KR101688318B1 - Compressed powder core, method of manufacturing the compressed powder core, electronic-electric component comprising the compressed powder core and electronic-electric device mounted with the electronic-electric component - Google Patents

Compressed powder core, method of manufacturing the compressed powder core, electronic-electric component comprising the compressed powder core and electronic-electric device mounted with the electronic-electric component Download PDF

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KR101688318B1
KR101688318B1 KR1020150074058A KR20150074058A KR101688318B1 KR 101688318 B1 KR101688318 B1 KR 101688318B1 KR 1020150074058 A KR1020150074058 A KR 1020150074058A KR 20150074058 A KR20150074058 A KR 20150074058A KR 101688318 B1 KR101688318 B1 KR 101688318B1
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powder
magnetic material
core
electronic
crystalline
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KR20150140567A (en
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료 나카바야시
도시오 다카하시
게이이치로 사토
아키노리 고지마
다카오 미즈시마
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알프스 덴키 가부시키가이샤
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/255—Magnetic cores made from particles
    • 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
    • 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
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Soft Magnetic Materials (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Powder Metallurgy (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Manufacturing & Machinery (AREA)

Abstract

A compaction core containing powder of a crystalline magnetic material and powder of an amorphous magnetic material and having excellent magnetic properties even in a high frequency band of 1 MHz or more.
[MEANS FOR SOLVING PROBLEMS As a compressed metal powder core containing the powder and the amorphous powder of the magnetic material of crystalline magnetic material, the effective maximum magnetic flux density (B m), the core loss measured at 15 mT of the conditions (Pcv) (unit: kW / m 3) (1), using the two constants k h and k e , the frequency (f) (unit: kHz)
Pcv = k h x f x B m 1.6 + k e x f 2 x B m 2 (1)
The constant k h of one 1.5 × 10 -3 kW / m 3 / kHz / (mT) 1.6 or less, and that of the other constant k e 3.0 × 10 -7 kW / m 3 / (kHz) 2 / (mT) 2 or less.

Description

TECHNICAL FIELD [0001] The present invention relates to a compacted core, a method for producing the compacted core, an electronic / electric part having the compacted core, and an electronic / electric device having the compacted electronic / electric part mounted thereon. COMPONENT COMPRESSED POWDER CORE < RTI ID = 0.0 > ELECTRONIC-ELECTRIC DEVICE MOUNTED WITH THE ELECTRONIC-ELECTRIC COMPONENT &

TECHNICAL FIELD The present invention relates to a pressurized core, a method of manufacturing the pressurized core, an electronic / electrical component including the pressurized core, and an electronic / electric appliance in which the electronic / electrical component is mounted.

A compacting core used for a booster circuit such as a hybrid car, a reactor used for power generation, a power plant, a transformer or a choke coil can be obtained by compacting a large number of soft magnetic powders and heat-treating the obtained compact. Patent Document 1 below discloses an example of a compact cored core.

Patent Literature 1 discloses an inductor having a core strength and an insulation resistance higher than those of the prior art and having a smaller core loss, and has a composition ratio of 90 to 98 mass% of an amorphous soft magnetic powder and 2 to 10 mass% of a crystalline soft magnetic powder An inductor having a magnetic core (compact core) including a mixed powder and a mixture of an insulating material solidified is disclosed.

Patent Document 1: JP-A-2010-118486

BACKGROUND ART [0002] In recent years, electronic and electric parts such as inductors using a compacted core have been required to cope with high frequency operation frequencies. However, in Patent Document 1, the excitation condition for evaluating the core loss of the toroidal core using the magnetic core (compaction core) stays at 300 kHz, and in the high frequency band of 1 MHz or more, the crystalline soft magnetic powder and the amorphous soft magnetic powder It is not known at all whether or not the material containing the iron core is suitable as the material for the core (compact core).

It is an object of the present invention to provide a compacted core containing powder of a crystalline magnetic material and powder of an amorphous magnetic material and having excellent magnetic properties even in a high frequency band of 1 MHz or more. It is another object of the present invention to provide such a method for producing a compact cored core, to provide electronic and electric parts having such a compacted core, and to provide electronic and electric devices in which such electronic and electric parts are mounted.

The present inventors have found that the frequency f of the iron loss Pcv (unit: kW / m 3 ) measured in the condition that the effective maximum magnetic flux density B m is 15 mT (unit: kHz) ) Dependence, it is possible to provide a compaction core having excellent magnetic properties even in a high frequency band of 1 MHz or more.

The inventions completed by these findings are as follows.

One aspect of the present invention is a compressed metal powder core containing the powder and the amorphous powder of the magnetic material of crystalline magnetic material, the effective maximum magnetic flux density (B m) core loss measured at 15 mT of the conditions (Pcv) (unit: kW / frequency (f) (unit of m 3): a kHz) dependent, when nd represented by the formula 2 below using the constants k and h k e (1),

Pcv = k h x f x B m 1.6 + k e x f 2 x B m 2 (1)

The constant k h is 1.5 × 10 -3 kW / m 3 / kHz / (mT) 1.6 or less, and that the constant k e 3.0 × 10 -7 kW / m 3 / (kHz) 2 / (mT) 2 or less compressed metal powder Core.

As the constants k h and k e are in the above range, the degree of rise of the iron loss (Pcv) of the compacting core as the frequency (f) rises becomes gentle. Therefore, even if the high frequency is 1 MHz or more, the iron loss (Pcv) of the compaction core is not increased sufficiently.

The mass ratio of the content of the crystalline magnetic material powder to the total of the content of the crystalline magnetic material powder and the amorphous magnetic material powder is preferably 5 mass% or more and 40 mass% or less. When the mass ratio is within the above range, the insulation resistance of the compaction core is improved and the iron loss (Pcv) in the low frequency band is reduced more stably.

According to another aspect of the present invention, there is provided a compost core containing a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, wherein the crystalline magnetic material has a ratio of a content of the powder of the crystalline magnetic material to a content of the powder of the amorphous magnetic material Wherein the mass ratio of the content of the powder of the material is 5 mass% or more and 40 mass% or less. When the mass ratio is within the above range, reduction of the iron loss (Pcv) of the compact core is stably realized.

The crystalline magnetic material may be at least one selected from the group consisting of Fe-Si-Cr alloys, Fe-Ni alloys, Fe-Co alloys, Fe-V alloys, Fe-Al alloys, Fe- An alloy, a carbonyl iron, and a pure iron.

The crystalline magnetic material is preferably made of carbonyl iron.

The amorphous magnetic material may include one or more materials selected from the group consisting of Fe-Si-B alloys, Fe-P-C alloys and Co-Fe-Si-B alloys.

The amorphous magnetic material is preferably made of an Fe-P-C alloy.

The powder of the crystalline magnetic material is preferably made of a material subjected to an insulation treatment. Within the above range, the insulation resistance of the compacted core can be improved and the iron loss (Pcv) in the low frequency band can be reduced more stably.

The median diameter (D50) of the powder of the amorphous magnetic material is preferably 6 mu m or less. In some cases such a median diameter (D50) is by not more than 6 ㎛, constant k e is to be easy to be reduced. The median diameter (D50) of the amorphous magnetic material powder is preferably 5 占 퐉 or less. When the median diameter (D50) is 5 占 퐉 or less, the iron loss (Pcv) in the high frequency band is likely to be reduced or the direct current superimposition characteristic is likely to be improved.

