is more preferably 78.0% or more, and most preferably 79.0% or more.
  • the composition of the granular powder of the Fe-Si-B amorphous magnetic material is (Fe 1-x Cr x ) a (Si 1-y B y ) 100-ab C b (where x and y are atomic ratios, a and b represent atomic%, and preferably satisfy 0 ⁇ x ⁇ 0.06, 0.3 ⁇ y ⁇ 0.7, 70 ⁇ a ⁇ 81, and 0 ⁇ b ⁇ 2, respectively.
  • Cr improves the oxidation resistance and corrosion resistance of the alloy
  • Si, B and C are effective elements for improving amorphization.
  • Mn may be included as an optional element in an atomic% of 3.0% or less.
  • inevitable impurities such as Al, P, and S may be included.
  • the composition of the granular powder of the Fe-PC amorphous magnetic material is Fe 100-xy P x C y (however, in atomic%, 6.8% ⁇ x ⁇ 13.0%, 2.2% ⁇ y ⁇ 13.0% is satisfied) It is preferable.
  • P and C are effective elements for improving amorphization.
  • at least one element of Ni, Sn, Cr, B and Si may be further included as an optional element.
  • Ni is 10.0% or less
  • Sn is 3.0% or less
  • Cr is 6.0% or less
  • B is 9.0% or less
  • Si 7.0% or less.
  • Other inevitable impurities may be included.
  • the powder for a magnetic core is suitable for a dust core or a metal composite.
  • the powder for the magnetic core is mixed with an insulating material and a binder that functions as a binder.
  • the binder include, but are not limited to, an epoxy resin, an unsaturated polyester resin, a phenol resin, a xylene resin, a diallyl phthalate resin, a silicone resin, a polyamideimide, a polyimide, and water glass.
  • the mixture of powder for magnetic core and binder is mixed with a lubricant such as zinc stearate if necessary, then filled in a molding die, and a molding pressure of about 10 MPa to 2 GPa with a hydraulic press molding machine etc. To form a green compact of a predetermined shape.
  • FIG. 2 shows an embodiment of the magnetic core 1.
  • the magnetic core 1 may have an annular shape as shown in FIG. 2, an annular body such as a rectangular frame shape, or a rod-like or plate-like form, and the form is variously selected according to the purpose. can do.
  • FIG. 3 shows an embodiment of the coil component 10 using the magnetic core 1 shown in FIG.
  • a coil 5 can be formed by winding a copper wire around the magnetic core 1 to form a coil 5.
  • a coil component (not shown) in which a coil is buried in a mixture containing a magnetic core powder and a binder may be used.
  • a thermoplastic resin or a thermosetting resin is appropriately selected as the binder
  • a metal composite core (coil component) in which a coil is easily sealed by a known molding means such as injection molding can be obtained.
  • a mixture containing the magnetic core powder and the binder may be formed into a sheet-like magnetic core by a known sheet forming means such as a doctor blade method. Further, a mixture containing a magnetic core powder and a binder may be used as the amorphous shielding material.
  • a powder of a crystalline metallic soft magnetic material such as pure iron, FeSi, FeSiCr, FeSiAl, etc. may be added to the magnetic core.
  • the obtained magnetic core has excellent DC characteristics with improved DC superposition characteristics, and is suitably used for inductors, noise filters, choke coils, transformers, reactors, and the like.
  • composition A Fe bal. Cu 1.2 Si 4.0 B 15.5 Cr 1.0 Sn 0.2 C 0.2
  • Composition B Fe bal. Cu 1.0 Si 13.5 B 11.0 Nb 3.0 Cr 1.0
  • the atomizing device used is capable of injecting a frame jet toward a container for storing molten metal, a pouring nozzle provided at the center of the bottom of the container and communicating with the inside of the container, and toward the molten metal flowing downward from the pouring nozzle.
  • a jet burner manufactured by Hard Industry Co., Ltd.
  • a cooling means for cooling the crushed molten metal are provided.
  • This atomizing apparatus is configured to be able to form molten metal powder by pulverizing molten metal with a flame jet, and each jet burner can inject a flame as a flame jet at a supersonic speed or a speed close to the sonic speed.
  • the cooling means has a plurality of cooling nozzles configured to be able to inject a cooling medium toward the crushed molten metal.
  • a cooling medium water, liquid nitrogen, liquefied carbon dioxide, or the like can be used.
  • the temperature of the flame jet to be injected was 1300 ° C, and the dripping speed of the raw molten metal was about 3 to 6 kg / min.
  • Water was used as a cooling medium, and a liquid mist was sprayed from the cooling nozzle.
  • the cooling rate of the molten metal was adjusted at a water injection rate of 4.5 liter / min to 8.5 liter / min.
  • composition A and composition B were classified with a centrifugal airflow classifier (TC-15 manufactured by Nissin Engineering Co., Ltd.) to obtain a crystalline magnetic material powder (before heat treatment) having a d50 of about 6 ⁇ m. .
  • TC-15 centrifugal airflow classifier
  • Fe-Si-B amorphous metal powder KUAMET 6B2 (manufactured by Epson Atmix Co., Ltd., median diameter 50 ⁇ m, KUAMET is a registered trademark) was prepared.
  • the KUAMET-6B2 powder was classified by a centrifugal airflow classifier (TC-15 manufactured by Nisshin Engineering Co., Ltd.) to obtain a granular powder of sample No. 3 amorphous magnetic material.
  • the powders of Sample Nos. 1 to 3 were mixed at the blending ratio shown in Table 2 to obtain a mixed powder.
  • An annular magnetic core of sample No. 14 * of ⁇ 13.5 mm ⁇ ⁇ 7.7 mm ⁇ t2.0 mm was prepared from 4 *.
  • FIG. 10 shows the X-ray diffraction pattern of the mixed powder used for the magnetic core of Sample No. 8.
  • the magnetic core of the annular body is the object to be measured, and the primary side winding and the secondary side winding are wound 18 turns each, and the maximum magnetic flux density is 30 mT and the frequency is 2 MHz by BH analyzer SY-8218 manufactured by Iwatatsu Measurement Co., Ltd. Under these conditions, the core loss (kW / m 3 ) was measured at room temperature (25 ° C.).
  • Samples Nos. 6 to 10 containing a granular powder of crystalline magnetic material A and having a peak intensity ratio (I P1 / I P2 ) of more than 1.5 and not more than 6.5 have a granular powder of amorphous magnetic material C of 100% by mass.
  • the ⁇ / ⁇ i was larger than Sample No. 4 *, and the direct current superposition characteristics were excellent.
  • the initial permeability ⁇ i was larger than the sample No. 12 *.
  • the core loss Pcv decreased with increasing peak intensity ratio (I P1 / I P2 ).
  • Sample No. 14 * is a sample in which the granular powder of crystalline magnetic material B is 100% by mass. Compared to sample No. 12 * in which the granular powder of crystalline magnetic material A is 100% by mass, Although the magnetic susceptibility ⁇ i is large and the core loss Pcv is small, ⁇ / ⁇ i is small and the direct current superposition characteristics are inferior.
  • the magnetic core (sample Nos. 6 to 10) using the magnetic core powder of the present invention has a large ⁇ / ⁇ i, excellent DC superposition characteristics, and a large initial permeability ⁇ i. If the magnetic permeability is low, it is necessary to increase the cross-sectional area of the magnetic core and increase the number of turns of the winding in order to obtain the required inductance, and as a result, the outer shape of the coil component becomes large. Therefore, it can be seen that the magnetic core powder of the present invention is more advantageous in terms of downsizing the coil component and obtaining excellent DC superposition characteristics.

