JP7490337B2 - Composite magnetic material and metal composite core made of this composite magnetic material - Google Patents
Composite magnetic material and metal composite core made of this composite magnetic material Download PDFInfo
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- 239000002131 composite material Substances 0.000 title claims description 34
- 239000000696 magnetic material Substances 0.000 title claims description 34
- 239000002905 metal composite material Substances 0.000 title claims description 8
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 23
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Description
本発明は、磁性粉末と樹脂から成る複合磁性材料及びこの複合磁性材料によって構成されたメタルコンポジットコアに関する。 The present invention relates to a composite magnetic material made of magnetic powder and resin, and a metal composite core made of this composite magnetic material.
ＯＡ機器、太陽光発電システム、自動車など様々な用途にリアクトルが用いられている。様々な用途に対応するため、リアクトルに用いられるコアの形状の多様化が要求されている。この要求に応えるため、リアクトルは、メタルコンポジットコア（以下、ＭＣコアとも称する）と呼ばれるコアが用いられる。 Reactors are used in a variety of applications, including office equipment, solar power generation systems, and automobiles. To accommodate these diverse applications, there is a demand for diversification of the shapes of cores used in reactors. To meet this demand, reactors use cores called metal composite cores (hereafter also referred to as MC cores).
このＭＣコアは、磁性粉末と樹脂とを混合させた複合磁性材料を所定の形状に成型し、固化させて成るコアである。複合磁性材料は粘土状である。そのため、複合磁性材料を容器に流し込みやすいので、容器の形状に合わせて成型しやすく、コアを所望の形状に成型できる。 This MC core is made by molding a composite magnetic material made by mixing magnetic powder and resin into a specific shape and then solidifying it. The composite magnetic material is clay-like. Therefore, the composite magnetic material can be easily poured into a container, and it can be easily molded to fit the shape of the container, allowing the core to be molded into the desired shape.
リアクトルは、使用する用途に合わせた鉄損などの磁気特性が要求される。例えば、電圧昇降用のコンバータに用いられるリアクトルは、エネルギー変換効率の向上が求められるため、エネルギー損失である鉄損をより小さくすることが求められる。鉄損は、渦電流損失と、ヒステリシス損失の和で表される。 Reactors are required to have magnetic properties such as iron loss that are suited to their use. For example, reactors used in converters for stepping up and down voltages are required to improve energy conversion efficiency, so iron loss, which is an energy loss, must be reduced. Iron loss is expressed as the sum of eddy current loss and hysteresis loss.
渦電流損失は、渦電流が発生するために生じる損失である。ＭＣコアにおいて、この渦電流は、磁性粉末の接触によって生じる可能性がある。そして、ＭＣコアの製造過程において、磁性粉末に応力が加えられることがある。この応力によって、磁性粉末同士が接触することがある。 Eddy current loss is a loss that occurs due to the generation of eddy currents. In MC cores, these eddy currents can occur due to contact between magnetic powder particles. During the manufacturing process of MC cores, stress can be applied to the magnetic powder particles. This stress can cause the magnetic powder particles to come into contact with each other.
そこで、例えば、磁性粉末を絶縁性の樹脂で覆い、磁性粉末同士の接触を抑制し、渦電流損失を低減させる手法がある。しかし、近年、リアクトルの使用用途の多様化に伴い、渦電流損失の更なる低減が求められる。 One approach to this problem is to cover the magnetic powder with insulating resin, which prevents the magnetic powder from coming into contact with itself, thereby reducing eddy current loss. However, in recent years, as the uses of reactors have become more diverse, there is a demand for further reductions in eddy current loss.
本発明の目的は、上記課題を解決するために提案されたものであり、渦電流損失を抑制することができる複合磁性材料及びこの複合磁性材料を用いたメタルコンポジットコアを提供することにある。 The object of the present invention is to solve the above problems and to provide a composite magnetic material capable of suppressing eddy current loss and a metal composite core using this composite magnetic material.
上記目的を達成するため、本発明は、磁性粉末と樹脂とを混合してなる複合磁性材料であって、前記磁性粉末は、第１の粉末と、前記第１の粉末より平均粒子径が小さい第２の粉末と、を有し、前記第１の粉末は、フッ素系樹脂のみから構成される絶縁被膜で覆われており、前記磁性粉末に混合される前記樹脂の添加量は、前記磁性粉末に対して３ｗｔ％以上１０ｗｔ％以下であり、前記絶縁被膜の添加量は、前記第１の磁性粉末に対して０．１ｗｔ％以上１．０ｗｔ％以下であること、を特徴とする。 In order to achieve the above-mentioned object, the present invention provides a composite magnetic material obtained by mixing a magnetic powder and a resin, the magnetic powder comprising a first powder and a second powder having an average particle diameter smaller than that of the first powder, the first powder being covered with an insulating coating composed only of a fluororesin, the amount of the resin added to the magnetic powder being 3 wt % or more and 10 wt % or less with respect to the magnetic powder, and the amount of the insulating coating being 0.1 wt % or more and 1.0 wt % or less with respect to the first magnetic powder .