The compacting core may contain a binder component for binding the powder of the crystalline magnetic material and the powder of the amorphous magnetic material to another material contained in the compacting core.

It is preferable that the binder component includes a component based on a resin material.

According to another aspect of the present invention, there is provided a method for producing the compact cored core, which comprises the steps of: forming a mixture containing the powder of the crystalline magnetic material and a powder of the amorphous magnetic material and a binder component comprising the resin material; And a forming step of obtaining a molded product by the method of the present invention. With this manufacturing method, it is possible to manufacture the compacted core more efficiently.

In the above manufacturing method, the molded product obtained by the molding step may be the compacted core. Or a heat treatment step of obtaining the compacted core by a heat treatment for heating the molded product obtained by the molding step.

According to another aspect of the present invention, there is provided an electronic / electrical component comprising a compression core, a coil, and a connection terminal connected to each end of the coil, wherein at least a part of the compression core includes: And is disposed in the induction magnetic field generated by the current when the current is passed through the coil through the coil. When such an electric / electronic component is an inductance element, it is possible to achieve both high frequency and superior direct current superimposition characteristics and low loss based on excellent characteristics of the compacted core.

According to another aspect of the present invention, there is provided an electronic or electric device in which the electronic or electric component is mounted, wherein the electronic or electric component is connected to the board by the connection terminal. Examples of such electronic / electric apparatuses include a power supply apparatus having a power supply switching circuit, a voltage raising and lowering circuit, a smoothing circuit, etc., and a small portable communication apparatus. Since the electronic / electric apparatus according to the present invention is provided with the above-described electronic / electrical parts, it is easy to cope with miniaturization and high-speed operation.

The compacted core according to the present invention has excellent magnetic properties even in a high frequency band of 1 MHz or more. Further, according to the present invention, there is provided a method for producing the compacted core, an electronic / electric part having the compacted core, and an electric / electronic device having the electronic / electric part mounted.

1 is a perspective view conceptually showing a shape of a compacted core according to an embodiment of the present invention.
2 is a view conceptually showing a spray dryer apparatus and its operation used in an example of a method of manufacturing granulated powder.
Fig. 3 is a perspective view conceptually showing the shape of a toroidal core, which is an electric / electronic part having a compacted core according to an embodiment of the present invention.
Fig. 4 is a perspective view showing a part of an overall configuration of an inductance element which is an electric / electronic part having a compacted core according to another embodiment of the present invention. Fig.
5 is a partial front view showing a state in which the inductance element shown in Fig. 4 is mounted on a mounting substrate.
6 is a graph showing the measurement results of the frequency dependence of the iron loss Pcv in the embodiment.
7 is a graph showing the dependence of the constant k h on the first mixing ratio.
Figure 8 is a graph showing the dependence of the constant k e on the first mixing ratio.
9 is a graph showing the dependency of the rate of change of iron loss at 100 kHz and 2 MHz on the first mixing ratio.
10 is a graph showing the dependence of the insulation resistance on the first mixing ratio based on Tables 2 and 4;
11 is a graph showing the dependency of the iron loss (Pcv) on the first mixing ratio in the case where the frequency is 100 kHz.
Fig. 12 is a graph showing the dependence of the iron loss (Pcv) on the first mixing ratio in the case where the frequency is 1 MHz.
13 is a graph showing the dependence of the iron loss (Pcv) on the first mixing ratio in the case where the frequency is 2 MHz.
14 is a graph showing the dependence of the iron loss (Pcv) on the first mixing ratio in the case where the frequency is 3 MHz.
Applied at the time 15 is when the application of superimposed electric current around the ratio (ΔL / L 0) is 30% of the (initial) of the inductance (L) variation (ΔL) of the inductance (L) to the value (L 0) Is a graph showing the dependence of the current value Isat on the first mixing ratio.

Hereinafter, embodiments of the present invention will be described in detail.

1. Popcorn core

The compact powder core 1 according to one embodiment of the present invention shown in Fig. 1 has a ring-like appearance and contains a powder of a crystalline magnetic material and a powder of an amorphous magnetic material. The compact powder core 1 according to the present embodiment is manufactured by a manufacturing method including a forming process including press molding of a mixture containing these powders. As an example which is not limiting, the compact powder core 1 according to the present embodiment is a powder compact in which powder of a crystalline magnetic material and powder of an amorphous magnetic material are mixed with another material contained in the press compaction core 1 (which may be the same kind of material, And may be a heterogeneous material). Hereinafter, these components will be described.

(1) Powder of crystalline magnetic material

The crystalline magnetic material imparting the powder of the crystalline magnetic material contained in the compacted powder core 1 according to the embodiment of the present invention may be crystalline (it is preferable to use a general X-ray diffraction measurement, A diffraction spectrum having a peak is obtained), and the specific kind is not limited as far as it is satisfied that it is a ferromagnetic substance. Examples of the crystalline magnetic material include Fe-Si-Cr alloys, Fe-Ni alloys, Fe-Co alloys, Fe-V alloys, Fe-Al alloys, Fe- Al-based alloys, carbonyl iron and pure iron. The crystalline magnetic material may be composed of one kind of material or a plurality of kinds of materials. The crystalline magnetic material for imparting the powder of the crystalline magnetic material is preferably one or more kinds of materials selected from the group consisting of the above materials. Among these, the material containing carbonyl iron is preferable, and the material containing carbonyl iron More preferable.

The shape of the powder of the crystalline magnetic material contained in the compacted powder cores 1 according to one embodiment of the present invention is not limited. The shape of the powder may be spherical or non-spherical. In the case of the non-spherical shape, it may be a shape having a shape anisotropy such as scales, an ellipse spherical shape, a liquid droplet shape, a needle shape, or a pseudo shape having no particular shape anisotropy. Examples of the indefinite powder include a case in which a plurality of spherical powders are bonded to each other or are partially buried in other powders. Such irregular powder is liable to be observed in carbonyl iron.

The shape of the powder may be a shape obtained in the step of producing the powder, or a shape obtained by secondary processing the produced powder. Examples of the former shape include spherical shape, elliptical spherical shape, droplet shape, needle shape and the like, and the latter shape is a sculptural shape.

The particle size of the powder of the crystalline magnetic material contained in the compacted powder 1 according to the embodiment of the present invention is not limited. When the particle diameter is defined by the median diameter (D50) (the particle diameter when the volume cumulative value in the volume distribution of the particle diameter of the soft magnetic powder measured by the laser diffraction scattering method is 50%), the particle diameter is usually 1 mu m to 20 mu m . The median diameter D50 of the powder of the crystalline magnetic material (in the present specification, " the first median diameter (d1) ", " ) Is preferably 1 mu m or more and 15 mu m or less, more preferably 1 mu m or more and 10 mu m or less, and particularly preferably 1 mu m or more and 5 mu m or less.

The content of the crystalline magnetic material powder in the compacting powder core 1 according to the embodiment of the present invention is such that the compacting core 1 satisfies the condition relating to the iron loss Pcv to be described later Is set in relation to the content of the amorphous magnetic material.

