JP2002289445A - Inductance component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for an inductance component with which a permanent magnet can be magnetized and adhered/fixed onto a magnetic core by a single process and working costs can be reduced by shortening processes. SOLUTION: In the inductance component 10, which is combined with a drum-shaped, sleeve-shaped or cap-shaped magnetic core, arranging the permanent magnet in the void part (bonding part of an outer peripheral flange) of the sleeve-shaped or cap-shaped magnetic core having a magnetic void, the permanent magnet 2 is configured by applying a viscous body, with which magnetic powder and resin (adhesive agent) are mixed, to the void part (bonding part of the outer peripheral flange) of the magnetic core, heating, hardening and magnetizing is together with the magnetic core 3.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a magnetic element having a coil wound around a magnetic core, and more particularly, to a magnetic element used in various electronic devices and switching power supplies, to which a DC bias is applied, such as a transformer or an inductor. Related to parts.

[0002]

2. Description of the Related Art FIG.
And what is shown in FIG. 4 is known.

FIG. 3 is a diagram showing an example of a conventional inductance component and its drum-shaped and sleeve-shaped magnetic core shapes. FIG. 3A is a perspective view of a sleeve-shaped magnetic core.
(B) is a sectional view of the sleeve-shaped magnetic core of (a), (c)
3 is a perspective view of the permanent magnet portion, (d) is a sectional view of the permanent magnet portion of (c), (e) is a side view of the coil portion, and (f) is a sectional view of the inductance component.

A conventional inductance component 50 shown in FIG. 3 (f) is magnetized on the outer flange joining surface of a bobbin 54 of a coil portion 53 having a sleeve-shaped magnetic core 51 and a drum-shaped magnetic core. It is formed by mounting a permanent magnet portion (M) 52 made of a thin plate in a ring state.

[0005] As shown in FIGS. 3A and 3B, the magnetic core portion 51 has a sleeve shape.

As shown in FIGS. 3C and 3D, the permanent magnet portion (M) 52 has a ring-shaped thin plate shape.

[0007] As shown in FIG.
Is formed by winding a winding 55 around a bobbin 54 formed of a drum-shaped magnetic core having flanges having different diameters at both ends.

As shown in FIG. 3 (f), a coil portion 53 wound around a bobbin 54 in which a winding 55 is wound around a bobbin 54 of a drum-shaped magnetic core is applied to an inner peripheral portion. The ring-shaped permanent magnet portion 52 is inserted so as to be in contact with the magnetic core portion 51, and is formed so as to cover the magnetic core portion 51.

FIG. 4 is a view showing another example of the shape of the conventional inductance component, its one-drum magnetic core, and the cap-shaped magnetic core. FIG. 4A is a perspective view of the cap-type magnetic core. , (B) is a cross-sectional view of the cap-type magnetic core portion of (a), (c) is a perspective view of a ring-shaped permanent magnet portion, (d) is a cross-sectional view of the ring-shaped permanent magnet of (c), ( (e) is a side view showing a coil part provided with a one-drum-shaped magnetic core, and (f) is a sectional view of an inductance component.

As shown in FIG. 4 (f), the inductance component includes a ring formed on the joining (fitting) surface between the cap-shaped magnetic core 61 and the outer peripheral flange of the coil portion having the one-drum magnetic core. It is formed so as to sandwich the permanent magnet portion 52 (M) having the shape.

As shown in FIGS. 4A and 4B, the magnetic core portion 61 has a cap shape with one end opened.

As shown in FIG. 4 (e), the coil part 65 is a bobbin 64 composed of a one-drum-shaped magnetic core 64.
Is formed by winding a winding 55.

As shown in FIG. 4 (f), a ring-shaped thin permanent magnet 52 as shown in FIGS. 4 (c) and 4 (d) is inserted into the coil 65 and the cap-shaped magnetic core 6 is inserted.
1 and the outer peripheral surface inside the flange 64a.

Here, the aforementioned conventional inductance component 5
At 0,60, a permanent magnet part 5 for applying a bias
Arrangement method 2 is to insert a plate-shaped (here, donut-shaped) permanent magnet formed in advance to a fixed thickness into a pre-cut reed-shaped or cap-shaped magnetic core gap (joining portion of the outer peripheral flange). Adhesive to the drum-shaped magnetic core such as
Fix it.

However, in this case, since the gap size variation occurs due to the influence of the cutting accuracy of the magnetic core gap portion, the gap is generated as an air gap (bias invalid gap) even after the permanent magnet is provided.

