U.S. patent application number 10/570315 was filed with the patent office on 2007-02-15 for soft magnetic material and method for producing the same.
Invention is credited to Ryoji Mizutani, Haruhisa Toyoda.
Application Number | 20070036669 10/570315 |
Document ID | / |
Family ID | 37742714 |
Filed Date | 2007-02-15 |
United States Patent
Application |
20070036669 |
Kind Code |
A1 |
Toyoda; Haruhisa ; et
al. |
February 15, 2007 |
Soft magnetic material and method for producing the same
Abstract
Disclosed are a soft magnetic material having an optimum
electrical resistivity and a method for producing such a soft
magnetic material. The soft magnetic material comprises a plurality
of composite magnetic particles. Each of the composite magnetic
particles comprises a metal magnetic particle and an insulating
coating film which covers the surface of the metal magnetic
particle and contains at least one substance selected from the
group consisting of zirconium oxide, aluminum oxide and silicon
oxide. The soft magnetic material has an electrical resistivity of
not less than 3,000 .mu..OMEGA.cm and not more than 50,000
.mu..OMEGA.cm, and a magnetic permeability .mu. of not less than
2,000 and not more than 4,000. A method for producing such a soft
magnetic material comprises a step for pressure forming a
compaction by compressing a plurality of the composite magnetic
particles and a step for subjecting the compaction to a first heat
treatment at not less than 400.degree. C. and not more than
900.degree. C.
Inventors: |
Toyoda; Haruhisa; (Hyogo,
JP) ; Mizutani; Ryoji; (Aichi, JP) |
Correspondence
Address: |
MCDERMOTT WILL & EMERY LLP
600 13TH STREET, N.W.
WASHINGTON
DC
20005-3096
US
|
Family ID: |
37742714 |
Appl. No.: |
10/570315 |
Filed: |
September 3, 2004 |
PCT Filed: |
September 3, 2004 |
PCT NO: |
PCT/JP04/12846 |
371 Date: |
March 2, 2006 |
Current U.S.
Class: |
419/8 |
Current CPC
Class: |
H01F 1/33 20130101; B22F
2003/026 20130101; B22F 3/02 20130101; B22F 3/10 20130101; B22F
1/0059 20130101; B22F 1/02 20130101; B22F 2998/10 20130101; C22C
33/0228 20130101; H01F 1/24 20130101; B22F 1/02 20130101; B22F
2998/10 20130101; H01F 41/0246 20130101; B22F 2003/023
20130101 |
Class at
Publication: |
419/008 |
International
Class: |
B22F 7/00 20060101
B22F007/00 |
Claims
1. A soft magnetic material comprising a plurality of composite
magnetic particles, wherein each of said plurality of composite
magnetic particles has a metal magnetic particle and an insulating
coating film, containing at least one substance selected from a
group consisting of aluminum oxide, zirconium oxide and silicon
oxide, surrounding the surface of said metal magnetic particle, and
electric resistivity .rho. is at least 3000 .mu..OMEGA.cm and not
more than 50000 .mu..OMEGA.cm and magnetic permeability .mu. is at
least 2000 and not more than 4000.
2. (canceled)
3. A method for producing the soft magnetic material according to
claim 1, comprising the steps of: preparing a compaction by
pressing a plurality of composite magnetic particles having metal
magnetic particles and insulating coating films, containing at
least one substance selected from a group consisting of aluminum
oxide, zirconium oxide and silicon oxide, surrounding the surfaces
of said metal magnetic particles; and performing first heat
treatment on said compaction under the atmospheric pressure at a
temperature of at least 400.degree. C. and not more than
900.degree. C.
4. The method for producing a soft magnetic material according to
claim 3, further comprising the step of pressing said compaction
after performing said first heat treatment and thereafter
performing second heat treatment under the atmospheric pressure at
a temperature of at least 400.degree. C. and not more than
900.degree. C.
Description
TECHNICAL FIELD
[0001] The present invention relates to a soft magnetic material
and a method for producing the same, and more specifically, it
relates to a soft magnetic material comprising composite magnetic
particles having metal magnetic particles and insulating coating
films and a method for producing the same.
BACKGROUND ART
[0002] Electrical/electronic components have recently been
densified and downsized, and capability of performing more precise
control with saved power is demanded in relation to motor cores and
transformer cores. Therefore, development of a soft magnetic
material, used for these electrical/electronic components, having
excellent magnetic characteristics in intermediate and high
frequency domains is in progress. In order to exhibit excellent
magnetic characteristics in the intermediate and high frequency
domains, the soft magnetic material must have high saturation
magnetic flux density, high magnetic permeability and high electric
resistivity.