It is preferable that at least a part of the powder of the crystalline magnetic material is made of a material subjected to an insulation treatment, and the powder of the crystalline magnetic material is more preferably made of a material subjected to an insulation treatment. When the powder of the crystalline magnetic material is subjected to the insulation treatment, the insulation resistance of the compaction core tends to be improved. In addition, there is a tendency that the iron loss (Pcv) tends to decrease not only in the high frequency band but also in the low frequency band.

The kind of insulation treatment to be performed on the powder of the crystalline magnetic material is not limited. Phosphoric acid treatment, phosphate treatment, oxidation treatment and the like.

When the powder of the crystalline magnetic material is composed of the material subjected to the insulation treatment, the ratio of the mass of the content of the crystalline magnetic material powder to the total of the content of the powder of the crystalline magnetic material and the content of the powder of the amorphous magnetic material %, In the present specification, also referred to as " first mixing ratio ") is preferably 5 mass% or more and 40 mass% or less. When the first mixing ratio is within the above range, the iron loss Pcv tends to decrease in the high frequency band and the low frequency band. The first mixing ratio is more preferably 5 mass% or more and 35 mass% or less, still more preferably 5 mass% or more and 30 mass% or less, still more preferably 5 mass% or more and 25 mass% or less, or 10 mass% or more and 20 mass % Or less by mass.

(2) Powder of amorphous magnetic material

The amorphous magnetic material imparting the powder of the amorphous magnetic material contained in the compacted core 1 according to the embodiment of the present invention may be amorphous (it may be amorphous (by general X-ray diffraction measurement, A diffraction spectrum having a peak can not be obtained), and a specific kind is not limited as long as it is a ferromagnetic substance, particularly a soft magnetic material substance. Specific examples of the amorphous magnetic material include Fe-Si-B alloys, Fe-P-C alloys and Co-Fe-Si-B alloys. The amorphous magnetic material may be composed of one kind of material or a plurality of kinds of materials. The magnetic material constituting the powder of the amorphous magnetic material is preferably one or more kinds of materials selected from the group consisting of the above materials. Of these, the Fe-PC based alloy is preferable, and the Fe-PC based Alloy is more preferable.

As a specific example of the Fe-PC-based alloy, the composition formula is represented by Fe 100-abcxyzt Ni a Sn b Cr c P x C y B z Si t , where 0 at% a% 10 at%, 0 at% ? 3 atomic%, 0 atomic%? C 6 atomic%, 6.8 atomic%? X? 10.8 atomic%, 2.2 atomic%? Y? 9.8 atomic%, 0 atomic%? Z? 4.2 atomic%, 0 atomic%? T 7 atomic% of Fe-based amorphous alloy. In the above composition formula, Ni, Sn, Cr, B, and Si are optional additional elements.

The addition amount a of Ni is preferably 0 atomic% or more and 6 atomic% or less, more preferably 0 atomic% or more and 4 atomic% or less. The addition amount b of Sn is preferably 0 atomic% or more and 2 atomic% or less, more preferably 1 atomic% or more and 2 atomic% or less. The addition amount c of Cr is preferably 0 atomic% or more and 2 atomic% or less, more preferably 1 atomic% or more and 2 atomic% or less. The addition amount x of P is preferably 8.8 atomic% or more. The addition amount y of C is preferably 5.8 at.% Or 8.8 at.% Or less. The addition amount z of B is preferably 0 atomic% or more and 3 atomic% or less, more preferably 0 atomic% or more and 2 atomic% or less. The addition amount t of Si is preferably 0 atomic% or more and 6 atomic% or less, more preferably 0 atomic% or more and 2 atomic% or less.

The shape of the powder of the amorphous magnetic material contained in the compacted powder 1 according to one embodiment of the present invention is not limited. Since the shape of the powder is the same as that of the powder of the crystalline magnetic material, its explanation is omitted. The amorphous magnetic material may be spherical or ellipsoidal in some cases in terms of the manufacturing method. In general, since the amorphous magnetic material is harder than the crystalline magnetic material, it is sometimes preferable to make the crystalline magnetic material non-spherical so as to be easily deformed at the time of pressure molding.

The shape of the powder of the amorphous magnetic material contained in the compacted powder cores 1 according to the embodiment of the present invention may be a shape obtained at the stage of producing the powder or a shape obtained by secondary processing of the produced powder. Examples of the former shape include spherical shape, elliptical spherical shape, needle shape and the like, and the latter shape is exemplified by a sculptural shape.

The particle size of the powder of the amorphous magnetic material contained in the compacted powder 1 according to the embodiment of the present invention is not limited. When the particle diameter is defined by the median diameter (D50), it is usually in the range of 1 to 20 mu m. The median diameter D50 (also referred to as " second median diameter d2 " in the present specification) of the powder of the amorphous magnetic material is preferably 1 mu m or more, more preferably 2 mu m or more More preferably 3 mu m or more.

The median diameter (D50) of the powder of the amorphous magnetic material is preferably 15 mu m or less and more preferably 12 mu m or less from the viewpoint of increasing the filling density of the amorphous and crystalline magnetic material powder in the compaction core 1 More preferably 6 mu m or less. Further, in order to realize high insulation resistance and low iron loss (Pcv) of the dust compact core 1, it is preferable to set the median diameter (D50) of the amorphous magnetic material powder to 6 mu m or less. From the viewpoint of realizing excellent direct current superimposition characteristic of the compaction core 1 and low iron loss (Pcv) in a high frequency band, it is preferable to set the median diameter (D50) of the amorphous magnetic material powder to 5 m or less.

The relationship between the first median diameter d1 and the second median diameter d2 is not limited. As a general matter, since the amorphous magnetic material is harder than the crystalline magnetic material, the first median diameter d1 is made relatively small so that the gap portion formed when the powder of the amorphous magnetic material is filled can be easily filled with the powder of the crystalline magnetic material In some cases. In this case, d1 / d2 is preferably 0.8 or less, more preferably 0.5 or less.

The content of the powder of the amorphous magnetic material in the compacting core 1 according to the embodiment of the present invention is such that the compacting core 1 satisfies the condition relating to the iron loss Pcv to be described later Is set in relation to the content of the crystalline magnetic material.

(3) Frequency dependence of iron loss (Pcv)

The compacting core 1 according to the embodiment of the present invention satisfies the following relation with respect to the frequency f (unit: kHz) dependency of the iron loss Pcv (unit: kW / m 3 ). That is, the effective maximum magnetic flux density (B m) is displayed nd the frequency (f) dependence of the core loss (Pcv) as measured at 15 mT of the conditions, by the second equation below using the constants k h and k e (1) time, the constant k h of one 1.5 × 10 -3 kW / m 3 / kHz / (mT) 1.6 or less, and the other constant k e is 3.0 × 10 -7 kW / m 3 / (kHz) 2 / ( mT) 2 or less.

Pcv = k h x f x B m 1.6 + k e x f 2 x B m 2 (1)

In this specification, the constants k h and k e are calculated based on the dependence of the iron loss (Pcv) on the frequency f in the range of 1 MHz to 3 MHz.

