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1. 发明专利

JP2012230948A Powder for magnetic core, dust core, and method of manufacturing the same 审中-公开
标题翻译：用于磁芯，粉芯及其制造方法的粉末
公开(公告)号：JP2012230948A
公开(公告)日：2012-11-22
申请号：JP2011096860
申请日：2011-04-25
申请人： Toyota Central R&D Labs Inc , 株式会社豊田中央研究所 , Toyota Motor Corp , トヨタ自動車株式会社
发明人： OTSUBO MASASHI , TANI MASAAKI , HATTORI TAKESHI , OISHI YUSUKE , OKAMOTO DAISUKE
IPC分类号： H01F1/24 , B22F1/02 , B22F3/00 , B22F3/24 , C22C38/00 , H01F1/33 , H01F27/255 , H01F41/02
CPC分类号： H01F1/33 , B22F1/02 , B22F2998/00 , C22C2202/02 , H01F1/24 , H01F41/0246 , B22F3/02 , B22F3/10
摘要： PROBLEM TO BE SOLVED: To provide a dust core excellent in specific resistance and strength.SOLUTION: The dust core includes soft magnetic particles, and a grain boundary phase formed among the soft magnetic particles. The grain boundary phase has a such composite dispersion system in which fine particles containing a high temperature softening material (nano particles of silica and aluminum) which contain a second inorganic oxide having a softening point higher than an annealing temperature are dispersed in the matrix containing a low temperature softening material (low-melting point glass particles) that contains a first inorganic oxide having a softening point lower than the annealing temperature of the soft magnetic particle. Since the grain boundary phase has the composite dispersion system like this, the soft magnetic particles are strongly coupled by the low temperature softening material and a predetermined interval is held by the high temperature softening material, to assure insulation property. Thus the dust core in which both a high specific resistance and a high strength are provided in a high dimension is provided.
摘要翻译：要解决的问题：提供具有优异的电阻和强度的防尘芯。解决方案：灰尘芯包括软磁性颗粒和在软磁性颗粒之间形成的晶界相。晶界相具有这样的复合分散体系，其中含有含有软化点高于退火温度的第二无机氧化物的高温软化材料（二氧化硅和铝的纳米颗粒）的微粒分散在含有低温软化材料（低熔点玻璃粒子），其含有软化点低于软磁性粒子的退火温度的第一无机氧化物。由于晶界相具有这样的复合分散体系，因此软磁性粒子通过低温软化材料强耦合，高温软化材料保持规定间隔，保证绝缘性。因此，提供高尺寸设置高电阻率和高强度的防尘芯。版权所有（C）2013，JPO＆INPIT

2. 发明专利

JP2012044156A Manufacturing method of dust core and manufacturing method of powder for core 有权
标题翻译：核心粉末制造方法和粉末制造方法
公开(公告)号：JP2012044156A
公开(公告)日：2012-03-01
申请号：JP2011157276
申请日：2011-07-16
申请人： Toyota Central R&D Labs Inc , Toyota Motor Corp , トヨタ自動車株式会社 , 株式会社豊田中央研究所
发明人： FAN JONHAN , HATTORI TAKESHI , HIRANO MASATERU , SUGIYAMA MASAKI , OISHI YUSUKE , OKAMOTO DAISUKE , YAMAMOTO HIDENARI
IPC分类号： H01F41/02 , B22F1/02 , B22F3/00 , C22C38/00 , H01F1/26 , H01F27/255
CPC分类号： H01F41/0246 , B22F1/0077 , C22C2202/02 , H01F1/26 , H01F27/255 , H01F41/0266
摘要： PROBLEM TO BE SOLVED: To provide a manufacturing method of a dust core that uses powder for a core excelling in coatability of magnetic powder composed of a resin, a filling property, and green compact formability.SOLUTION: The manufacturing method of the dust core comprises: a powder preparation step of acquiring the powder for the core by mixing resin powder composed of magnetic powder and a thermosetting resin in a warm state; a power filling step of filling a mold with the powder for the core; a pressure forming step of pressuring and forming the powder for the core; and a green compact heating step of heating the green compact after the forming step in the high temperature state in which the thermosetting resin is cured.
摘要翻译：要解决的问题：提供一种使用粉末的粉芯的制造方法，该芯用于由树脂构成的磁粉的涂布性优异，填充性和生坯成型性优异。解决方案：粉芯的制造方法包括：粉末制备步骤，通过将由磁性粉末组成的树脂粉末和热固性树脂混合在一起，获得用于芯的粉末; 功率填充步骤，用于为所述芯体填充所述粉末; 对芯的粉末进行加压成形的压力成形工序; 以及在固化热固性树脂的高温状态下，在成形步骤之后加热生坯的绿色紧凑型加热步骤。版权所有（C）2012，JPO＆INPIT