[0016]

As described above, in a bias inductance component manufactured by a conventional method, a bonding step of a magnetic core with a gap and a permanent magnet and an adhesive are indispensable.

Also, due to the gap size variation of the magnetic core, an unnecessary (ineffective) air gap after the permanent magnet is provided is generated, and the bias effect is reduced.

Accordingly, a technical problem of the present invention is to provide a method of manufacturing an inductance component which can perform magnetization of a permanent magnet and adhere and fix it to a magnetic core in a single step, thereby reducing processing costs by shortening the steps. Is to do.

[0019]

According to the present invention, there is provided an inductance component formed by a combination of a drum-shaped magnetic core and a sleeve-shaped or cap-shaped magnetic core, wherein a magnetic component is provided between the magnetic component and the drum-shaped magnetic core. In the inductance component, a permanent magnet is disposed in the magnetic gap of the sleeve-shaped or cap-shaped magnetic core having a gap,
The above-mentioned permanent magnet is obtained by applying a viscous material obtained by mixing a magnetic powder and a resin to the above-mentioned magnetic gap portion, heating and hardening, and then magnetizing the magnetic core together with the magnetic core. .

According to the present invention, in the inductance component, the magnetic powder of the permanent magnet has a specific coercive force of 10 KOe (79 kA / m) or more and a Curie temperature Tc5.
00 ° C. or higher, with a rare-earth magnetic powder having an average particle size 2.5～50Myuemu, its composition formula _{Sm (Co bal.} Fe
_0.15-0.25 Cu _0.05-0.06 Zr
_0. A magnetic powder represented by _{02-0.03) 7.0-8.5,} any of the polyimide resin, polyamideimide resin, epoxy resin, polyphenylene sulfide resin, silicone resin, polyester resin, aromatic nylon, liquid crystal polymer resin Alternatively, an inductance component can be obtained which is formed of a composite material and has a specific resistance of 0.1 Ωcm or more.

Further, according to the present invention, in any one of the inductance components, the surface of the rare earth magnetic powder has a volume ratio of 0.1 to 10% of Zn, Al, Ga, In,
An inductance component characterized by being coated with one or an alloy of Mg, Pb, Sb, and Sn or forming a composite is obtained.

According to the invention, in any one of the inductance components, the magnetic powder is subjected to a surface treatment with a dispersing material such as a silane coupling material or a titanium coupling material before being mixed with the resin. Thus, an inductance component characterized by magnetic powder obtained is obtained.

Further, according to the present invention, there is provided a method of manufacturing an inductive component in which a drum-shaped magnetic core and a sleeve-shaped or cap-shaped magnetic core are combined, wherein a magnetic gap is provided between the magnetic core and the drum-shaped magnetic core. In the method of manufacturing an inductance component, wherein a permanent magnet is disposed in the magnetic gap of a sleeve-shaped or cap-shaped magnetic core having a portion, the permanent magnet is formed by mixing a viscous material obtained by mixing a magnetic powder and a resin with the magnetic gap. A method for manufacturing an inductance component is characterized in that the magnetic core is magnetized together with the magnetic core after being applied to the portion and cured by heating.

According to the present invention, in the method of manufacturing an inductance component, the magnetic powder of the permanent magnet may be
A rare-earth magnetic powder having a specific coercive force of 10 KOe (790 kA / m) or more, a Curie temperature Tc of 500 ° C. or more, and an average particle size of 2.5 to 50 μm, the composition of which is represented by the general formula Sm (Co
_bal. Fe _0.15-0.25 Cu _0.05-
0.06 Zr _0.02-0.03 ) _7.0-8.5
The magnetic powder represented by, polyimide resin, polyamide imide resin, epoxy resin, polyphenylene sulfide resin, silicone resin, polyester resin, aromatic nylon, liquid crystal polymer resin or any one of the composite or composite, its specific resistance A method for manufacturing an inductance component, characterized by using a material having a resistance of 0.1 Ωcm or more, is obtained.

According to the invention, in any one of the above-described methods of manufacturing an inductance component, the surface of the rare-earth magnetic powder may have a volume ratio of 0.1 to 10% of Zn, Al, and G.
A method for producing an inductance component, characterized in that it is coated with one or an alloy of a, In, Mg, Pb, Sb, and Sn or a composite is formed.

According to the invention, in any one of the above-described methods for manufacturing an inductance component, the magnetic powder is surface-treated with a dispersing material such as a silane coupling material or a titanium coupling material before being mixed with the resin. A method for producing an inductance component, characterized by using magnetic powder subjected to the above, is obtained.