When the constants k h and k e are within the above ranges, the degree of increase of the iron loss Pcv due to the increase of the frequency f becomes gentle and the iron loss Pcv does not become high even if the frequency becomes 1 MHz or more. From the viewpoint of the frequency (f) dependence of the core loss (Pcv) as well as a more reliable, constant k h is, 1.0 × 10 -3 kW / m 3 / kHz / (mT) 1.6 or less, and preferably, 0.8 × 10 - And more preferably 3 kW / m 3 / kHz / (mT) 1.6 or less. Further, in view of the above, the constant k e is, 2.8 × 10 -7 kW / m 3 / (kHz) 2 / (mT) 2 is preferably, 2.7 × 10 -7 kW / m 3 / (kHz) less than or equal to 2 / (mT) 2 or less.

The lower limit of the constants k h and k e is not limited in view of more stably improving the dependency of the iron loss Pcv on the frequency f. Typically, the constant k h is 1.0 × 10 -4 kW / m 3 / kHz / (mT) is at least 1.6, the constant k e is 1.0 × 10 -7 kW / m 3 / (kHz) 2 / (mT) is at least 2 .

The influence of the relationship between the content of the crystalline magnetic material powder and the content of the amorphous magnetic material powder in the compacted powder cores 1 according to the embodiment of the present invention on the constants k h and k e is as follows .

As a basic tendency, the higher the ratio of the first mixing ratio (the ratio of the content of the crystalline magnetic material to the content of the crystalline magnetic material to the total of the content of the crystalline magnetic material and the amorphous magnetic material), the more the two constants k h , k e all increase. Therefore, the higher the first mixing ratio, the higher the iron loss (Pcv) tends to be.

When the relationship between the change in the first mixing ratio and the change in the constants k h and k e is examined in detail, nonlinearity is confirmed in this relationship, and the tendency is more remarkable as the first mixing ratio is lower. That is, when the first mixing ratio is about 40% by mass or less, the degree of increase in both constants k h and k e is relatively small even if the first mixing ratio is increased. According to the above equation (1), even if the two constants k h and k e are lower and the effective maximum magnetic flux density B m and the frequency f are increased, the iron loss Pcv does not increase very much. Therefore, the function of suppressing the rise of the iron loss (Pcv) (hereinafter also referred to as " iron loss suppressing function ") tends to be effectively exhibited when the first mixing ratio is low. The first mixing ratio is preferably 35 mass% or less, more preferably 30 mass% or less, particularly preferably 20 mass% or less, from the viewpoint that the iron loss suppressing function can be more effectively exhibited. In order to improve the direct current superimposition characteristic, the first mixing ratio is preferably 5 mass% or more, more preferably 10 mass% or more, and particularly preferably 15 mass% or more. The first mixing ratio is preferably 5% by mass or more and 40% by mass or less, more preferably 15% by mass or more and 30% by mass or less, from the viewpoint that the compacting core 1 exhibits the iron loss- Is more preferable.

As the primary mixing ratio increases, the iron loss (Pcv) increases as a basic tendency, and the tendency of the increase is the frequency dependency as follows. That is, the iron loss ratio obtained by normalizing the iron loss (Pcv) in the case of an arbitrary first mixing ratio to the iron loss (Pcv) in the case where the first mixing ratio is 0 mass% (only the powder of the amorphous magnetic material) The higher the ratio is, the larger the degree of increase of the iron loss rate becomes, the higher the frequency becomes, the more gradual. As described in the following embodiments, the first mixing ratio dependency of the increase in the iron loss change rate at 2 MHz is about half of the first mixing ratio dependency of the increase in the iron loss change rate at 100 kHz. Therefore, in the case of an electronic / electrical component having a compacted core 1 according to an embodiment of the present invention, the influence of the iron loss Pcv on the use in a high frequency band is less likely to occur.

(4) Binder component

The binder component is a powder of a crystalline magnetic material and powder of an amorphous magnetic material contained in the compacted powder cores 1 according to the present embodiment (in this specification, these powders may be collectively referred to as " magnetic powder " The composition is not limited as long as it is a material contributing to the formation. Examples of materials constituting the binder component include organic materials and inorganic materials such as resin materials and pyrolysis residues of the resin materials (herein, these are collectively referred to as " components based on a resin material & do. As the resin material, acrylic resin, silicone resin, epoxy resin, phenol resin, urea resin, melamine resin and the like are exemplified. Examples of the binder component made of an inorganic material include glass-based materials such as water glass. The binding component may be composed of one kind of material or a plurality of materials. The binder component may be a mixture of an organic material and an inorganic material.

As the binder component, an insulating material is usually used. As a result, it becomes possible to increase the insulating property as the dust compact core 1.

2. Manufacturing method of potato core

The production method of the compacted powder cores 1 according to the embodiment of the present invention is not particularly limited, but it is possible to manufacture the compacted cores 1 more efficiently by employing the production method described below.

The method of manufacturing the compacted core 1 according to one embodiment of the present invention may include a forming step, which will be described below, and may further include a heat treatment step.

(1) Molding process

First, a mixture containing a magnetic powder and a component imparting a binding component in the pression core 1 is prepared. The component (also referred to as " binder component " in the present specification) imparting the binder component may be a binder component itself or may be a material different from the binder component. As a concrete example of the latter, the case where the binder component is a resin material and the binder component is a pyrolysis residue.

A molded product can be obtained by a molding process including press molding of the mixture. The pressurizing conditions are not limited, but are appropriately determined based on the composition of the binder component and the like. For example, in the case where the binder component is made of a thermosetting resin, it is preferable to heat the resin together with the pressurization to advance the curing reaction of the resin in the mold. On the other hand, in the case of compression molding, although the pressing force is high, heating is not a necessary condition and the pressing is performed for a short time.

Hereinafter, the case where the mixture is a granulated powder and compression molding is performed will be described in more detail. Since the granulated powder is excellent in handling property, it is possible to improve the workability of a compression molding process having a short molding time and excellent productivity.

(1-1) Assembly powder

The granulated powder contains a magnetic powder and a binder component. The content of the binder component in the granulated powder is not particularly limited. When such a content is excessively low, it is difficult for the binder component to retain the magnetic powder. In addition, when the content of the binder component is excessively low, it is difficult to isolate the plurality of magnetic powders from each other in the binder component comprising the decomposition residue of the binder component in the compacted core 1 obtained through the heat treatment process. On the other hand, when the content of the binder component is excessively high, the content of the binder component contained in the compacting core 1 obtained through the heat treatment process tends to be high. If the content of the binder component in the press powder core 1 is increased, the magnetic powder characteristic of the press powder core 1 is likely to be lowered. Therefore, it is preferable that the content of the binder component in the granulated powder is 0.5% by mass or more and 5.0% by mass or less with respect to the whole granulated powder. From the viewpoint of more stably reducing the possibility that the magnetic characteristic of the compacting core 1 is lowered, the content of the binder component in the granulated powder is such that the content is 1.0% by mass or more and 3.5% by mass or less with respect to the whole granulated powder , More preferably not less than 1.2 mass% and not more than 3.0 mass%.