3. 发明专利

JP2017092162A 圧粉磁心の製造方法审中-公开
公开(公告)号：JP2017092162A
公开(公告)日：2017-05-25
申请号：JP2015218130
申请日：2015-11-06
申请人：トヨタ自動車株式会社 , Toyota Motor Corp , 株式会社豊田中央研究所 , Toyota Central R&D Labs Inc
发明人： IWATA NAOKI , SAEGUSA SHINJIRO , ISHII KOHEI , OKAMOTO DAISUKE , OTSUBO MASASHI , FAN JONHAN , HATTORI TAKESHI
IPC分类号： H01F41/02 , B22F1/00 , B22F1/02 , B22F3/00 , B22F3/24 , H01F1/24
摘要：【課題】強度の低下を抑制した圧粉磁心を製造する圧粉磁心の製造方法の提供。【解決手段】複数の粒子を含む合金粉末を、加圧成形して圧粉磁心を製造する製造方法である。複数の粒子は、Alと、主成分としてFeと、を含む。合金粉末を熱処理温度800℃〜1000℃で加熱保持(ST1)した後、加熱保持した合金粉末を加圧成形する(ST2)。このような製造方法によって、強度の低下を抑制した圧粉磁心を製造することができる。また、合金粉末を熱処理温度800℃〜1000℃で加熱保持することによって、合金粉末の複数の粒子の表面に絶縁膜を形成してもよい。【選択図】図3

4. 发明专利

JP2015026749A 軟磁性粉末、圧粉磁心および軟磁性合金审中-公开
标题翻译：软磁粉，粉末磁芯和软磁合金
公开(公告)号：JP2015026749A
公开(公告)日：2015-02-05
申请号：JP2013156198
申请日：2013-07-27
申请人：株式会社豊田中央研究所 , Toyota Central R&D Labs Inc , トヨタ自動車株式会社 , Toyota Motor Corp
发明人： HATTORI TAKESHI , OKAMOTO DAISUKE
IPC分类号： H01F1/147 , B22F1/00 , B22F3/00 , C22C38/00 , H01F1/20
摘要：【課題】高磁気特性と低損失を高次元で両立できる圧粉磁心が得られる軟磁性粉末を提供する。【解決手段】本発明の軟磁性粉末は、SiおよびAlを含む鉄合金からなり、鉄合金は全体を100質量%としたときに、Si:4.5〜7.5%と、Al:2.5〜5.5%と、SiとAlの合計:10%以下と、残部:Feと、からなることを特徴とする。このような特定範囲内の合金組成からなる軟磁性粉末は、例えば、飽和磁化が高く、保磁力が低く、最大磁束密度が大きく鉄損(ヒステリシス損失および渦電流損)が小さい圧粉磁心が得られ易い。さらに本発明の軟磁性粉末の平均アスペクト比が6以下である場合、圧粉磁心の損失をより低減することが可能となる。本発明に係る圧粉磁心は、例えば、電気自動車やハイブリッド車等に搭載される変圧用リアクトル等に好適である。【選択図】図2
摘要翻译：要解决的问题：提供软磁粉末，其可以获得能够实现高磁性和低损耗的粉末致密磁芯。解决方案：软磁粉末包括铁合金含Si和Al。铁合金包含4.5-7.5％的Si和2.5-5.5％的Al，余量由Fe至100质量％组成，条件是Si和Al的总含量为10％以下。使用具有这样的特定范围内的合金组成的软磁性粉末，例如，可以容易地获得饱和磁化强度大，矫顽力低，最大磁通密度大，铁损小（磁滞损耗和涡流损耗）小的粉末状磁芯。此外，在平均纵横比为6以下的本发明的软磁性粉末的情况下，能够进一步减小粉末状小型磁芯的损耗。根据本发明的粉末 - 小型磁芯适用于例如，在电动车辆，混合动力车辆等中设置用于电压转换的电抗器。