As described above, in the inductance component manufactured by the method of the present invention, (a) the permanent magnet for biasing uses a viscous material in which magnetic powder and an adhesive (resin) are mixed;
(A) The viscous magnet is applied to the joint of the outer peripheral flange of the sleeve-shaped or cap-shaped magnetic core, cured by heating, and then magnetized together with the magnetic core, so that the magnetization of the permanent magnet and the magnetic core The bonding and fixing can be performed in a single process, and the processing cost can be reduced by shortening the manufacturing process.

[0028]

Embodiments of the present invention will be described below with reference to the drawings.

FIGS. 1A and 1B are diagrams showing the shape of an inductance component and its drum-shaped magnetic core and sleeve-shaped magnetic core according to a first embodiment of the present invention. FIG. 1A is a perspective view, and FIG.
3A is a cross-sectional view, FIG. 3C is a side view, and FIG. 3D is a cross-sectional view of an inductance component.

As shown in FIGS. 1 (a) and 1 (b), after coating (adhesion) and drying on the outer peripheral flange joining (fitting) surface of the sleeve-shaped magnetic core portion 1, the magnetic core portion 1 The magnetic core 3 is formed by fixing the magnetized permanent magnet portion (M) 2 (mixed magnet of magnetic powder and adhesive).

Next, as shown in FIG. 1C, the magnetic core 3 is previously wound around a bobbin 4 made of a drum-shaped magnetic core.
Over the coil portion 6 in a state where
An inductance component 10 including a transformer as shown in (d) is formed.

Here, as the material of the magnetic core portion 1 and the bobbin 4, Mn-Zn-based ferrite can be used, but any soft magnetic material can be used.

The permanent magnet portion (M) 2 is made of a bonded magnet formed of a viscous material in which a magnetic powder and a resin are mixed. As long as the specific resistance of the bonded magnet is 0.1Ω, any magnetic powder or any resin can be used.

The magnetic powder has a fixed coercive force of 10K.
Oe (790 kA / m) or more, Curie temperature (Tc) 5
Any magnetic powder can be used as long as it is a magnetic powder having a temperature of at least 00 ° C. and an average particle diameter of 2.5 to 5.0 μm.

The magnetic powder is used in a volume ratio of 0.1 to 1
0% Zn, Al, Bi, Ga, In, Mg, Pb, S
Preferably, it is coated with one or an alloy of b and Sn, or a composite is formed.

Further, the magnetic powder is preferably subjected to a surface treatment by adding a dispersant such as a silane coupling material or a titanium coupling material before being mixed with the resin.

Further, as a resin for binding the magnetic powder,
Polyimide resin, polyamide imide resin, epoxy resin, polyphenylene sulfide resin, silicone resin,
Any of a polyester resin, an aromatic nylon, a liquid crystal polymer resin, or a composite of these resins can be used.

Next, a specific example of manufacturing an inductance component according to the first embodiment of the present invention will be described.

As the magnetic powder, a fixed coercive force of 15 KOe
(1185 kA / m), Curie temperature (Tc) 770
° C and an average particle size of 10 µm are represented by the general formula Sm (Coba
l. Fe _0.15-0.25Cu
_0.05-0.06ZrO_0.02-0.03)
_7.0-8.5Of rare earth magnet powder of 1 volume ratio
% Zn. In addition, a silane coupling agent
Addition, surface treatment, aromatic nylon as resin
Was mixed. The viscous material of this mixture is shown in FIG.
And apply it to one end of the cylindrical magnetic core, dry it,
(Above), and the coil 6 shown in FIG.
The magnetic core portion 1 of FIG.
The conductance component 10 was obtained.

FIG. 2 is a view showing the shape of an inductance component, a one-drum magnetic core and a cap-shaped magnetic core according to a second embodiment of the present invention, and (a) is a perspective view of the cap-shaped magnetic core. FIG. 2B is a cross-sectional view of the cap-shaped magnetic core of FIG. 2A, FIG. 2C is a side view of a coil portion using the one-drum magnetic core, and FIG. 2D is a cross-sectional view of an inductance component. The inductance component according to the second embodiment is assembled as follows.

First, as shown in FIG. 2A, the cap-shaped magnetic core portion 11 and the outer peripheral flange 14a of the drum piece magnetic core 14 are formed.
After applying (adhering) and drying the permanent magnet portion (M) 2 on the joint (fitting) surface with the magnetic core portion 11, the permanent magnet portion (M) 2 (magnetic powder and adhesive) 2B) to obtain the magnetic core 13 shown in FIG.