The granulated powder may contain a material other than the magnetic powder and the binder component. Examples of such a material include a lubricant, a silane coupling agent, and an insulating filler. In the case of containing a lubricant, the kind thereof is not particularly limited. The lubricant may be an organic lubricant or an inorganic lubricant. Specific examples of the organic lubricant include metallic soaps such as zinc stearate and aluminum stearate. It can be considered that such an organic lubricant is vaporized in the heat treatment process and hardly remains in the pressurized core 1.

The manufacturing method of the assembled powder is not particularly limited. A granulated powder obtained by directly kneading the component imparting the granulated powder and pulverizing the obtained kneaded product by a known method may be used to obtain a granulated powder, and a slurry obtained by adding a dispersion medium (water as an example) , And the slurry is dried and pulverized to obtain a granulated powder. Sieve separation or classification may be performed after the pulverization to control the particle size distribution of the granulated powder.

As an example of a method for obtaining granulated powder from the slurry, there is a method using a spray dryer. 2, a rotor 201 is provided in the spray dryer apparatus 200, and the slurry S is injected toward the rotor 201 from the upper portion of the apparatus. The rotor 201 is rotated by a predetermined number of revolutions and atomizes the slurry S in the chamber inside the apparatus 200 as a droplet by centrifugal force. Further, hot air is introduced into the chamber inside the apparatus 200, and the dispersion medium (water) contained in the small droplet-shaped slurry S is volatilized while maintaining a small droplet shape. As a result, granulated powder (P) is formed from the slurry (S). This assembly powder P is recovered from the lower portion of the apparatus 200. The parameters such as the number of rotations of the rotor 201, the temperature of hot air to be introduced into the spray drier 200, and the temperature of the lower portion of the chamber may be appropriately set. As a specific example of the setting range of these parameters, the rotational speed of the rotor 201 is 4000 to 6000 rpm, the hot air temperature to be introduced into the spray drier 200 is 130 to 170 占 폚, . Also, the atmosphere in the chamber and its pressure may be appropriately set. As an example, the inside of the chamber is made to be an air (air) atmosphere, and the pressure is set to 2 mmH 2 O (about 0.02 kPa) by a pressure difference with atmospheric pressure. The particle size distribution of the obtained granulated powder (P) may be further controlled by sieving or the like.

(1-2) Pressurizing conditions

The pressing condition in the compression molding is not particularly limited. The composition of the granulated powder, the shape of the molded product, and the like. When the pressing force at the time of compression molding of the assembly powder is excessively low, the mechanical strength of the molded article is lowered. As a result, the handling property of the molded article is lowered, and the mechanical strength of the compacted core 1 obtained from the molded article is lowered. In some cases, the magnetic powder characteristic of the dust compact core 1 may be deteriorated or the insulating property may be deteriorated. On the other hand, when the pressing force at the time of compression molding of the granulated powder is excessively high, it becomes difficult to manufacture a molding die capable of withstanding the pressure. From the viewpoint of more stably reducing the possibility that the compression pressurizing process adversely affects the mechanical characteristics and the magnetic properties of the compaction core 1 and facilitating mass production on an industrial scale, the pressing force at the time of compression- More preferably from 0.3 GPa to 2 GPa, more preferably from 0.5 GPa to 2 GPa, and particularly preferably from 0.8 GPa to 2 GPa.

In the compression molding, pressing may be performed while heating, or may be performed at room temperature.

(2) Heat treatment process

The compacted product obtained by the molding process may be the compacted powder core 1 according to the present embodiment, and the compacted product 1 may be obtained by subjecting the molded product to a heat treatment process as described below.

In the heat treatment step, the molded product obtained by the above-mentioned molding step is heated to adjust the magnetic properties by modifying the distance between the magnetic powders, and to alleviate the distortion imparted to the magnetic powder in the molding step, To obtain a compact powder core (1).

Since the heat treatment process is aimed at adjusting the magnetic properties of the powder compact core 1 as described above, the heat treatment conditions such as the heat treatment temperature are set so that the magnetic powder characteristic of the powder compact core 1 is the best. One example of a method of setting the heat treatment conditions is to change the heating temperature of the molded product and to keep the other conditions such as the heating rate and the holding time at the heating temperature constant.

The criteria for evaluating the magnetic properties of the dust compact core 1 when setting the heat treatment conditions are not particularly limited. As a concrete example of the evaluation item, iron loss (Pcv) of the press compaction core (1) can be mentioned. In this case, the heating temperature of the molded product may be set so that the iron loss (Pcv) of the compacted core (1) is the lowest. The measurement conditions of the iron loss (Pcv) are appropriately set and, as an example, there is a condition that the frequency is 100 kHz and the maximum magnetic flux density is 100 mT.

The atmosphere at the time of heat treatment is not particularly limited. In the case of an oxidizing atmosphere, it is preferable to perform the heat treatment in an inert atmosphere such as nitrogen or argon or a reducing atmosphere such as hydrogen because the possibility that the thermal decomposition of the binder component excessively progresses or the oxidation of the magnetic powder proceeds becomes high.

3. Electronic and electrical parts

An electric / electronic component according to an embodiment of the present invention includes a compacting core (1) according to one embodiment of the present invention, a coil, and connection terminals connected to the respective ends of the coil. Here, at least a part of the compaction core 1 is disposed so as to be located in the induction magnetic field generated by the current when the current is passed through the coil through the connection terminal.

An example of such an electric / electric part is the toroidal coil 10 shown in Fig. The toroidal coil 10 has a coil 2a formed by winding a coated conductive wire 2 on a ring-shaped compacted cored wire (toroidal core) 1. The end portions 2d and 2e of the coil 2a are positioned at the portions of the conductive wire located between the coil 2a made of the wound coated conductive wire 2 and the end portions 2b and 2c of the coated conductive wire 2, Can be defined. As described above, in the electric / electronic part according to the present embodiment, the member constituting the coil and the member constituting the connection terminal may be constituted by the same member.

The electric / electronic part according to one embodiment of the present invention includes a compacting core having a shape different from that of the compacting core 1 according to the embodiment of the present invention. As a specific example of such an electric / electric part, there is an inductance element 20 shown in Fig. Fig. 4 is a perspective view showing a part of the overall configuration of the inductance element 20 according to the embodiment of the present invention. In Fig. 4, the lower surface (mounting surface) of the inductance element 20 is shown in an upward posture. 5 is a partial front view showing a state in which the inductance element 20 shown in Fig. 4 is mounted on the mounting board 100. Fig.

The inductance element 20 shown in Fig. 4 includes a compaction core 3, an air core coil 5 as a coil embedded in the compaction core 3, and an air core coil 5, And a pair of terminal portions 4 as connection terminals which are electrically connected to each other.

The air core coil (5) is formed by spirally winding an insulated conductor wire. The air core coil 5 is constituted by the winding section 5a and the leading end sections 5b and 5b drawn out from the winding section 5a. The winding number of the air core coil 5 is appropriately set in accordance with the required inductance.

4, in the compaction core 3, a housing recess 30 for accommodating a part of the terminal portion 4 is formed in the mounting surface 3a with respect to the mounting board. The accommodating concave portion 30 is formed on both sides of the mounting surface 3a and is formed so as to be freely opened toward the side surfaces 3b and 3c of the compaction core 3.