5. 发明专利

JP2011018822A Dust core and method for manufacturing the same 有权
标题翻译：粉尘芯及其制造方法
公开(公告)号：JP2011018822A
公开(公告)日：2011-01-27
申请号：JP2009163431
申请日：2009-07-10
申请人： Toyota Central R&D Labs Inc , Toyota Motor Corp , トヨタ自動車株式会社 , 株式会社豊田中央研究所
发明人： OTSUBO MASASHI , TANI MASAAKI , HATTORI TAKESHI , OKAMOTO DAISUKE , SUGIYAMA MASAKI
IPC分类号： H01F1/26 , B22F1/00 , B22F1/02 , B22F3/00 , B22F3/02 , B22F3/24 , C22C38/00 , H01F27/255 , H01F41/02
摘要： PROBLEM TO BE SOLVED: To provide a dust core that satisfies low magnetic permeability, high magnetic-flux density and high strength.SOLUTION: The dust core is composed of a green compact formed by pressing powder for a magnetic core manufactured by executing a first-coating-layer forming step and a second-coating-layer forming step, respectively, in which soft-magnetic powder and a solution of a heat-curable silicone resin are brought into contact with each other and dried, while setting the drying temperature of the second-coating-layer forming step lower than that of the first-coating-layer forming step. The ratio of the second coating layer is set to 40-90 mass%; and by having the density ratio (ρ/ρ:%) that is the ratio of the bulk density (ρ) of a green compact to the true density (ρ) of the soft-magnetic powder set to 85-91%, it is possible to obtain a dust core that satisfies low magnetic permeability, high magnetic-flux density and high strength.
摘要翻译：要解决的问题：提供一种满足低磁导率，高磁通密度和高强度的防尘芯。解决方案：防尘芯由通过压制粉末形成的绿色压块构成，分别将软磁性粉末和可热固化的有机硅树脂的溶液彼此接触并干燥，同时设定干燥温度的第一涂覆层形成步骤和第二涂覆层形成步骤第二被覆层形成工序比第一被覆层形成工序低。第二涂层的比例设定为40〜90质量％。通过将生坯的体积密度（ρ）与软磁粉末的真密度（ρ）的比率设定为85-91％的密度比（ρ/ρ：％），为可以获得满足低磁导率，高磁通密度和高强度的防尘芯。