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Abstract

L'invention concerne une poudre destinée à un noyau magnétique, contenant une poudre granulaire d'un matériau magnétique cristallin à base de Fe-Cu-Si-B-Cr-Sn-C et d'un matériau magnétique amorphe à base de Fe-Si-B et/ou de Fe-P-C, dans un spectre de diffraction des rayons X mesuré à l'aide de rayons X caractéristiques Cu-Kα, le rapport d'intensité de pic (IP1/IP2) entre l'intensité de pic IP1 d'un pic de diffraction (P1) d'un cristal de FeSi possédant une structure bcc à proximité d'un angle de diffraction 2θ de 45° et l'intensité de pic IP2 d'un pic de diffraction de halo principal (P2) d'une phase amorphe étant supérieur à 1,5 mais inférieur à 6,5.
PCT/JP2019/022543 2018-06-08 2019-06-06 Poudre destinée à un noyau magnétique, et noyau magnétique et élément de bobine mettant en œuvre ladite poudre Ceased WO2019235574A1 (fr)

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Publication number Priority date Publication date Assignee Title
JP2022050132A (ja) * 2020-09-17 2022-03-30 日本製鉄株式会社 Ｆｅ系合金、Ｆｅ系合金薄帯、Ｆｅ系非晶質合金及びＦｅ系非晶質合金薄帯
TWI890223B (zh) * 2022-12-06 2025-07-11 日商大同特殊鋼股份有限公司 軟磁性金屬粉體

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JPH1046301A (ja) * 1996-07-29 1998-02-17 Hitachi Metals Ltd Ｆｅ基磁性合金薄帯ならびに磁心
JP2007134591A (ja) * 2005-11-11 2007-05-31 Nec Tokin Corp 複合磁性材料とそれを用いた圧粉磁芯および磁性素子
JP2014240516A (ja) * 2013-06-12 2014-12-25 日立金属株式会社 ナノ結晶軟磁性合金及びこれを用いた磁性部品
JP6309149B1 (ja) * 2017-02-16 2018-04-11 株式会社トーキン 軟磁性粉末、圧粉磁芯、磁性部品及び圧粉磁芯の製造方法

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JPH1046301A (ja) * 1996-07-29 1998-02-17 Hitachi Metals Ltd Ｆｅ基磁性合金薄帯ならびに磁心
JP2007134591A (ja) * 2005-11-11 2007-05-31 Nec Tokin Corp 複合磁性材料とそれを用いた圧粉磁芯および磁性素子
JP2014240516A (ja) * 2013-06-12 2014-12-25 日立金属株式会社 ナノ結晶軟磁性合金及びこれを用いた磁性部品
JP6309149B1 (ja) * 2017-02-16 2018-04-11 株式会社トーキン 軟磁性粉末、圧粉磁芯、磁性部品及び圧粉磁芯の製造方法

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2022050132A (ja) * 2020-09-17 2022-03-30 日本製鉄株式会社 Ｆｅ系合金、Ｆｅ系合金薄帯、Ｆｅ系非晶質合金及びＦｅ系非晶質合金薄帯
JP7610097B2 (ja) 2020-09-17 2025-01-08 日本製鉄株式会社 Ｆｅ系合金薄帯及びＦｅ系非晶質合金薄帯
TWI890223B (zh) * 2022-12-06 2025-07-11 日商大同特殊鋼股份有限公司 軟磁性金屬粉體

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