A part of the terminal portion 4 projecting from the side surfaces 3b and 3c of the compaction core 3 is bent toward the mounting surface 3a and housed in the accommodating concave portion 30. [

The terminal portion 4 is formed of a thin plate-like Cu base material. The terminal portion 4 is provided with a connection end portion 40 buried in the inside of the compaction core 3 and electrically connected to the lead-out end portions 5b and 5b of the air-core coil 5, And a first curved portion (curved portion) 42a and a second curved portion 42b which are formed by being bent in order from the side surfaces 3b and 3c of the compaction core 3 to the mounting surface 3a . The connecting end portion 40 is a welded portion welded to the air-core coil 5. The first curved portion 42a and the second curved portion 42b are solder joint portions that are soldered to the mounting substrate 100. [ The solder joint portion is a portion exposed from the pressurized core 3 in the terminal portion 4 and means at least a surface directed toward the outside of the compaction core 3.

The connection end portion 40 of the terminal portion 4 and the lead-out end portion 5b of the air-core coil 5 are joined by resistance welding.

As shown in Fig. 5, the inductance element 20 is mounted on the mounting board 100. Fig.

A conductor pattern is formed on the surface of the mounting substrate 100 so as to communicate with an external circuit. A part of the conductor pattern forms a pair of land portions 110 for mounting the inductance element 20.

5, in the inductance element 20, the first curved portion 42a and the second curved portion 42a, which are exposed to the outside from the compaction core 3 with the mounting surface 3a facing toward the mounting substrate 100, The second bending portion 42b is bonded to the land portion 110 of the mounting substrate 100 by the solder layer 120. [

In the soldering process, after the paste type solder is applied to the land portion 110 in the printing process, the inductance element 20 is mounted so that the second curved portion 42b faces the land portion 110, The solder is melted. 4 and 5, the second bending portion 42b is opposed to the land portion 110 of the mounting substrate 100, and the first bending portion 42a is formed on the side surface of the inductance element 20 The solder layer 120 of the fillet type is adhered to the land portion 110 and the solder material is soldered to both the second curved portion 42b which is a solder joint portion and the first curved portion 42a It spreads firmly on the surface and is fixed.

4. Electronic and electrical equipment

An electronic / electrical apparatus according to an embodiment of the present invention is an electronic / electrical apparatus having a compacted core according to an embodiment of the present invention. Examples of such electronic and electric devices include a power supply device having a power supply switching circuit, a voltage rising and falling circuit, a smoothing circuit, and the like, and a small portable communication device.

The power supply switching circuit, the voltage raising circuit, the smoothing circuit, and the like are generally made smaller and higher in frequency and increase in loss. When the electronic / electric part according to the embodiment of the present invention is the inductance element 20, it is possible to combine high frequency, excellent direct current superimposition characteristic and low loss. Therefore, even when the electronic / electric device evolves into miniaturization and high-speed (high frequency), realization of a high-efficiency circuit becomes easy as in the prior art, and power consumption of the electronic / electric device can be prevented from increasing.

The above-described embodiments are described for the purpose of facilitating understanding of the present invention, and are not described for limiting the present invention. Therefore, each element disclosed in the above embodiment is intended to include all design modifications and equivalents falling within the technical scope of the present invention.

For example, a compacting core according to an embodiment of the present invention is a compacting core containing a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, and a compacted core comprising a powder of a crystalline magnetic material and a powder of an amorphous magnetic material, The mass ratio of the content of the powder of the crystalline magnetic material to the magnetic material is not less than 5 mass% and not more than 40 mass%. Then, the compressed metal powder core having the above characteristics, also the above-mentioned formula (1) the above-described characteristics (a constant of one k h is 1.5 × 10 -3 kW / m 3 / kHz / (mT) 1.6 or less related to, but also other (K e) of 3.0 × 10 -7 kW / m 3 / (kHz) 2 / (mT) 2 or less) may be provided.

Example

Hereinafter, the present invention will be described in more detail with reference to Examples and the like, but the scope of the present invention is not limited to these Examples and the like.

(Example 1)

(1) Fabrication of Fe group base amorphous alloy powder

A powder of an amorphous magnetic material obtained by weighing the mixture so as to have a composition of Fe 71 atomic% Ni 6 atomic% Cr 2 atomic% P 11 atomic% C 8 atomic% B 2 atomic% by water atomization method was produced as a magnetic powder . The first mixing ratio (the mass ratio of the content of the crystalline magnetic material powder to the total of the content of the crystalline magnetic material powder and the amorphous magnetic material powder) was 0 mass%.

The particle size distribution of the obtained magnetic powder was measured by volume distribution using "Microtrack particle size distribution measuring apparatus MT3300EX" manufactured by Nikkiso Co., Ltd. As a result, the median diameter (D50), which was 50% of the volume distribution, was 5 占 퐉.

(2) Fabrication of assembly powder

97.2 parts by mass of the magnetic powder, 2 to 3 parts by mass of an insulating binder made of an acrylic resin and a phenol resin, and 0 to 0.5 parts by mass of a lubricant composed of zinc stearate were mixed with water as a solvent to obtain a slurry.

The obtained slurry was granulated (granulated) under the above-mentioned conditions by using the spray dryer apparatus 200 shown in Fig. 2 to obtain granulated powder.

(3) Compression molding

The resulting assembly powder was filled in a metal mold and subjected to pressure molding at a surface pressure of 0.5 to 1.5 GPa to obtain a molded body having a ring shape having an outer diameter of 20 mm x inner diameter of 12 mm x thickness of 3 mm.

(4) Heat treatment

The obtained molded body was placed in a furnace in an atmosphere of nitrogen gas flow and the furnace temperature was heated from room temperature (23 ° C) to a temperature of 200 ° C to 400 ° C which is an optimal core heat treatment temperature at a heating rate of 10 ° C / Thereafter, a heat treatment was performed in which the furnace was cooled to room temperature to obtain a toroidal core comprising a compacted core.

(Examples 2 and 3)

Powder of an amorphous magnetic material used in Example 1 and powder of a crystalline magnetic material made of carbonyl iron subjected to an insulation treatment (median diameter (D50): 4.3 mu m) were mixed at the time of preparing the magnetic powder, A toroidal core was produced in the same manner as in Example 1 except that a magnetic powder having a mixing ratio of 10 mass% in Example 2 and 20 mass% in Example 3 was used.

(Example 4)

In the preparation of the magnetic powder, the whole amount of the carbonyl iron subjected to the insulation treatment used in Example 2 or the like was used in place of the amorphous magnetic material powder used in Example 1, that is, the first mixing ratio of the magnetic powder was 100 By mass in terms of mass%, the same procedure as in Example 1 was carried out to prepare a toroidal core.

(Examples 5, 6 and 7)

Powder of an amorphous magnetic material used in Example 1 and powder of a crystalline magnetic material made of carbonyl iron subjected to an insulation treatment (median diameter (D50): 4.3 mu m) were mixed at the time of preparing the magnetic powder, A toroidal core was produced in the same manner as in Example 1 except that the magnetic powder having the following mixing ratio was used.

Example 5 5%

Example 6 15 mass%

Example 7 30%

(Examples 8 to 12)

(Median diameter (D50): 4.3 mu m) made of carbonyl iron to which no insulating treatment was applied was used instead of the powder of the crystalline magnetic material used in Examples 2 to 4 when preparing the magnetic powder A powder of the crystalline magnetic material and the powder of the amorphous magnetic material prepared in Example 1 were mixed and a magnetic powder having a first mixing ratio of the following value was used, Toroidal core was prepared.