6. 发明专利

JP2009147176A Iron powder for dust core 有权
标题翻译：铁粉铁粉
公开(公告)号：JP2009147176A
公开(公告)日：2009-07-02
申请号：JP2007323925
申请日：2007-12-14
申请人： Jfe Steel Corp , Jfeスチール株式会社 , Toyota Central R&D Labs Inc , Toyota Motor Corp , トヨタ自動車株式会社 , 株式会社豊田中央研究所
发明人： KONO TAKASHI , MAKIISHI NORIKO , HIRATANI TATSUHIKO , NAKAMURA NAOMICHI , OISHI YUSUKE , HOSHINA EISUKE , YAMAGUCHI TOSHIYA , OKAMOTO DAISUKE , HATTORI TAKESHI
IPC分类号： H01F1/33 , B22F1/02
CPC分类号： H01F1/33 , B22F1/02 , B22F2998/00 , H01F1/24 , Y10T428/12181 , Y10T428/2991 , Y10T428/2993 , B22F2301/35 , B22F2302/256
摘要： PROBLEM TO BE SOLVED: To provide iron powder for dust core having high resistance and excellent iron loss characteristics without causing decrease in mechanical strength. SOLUTION: The surface of iron powder is covered with an oxide film composed of Si-based oxide in which the atomic number ratio between Si and Fe satisfies the following relation: Si/Fe≥0.8. COPYRIGHT: (C)2009,JPO&INPIT
摘要翻译：要解决的问题：提供具有高电阻和优异的铁损特性的粉芯的铁粉，而不会降低机械强度。
解决方案：铁粉表面被由Si和Fe之间的原子序数比满足Si /Fe≥0.8的Si基氧化物构成的氧化膜覆盖。版权所有（C）2009，JPO＆INPIT

7. 发明专利

JP2009117471A Powder for core, dust core, and their production methods 有权
标题翻译：核心粉饼，粉饼及其生产方法
公开(公告)号：JP2009117471A
公开(公告)日：2009-05-28
申请号：JP2007286314
申请日：2007-11-02
申请人： Toyota Central R&D Labs Inc , Toyota Motor Corp , トヨタ自動車株式会社 , 株式会社豊田中央研究所
发明人： TAJIMA SHIN , TANI MASAAKI , OKAMOTO DAISUKE , HOSHINA EISUKE , KISHIMOTO HIDESHI , ICHIKIZAKI DAISUKE
IPC分类号： H01F1/24 , B22F1/02 , B22F3/00 , C21D6/00 , H01F3/08 , H01F41/02
CPC分类号： H01F1/24 , B22F1/0062 , B22F2003/026 , B22F2003/248 , B22F2998/10 , C21D8/1216 , C21D8/1244 , C22C1/002 , C22C33/02 , H01F1/14 , H01F1/26 , H01F41/0246 , Y10T428/12014 , Y10T428/12181 , B22F9/082 , B22F3/02 , B22F3/24
摘要： PROBLEM TO BE SOLVED: To provide a powder for a core having high resistivity and low iron loss, while maintaining a high density and a high magnetic flux density, and to provide a dust core using the same, and production methods thereof. SOLUTION: This production method of this powder for a core includes an alkoxide coating film forming process for forming an alkoxide coating film, containing an Al-Si-O-based composite oxide on the surface of a pure iron powder, by immersing a pure iron powder in an alkoxide-containing solution produced by mixing in a water-free organic solvent, a Si alkoxide and Al alkoxide having an organic group having a polar group containing one or more types of N, P, S and O atoms and by drying the resultant mixture to remove the water-free organic solvent; and a silicone resin coating film forming process for forming a silicone resin coating film on the alkoxide coating film, by immersing the pure iron powder coated with the alkoxide coating film in a silicone resin-containing solution produced by mixing a silicone resin in an organic solvent and by drying the resultant mixture to remove the organic solvent, wherein an insulating coating film comprising the alkoxide coating film and the silicone resin coating film is formed on the surface of the pure iron powder. COPYRIGHT: (C)2009,JPO&INPIT
摘要翻译：要解决的问题：为了提供具有高电阻率和低铁损的铁芯粉末，同时保持高密度和高磁通密度，并提供使用该粉末的压粉芯及其制造方法。解决方案：该芯粉的制造方法包括在纯铁粉末的表面上形成含有Al-Si-O系复合氧化物的醇盐涂膜的醇盐涂膜成膜方法，通过在无水有机溶剂，Si醇盐和具有含有一种或多种N，P，S和O原子的极性基团的有机基团的Al醇盐中混合制备的含醇盐溶液中的纯铁粉末，以及通过干燥所得混合物以除去无水有机溶剂; 以及通过将涂覆有醇盐涂膜的纯铁粉浸渍在通过将有机硅树脂混合在有机溶剂中制备的含硅树脂溶液中的情况下，在醇盐涂膜上形成有机硅树脂涂膜的有机硅树脂涂膜形成方法并通过干燥所得混合物以除去有机溶剂，其中在纯铁粉末的表面上形成包含醇盐涂膜和有机硅树脂涂膜的绝缘涂膜。版权所有（C）2009，JPO＆INPIT