本発明によれば、渦電流損失を抑制した磁気特性に優れた複合磁性材料及びこの複合磁性材料を用いたメタルコンポジットコアを得ることができる。 The present invention makes it possible to obtain a composite magnetic material with excellent magnetic properties that suppresses eddy current loss, and a metal composite core using this composite magnetic material.
（実施形態）
まず、本実施形態の構成について説明する。本実施形態のメタルコンポジットコア（以下、ＭＣコアとも称する）は、複合磁性材料を所定の容器に充填し、加圧することで所定の形状のコアとなる。このＭＣコアは、リアクトルの磁性体として使用される。
(Embodiment)
First, the configuration of this embodiment will be described. The metal composite core (hereinafter also referred to as MC core) of this embodiment is made by filling a composite magnetic material in a specified container and pressurizing it to form a core of a specified shape. This MC core is used as a magnetic body of a reactor.
複合磁性材料は、磁性粉末と樹脂とを含み構成される。磁性粉末としては、軟磁性粉末が使用でき、特に、Ｆｅ粉末、Ｆｅ－Ｓｉ合金粉末、Ｆｅ－Ａｌ合金粉末、Ｆｅ－Ｓｉ－Ａｌ合金粉末（センダスト）、非晶質合金粉末、ナノクリスタル、又はこれら２種以上の粉末の混合粉などが使用できる。Ｆｅ－Ｓｉ合金粉末としては、例えば、Ｆｅ－６．５％Ｓｉ合金粉末、Ｆｅ－３．５％Ｓｉ合金粉末を使用できる。 The composite magnetic material is composed of magnetic powder and resin. As the magnetic powder, soft magnetic powder can be used, and in particular, Fe powder, Fe-Si alloy powder, Fe-Al alloy powder, Fe-Si-Al alloy powder (Sendust), amorphous alloy powder, nanocrystal, or a mixture of two or more of these powders can be used. As the Fe-Si alloy powder, for example, Fe-6.5% Si alloy powder or Fe-3.5% Si alloy powder can be used.
磁性粉末は、平均粒子径の異なる磁性粉末を使用する。つまり、磁性粉末は、第１の粉末と、第１の粉末より平均粒子径が小さい第２の粉末から成る。本明細書において平均粒子径とは、特に断りがない限り、Ｄ５０、すなわちメジアン径を指すものとする。また、第１の粉末と第２の粉末の種類は、同じものでもよいし、異なるものでもよい。なお、本実施形態では、磁性粉末は平均粒子径の異なる第１の粉末及び第２の粉末の２種類の粉末で構成されているが、磁性粉末は、第１の粉末のみ１種類で構成されてもよい。 The magnetic powder is made of magnetic powders with different average particle diameters. In other words, the magnetic powder is made of a first powder and a second powder with an average particle diameter smaller than that of the first powder. In this specification, the average particle diameter refers to D50, i.e., the median diameter, unless otherwise specified. The first powder and the second powder may be the same or different. In this embodiment, the magnetic powder is made of two types of powder, the first powder and the second powder, which have different average particle diameters, but the magnetic powder may be made of only one type of powder, the first powder.
第１の粉末の平均粒子径は１００μｍ～２００μｍ、第２の粉末の平均粒子径は、３μｍ～１０μｍが好ましい。この範囲とすることで、第１の粉末同士の隙間に平均粒子径の小さい第２の粉末が入り込み、密度及び透磁率の向上と低鉄損化を図ることができるからである。 It is preferable that the average particle size of the first powder is 100 μm to 200 μm, and that of the second powder is 3 μm to 10 μm. By setting the sizes in this range, the second powder, which has a smaller average particle size, can fill the gaps between the first powder particles, improving density and magnetic permeability and reducing iron loss.
また、第１の粉末と第２の粉末の重量比率は、第１の粉末：第２の粉末＝８０：２０～６０：４０とすることが好ましい。この範囲とすることで密度及び透磁率が向上するとともに、鉄損を小さくすることができる。 The weight ratio of the first powder to the second powder is preferably 80:20 to 60:40 (first powder:second powder). By setting the ratio in this range, the density and magnetic permeability can be improved and the iron loss can be reduced.
第１の粉末の周囲は、絶縁被膜により覆われている。絶縁被膜は、絶縁性を有する樹脂から成る。この樹脂の種類は、フッ素系の樹脂を含む。即ち、絶縁被膜は、フッ素系の樹脂を含み成る。絶縁被膜の厚さは、５ｎｍ～５００ｎｍであることが好ましい。絶縁被膜の厚さが５ｎｍよりも薄くなると、絶縁性能が悪化する。一方、絶縁被膜の厚さが５００ｎｍよりも厚くなると、密度が低下し磁気特性が悪化する。なお、本明細書において、絶縁被膜となる絶縁性を有する樹脂を絶縁被膜樹脂と呼ぶ場合がある。 The first powder is covered with an insulating coating. The insulating coating is made of a resin having insulating properties. The type of resin includes a fluorine-based resin. That is, the insulating coating contains a fluorine-based resin. The thickness of the insulating coating is preferably 5 nm to 500 nm. If the insulating coating is thinner than 5 nm, the insulating performance deteriorates. On the other hand, if the insulating coating is thicker than 500 nm, the density decreases and the magnetic properties deteriorate. In this specification, the resin having insulating properties that becomes the insulating coating may be called an insulating coating resin.