Example 8 [0071]

Example 9 10%

Example 10 20 mass%

Example 11 30%

(Example 12)

The magnetic powder was prepared in the same manner as in Example 1 except that the whole amount of the carbonyl iron not subjected to the insulation treatment used in Example 8 or the like was used in place of the amorphous magnetic material powder used in Example 1, To 100% by mass, the same procedure as in Example 1 was carried out to prepare a toroidal core.

(Example 13)

A powder of an amorphous magnetic material was prepared in the same manner as in Example 1 except that the median diameter (D50) was 6 占 퐉. A toroidal core was produced in the same manner as in Example 1 except that the powder of the amorphous magnetic material was used.

(Examples 14 and 15)

A powder of amorphous magnetic material having a median diameter (D50) of 6 mu m adjusted in Example 13 and a powder of crystalline magnetic material made of carbonyl iron subjected to insulation treatment used in Example 2 and the like (median diameter (D50): 4.3 Mu m) were mixed, and a magnetic powder having a first mixing ratio of the following value was used, to prepare a toroidal core.

Example 14 10% by mass

Example 15 20 wt%

(Test Example 1) Measurement of iron loss (Pcv)

With respect to the toroidal coil obtained by winding the coated copper wires 15 times on the primary side and 10 times on the secondary side respectively to the toroidal cores manufactured in Examples 1 to 15, a BH analyzer ("SY-8218" manufactured by Iwasaki Communication Co., Ltd.) (Measured frequency range: 100 kHz to 3 MHz) of the iron loss (Pcv) (unit: kW / m 3 ) was measured under the condition that the effective maximum magnetic flux density (B m ) was 15 mT. Part of the results are shown in Table 1. From the results of the frequency dependence in the range of 1 to 3 MHz in each core loss (Pcv) measured under the above conditions, two constants k h and k e were obtained. The results are shown in Tables 2 to 4. Tables 2 to 4 are arranged in the order of the first embodiment in which the first mixing ratio is low to the first embodiment in which the first mixing ratio is high. Also, as in the first embodiment, there is an embodiment in which a plurality of times are displayed for easy contrast. Each core loss of 100 kHz, 1 MHz, 2 MHz and 3 MHz are shown in Table 2 to 4 (Pcv) is effective maximum magnetic flux density (B m) for the conditions of each of 100 mT, 25 mT, 15 mT and 15 mT .

(Test Example 2) Measurement of permeability

With respect to the toroidal coil obtained by winding the coated copper wire on the primary side 40 times and the secondary side 10 times each to the toroidal core made according to the embodiment, an impedance analyzer ("4192A" manufactured by HP) , The initial magnetic permeability 占 and the direct current were superimposed on each other and the relative magnetic permeability 占 5500 when the direct current applied magnetic field was 5500 A / m was measured. The results are shown in Tables 2 to 4.

(Test Example 3) Measurement of direct current superposition characteristics

A direct current was superimposed on the toroidal coil in accordance with JIS C2560-2 by using the toroidal coil formed from the toroidal core manufactured by the embodiment. The applied current value Isat when the ratio? L / L 0 of the inductance L change amount L to the value L 0 of the inductance L before the application of the superposed current becomes 30% (Unit: A), the direct current superposition characteristic was evaluated. The results are shown in Tables 2 to 4.

(Test Example 4) Measurement of insulation resistance

The insulation resistance (unit: Ω) of the toroidal core produced by the examples was measured by the surface two-terminal method. The results are shown in Tables 2 and 4.

Figure 112015050947869-pat00001

Figure 112015050947869-pat00002

Figure 112015050947869-pat00003

Figure 112015050947869-pat00004

6 to 15 are graphs of the above results. Specifically, FIG. 6 is a graph showing the measurement results of the frequency dependency of the iron loss (Pcv) in the embodiment. 7 is a graph showing the dependence of the constant k h on the first mixing ratio. Figure 8 is a graph showing the dependence of the constant k e on the first mixing ratio. 9 is a graph showing the change in iron loss at 100 kHz and 2 MHz (a value obtained by normalizing an iron loss (Pcv) at an arbitrary first mixing ratio to an iron loss (Pcv) when the first mixing ratio is 0 mass%) And the dependency on the mixing ratio. Further, in FIG. 9, the iron loss rate is Toro is this month's core each primary winding 40 times the coated copper wire, the secondary-side wound 10 times, of 100 kHz is measured by B m = 100 mT, 2 MHz B m = 15 mT. ≪ / RTI > 10 is a graph showing the dependency of the insulation resistance on the first mixing ratio. 11-14 are graphs showing the relationship between the first mixing of the iron loss Pcv in the case where the frequencies are 100 kHz (Fig. 11), 1 MHz (Fig. 12), 2 MHz (Fig. 13) and 3 MHz Is a graph showing dependency on the ratio. The B m at the time of measurement was as shown in each graph and was 100 mT for 100 kHz, 25 mT for 1 MHz, and 15 mT for 2 MHz. Applied at the time 15 is when the application of superimposed electric current around the ratio (ΔL / L 0) is 30% of the (initial) of the inductance (L) variation (ΔL) of the inductance (L) to the value (L 0) Is a graph showing the dependence of the current value Isat on the first mixing ratio.

Based on Tables 1 to 4 and Figures 6 to 15, the following can be understood.

(A) A compact cored core containing a magnetic powder prepared so as to satisfy the formula (1) has excellent magnetic properties (iron loss (Pcv), initial permeability, direct current Overlapping property).

(B) From Figs. 7 and 8, it can be seen that as to the k e and k h , a low value is maintained when the first mixing ratio is 30 wt% or less, and a lower value is obtained when the first mixing ratio is 20 wt% or less. Therefore, it is understood that if the first mixing ratio is 30 wt% or less, preferably 20 wt% or less, the effect of suppressing the increase of the iron loss (Pcv) in the high frequency range is expected. On the contrary, when the first mixing ratio exceeds 30 wt%, k e and k h tend to increase, and consequently, the iron loss (Pcv) in the high frequency region is considerably increased. It is also seen from Fig. 15 that the applied current value Isat is improved when the first mixing ratio exceeds 10% by weight, and becomes even larger at 15% by weight or more.

When the first mixing ratio of the magnetic powder (C) is increased, the iron loss (Pcv) tends to increase. However, the iron loss (Pcv) does not increase even when the frequency is higher and the first mixing ratio is higher. This tendency can be seen from Fig. According to Fig. 9, in the case of 100 kHz, the rate of change of iron loss is 2.5 when the first mixing ratio is 10%, and the rate of change of iron loss is 3.6 when the first mixing ratio is 20% 1 Even if the mixing ratio is 20%, the increase of the iron loss rate stays at about 1.4. Therefore, in the case of an electric / electronic part having a compacted core according to the present embodiment, the effect is more likely to be realized when used in a high-frequency circuit. In addition, since electronic circuits in small and lightweight electronic and electric devices are made to have a high frequency, they are also suitable for DC-DC converters for mobile phones and the like.

