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Soft magnetic powder compound, core and electric reactor

A soft magnetic and composite technology, applied in the direction of magnetic objects, magnetic materials, inorganic materials, etc., to achieve the effects of easy operation, suppressing noise, and suppressing vibration

Active Publication Date: 2014-12-17
TAMURA KK
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

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Problems solved by technology

However, these prior art technologies focus on improving insulation performance, and do not aim at improving core strength or reducing noise.

Method used

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  • Soft magnetic powder compound, core and electric reactor
  • Soft magnetic powder compound, core and electric reactor
  • Soft magnetic powder compound, core and electric reactor

Examples

Experimental program
Comparison scheme
Effect test

Embodiment approach 1

[0067] (1) Soft magnetic powder

[0068] As the soft magnetic powder, sendust (Fe—Si—Al alloy) powder, Fe—Si alloy powder, pure iron powder, or the like can be used.

[0069] In addition, FeBPN (N is one or more elements selected from Cu, Ag, Au, Pt, and Pd) can be used as the soft magnetic powder. As the soft magnetic powder, those produced by a water atomization method, gas atomization method, or water-gas atomization method can be used, and those produced by a water atomization method are particularly preferable. The reason is that in the water atomization method, crystallization is difficult due to rapid cooling during atomization.

[0070] The average particle diameter of the soft magnetic powder is preferably 20 μm to 100 μm. The powder hardness (pressure required for 10% displacement) of the soft magnetic powder is preferably 100 MPa or more. For example, the powder hardness of amorphous alloy is 700 MPa, the powder hardness of Fe-6.5% Si alloy is 390 MPa, and the po...

Embodiment approach 2

[0101] The same soft magnetic powder, hardening accelerator, binder resin, and lubricating resin as in Embodiment 1 are used.

[0102] The condensed phosphoric acid metal compound uses the same material as in Embodiment 1. In the present embodiment, the added amount of the condensed phosphoric acid metal compound is preferably 0.20% by weight to 0.80% by weight relative to the soft magnetic powder.

[0103] In this embodiment, by further adding insulating fine powder, it is possible to prevent adhesion between the soft magnetic powders, to harden the insulating layer around the soft magnetic powder, to suppress vibration of the soft magnetic powder, and to obtain a noise suppression effect. From the viewpoint of the noise suppression effect, the average particle diameter of the insulating fine powder is preferably 7 nm to 1 μm. More preferably, it is 7 nm to 500 nm. As insulating fine powder, alumina powder (Al 2 o 3 ), SiO 2 , MgO, etc. In addition, the higher the hardn...

Embodiment approach 3

[0107] The same soft magnetic powder, hardening accelerator, binder resin, and lubricating resin as in Embodiment 1 are used.

[0108] The condensed phosphoric acid metal compound uses the same material as in Embodiment 1. In the present embodiment, the added amount of the condensed phosphoric acid metal compound is preferably 0.25% by weight to 2.0% by weight relative to the soft magnetic powder. When the added amount is more than 0.25% by weight, the effect of increasing the strength of the produced core can be obtained; when the added amount exceeds 2.0% by weight, the density of the core decreases and the strength also decreases.

[0109] The manufacturing method is the same as that of Embodiment 1. In the present embodiment, the step of heat-treating the molded body is performed in a non-reducing atmosphere such as an air atmosphere. As the non-reducing atmosphere, in addition to the air, an inert gas atmosphere such as 100% nitrogen may be used. For example, the molde...

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Abstract

The invention provides a low-noise electric reactor, soft magnetic compound for the low-noise electric reactor and a core capable of improving hardness of an insulation layer of soft magnetic powder and effectively preventing noise. The soft magnetic powder is mixed with condensed phosphoric acid metal compounds with 0.25 wt% to 2.0 wt%, so a wrapped layer made from the condensed phosphoric acid metal compounds is formed on the periphery of the soft magnetic powder; and preferentially, condensed aluminum phosphate, especially trimerization aluminum phosphate is chosen.

Description

technical field [0001] The present invention relates to a low-noise reactor and a high-strength reactor, a soft magnetic powder composition suitable for the low-noise reactor and a high-strength reactor, a core and a method for manufacturing the core. Background technique [0002] Choke coils are used in control power supplies such as OA equipment, solar power generation systems, automobiles, and uninterruptible power supplies, and ferrite cores or powder cores are used as their cores. Among these, ferrite cores have a disadvantage of low saturation magnetic flux density. On the other hand, powder cores produced by molding metal powder have a higher saturation magnetic flux density than soft ferrite, so they have excellent DC superposition characteristics. [0003] In view of the requirements of improving energy exchange efficiency and low heat dissipation, the powder magnetic core needs to have magnetic properties that can obtain a large magnetic flux density under a small...

Claims

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Application Information

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IPC IPC(8): H01F1/147H01F1/24H01F27/255
CPCH01F1/24H01F27/255H01F41/02
Inventor 大岛泰雄纲川昌明赤岩功太田村泰治中津良二宫亨和
Owner TAMURA KK
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