[0003] Japanese Patent Laying-Open No. 6-267723 (patent literature
1), for example, discloses such a soft magnetic material.
[0004] Patent Literature 1: Japanese Patent Laying-Open No.
6-267723
DISCLOSURE OF THE INVENTION
Problems to be Solved by the Invention
[0005] In the soft magnetic material disclosed in the
aforementioned literature, however, there has been such a problem
that electric resistivity is excessively high and magnetic flux
density is small.
[0006] Accordingly, the present invention has been proposed in
order to solve the aforementioned problem, and an object of the
present invention is to provide a soft magnetic material having
optimized electric resistivity and a method for producing the
same.
Means for Solving the Problems
[0007] The soft magnetic material according to the present
invention comprises a plurality of composite magnetic particles.
Each of the plurality of composite magnetic particles has a metal
magnetic particle and an insulating coating film, containing at
least one substance selected from a group consisting of aluminum
oxide, zirconium oxide and silicon oxide, surrounding the surface
of the metal magnetic particle. Electric resistivity .rho. of the
soft magnetic material is at least 3000 .mu..OMEGA.cm and not more
than 50000 .mu..OMEGA.cm.
[0008] More preferably, magnetic permeability .mu. of the soft
magnetic material is at least 2000 and not more than 4000. The
method for producing a soft magnetic material according to the
present invention is a method for producing the aforementioned soft
magnetic material and comprises the steps of preparing a compaction
by pressing a plurality of composite magnetic particles having
metal magnetic particles and insulating coating films, containing
at least one substance selected from a group consisting of aluminum
oxide, zirconium oxide and silicon oxide, surrounding the surfaces
of the metal magnetic particles and performing first heat treatment
on the compaction at a temperature of at least 400.degree. C. and
not more than 900.degree. C.
[0009] Preferably, the method for producing a soft magnetic
material further comprises the step of pressing the compaction
after the first heat treatment and thereafter performing second
heat treatment on the compaction under the atmospheric pressure at
a temperature of at least 400.degree. C. and not more than
900.degree. C.
Effects of the Invention
[0010] According to the present invention, a soft magnetic material
having desired magnetic characteristics and a method for producing
the same can be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a typical diagram showing a section of a soft
magnetic material according to an embodiment of the present
invention.
DESCRIPTION OF THE REFERENCE SIGNS
[0012] 10 metal magnetic particle, 20 insulating coating film, 30
composite magnetic particle.
BEST MODES FOR CARRYING OUT THE INVENTION
[0013] A soft magnetic material according to the present invention
has a plurality of composite magnetic particles, and each of the
composite magnetic particles has a metal magnetic particle and an
insulating coating film surrounding the surface of the metal
magnetic particle.
[0014] The metal magnetic particles are generally made of iron
(Fe). However, the metal magnetic particles are not restricted to
iron, but may alternatively be formed by other magnetic particles.
For example, the metal magnetic particles may be made of an iron
(Fe)-silicon (Si) alloy, an iron (Fe)-nitrogen (N) alloy, an iron
(Fe)-nickel (Ni) alloy, an iron (Fe)-carbon (C) alloy, an iron
(Fe)-boron (B) alloy, an iron (Fe)-cobalt (Co) alloy, an iron
(Fe)-phosphorus (P) alloy, an iron (Fe)-nickel (Ni)-cobalt (Co)
alloy or an iron (Fe)-aluminum (Al)-silicon (Si) alloy. The metal
magnetic particles may be of a simple substance of metal or an
alloy.
[0015] The average particle diameter of the metal magnetic
particles is preferably at least 5 .mu.m and not more than 200
.mu.m. If the average particle diameter of the metal magnetic
particles is less than 5 .mu.m, the metal is so easily oxidized
that the magnetic characteristics of the soft magnetic material may
be reduced. If the average particle diameter of the metal magnetic
particles exceeds 20 .mu.m, compressibility of mixed powder is
reduced in a subsequent pressure-forming step. Thus, the density of
a compaction obtained through the pressure-forming step may be so
reduced that it is difficult to handle the compaction.
[0016] It is to be noted that the average particle size described
herein refers to a particle size obtained when the sum of masses of
particles added in ascending order of particle size in a histogram
of particle sizes measured by sieving reaches 50% of the total
mass, that is, 50% particle size D.
[0017] The insulating coating films can be made of an oxide
insulator containing aluminum and/or zirconium and/or silicon. The
electric resistivity .rho. of the soft magnetic material can be
increased by covering the surfaces of the metal magnetic particles
with the insulating coating films. Thus, iron loss of the soft
magnetic material resulting from eddy current can be reduced by
inhibiting the eddy current from flowing between the metal magnetic
particles.