絶縁被膜となるフッ素系の樹脂の添加量は、磁性粉末に対して、０．１ｗｔ％以上１．０ｗｔ％以下の範囲が好ましい。フッ素系樹脂の添加量が０．１ｗｔ％未満になると、渦電流損失（Ｐｅ）の低減効果が低い。一方、フッ素系樹脂の添加量が１．０ｗｔ％を超えると、ＭＣコアの密度が低下し、ヒステリシス損失（Ｐｈ）が増加する。 The amount of fluororesin added to form the insulating coating is preferably in the range of 0.1 wt% to 1.0 wt% of the magnetic powder. If the amount of fluororesin added is less than 0.1 wt%, the effect of reducing eddy current loss (Pe) is low. On the other hand, if the amount of fluororesin added exceeds 1.0 wt%, the density of the MC core decreases and the hysteresis loss (Ph) increases.
複合磁性材料を構成する樹脂は、磁性粉末と混合され、磁性粉末を保持する。樹脂としては、熱硬化性樹脂、紫外線硬化樹脂、又は熱可塑性樹脂を使用することができる。熱硬化性樹脂としては、フェノール樹脂、エポキシ樹脂、不飽和ポリエステル樹脂、ポリウレタン、ジアリルフタレート樹脂、シリコーン樹脂などが使用できる。紫外線硬化性樹脂としては、ウレタンアクリレート系、エポキシアクリレート系、アクリレート系、エポキシ系の樹脂を使用できる。熱可塑性樹脂としては、ポリイミドやフッ素樹脂などの耐熱性に優れた樹脂を使用することが好ましい。 The resin that constitutes the composite magnetic material is mixed with the magnetic powder and holds the magnetic powder. As the resin, a thermosetting resin, an ultraviolet-curing resin, or a thermoplastic resin can be used. As the thermosetting resin, a phenolic resin, an epoxy resin, an unsaturated polyester resin, a polyurethane, a diallyl phthalate resin, a silicone resin, etc. can be used. As the ultraviolet-curing resin, a urethane acrylate-based, an epoxy acrylate-based, an acrylate-based, or an epoxy-based resin can be used. As the thermoplastic resin, it is preferable to use a resin with excellent heat resistance such as polyimide or fluororesin.
また、樹脂は、磁性粉末に対して３～１０ｗｔ％含有されていることが好ましい。樹脂の含有量が３ｗｔ％より少ないと、磁性粉末の接合力が不足し、ＭＣコアの機械的強度が低下する。また、樹脂の含有量が１０ｗｔ％より多いと、磁性粉末を隙間なく保持することができなくなるなど、ＭＣコアの密度が低下し、透磁率が低下する。 It is also preferable that the resin content is 3 to 10 wt% relative to the magnetic powder. If the resin content is less than 3 wt%, the bonding strength of the magnetic powder will be insufficient, and the mechanical strength of the MC core will decrease. If the resin content is more than 10 wt%, the magnetic powder will no longer be able to be held without gaps, and the density of the MC core will decrease, lowering the magnetic permeability.
次に、この複合磁性材料を用いたＭＣコアの製造方法について説明する。本実施形態におけるＭＣコアの製造方法は、（１）被覆工程、（２）混合工程、（３）成型工程、（４）硬化工程を有する。 Next, we will explain the manufacturing method of the MC core using this composite magnetic material. The manufacturing method of the MC core in this embodiment includes (1) a coating process, (2) a mixing process, (3) a molding process, and (4) a curing process.
（１）被覆工程
被覆工程は、第１の粉末をフッ素系樹脂から成る絶縁被膜で覆う工程である。被覆工程では、第１の粉末とフッ素系樹脂を混合し、乾燥させることで、第１の粉末の周囲にフッ素系樹脂を被覆させる。第１の粉末とフッ素系樹脂の混合は、所定の混合器を用いて自動又は手動で行うことができる。混合する時間は、適宜設定することができる。混合する時間は、例えば２分間である。また、乾燥温度や乾燥時間は、フッ素系樹脂で第１の粉末を被覆できるのであれば、適宜な温度及び時間を設定できるが、例えば、１８０度で１２０分間乾燥する。
(1) Coating process The coating process is a process of covering the first powder with an insulating coating made of a fluororesin. In the coating process, the first powder and the fluororesin are mixed and dried to coat the first powder with the fluororesin. The first powder and the fluororesin can be mixed automatically or manually using a predetermined mixer. The mixing time can be set appropriately. The mixing time is, for example, 2 minutes. In addition, the drying temperature and drying time can be set appropriately as long as the first powder can be coated with the fluororesin, and for example, drying is performed at 180 degrees for 120 minutes.