8. 发明专利

JP2009235517A Metal powder for dust core and method for producing dust core 审中-公开
标题翻译：用于粉尘的金属粉末和用于生产除尘芯的方法
公开(公告)号：JP2009235517A
公开(公告)日：2009-10-15
申请号：JP2008084480
申请日：2008-03-27
申请人： Jfe Steel Corp , Jfeスチール株式会社 , Toyota Central R&D Labs Inc , Toyota Motor Corp , トヨタ自動車株式会社 , 株式会社豊田中央研究所
发明人： FUJITA AKIRA , HIRATANI TATSUHIKO , MAETANI TOSHIO , KONO TAKASHI , NAKAMURA NAOMICHI , OISHI YUSUKE , HOSHINA EISUKE , YAMAGUCHI TOSHIYA , OKAMOTO DAISUKE , HATTORI TAKESHI
IPC分类号： B22F1/00 , B22F1/02 , B22F3/00 , B22F3/24 , H01F1/24 , H01F27/255 , H01F41/02
摘要： PROBLEM TO BE SOLVED: To provide metal powder for a dust core in which high insulation properties are maintained even when, for increasing the electric resistance between each powders, the amount of insulated coating applied to the surface of the powder is remarkably reduced or is made zero, and thus both of high saturated magnetic flux density and high electric resistance are improved.
SOLUTION: Pure iron powder having grain size of 10 to 500 μm and purity of ≥99 mass% is heated to the temperature range of 600 to 1,000°C, Si is concentrated on the surface of the pure iron powder in the above temperature range by vapor phase reaction, the average Si concentration in the depth range from the surface to 1 μm of the concentrated layer is controlled to 0.05 to 2 mass%, and thereafter, an Si oxide layer with a thickness of 1 to 500 nm is formed on the surface of the powder by oxidation treatment.
COPYRIGHT: (C)2010,JPO&INPIT
摘要翻译：要解决的问题：为了提高高绝缘性能的金属粉末，即使为了提高各粉末之间的电阻，施加到粉末表面的绝缘涂层的量显着降低或者为零，从而提高高饱和磁通密度和高电阻。解决方案：将粒径为10〜500μm，纯度≥99质量％的纯铁粉末加热至600〜1000℃的温度范围，将Si浓缩在上述纯铁粉末的表面上通过气相反应的温度范围，从浓缩层的表面到1μm的深度范围内的平均Si浓度被控制为0.05〜2质量％，之后，厚度为1〜500nm的Si氧化物层为通过氧化处理在粉末表面形成。版权所有（C）2010，JPO＆INPIT

