Composite magnetic material and method of manufacturing the same

Abstract

Provided is a composite magnetic material which provides superior magnetic properties such as magnetic permeability and core loss, and practical strength, and a manufacturing method for a composite magnetic material which improves the moldability of the dust core and lowers manufacturing costs. A composite magnetic material for an inductor which combines soft magnetic metal particles with a non-magnetic material and a manufacturing method thereof, wherein a first binder composed of a non-magnetic material is mixed at a specific ratio in soft magnetic metal particles; the mixture is molded into the desired shape; the molded body is heat treated under specified conditions; and a second binder composed of one or two or more materials selected from the group composed of silicone resin, organic resin, and water glass is impregnated under the specified conditions into the molded body after the heat treatment.

Description

technical field [0001] The present invention relates to a method for manufacturing an inductor wound on a metal-based soft magnetic alloy composite material used in electronic circuits such as power circuits, and more particularly to a powdered iron core used as an iron core with excellent magnetic properties. Composite magnetic material and manufacturing method thereof. Background technique [0002] In recent years, along with the demand for miniaturization and power saving of electric and electronic equipment, miniaturization and high efficiency of electronic components to which these are applied are also required. Most inductors used in this circuit currently use ferrite, but as the circuit becomes lower in voltage and higher in current, since the low saturation magnetization of ferrite is approaching the limit of its performance, it is expected that the saturation magnetization can be applied. higher material. [0003] At present, powdered iron cores in which powders o...

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Problems solved by technology

[0009] On the premise of the above-mentioned problems, when further observing the existing crystalline soft magnetic metal powder, there are problems such as making the powder shape close to a spherical shape in order to improve the DC current superposition characteristics, or obtaining a Fe-Si-Al alloy with a low Si and Al content. When the alloy powder is made into powder by water atomization or gas atomization (because the alloy is soft and cannot be crushed mechanically), spherical particles are obtained, and the powdered iron core using this powder is not strong enough, so it is difficult to apply in practice

The reason is that the powdered iron core has poor formability, is easily broken and incomplete during forming, so the manufacturing output is low, and the actual manufacturing cost will be higher than that of ferrite.

For example, in the existing method of Patent Document 3, when amorphous alloy powder is used as atomized powder in the forming process, the fluidity of mixing with the silicone resin is poor, so it is difficult to increase the forming speed, and the powder will be sandwiched between the mold and the Between the punching machines, the mold and the punching machine are damaged, and the utilization rate of the equipment is reduced accordingly, and the yield is low due to the occurrence of unqualified molded objects, and various problems such as the inability to ensure the arbitrary shape of the molded objects possessed by ferrite

Due to this poor formability, powdered iron cores have long been at a disadvantage compared to ferrite, which has become the main reason for their competitive disadvantage.

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