（２）混合工程
混合工程は、磁性粉末と樹脂を混合する工程である。混合工程では、まず、被覆工程を経た第１の粉末と、第２の粉末を混合することで、磁性粉末を得る。そして、この磁性粉末に、磁性粉末に対して３～１０ｗｔ％の樹脂を添加し、磁性粉末と樹脂を混合する。この混合工程を経ることで、磁性粉末と樹脂との混合物である複合磁性材料を得ることができる。
(2) Mixing process The mixing process is a process for mixing the magnetic powder and the resin. In the mixing process, the first powder that has been through the coating process is first mixed with the second powder to obtain a magnetic powder. Then, 3 to 10 wt % of resin relative to the magnetic powder is added to this magnetic powder, and the magnetic powder and the resin are mixed. Through this mixing process, a composite magnetic material, which is a mixture of the magnetic powder and the resin, can be obtained.
（３）成型工程
成型工程は、複合磁性材料を製造するコアの形状に合わせて成型する工程である。成型工程では、まず、製造するコアの形状に合わせた容器に複合磁性材料を充填する。その後、容器に充填された複合磁性材料を、押圧部材で加圧する。この押圧部材で加圧することで、容器の形状に複合磁性材料を押し広げるとともに、複合磁性材料に含まれていた空隙を減少させることでコアの密度が大きくなる。
(3) Molding process The molding process is a process in which the composite magnetic material is molded to fit the shape of the core to be manufactured. In the molding process, first, the composite magnetic material is filled into a container that matches the shape of the core to be manufactured. Then, the composite magnetic material filled in the container is pressed with a pressing member. By applying pressure with this pressing member, the composite magnetic material is expanded to fit the shape of the container and the voids contained in the composite magnetic material are reduced, thereby increasing the density of the core.
複合磁性材料を加圧する圧力は、数ｔｏｎ～数十ｔｏｎで磁性粉末を押し固めて成形する圧粉磁心とは異なり、数ｋｇ～数十ｋｇと低い圧力をかければ足りる。そのため、圧粉磁心は磁性粉末が変形するが、ＭＣコアは、加圧しても磁性粉末は変形しない。なお、ＭＣコアの成型においては、圧粉磁心の成型のように加圧することは、必須要件ではないため、複合磁性材料を押圧部材で加圧しなくてもよい。 The pressure applied to the composite magnetic material is different from that applied to powder magnetic cores, which are formed by compressing magnetic powder with a few tons to a few tens of tons. A low pressure of a few to a few tens of kg is sufficient. Therefore, while the magnetic powder in a powder magnetic core deforms, the magnetic powder in an MC core does not deform even when pressure is applied. Note that, since applying pressure is not a mandatory requirement for molding an MC core, as is the case with powder magnetic cores, the composite magnetic material does not need to be pressed with a pressing member.
（４）硬化工程
硬化工程は、複合磁性材料に含まれる樹脂を硬化させる工程である。樹脂の硬化は、樹脂の種類によって適宜の方法で硬化すればよい。例えば、樹脂が熱硬化性樹脂の場合には、熱を加えることで樹脂を硬化させる。
(4) Curing process The curing process is a process for curing the resin contained in the composite magnetic material. The resin may be cured by an appropriate method depending on the type of resin. For example, when the resin is a thermosetting resin, the resin is cured by applying heat.
このように、所望の形状の容器に複合磁性材料を充填し、複合磁性材料に含まれる樹脂を硬化させることで、所望の形状となったＭＣコアが作製される。つまり、ＭＣコアにおいては、混合工程において添加した樹脂は硬化するだけなので、当該樹脂の成分は、分解されない。一方、圧粉磁心では、絶縁被膜として添加した樹脂は、焼鈍工程を経るため熱分解され、残った無機成分などが粉末間のバインダとして機能する。また、圧粉磁心は、数ｔｏｎ～数十ｔｏｎで加圧成形することで、所望の形状にしており、樹脂を硬化させることでコアの形状を形成させるＭＣコアとは異なる。 In this way, a container of the desired shape is filled with the composite magnetic material, and the resin contained in the composite magnetic material is cured to produce an MC core with the desired shape. That is, in MC cores, the resin added in the mixing process simply hardens, so the resin components do not decompose. On the other hand, in powder cores, the resin added as an insulating coating is thermally decomposed as it goes through the annealing process, and the remaining inorganic components function as binders between the powder. Also, powder cores are pressurized with several tons to several tens of tons to give them the desired shape, which differs from MC cores in that the core shape is formed by curing the resin.
（実施例）
本発明の実施例を表１及び図１－図５を参照しつつ説明する。
(Example)
An embodiment of the present invention will be described with reference to Table 1 and FIGS.