[0018] According to the present invention, the electric resistivity
.rho. of the soft magnetic material is at least 3000 .mu..OMEGA.cm
and not more than 50000 .mu..OMEGA.cm. If the electric resistivity
.rho. is less than 3000 .mu..OMEGA.m, the electric resistivity is
reduced to reduce the effect of suppressing the eddy current.
[0019] If the electric resistivity .rho. exceeds 50000
.mu..OMEGA.cm contrarily thereto, the electric resistivity is
unpreferably excessively increased. More specifically, increase of
the electric resistivity .rho. means increase of the quantity of
the insulating coating films. If the quantity of the insulating
coating films is excessively increased, magnetic characteristics
such as magnetic permeability and magnetic flux density are
deteriorated.
[0020] In order to improve the aforementioned effect, the electric
resistivity .rho. of the soft magnetic material is preferably at
least 6000 .mu..OMEGA.cm and not more than 15000 .mu..OMEGA.cm,
more preferably at least 8000 .mu..OMEGA.cm and not more than 10000
.mu..OMEGA.cm.
[0021] The thickness of the insulating coating films is preferably
at least 0.005 .mu.m and not more than 20 .mu.m. Energy loss
resulting from eddy current can be effectively suppressed by
setting the thickness of the insulating coating films to at least
0.005 .mu.m. When the thickness of the insulating coating films is
set to not more than 20 .mu.m, the volume ratio of the insulating
coating films occupying the soft magnetic material is not
excessively increased. Thus, a soft material having prescribed
saturation magnetic flux density can be formed.
[0022] More preferably, magnetic permeability .mu. of the soft
magnetic material is at least 2000 and not more than 4000. Further
preferably, the magnetic permeability .mu. of the soft magnetic
material is at least 2500 and not more than 3500.
[0023] A method for producing the aforementioned soft magnetic
material is now described. First, a plurality of composite magnetic
particles are prepared. These composite magnetic particles are
introduced into a powder compaction, and mixed powder is
pressure-formed under a condition of pressure of at least 390 MPa
and not more than 1500 MPa, for example. Thus, the mixed powder is
so compressed that a compaction can be obtained. The pressure
forming is preferably performed under an inert gas atmosphere or a
decompressed atmosphere. In this case, the mixed powder can be
prevented from oxidation by oxygen in the atmosphere. In the step
of preparing the compaction, well-known warm pressing or die wall
lubrication is so employed as to density the compaction, improve
the space factor and improve the magnetic characteristics. The
powder temperature in the warm pressing is preferably 100.degree.
C. to 180.degree. C.
[0024] In order to reinforce bonding between the composite magnetic
particles, organic matter may intervene between the composite
magnetic particles. In this case, the composite magnetic particles
and the organic matter must be previously mixed with each other.
The mixing method is not restricted but any of mechanical alloying,
vibration ball milling, satellite ball milling, mechanofusion,
coprecipitation, chemical vapor deposition (CVD), physical vapor
deposition (PVD), plating, sputtering, vapor deposition and a
sol-gel process can be used.
[0025] Thermoplastic resin such as thermoplastic polyimide,
thermoplastic polyamide, thermoplastic polyamidimide, polyphenylene
sulfide, polyamidimide, poly(ethersulfone), polyether imide or
poly(etheretherketone) can be employed for the organic matter. This
organic matter is so provided that the organic matter functions as
a lubricant between the plurality of composite magnetic particles.
Thus, breakage of the insulating coating films can be suppressed in
the pressure-forming step.
[0026] Then, the compaction obtained by the pressure forming is
heat-treated at a temperature of at least 400.degree. C. and not
more than 900.degree. C. Large numbers of strains and dislocations
are caused in the compaction obtained through the pressure-forming
step, and the strains and the dislocations result in reduction of
the magnetic permeability and increase of the coercive force. The
heat treatment is performed on the compaction, in order to
eliminate these strains and dislocations. Such heat treatment is
required also when the organic matter intervenes between the
composite magnetic particles.
[0027] In order to improve the density of the soft magnetic
material and eliminate the dislocations and the strains from the
soft magnetic material, the soft magnetic material is compressed
again to be improved in density, and thereafter heat-treated under
the atmospheric pressure at a temperature of 400.degree. C. and not
more than 900.degree. C.
[0028] Thus, the inventive soft magnetic material can be
produced.
[0029] In general, hysteresis loss is reduced if the coercive force
of the soft magnetic material is small, the coercive force is also
increased if the hysteresis loss is large, and the magnetic
permeability is increased if the coercive force is small.