Next, as shown in FIG. 2 (c), the magnetic core 13 is covered over the coil portion 16 in which the winding 5 is wound on the bobbin 14 made of a single-drum magnetic core in advance.
An inductance component 20 composed of a transformer as shown in FIG. 2D is formed.

Here, according to the second embodiment of the present invention, the materials of the magnetic powder, the resin, the one-drum magnetic core 14 and the cap-shaped magnetic core 11 are the same as those according to the first embodiment. Material can be obtained.

As described above, the inductance components 10 and 20 according to the first and second embodiments of the present invention are different from the conventional method in which a permanent magnet made of a ring-shaped thin plate manufactured in advance is bonded between magnetic cores. The processing steps can be simplified, the gap between the magnetic core and the permanent magnet (bias invalid space) can be reduced, and an inductance component with the bias effect (quality) maximized can be realized.

In addition, in the inductance components 10 and 20 according to the first and second embodiments of the present invention, the magnetic powder adheres to the irregularities on the joining surfaces of the magnetic cores 1, 4, 11, 14 and the permanent magnet. Since the variation in the gap size due to the cutting accuracy of the magnetic core gap is adjusted by the amount of the permanent magnetic powder, the unnecessary air gap after the combination of the magnetic cores can be reduced to zero or small.

According to the first and second embodiments of the present invention, as described above, since the permanent magnet portion formed of the viscous body is used, the gap effect (because no gap is generated) causes the bias effect. Is further improved, and the manufacturing method (process)
In addition, there is no need to bond the magnetic core and the permanent magnet, and the manufacturing process can be simplified.

Further, according to the present invention, irreversible demagnetization due to reflow solder heat and demagnetization due to oxidation of the magnetic powder of the permanent magnet can be prevented by using the above magnet powder, resin, surface coating and treatment material. .

[0048]

As described above, in the inductance component according to the present invention, the magnetic powder adheres to the irregularities on the joining surface of the magnetic core and the permanent magnet, and the gap size due to the cutting accuracy of the magnetic core gap is reduced by the permanent magnet. An unnecessary air gap amount can be reduced to zero or small after the magnetic core is combined in order to adjust with the amount of powder, thereby providing an inductance component having no variation in characteristics and a manufacturing method thereof.

Further, according to the present invention, it is possible to provide an inductance component having a further improved bias effect and a method of manufacturing the same, since the joining portion does not generate a gap.

Further, according to the present invention, in the production method (process),
It is not necessary to bond the magnetic core and the permanent magnet, and it is possible to provide an inductance component capable of simplifying the manufacturing process and a method of manufacturing the same.

Further, according to the present invention, by using a material having the specified composition and characteristics for the permanent magnet, irreversible demagnetization due to reflow soldering heat and demagnetization due to oxidation of the magnetic powder constituting the permanent magnet are prevented. It is possible to provide an inductance component that can be prevented and a method of manufacturing the same.

[Brief description of the drawings]

FIGS. 1A and 1B are diagrams showing a drum-shaped and sleeve-shaped magnetic core of an inductance component according to a first embodiment of the present invention, wherein FIG. 1A is a perspective view, FIG. 1B is a cross-sectional view of FIG. )
Is a side view, and (d) is a sectional view of an inductance component.

FIGS. 2A and 2B are diagrams showing a one-drum shape of an inductance component and a magnetic core shape of a cap according to a second embodiment of the present invention, wherein FIG. 2A is a perspective view, FIG.
(C) is a side view of the coil portion, and (d) is a cross-sectional view of the inductance component.

3A and 3B are diagrams showing an example of a drum-shaped and sleeve-shaped magnetic core shape of an inductance component according to the related art, wherein FIG. 3A is a perspective view, FIG. 3B is a cross-sectional view of FIG. (D) is a cross-sectional view of the permanent magnet portion of (c),
(E) is a side view of the coil portion, and (f) is a cross-sectional view of the inductance component.