実施例１－５は、第１の粉末としては、平均粒子径が１５０μｍのＦｅ－６．５Ｓｉ合金粉末を使用した。実施例１－５は、絶縁被膜としてフッ素系樹脂を使用し、第１の粉末の周囲を被覆する。実施例１－５は、このフッ素系の樹脂を第１の粉末に対してそれぞれ１．０ｗｔ％、０．７５ｗｔ％、０．５ｗｔ％、０．２５ｗｔ％、０．１ｗｔ％添加した。 In Example 1-5, Fe-6.5Si alloy powder with an average particle size of 150 μm was used as the first powder. In Example 1-5, a fluororesin was used as an insulating coating to coat the periphery of the first powder. In Example 1-5, 1.0 wt%, 0.75 wt%, 0.5 wt%, 0.25 wt%, and 0.1 wt% of this fluororesin was added to the first powder.
一方、比較例１－３は、第１の粉末を被覆する絶縁被膜の有無及び種類を実施例と変え、その他は実施例と同様に作製した。具体的には、比較例１は、第１の粉末を絶縁被膜の樹脂で被覆せず、即ち、第１の粉末そのものである。比較例２は、被膜樹脂の種類として、アクリルを使用し、このアクリルを第１の粉末に対して１．０ｗｔ％添加した。比較例３は、被膜樹脂の種類としてシリコーンを使用し、このシリコーンを第１の粉末に対して１．０ｗｔ％添加した。 On the other hand, Comparative Examples 1-3 were made in the same manner as the Examples, except for the presence or absence and type of insulating coating that covers the first powder. Specifically, in Comparative Example 1, the first powder was not coated with an insulating coating resin, i.e., it was the first powder itself. In Comparative Example 2, acrylic was used as the type of coating resin, and 1.0 wt% of this acrylic was added to the first powder. In Comparative Example 3, silicone was used as the type of coating resin, and 1.0 wt% of this silicone was added to the first powder.
次に、実施例１－５及び比較例１－３の第１の粉末から混合工程、成型工程、硬化工程を経て、ＭＣコアを作製した。作製したＭＣコアは、外径３５ｍｍ、内径２０ｍｍ、高さ１０ｍｍのトロイダル形状とした。なお、本実施例では、第２の粉末は使用せず、複合磁性材料を作製した。 Next, MC cores were produced from the first powders of Examples 1-5 and Comparative Examples 1-3 through a mixing process, molding process, and hardening process. The produced MC cores had a toroidal shape with an outer diameter of 35 mm, an inner diameter of 20 mm, and a height of 10 mm. In this example, the composite magnetic material was produced without using the second powder.
絶縁被膜樹脂で被覆した磁性粉末に、磁性粉末に対して６ｗｔ％のエポキシ樹脂を添加し、２分間ヘラを用いて手動で混合し、複合磁性材料を形成した。この複合磁性材料を容器に充填し、加圧は行わなかった。そして、容器ごと複合磁性材料を大気中にて８５℃で２時間乾燥させ、その後１２０℃で１時間乾燥させ、さらに１５０℃で４時間乾燥することで樹脂を硬化した。このようにして、ＭＣコアを作製した。そして、作製したＭＣコアに、巻線を巻回し、リアクトルを作製した。 Epoxy resin (6 wt % relative to the magnetic powder) was added to the magnetic powder coated with insulating resin, and mixed manually with a spatula for 2 minutes to form a composite magnetic material. This composite magnetic material was filled into a container without being pressurized. The composite magnetic material, including the container, was then dried in air at 85°C for 2 hours, then dried at 120°C for 1 hour, and then further dried at 150°C for 4 hours to harden the resin. In this way, an MC core was produced. A winding was then wound around the produced MC core to produce a reactor.
以上のように作製した実施例１－５及び比較例１－３のリアクトルの透磁率、鉄損及びＭＣコアの密度を下記の条件の下で測定した。 The magnetic permeability, iron loss, and MC core density of the reactors of Examples 1-5 and Comparative Examples 1-3 prepared as described above were measured under the following conditions.
ＭＣコアの密度は、見かけ密度である。即ち、実施例１－５及び比較例１－３のＭＣコアの外径、内径、及び高さを測り、これらの値から各ＭＣコアの体積（ｃｍ３）を、π×（外径２－内径２）×高さに基づき算出した。そして、各ＭＣコアの質量を測定し、測定した質量を算出した体積で除してコアの密度を算出した。 The density of the MC core is the apparent density. That is, the outer diameter, inner diameter, and height of the MC cores of Examples 1-5 and Comparative Examples 1-3 were measured, and the volume (cm 3 ) of each MC core was calculated from these values based on π × (outer diameter 2 − inner diameter 2 ) × height. Then, the mass of each MC core was measured, and the measured mass was divided by the calculated volume to calculate the density of the core.