Improvement of the magnetic permeability leads to reduction of the
hysteresis loss. According to the present invention, the material
is so constituted as to increase the magnetic permeability, leading
to reduction of the hysteresis loss.
[0030] In order to reduce eddy current loss, it is important to
keep insulation between the composite magnetic particles. Increase
of specific resistance of the soft magnetic material as a bulk body
leads to reduction of the eddy current loss. In particular, the
eddy current loss includes eddy current loss in the respective
particles and eddy current loss caused between the particles. The
eddy current loss between the particles must be reduced, and it is
possible to reduce the eddy current loss according to the present
invention since the specific resistance of the soft magnetic
material is increased in the range not damaging the magnetic
characteristics.
[0031] The compositions of aluminum oxide, zirconium oxide and
silicon oxide constituting the insulating coating films in the
present invention are not particularly restricted. More
specifically, the composition of aluminum oxide is not restricted
to Al.sub.2O.sub.3, and the atomic ratio between aluminum and
oxygen may be properly changed. Also as to the composition ratio of
zirconium oxide, the ratio between zirconium and oxygen may be
properly changed. Further, the ratio between silicon and oxygen may
be properly changed also as to the composition ratio of silicon
oxide.
[0032] FIG. 1 is a schematic diagram showing a section of a soft
magnetic material according to an embodiment of the present
invention. Referring to FIG. 1, the soft magnetic material
comprises a plurality of composite magnetic particles 30. Each of
the plurality of composite magnetic particles 30 has a metal
magnetic particle 10 and an insulating coating film 20, containing
at least one substance selected from a group consisting of aluminum
oxide, zirconium oxide and silicon oxide, surrounding the surface
of the metal magnetic particle 10. The electric resistivity .rho.
of the soft magnetic material is at least 3000 .mu..OMEGA.cm and
not more than 50000 .mu..OMEGA.cm. Organic matter 40 intervenes
between the composite magnetic particles 30.
EXAMPLE 1
[0033] According to Example 1, a soft magnetic material according
to the present invention was produced. First, iron particles having
an average particle diameter of 70 .mu.m were prepared as metal
magnetic particles. These iron particles were coated with
Al.sub.2O.sub.3 films serving as insulating coating films by a wet
method. At this time, the thickness of the insulating coating films
was set to about 100 nm. Composite magnetic particles were formed
by surrounding the surfaces of the iron particles with the
Al.sub.2O.sub.3 films through this coating.
[0034] Mixed powder was prepared by mixing the composite magnetic
particles and particles of polyphenylene sulfide resin having an
average particle diameter of not more than 100 .mu.m with each
other. The mixed powder was introduced into a metal mold and
subjected to pressure molding. At this time, the pressure molding
was performed in a nitrogen gas atmosphere, the metal mold was set
to the normal temperature, and the pressure was set to 882 MPa.
Thus, a sample of a compaction was obtained. Then, the compaction
was heat-treated. The heat treatment was performed in a nitrogen
gas atmosphere at a temperature of 800.degree. C. for 3 hours.
Electric resistivity, density and magnetic permeability .mu. of the
sample thereafter measured were 5670 .mu..OMEGA.cm, 7.5 g/cm.sup.3
and 2050 respectively.
COMPARATIVE EXAMPLE
[0035] In comparative example 1, Somalloy 500 (trade name) was
prepared as composite magnetic particles. Somalloy 500 is composite
magnetic particles prepared by molding phosphate coating films on
the surfaces of iron particles. Mixed powder was prepared by mixing
particles of polyphenylene sulfide into the composite magnetic
particles. The mixed powder was introduced into a compaction and
subjected to pressure forming. At this time, the pressure forming
was performed in a nitrogen gas atmosphere, the metal mold was set
to the normal temperature, and the pressure was set to 882 MPa.
Thus, a compaction was obtained.
[0036] Then, the compaction was heat-treated. The heat treatment
was performed in a nitrogen gas atmosphere at a temperature of
300.degree. C. for 0.5 hours. Thereafter electric resistivity and
magnetic permeability of the compaction were measured. The electric
resistivity was 350 .mu..OMEGA.cm, and the magnetic permeability
.mu. was 600.
[0037] From the aforementioned results, it has been confirmed that
the inventive soft magnetic material can satisfy the magnetic
characteristics required to the soft magnetic material.
[0038] The embodiment and Example disclosed this time must be
considered as illustrative in all points and not restrictive. The
scope of the present invention is shown not by the above
description but by the scope of claim for patent, and it is
intended that all modifications within the meaning and range
equivalent to the scope of claim for patent are included.
* * * * *