(D) As shown in FIG. 10, in the case of using the magnetic powder including the powder of the crystalline magnetic material subjected to the insulation treatment, when the magnetic powder containing the powder of the crystalline magnetic material without the insulating treatment is used The insulation resistance of the compaction core tends to increase.

(E) As shown in FIG. 11, in the case of using the magnetic powder including the powder of the crystalline magnetic material subjected to the insulation treatment, when the magnetic powder containing the powder of the crystalline magnetic material not subjected to the insulating treatment is used It can be seen that the iron loss Pcv is small in the low frequency band. This can be understood from the frequency dependence of the constant k h shown in Fig.

(F) With respect to the frequency dependency of the constant k e shown in FIG. 8, the case of using the magnetic powder containing the powder of the crystalline magnetic material subjected to the insulation treatment and the case of using the powder of the crystalline magnetic material The same results were obtained. On the basis of these results, in the case of using the magnetic powder containing the powder of the crystalline magnetic material subjected to the insulating treatment and the case of using the magnetic powder containing the powder of the crystalline magnetic material without the insulating treatment, (Pcv) are considered to be equivalent. However, as shown in Figs. 12 to 14, in the case of using the magnetic powder including the powder of the crystalline magnetic material subjected to the insulation treatment, the frequency of the high frequency Resulting in low iron loss (Pcv) in the band.

When the median diameter (D50) of the powder of the amorphous magnetic material contained in the magnetic powder is 5 占 퐉 in the case where the magnetic powder contains the crystalline magnetic material subjected to the (G) insulation treatment, the amorphous magnetic material The iron loss Pcv in the high frequency band tended to be lower than in the case where the median diameter (D50) of the powder of the material was 6 mu m (Figs. 12 to 14). This tendency became more pronounced at higher frequencies. Further, when the amorphous magnetic material powder having a median diameter (D50) of 5 占 퐉 is used, the DC superposition property tends to be better than that of the amorphous magnetic material powder having a median diameter (D50) of 6 占 퐉 (Fig. 15). On the other hand, when the median diameter (D50) of the powder of the amorphous magnetic material contained in the magnetic powder is 6 mu m when the magnetic powder contains the crystalline magnetic material subjected to the insulation treatment, the amorphous magnetic material The insulation resistance tended to be higher than that when the median diameter D50 of the powder of 5 mu m was 5 mu m (Fig. 10). Therefore, it has been confirmed by this embodiment that it is effective to control the median diameter (D50) of the powder of the amorphous magnetic material contained in the magnetic powder according to the characteristics required for the compaction core.

(H) From the above results, it is confirmed that the iron loss (Pcv) in the high frequency band is reduced by using the magnetic powder composed of the powder of the amorphous magnetic material and the powder of the crystalline magnetic material irrespective of whether or not the insulation treatment is performed . It has also been confirmed that when the crystalline magnetic material is a magnetic powder composed of a material subjected to an insulation treatment, the iron loss (Pcv) is also small in the low frequency band. It was also confirmed that the magnetic properties and electric characteristics of the dust compact core can be adjusted by controlling the median diameter (D50) of the powder of the amorphous magnetic material contained in the magnetic powder.

The electric / electronic part using the compacted core of the present invention can be suitably used as a booster circuit of a hybrid automobile or the like, a reactor used for power generation, a substation facility, a transformer or a choke coil.

The present invention relates to a method for manufacturing a coiled cored wire, which comprises the steps of: (1) pressing a core (toroidal core) 10 toroidal coil 2 covered conductor wire 2a coil 2b 2c end of coated conductive wire 2d 2e end of coil 2a, 3 is a side view of the pinion core 3; 4 is a terminal portion; 5 is an air core coil; 5a is a side view of the air core coil 5; A first connecting part connected to the first connecting part and a second connecting part connecting the first connecting part and the second connecting part to each other; : Solder layer, 200: spray drier, 201: rotor, S: slurry, P: assembly powder

Claims (16)

A pressurized core containing a powder of a crystalline magnetic material and a powder of an amorphous magnetic material,
(Unit: kHz) dependence of the iron loss (Pcv) (unit: kW / m 3 ) measured under the condition that the effective maximum magnetic flux density (B m ) is 15 mT is expressed by two constants k h and k e , When expressed by the following formula (1)
Pcv = k h x f x B m 1.6 + k e x f 2 x B m 2 (1)
The constant k h is 1.5 × 10 -3 kW / m 3 / kHz / (mT) 1.6 or less, and
Wherein the constant k e is 3.0 × 10 -7 kW / m 3 / (kHz) 2 / (mT) 2 or less. The magnetic recording medium according to claim 1, wherein the mass ratio of the content of the crystalline magnetic material powder to the total of the content of the powder of the crystalline magnetic material and the content of the powder of the amorphous magnetic material is 5% by mass or more and 40% Poppy core. delete The magnetic recording medium according to claim 1 or 2, wherein the crystalline magnetic material is at least one selected from the group consisting of an Fe-Si-Cr alloy, an Fe-Ni alloy, an Fe-Co alloy, an Fe-V alloy, Si-based alloy, Fe-Si-Al-based alloy, carbonyl iron, and pure iron. The compact core according to claim 4, wherein the crystalline magnetic material is made of carbonyl iron. The amorphous magnetic material according to claim 1 or 2, wherein the amorphous magnetic material is at least one selected from the group consisting of Fe-Si-B alloy, Fe-PC alloy and Co-Fe-Si- Wherein the core comprises a material. The compact core according to claim 6, wherein the amorphous magnetic material is made of an Fe-P-C alloy. 3. The particulate core according to claim 1 or 2, wherein the powder of the crystalline magnetic material is made of a material subjected to an insulation treatment. 3. The particulate core according to claim 1 or 2, wherein the median diameter (D50) of the amorphous magnetic material powder is 6 占 퐉 or less. The compacting core according to claim 1 or 2, wherein the particulate core contains a binder for binding the powder of the crystalline magnetic material and the powder of the amorphous magnetic material to another material contained in the press compaction core. 11. The compaction core according to claim 10, wherein the binder component comprises a component based on a resin material. 13. A method for producing a press compaction core according to claim 11,
And a molding step of obtaining a molded product by a molding process including press molding of a mixture containing the powder of the crystalline magnetic material and the powder of the amorphous magnetic material and a binder component of the resin material, ≪ / RTI > 13. The method according to claim 12, wherein the molded product obtained by the molding step is the compacted core. 13. The method according to claim 12, comprising a heat treatment step of obtaining the compacted cores by a heat treatment for heating the molded product obtained by the shaping step. An electric / electronic part comprising the compaction core, the coil and the connection terminal connected to the respective ends of the coil according to claim 1 or 2,
Wherein at least a part of the compaction core is disposed so as to be located in an induction magnetic field generated by the current when a current is passed through the coil through the connection terminal. An electronic / electric apparatus mounted with the electronic / electric part according to claim 15,
And the electronic / electric part is connected to the board by the connection terminal.
KR1020150074058A 2014-06-06 2015-05-27 Compressed powder core, method of manufacturing the compressed powder core, electronic-electric component comprising the compressed powder core and electronic-electric device mounted with the electronic-electric component KR101688318B1 (en)

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