透磁率及び鉄損の測定条件は、周波数１００ｋＨｚ、最大磁束密度Ｂｍ＝３０ｍＴとした。透磁率は、鉄損Ｐｃｖ測定時に最大磁束密度Ｂｍを設定したときの振幅透磁率とした。鉄損については、ＭＣコアにφ１．２ｍｍの銅線で１次巻線４０ターン、２次巻線３ターンの巻線を巻回し、磁気計測機器であるＢＨアナライザ（岩通計測株式会社：ＳＹ－８２１９）を用いて算出した。この算出は、鉄損の周波数曲線を次の（１）～（３）式で最小２乗法により、ヒステリシス損失係数、渦電流損失係数を算出することで行った。 The measurement conditions for magnetic permeability and iron loss were a frequency of 100 kHz and a maximum magnetic flux density Bm = 30 mT. The magnetic permeability was taken as the amplitude magnetic permeability when the maximum magnetic flux density Bm was set during the measurement of iron loss Pcv. The iron loss was calculated using a magnetic measuring device, a BH analyzer (Iwatsu Measurement Corporation: SY-8219), with 40 turns of primary winding and 3 turns of secondary winding wound around the MC core with φ1.2 mm copper wire. This calculation was performed by calculating the hysteresis loss coefficient and eddy current loss coefficient from the frequency curve of iron loss using the following formulas (1) to (3) using the least squares method.
Ｐｃｖ ＝Ｋｈ×ｆ＋Ｋｅ×ｆ２・・（１）
Ｐｈ ＝Ｋｈ×ｆ・・（２）
Ｐｅ ＝Ｋｅ×ｆ２・・（３）
Ｐｃｖ：鉄損
Ｋｈ ：ヒステリシス損失係数
Ｋｅ ：渦電流損失係数
ｆ ：周波数
Ｐｈ ：ヒステリシス損失
Ｐｅ ：渦電流損失
Pcv = Kh × f + Ke × f 2 (1)
Ph = Kh × f (2)
Pe = Ke × f2 (3)
Pcv: Iron loss Kh: Hysteresis loss coefficient Ke: Eddy current loss coefficient f: Frequency Ph: Hysteresis loss Pe: Eddy current loss
（フッ素系樹脂の添加量による特性の比較）
表１は、実施例１－５及び比較例１－３の密度及び鉄損（鉄損Ｐｃｖ、ヒステリシス損失Ｐｈ、渦電流損失Ｐｅ）を示す表である。図１は、絶縁被膜樹脂の添加量と密度の関係を示すグラフである。図２は、絶縁被膜樹脂の添加量と鉄損の関係を示すグラフである。図３は、絶縁被膜樹脂の添加量とヒステリシス損失の関係を示すグラフである。図４は、絶縁被膜樹脂の添加量と渦電流損失の関係を示すグラフである。 Table 1 shows the density and core loss (core loss Pcv, hysteresis loss Ph, eddy current loss Pe) of Examples 1-5 and Comparative Examples 1-3. Figure 1 is a graph showing the relationship between the amount of insulating coating resin added and density. Figure 2 is a graph showing the relationship between the amount of insulating coating resin added and core loss. Figure 3 is a graph showing the relationship between the amount of insulating coating resin added and hysteresis loss. Figure 4 is a graph showing the relationship between the amount of insulating coating resin added and eddy current loss.
表１、図４に示すように、フッ素系樹脂で第１の粉末を被覆した実施例１－５は、絶縁被膜によって第１の粉末を被覆していない比較例１よりも渦電流損失Ｐｅが低減している。即ち、フッ素系樹脂を０．１ｗｔ％以上添加することで、第１の粉末を被覆しない場合と比べて、渦電流損失Ｐｅを抑制することができる。これは、第１の粉末をフッ素系樹脂で覆ったことで、第１の粉末同士の接触を抑制することができたため、第１の粉末を絶縁被膜で覆わなかった比較例１よりも渦電流損失Ｐｅが低減したと考える。よって、フッ素系樹脂の添加量は、０．１ｗｔ％以上とすることで、渦電流損失Ｐｅが低減できる。 As shown in Table 1 and Figure 4, in Examples 1-5 in which the first powder was coated with fluororesin, the eddy current loss Pe was reduced more than in Comparative Example 1 in which the first powder was not coated with an insulating coating. In other words, by adding 0.1 wt% or more of fluororesin, the eddy current loss Pe can be suppressed more than in the case where the first powder is not coated. This is because by covering the first powder with fluororesin, contact between the first powder particles can be suppressed, and therefore the eddy current loss Pe is reduced more than in Comparative Example 1 in which the first powder was not covered with an insulating coating. Therefore, the eddy current loss Pe can be reduced by adding 0.1 wt% or more of fluororesin.