9. 发明专利

JP2013142182A Coated particle powder and method for producing the same 有权
标题翻译：涂覆颗粒粉末及其制造方法
公开(公告)号：JP2013142182A
公开(公告)日：2013-07-22
申请号：JP2012003688
申请日：2012-01-12
申请人： Toyota Central R&D Labs Inc , 株式会社豊田中央研究所 , Toyota Motor Corp , トヨタ自動車株式会社
发明人： FAN JONHAN , TANI MASAAKI , HATTORI TAKESHI , OKAMOTO DAISUKE , OISHI YUSUKE
IPC分类号： B22F1/02 , H01F1/26
摘要： PROBLEM TO BE SOLVED: To provide coated particle powder which is composed of metal powder and a silicone resin and is suitable for the production of a molding or the like.SOLUTION: The coated particle powder is composed of a coated particle including: a metal particle; and a coating material made of a thermosetting resin coating the surface of the metal particle. Then, the coating material is composed of a silicone resin (specified silicone resin) having a trifunctional type molecular structure with the main chain in which Si bonded with three Os is siloxane-bonded (-Si-O-Si-bonded) and side chains made of a methyl group or a phenyl group, and having the average molecular weight (Mz1) of ≤10,000. In the specified silicone resin composing the coating material, crosslinking and condensation polymerization hardly progress, and it exhibits characteristics similar to those of a resin raw material. For example, its molecular weight distribution is hardly changed before and after the coating, and it is softened till the minimum viscosity reaches ≤100 Pa s, and further reaches ≤10 Pa s when temperature is increased from its solid state.
摘要翻译：要解决的问题：提供由金属粉末和有机硅树脂构成的适用于模制品等的制造的涂层颗粒粉末。溶胶：涂覆颗粒粉末由包括以下的涂覆颗粒组成：金属颗粒 ; 以及由涂覆金属颗粒表面的热固性树脂制成的涂料。然后，涂料由具有三官能型分子结构的硅氧烷树脂（指定的有机硅树脂）与主链相连，其中与三个Os键合的硅与硅氧烷键合（-Si-O-Si键合）和侧链由甲基或苯基构成，平均分子量（Mz1）≤1000。在构成涂料的规定的有机硅树脂中，交联和缩聚几乎不进行，表现出与树脂原料相似的特性。例如，其涂布前后的分子量分布几乎不发生变化，软化至最低粘度达到100Pa·s以下，当温度从固态升高时，达到≤10Pa·s。

10. 发明专利

JP2012049203A Powder magnetic core, powder for magnetic core and manufacturing method for the same 审中-公开
标题翻译：粉末磁芯，磁芯用粉末及其制造方法
公开(公告)号：JP2012049203A
公开(公告)日：2012-03-08
申请号：JP2010187690
申请日：2010-08-24
申请人： Toyota Central R&D Labs Inc , Toyota Motor Corp , トヨタ自動車株式会社 , 株式会社豊田中央研究所
发明人： OTSUBO MASASHI , HATTORI TAKESHI , TANI MASAAKI , OKAMOTO DAISUKE , OISHI YUSUKE
IPC分类号： H01F1/24 , H01F27/255 , H01F41/02
摘要： PROBLEM TO BE SOLVED: To provide a powder magnetic core having high specific resistance and strength.SOLUTION: A powder magnetic core comprises a soft magnetic particle, a first coating layer which is formed of heat-hardening silicon resin and covers the surface of the soft magnetic particle, and a second coating layer which is formed of low softening point glass having a lower softening point than the annealing temperature of the soft magnetic particle and covers the surface of the first coating layer, and has high specific resistance and strength. A coating film having a two-layer structure of the first and second coating layers is formed on the surface of the soft magnetic particle constituting the powder magnetic core. These coating layers have a synergistic effect, thereby providing the powder magnetic core having both high specific resistance and high strength.
摘要翻译：要解决的问题：提供具有高电阻率和强度的粉末磁芯。解决方案：粉末磁芯包括软磁性颗粒，由加热硬化硅树脂形成并覆盖软磁性颗粒的表面的第一涂层和由低软化点形成的第二涂层具有比软磁性颗粒的退火温度低的软化点的玻璃，并且覆盖第一涂层的表面，并且具有高电阻率和强度。在构成粉末磁芯的软磁性体的表面上形成具有第一和第二涂层的两层结构的涂膜。这些涂层具有协同效应，从而提供具有高电阻和高强度的粉末磁芯。版权所有（C）2012，JPO＆INPIT

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