FIG. 4 is a diagram showing an example of a one-drum shape of an inductance component and a magnetic core shape of a cap according to the related art;
(A) is a perspective view of a cap-type magnetic core, (b) is (a)
, (C) is a perspective view of the ring-shaped permanent magnet, (d) is a cross-sectional view of the ring-shaped permanent magnet, and (e) is a single-drum-shaped coil. FIG. 3F is a side view showing a part, and FIG.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Magnetic core part 2 Permanent magnet part (M) 3 Magnetic core 4 Bobbin (drum type magnetic core) 5 Winding 6 Coil part 10 Inductance component 11 Magnetic core part 13 Magnetic core 14 Magnetic core (bobbin) 16 Coil part 20 Inductance Components 50 Inductance component 51 Magnetic core part 52 Permanent magnet part (M) 53 Coil part 54 Bobbin (drum type magnetic core) 55 Winding 60 Inductance part 61 Magnetic core part 64 Bobbin (single drum magnetic core)

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Teruhiko Fujiwara 6-7-1, Koriyama, Taishiro-ku, Sendai, Miyagi Prefecture Tokin Co., Ltd. (72) Hatsune Matsumoto 7, 7-Koriyama, Koriyama, Taishiro-ku, Sendai, Miyagi Prefecture. No.1 F-term in Tokin Co., Ltd. (Reference) 5E040 AA06 BB04 BB05 BB06 BC05 CA01 NN01 NN12 5E062 CC03 CD05

Claims (8)

[Claims] 1. An inductance component comprising a combination of a drum-shaped magnetic core and a sleeve-shaped or cap-shaped magnetic core, wherein the sleeve-shaped or cap-shaped has a magnetic gap between the drum-shaped magnetic core. In the inductance component, in which a permanent magnet is disposed in the magnetic gap of the magnetic core, the permanent magnet is formed by applying a viscous material obtained by mixing a magnetic powder and a resin to the magnetic gap, and heat-curing. And then magnetizing the entire magnetic core. 2. The inductance component according to claim 1,
The magnetic powder of the permanent magnet has a specific coercive force of 10 KOe.
(79 kA / m) or higher, Curie temperature Tc 500 ° C or lower
Above, a rare earth magnetic powder having an average particle size of 2.5 to 50 μm.
Of the general formula Sm (Co_bal.Fe
_0.15-0.25Cu_0.05-0.06Zr
_0.02-0.03)_7.0-8.5Magnetism indicated by
Powder, polyimide resin, polyamide-imide resin, epoxy resin
Xylene resin, polyphenylene sulfide resin, silicon
Resin, polyester resin, aromatic nylon, liquid crystal poly
Formed with any of the polymer resins or the complex, and its ratio
An inductor characterized in that the resistance is 0.1 Ωcm or more.
Reactance parts. 3. The inductance component according to claim 1, wherein the surface of the rare earth magnetic powder has a volume ratio of 0.1 to 0.3.
1 to 10% Zn, Al, Ga, In, Mg, Pb, S
An inductance component, which is coated with one or an alloy of b and Sn or formed of a composite. 4. The inductance component according to claim 1, wherein the magnetic powder is a dispersion material such as a silane coupling material or a titanium coupling material before being mixed with the resin. An inductance component, which is a magnetic powder subjected to a surface treatment. 5. A method for manufacturing an inductive component in which a drum-shaped magnetic core and a sleeve-shaped or cap-shaped magnetic core are combined, wherein the sleeve-shaped or magnetic core has a magnetic gap between the drum-shaped magnetic core and the sleeve. In the method for manufacturing an inductance component, wherein a permanent magnet is disposed in the magnetic gap of the cap-shaped magnetic core, the permanent magnet is formed by applying a viscous material obtained by mixing a magnetic powder and a resin to the magnetic gap and heat-curing. And then magnetizing the magnetic core together with the magnetic core. 6. Production of the inductance component according to claim 5.
The magnetic powder of the permanent magnet,
10 KOe or more, Curie temperature Tc 500 ℃ or more, average
A rare earth magnetic powder having a particle size of 2.5 to 50 μm,
The composition is represented by the general formula Sm (Co_bal.Fe
_0.15-0.25Cu_0.05-0.06Zr
_0.02-0.03)_7.0-8.5Magnetism indicated by
Powder, polyimide resin, polyamide-imide resin, epoxy resin
Xylene resin, polyphenylene sulfide resin, silicon
Resin, polyester resin, aromatic nylon, liquid crystal poly
Formed with any of the polymer resins or the composite, and its specific resistance
The characteristic is that the resistance is 0.1Ωcm or more.
Manufacturing method of inductance components. 7. The method of manufacturing an inductance component according to claim 5, wherein the surface of the rare earth magnetic powder has a volume ratio of 0.1 to 10% of Zn, Al, Ga, In, Mg,
A method for manufacturing an inductance component, wherein the component is coated with one or an alloy of Pb, Sb, and Sn or a composite is formed. 8. The method for manufacturing an inductance component according to claim 5, wherein the magnetic powder is mixed with the resin before the silane coupling material.
A method for manufacturing an inductance component, comprising using magnetic powder subjected to a surface treatment with a dispersing material such as a titanium coupling material.