もっとも、図３に示すように、フッ素系樹脂の添加量を増加させると、ヒステリシス損失Ｐｈが増加する。これは、図１に示すように、フッ素系樹脂の添加量を増加させるとＭＣコアの密度が低下することに関連する。特に、フッ素系樹脂を１．０ｗｔ％添加した場合のヒステリシス損失Ｐｈは大きくなっており、１．０ｗｔ％よりも添加量を増加させると更にヒステリシス損失Ｐｈが増加することが推察できる。よって、フッ素系樹脂の添加量は１．０ｗｔ％以下であることが好ましい。以上より、フッ素系樹脂の添加量は０．１ｗｔ％～１．０ｗｔ％の範囲であることが好ましい。 However, as shown in Figure 3, increasing the amount of fluororesin added increases the hysteresis loss Ph. This is related to the fact that, as shown in Figure 1, increasing the amount of fluororesin added decreases the density of the MC core. In particular, the hysteresis loss Ph is large when 1.0 wt% of fluororesin is added, and it can be inferred that the hysteresis loss Ph will increase further if the amount added is increased beyond 1.0 wt%. Therefore, it is preferable that the amount of fluororesin added is 1.0 wt% or less. For the above reasons, it is preferable that the amount of fluororesin added is in the range of 0.1 wt% to 1.0 wt%.
（絶縁被膜の樹脂の種類による特性の比較）
また、表１を参照すると、実施例１－５は、アクリル樹脂又はシリコーン樹脂で第１の粉末を被覆している比較例２、３と比べても、渦電流損失Ｐｅは低い。これは、フッ素系樹脂で磁性粉末を被覆することで、磁性粉末の電気抵抗値が高くなることに起因するものと推察する。つまり、磁性粉末の電気抵抗値が高くなったことで、渦電流が流れにくくなり、その結果、大きな渦電流の発生を抑制することができたからであると推察する。よって、アクリル樹脂、シリコーン樹脂で被覆した比較例２及び比較例３よりも、フッ素系樹脂で被覆した実施例１－５の方が、渦電流損失を抑制することができる。
(Comparison of characteristics based on type of insulating resin)
Also, referring to Table 1, the eddy current loss Pe of Examples 1-5 is lower than that of Comparative Examples 2 and 3 in which the first powder is coated with acrylic resin or silicone resin. This is presumably due to the fact that the electrical resistance value of the magnetic powder increases by coating the magnetic powder with a fluororesin. In other words, it is presumed that the increased electrical resistance value of the magnetic powder makes it difficult for eddy currents to flow, and as a result, it is possible to suppress the generation of large eddy currents. Therefore, eddy current loss can be suppressed more in Examples 1-5 coated with a fluororesin than in Comparative Examples 2 and 3 coated with an acrylic resin or silicone resin.
以上に示すように、第１の粉末に添加量０．１ｗｔ％～１．０ｗｔ％のフッ素系樹脂で被覆することで、渦電流損失を抑制できる。そして、この結果は、１００ｋＨｚという高周波において用いた場合にも、同様に渦電流損失を抑制できることを示している。なお、高周波とは、１００ｋＨｚのみを指すものではなく、２０ｋＨｚを超えていれば高周波といえる。 As shown above, eddy current loss can be suppressed by coating the first powder with a fluororesin with an additive amount of 0.1 wt% to 1.0 wt%. Furthermore, this result shows that eddy current loss can be similarly suppressed when used at a high frequency of 100 kHz. Note that high frequency does not only refer to 100 kHz, but can be considered high frequency as long as it exceeds 20 kHz.
（直流重畳特性の比較）
次に、フッ素系樹脂の添加量の違いによる透磁率の変化について検討する。図５は、各フッ素系樹脂の添加量における透磁率の変化率を示すグラフである。透磁率は、ＬＣＲメータ（アジレント・テクノロジー株式会社製：４２８４Ａ）を使用して、１００ｋＨｚ、１．０Ｖにおける各磁界の強さのインダクタンスから算出した。そして、透磁率の変化率は、各実施例における直流を重畳させていない状態、即ち、磁界の強さが０Ｈ（Ａ／ｍ）の値（初透磁率）を基準にして、各磁界の強さにおける値を初透磁率で除すことで算出した。
(Comparison of DC superposition characteristics)
Next, the change in magnetic permeability due to the difference in the amount of fluororesin added will be examined. Figure 5 is a graph showing the rate of change in magnetic permeability for each amount of fluororesin added. The magnetic permeability was calculated from the inductance of each magnetic field strength at 100 kHz and 1.0 V using an LCR meter (Agilent Technologies: 4284A). The rate of change in magnetic permeability was calculated by dividing the value at each magnetic field strength by the initial magnetic permeability, based on the value (initial magnetic permeability) of the state in which no direct current was superimposed in each example, that is, the magnetic field strength of 0 H (A/m).
