Abstract:
The present invention provides a non-contact power feeding coil (1) provided with: a coil (31) ; and a core (41) that forms a part of a circulating magnetic path that is interlinked to the coil, and used in at least one of a power feeding-side device and a power receiving-side device of a non-contact power feeding system (9), in which the core is configured to connect three or more core units in one row, and the core units include one or more interlinked core units (E-type cores 5) that are interlinked to the coil and two non-interlinked core units (L-type cores 6) that are not interlinked to the coil respectively disposed on both ends in the connection direction of the one or more interlinked core units. Thereby, it is possible to provide a non-contact power feeding coil that suppresses an increase in leakage flux since the non-interlinked core units have a magnetic shield effect in which a contribution to electromagnetic coupling is reduced and magnetic flux that is generated by the coil does not leak to the outside.
Abstract:
The present invention provides a magnetic core having insulating properties, and a method for manufacturing the magnetic core. Provided is a magnetic core manufactured by compression molding and subsequent thermal curing of an iron-based soft magnetic powder having a resin coating formed on particle surfaces thereof. The iron-based soft magnetic powder is one in which the particle surfaces have been coated with an inorganic insulator; the resin coating is an uncured resin coating formed by dry blending the powder with a thermosetting resin at a temperature equal to or greater than the softening point of the thermosetting resin and lower than the thermal curing initiation temperature of the resin; the compression molding is carried out by using a mold to produce a compression molded body; and the thermal curing is carried out at a temperature equal to or greater than the thermal curing initiation temperature of the thermosetting resin.
Abstract:
Provided is a magnetic core coil which can be made small in thickness (radial size) and size, and can be produced in a reduced number of production steps and at low cost. The magnetic core coil has a coil wound around a core formed of a magnetic material, and has two terminal members formed of a conductive material. The two terminal members are fixed to the core in a state in which the two terminal members extend from one end, in an axial direction orthogonal to the coil winding cross section, of the core in the axial direction. The winding starting end and the winding ending end of the coil are electrically connected to those portions of the two terminal members which protrude in the axial direction from the one end of the core.
Abstract:
The present invention relates to an optimal condition in which a composition of a soft magnetic molding solution includes 94 to 98 wt% of a soft magnetic powder and 2 to 6 wt% of an organic vehicle, in order to manufacture a coil-embedded inductor having various advantages such as high inductance, a low core loss, and high reliability. Provided is a manufacturing method of a coil-embedded inductor having a structure in which a part of a coil is embedded in a magnetic core, which includes preparing an organic vehicle, preparing a soft magnetic molding solution having the density of 5.5 to 6.5 g/cc by mix-milling a soft magnetic powder with the organic vehicle, positioning and fixing a part of the coil in the case, and forming the magnetic core by injecting and curing the soft magnetic molding solution into the case.
Abstract:
Provided is a method for manufacturing a high-density integrally-molded inductor, comprising the following steps: (1) winding an enameled wire coil to be spiral; (2) mechanically pressing first ferromagnetic powder into a magnetic core; (3) mounting the magnetic core into a hollow cavity of the enameled wire coil; (4) mounting the enameled wire coil provided with the magnetic core into an injection mold; (5) uniformly mixing and stirring resin glue, a coupling agent and an accelerant, to obtain high-temperature resin glue; (6) uniformly stirring second ferromagnetic powder and the high-temperature resin glue, to obtain a magnetic composite material; (7) injecting the magnetic composite material into a mold cavity of the injection mold for molding, and solidifying the magnetic composite material to obtain an outer magnet; and (8) cooling and de-molding the outer magnet, to obtain a molded inductor. The inductor obtained using the above method is small in size, high in density, high in relative permeability, better in heat dissipation, and long in service life. The inductor is simply manufactured using an integral molding method, thus reducing the production cost.
Abstract:
A soft magnetic powder has a composition represented by Fe 100-a-b-c-d-e-f Cu a Si b B c M d M' e X f (at%) (wherein M is at least one element selected from the group consisting of Nb and the like, M' is at least one element selected from the group consisting of V and the like, X is at least one element selected from the group consisting of C and the like, and a, b, c, d, e, and f are numbers that satisfy the following formulae: 0.1 ≤ a ≤ 3, 0
Abstract:
This composite soft magnetic material having low magnetostriction and high magnetic flux density contains: pure iron-based composite soft magnetic powder particles that are subjected to an insulating treatment by a Mg-containing insulating film or a phosphate film; and Fe-Si alloy powder particles including 11% by mass to 16% by mass of Si. A ratio of an amount of the Fe-Si alloy powder particles to a total amount is in a range of 10% by mass to 60% by mass, and a boundary layer is included between the particles. This method for producing composite soft magnetic material having low magnetostriction and high magnetic flux density includes: mixing a pure iron-based composite soft magnetic powder that is subjected to an insulating treatment by a Mg-containing insulating film or a phosphate film, and an Fe-Si alloy powder including 11% by mass to 16% by mass of Si in such a manner that a ratio of an amount of the Fe-Si alloy powder to a total amount becomes in a range of 10% by mass to 60% by mass; subjecting a resultant mixture to compression molding; and subjecting a resultant molded body to a baking treatment in a non-oxidizing atmosphere. In the case where the composite soft magnetic powder is subjected to the insulation treatment by the Mg-containing insulation film, a baking temperature is set to be in a range of 500°C to 1,000°C, and in the case where the composite soft magnetic powder particles are subjected to the insulating treatment by the phosphate film, the baking temperature is set to be in a range of 350°C to 500°C.
Abstract:
An object of the invention is to provide a method that is for manufacturing a powder magnetic core through simple compression molding and capable of manufacturing a complicatedly shaped powder magnetic core with reliable high strength and insulating properties. The invention is directed to a method for manufacturing a powder magnetic core with a metallic soft magnetic material powder, the method including: a first step including mixing a soft magnetic material powder and a binder; a second step including compression molding the mixture obtained after the first step; a third step including performing at least one of grinding and cutting on the compact obtained after the second step; and a fourth step including heat-treating the compact after the third step, wherein in the fourth step, the compact is heat-treated so that an oxide layer containing an element constituting the soft magnetic material powder is formed on the surface of the soft magnetic material powder.
Abstract:
A magnetic core has a structure in which alloy phases 20 each including Fe, Al, Cr and Si are dispersed and any adjacent two of the alloy phases 20 are connected to each other through a grain boundary phase 30. In this grain boundary phase 30, an oxide region is produced which includes Fe, Al, Cr and Si, and includes Al in a larger proportion by mass than the alloy phases 20. This magnetic core includes Al in a proportion of 3 to 10% both inclusive by mass, Cr in a proportion of 3 to 10% both inclusive by mass, and Si in a proportion more than 1% and 4% or less by mass provided that the sum of the quantities of Fe, Al, Cr and Si is regarded as being 100% by mass; and includes Fe and inevitable impurities as the balance of the core.