High-frequency core and inductance component using the same

Inactive Publication Date: 2005-11-17
TOKIN CORP +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0014] It is an object of this invention to provide an inexpensive high-frequency core made of a soft magnetic material having a high saturation magnetic flux density and a high specific resistance and to provide an inductance component using the same.

Problems solved by technology

Thus, a magnetic material having both of a high saturation magnetic flux density and a high specific resistance is not yet provided.
Further, due to copper loss resulting from an electric resistance of a winding coil, heat generation of the coil or the transformer is increased.
In case of the soft ferrite, improvement of the saturation magnetic flux density is considered but, actually, no substantial improvement is made.
A multilayer core using such material is lowered in space factor, which may result in decrease in saturation magnetic flux density.
However, there are difficult problems to solve.
That is, a method of improving saturation magnetization of a soft magnetic powder used therefor and a method of forming a high-density molded body while maintaining insulation between powder particles are not established at present.
However, alloy compositions used as the soft magnetic material are restricted to Fe-based alloys which are generally classified into a PePCBSiGa alloy composition and a FeSiBM (M being a transition metal) alloy composition.
In this case, however, it is necessary to use an expensive metal such as Ga.
This results in a problem that the material itself is high in cost and, therefore, promotion of industrial application is inhibited.
However, in these patent documents, no technique for obtaining a high specific resistance and a high magnetic flux density is shown (this is presumably because a method of forming a powder and a method of forming a molded body which are suitable for the alloy composition are not found).
Thus, at present, it is difficult to use the material for the high-frequency core and an inductance component using the same.
However, because an existing soft magnetic metal material is used, reduction of loss is not sufficient.

Method used

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  • High-frequency core and inductance component using the same

Examples

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examples 1-26

, COMPARATIVE EXAMPLES 1-11

[0054] At first, as a powder preparing step, pure metal element materials including Fe, Si, B. Nb, Al, C, and substitute elements therefor or, if desired, various mother alloys were weighed so as to obtain predetermined compositions. By the use of these materials, various kinds of soft magnetic alloy powders were produced by water atomization generally used. It is noted here that a misch metal is a mixture of rare earth metals. Herein, a mixture of 30% La, 50% Ce, 15% Nd, and the balance other rare earth element or elements was used.

[0055] Next, as a molded body preparing step, each of the alloy powders was classified into those having a powder size of 45 μm or less. Thereafter, a silicone resin as a binder was mixed in an amount of 4% in mass ratio. Then, by the use of a die with a groove having an outer diameter of hope φOUT=27 mm×an inner diameter φIN=14 mm, various kinds of molded bodies were formed by applying a pressure of 1.18 GPa (about 12 t / cm2) ...

example 27

[0067] An alloy powder having a composition of (Fe0.8Co0.2)73Si9B14.5Nb2Al1.0C0.5 was prepared by water atomization. The powder thus obtained was classified into those having a size of 75 μm or less. XRD measurement was carried out to confirm a broad peak specific to a glass phase.

[0068] Next, thermal analysis by DSC was carried out to measure a glass transition temperature and a crystallization temperature to find out that ΔTx was 35K. Then, the powder was heat treated at 450° C. lower than the glass transition temperature for 0.5 hour in atmospheric air to form oxide on the surface of the powder. Next, the powder was mixed with 10%, 5%, 2.5%, 1%, and 0.5% silicone resin. By the use of a die of φ27×φ14, these powders were molded under three conditions at a room temperature, at 150° C. higher than a softening temperature of the resin, and at 550° C. in a supercooled liquid temperature range of this metallic glass powder. The powder filling rate, the magnetic flux density by d.c. ma...

example 28

[0070] In an example 28, an alloy powder having a composition of Fe72Si9B14.5Nb3Al1.0C0.5 was prepared by water atomization. Thereafter, the powder thus obtained was classified into those having a particle size of 75 μm or less. Then, XRD measurement was carried out to confirm a broad peak specific to a glass phase.

[0071] Further, thermal analysis by DSC was carried out to measure a glass transition temperature and a crystallization temperature to confirm that a vitrification start temperature range or a supercooled liquid temperature range ΔTx was 35K. Then, the powder was kept at a temperature condition of 450° C. lower than the glass transition temperature and heat treated for 0.5 hour in atmospheric air to form oxide on the surface of the powder.

[0072] Next, the powder with oxide formed thereon was mixed with, in mass ratio, 10%, 5%, 2.5%, 1%, and 0.5% silicone resin as a binder. By the use of a die with a groove having an outer diameter φOUT=27 mm×an inner diameter φIN=14 mm,...

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Abstract

A high-frequency core is a molded body obtained by molding a mixture of a soft magnetic metallic glass powder and a binder in an amount of 10% or less in mass ratio. The powder has an alloy composition represented by (Fe1-aCoa)100-x-y-z-q-r(M1-pM′p)xTyBzCqAlr(0<a<0.50, 0<p<0.5, 2 atomic %<x<5 atomic %, 8 atomic %<y<12 atomic %, 12 atomic %<z<17 atomic %, 0.1 atomic %<q<1.0 atomic %, 0.2 atomic %<r<2.0 atomic % and 25<(x+y+z+q+r)<30, M being at least one selected from Zr, Nb, Ta, Hf, Mo, Ti, V, Cr, and W, M′ being at least one selected from Zn, Sn, and R (R being at least one element selected from rare earth metals including Y), T being at least one selected from Si and P). An inductance component is formed by the core and a winding.

Description

[0001] This application claims priority to prior Japanese patent application JP 2004-146595, the disclosure of which is incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] This invention relates to a high-frequency core mainly using a soft magnetic material and an inductance component using the core. [0003] Heretofore, generally as a material of a high-frequency core, soft ferrite, high-silicon steel, an amorphous metal, a powder core, and the like have mainly been used. The reason why the above-mentioned materials are used is as follows. In case of the soft ferrite, the material itself has a high specific resistance. In case of other metal materials, the material may be formed into a thin plate or a powder so as to reduce an eddy current although the material itself has a low specific resistance. The above-mentioned materials are selectively used depending upon a working frequency or an intended use. Summarizing the reason therefor, the material high in specific re...

Claims

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Application Information

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IPC IPC(8): H01F1/153H01F3/14H01F17/06H01F41/02
CPCH01F1/15308H01F1/15316H01F1/15325H01F2017/048H01F3/14H01F17/062H01F41/0246H01F1/15375
Inventor FUJIWARA, TERUHIKOURATA, AKIRIINOUE
Owner TOKIN CORP
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