図５に示すように、実施例１及び３は、実施例５と比べて、磁界の強さＨが大きくなるにつれて透磁率の変化率が小さい。特に、磁界の強さ２０ｋＨ（Ａ／ｍ）の各実施例の値を参照すると、実施例５の変化率は約０．８２であるのに対し、実施例１及び３の変化率は０．９以上で、実施例１及び３の変化率は極めて良好な値である。このことから、フッ素系樹脂の添加量は０．５ｗｔ％以上とすることで、透磁率の変化率が低減するといえる。よって、フッ素系樹脂の添加量を０．５ｗｔ％～１．０ｗｔ％の範囲にすることで、渦電流損失を抑制するのみではなく、直流重畳特性をも向上させることができる。 As shown in Figure 5, in comparison with Example 5, Examples 1 and 3 have a smaller rate of change in magnetic permeability as the magnetic field strength H increases. In particular, looking at the values of each Example at a magnetic field strength of 20 kH (A/m), the rate of change in Example 5 is approximately 0.82, while the rates of change in Examples 1 and 3 are 0.9 or more, which are extremely good values. From this, it can be said that the rate of change in magnetic permeability is reduced by setting the amount of fluororesin added to 0.5 wt% or more. Therefore, by setting the amount of fluororesin added in the range of 0.5 wt% to 1.0 wt%, not only can eddy current loss be suppressed, but the DC superposition characteristics can also be improved.
（他の実施形態）
本明細書においては、本発明に係る実施形態を説明したが、この実施形態は例として提示したものであって、発明の範囲を限定することを意図していない。上記のような実施形態は、その他の様々な形態で実施されることが可能であり、発明の範囲を逸脱しない範囲で、種々の省略や置き換え、変更を行うことができる。実施形態やその変形は、発明の範囲や要旨に含まれると同様に、特許請求の範囲に記載された発明とその均等の範囲に含まれるものである。
Other Embodiments
In this specification, an embodiment of the present invention has been described, but this embodiment is presented as an example and is not intended to limit the scope of the invention. The above-mentioned embodiment can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the scope of the invention. The embodiment and its modifications are included in the scope of the invention and its equivalents described in the claims, as well as in the scope and gist of the invention.
Claims (3)
前記磁性粉末は、
第１の粉末と、
前記第１の粉末より平均粒子径が小さい第２の粉末と、
を有し、
前記第１の粉末は、フッ素系樹脂のみから構成される絶縁被膜で覆われており、
前記磁性粉末に混合される前記樹脂の添加量は、前記磁性粉末に対して３ｗｔ％以上１０ｗｔ％以下であり、
前記絶縁被膜の添加量は、前記第１の磁性粉末に対して０．１ｗｔ％以上１．０ｗｔ％以下であること、
を特徴とする複合磁性材料。 A composite magnetic material obtained by mixing a magnetic powder and a resin,
The magnetic powder is
A first powder;
a second powder having an average particle size smaller than that of the first powder;
having
the first powder is covered with an insulating coating made only of a fluorine-based resin;
The amount of the resin mixed with the magnetic powder is 3 wt % or more and 10 wt % or less with respect to the magnetic powder,
The amount of the insulating coating added is 0.1 wt % or more and 1.0 wt % or less with respect to the first magnetic powder ;
A composite magnetic material characterized by:
を特徴とする請求項２に記載のメタルコンポジットコア。
The resin mixed with the magnetic powder is cured.
The metal composite core according to claim 2 .
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| JP2017171947A (en) | 2016-03-18 | 2017-09-28 | Ntn株式会社 | Mixed powder for powder magnetic core and manufacturing method therefor |
| JP2017188680A (en) | 2016-03-31 | 2017-10-12 | Ntn株式会社 | Magnetic material, magnetic core and manufacturing method thereof |
| JP2018125501A (en) | 2017-02-03 | 2018-08-09 | 株式会社タムラ製作所 | Composite magnetic powder material, metal composite core and method for manufacturing metal composite core |
| JP2018125502A (en) | 2017-02-03 | 2018-08-09 | 株式会社タムラ製作所 | Composite magnetic powder material, metal composite core, and metal composite core manufacturing method |
| JP2018125503A (en) | 2017-02-03 | 2018-08-09 | 株式会社タムラ製作所 | Composite magnetic powder material, metal composite core and method for manufacturing metal composite core |
| JP2019041008A (en) | 2017-08-25 | 2019-03-14 | Ntn株式会社 | Manufacturing method of dust core and mixed powder for dust core used therefor |
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| JP2017171947A (en) | 2016-03-18 | 2017-09-28 | Ntn株式会社 | Mixed powder for powder magnetic core and manufacturing method therefor |
| JP2017188680A (en) | 2016-03-31 | 2017-10-12 | Ntn株式会社 | Magnetic material, magnetic core and manufacturing method thereof |
| JP2018125501A (en) | 2017-02-03 | 2018-08-09 | 株式会社タムラ製作所 | Composite magnetic powder material, metal composite core and method for manufacturing metal composite core |
| JP2018125502A (en) | 2017-02-03 | 2018-08-09 | 株式会社タムラ製作所 | Composite magnetic powder material, metal composite core, and metal composite core manufacturing method |
| JP2018125503A (en) | 2017-02-03 | 2018-08-09 | 株式会社タムラ製作所 | Composite magnetic powder material, metal composite core and method for manufacturing metal composite core |
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