Mixed magnetic powders and the electronic device using the same

Patent metadata

Field	Value
Publication number	US-10006110-B2
Application number	US-201715603460-A
Country	US
Kind code	B2
Filing date	May 24, 2017
Priority date	Sep 24, 2014
Publication date	Jun 26, 2018
Grant date	Jun 26, 2018

Abstract

Mixed magnetic powders for making a magnetic core or body is disclosed, wherein the mixed magnetic powders comprises a first magnetic powder and a second magnetic powder, each of the first magnetic powder and the second magnetic powder being made of a soft magnetic material, wherein the average particle diameter of the first magnetic powder is greater than that of the second magnetic powder, and each of the first magnetic powder and the second magnetic powder has a pre-configured particle size distribution for increasing the density of the magnetic body.

First claim

What is claimed is:

1. Mixed magnetic powders for making a magnetic body, comprising:
a first magnetic powder; and
a second magnetic powder, wherein each of the first magnetic powder and the second magnetic powder is made of a soft magnetic material, and the average particle diameter of the first magnetic powder is greater than that of the second magnetic powder, wherein the ratio of the D50 of the first magnetic powder to the D50 of the second magnetic powder is in the range of 5 to 12, wherein the first magnetic powder weighs 50 to 90 percent of the total weight of the first magnetic powder and the second magnetic powder, and the second magnetic powder weighs 10 to 50 percent of the total weight of the first magnetic powder and the second magnetic powder, wherein the D50 of the first magnetic powder is in the range of 17 to 36 um and the D50 of the second magnetic powder is in the range of 1.0 to 3.5 um; the D10 of the first magnetic powder is in the range of 8 to 26 um and the D10 of the second magnetic powder is in the range of 0.5 to 1.7 um; and the D90 of the first magnetic powder is in the range of 30 to 52 um and the D90 of the second magnetic powder is in the range of 2.8 to 5.6 um.

2. The mixed magnetic powders according to claim 1 , wherein each of the first magnetic powder and the second magnetic powder is made of amorphous alloy.

3. The mixed magnetic powders according to claim 1 , wherein the first magnetic powder weighs 60 to 80 percent of the total weight of the first magnetic powder and the second magnetic powder and the second magnetic powder weighs 20 to 40 percent of the total weight of the first magnetic powder and the second magnetic powder.

4. The mixed magnetic powders according to claim 1 , wherein the first magnetic powder weighs 60 to 70 percent of the total weight of the first magnetic powder and the second magnetic powder; and the second magnetic powder weighs 30 to 40 percent of the total weight of the first magnetic powder and the second magnetic powder.

5. The mixed magnetic powders according to claim 1 , wherein the mixed magnetic powders are made of amorphous alloy powder, wherein the weight ratio of the first magnetic powder and the second magnetic powder is substantially at 6:4 and the ratio of the D50 of the first magnetic powder to the D50 of the second magnetic powder is greater than 8.97.

6. The mixed magnetic powders according to claim 1 , wherein the mixed magnetic powders are made of amorphous alloy powder, wherein the weight ratio of the first magnetic powder and the second magnetic powder is substantially at 7:3 and the ratio of the D50 of the first magnetic powder to the D50 of the second magnetic powder is less than 8.97.

7. The mixed magnetic powders according to claim 3 , wherein the D50 of the first magnetic powder is in the range of 20 to 34 um and the D50 of the second magnetic powder is in the range of 1.8 to 3.2 um.

8. The mixed magnetic powders according to claim 1 , wherein the D50 of the first magnetic powder is in the range of 17 to 20 um and the D50 of the second magnetic powder is in the range of 1.0 to 1.8 um.

9. The mixed magnetic powders according to claim 1 , wherein the D50 of the first magnetic powder is in the range of 20 to 34 um and the D50 of the second magnetic powder is in the range of 1.8 to 3.2 um; the D10 of the first magnetic powder is in the range of 10˜23 um and the D10 of the second magnetic powder is in the range of 1˜1.7 um; and the D90 of the first magnetic powder is in the range of 3˜52 um and the D90 of the second magnetic powder is in the range of 3.5 to 5.6 um.

10. The mixed magnetic powders according to claim 1 , wherein the D50 of the first magnetic powder is in the range of 17 to 20 um and the D50 of the second magnetic powder is in the range of 1.0 to 1.8 um; the D10 of the first magnetic powder is in the range of 8˜10 um and the D10 of the second magnetic powder is in the range of 0.5˜1.0 um; and the D90 of the first magnetic powder is in the range of 30˜36 um and the D90 of the second magnetic powder is in the range of 2.8 to 3.5 um.

11. The mixed magnetic powders according to claim 1 , wherein the ratio of the D50 of the first magnetic powder to the D50 of the second magnetic powder is in the range of 10 to 12, wherein the ratio of the number of particles of the first magnetic powder at D50 to the number of particles of the first magnetic powder at D10 is greater than 3 and the ratio of the number of particles of the first magnetic powder at D50 to the number of particles of the first magnetic powder at D90 is greater than 1.5, and wherein the ratio of the number of particles of the second magnetic powder at D50 to the number of particles of the second magnetic powder at D10 is greater than 3 and the ratio of the number of particles of the second magnetic powder at D50 to the number of particles of the second magnetic powder at D90 is greater than 1.3.

12. The mixed magnetic powders according to claim 1 , wherein the mixed magnetic powders are made of iron powders.

13. The mixed magnetic powders according to claim 1 , wherein the mixed magnetic powders are made of amorphous alloy powder, wherein the first magnetic power comprising 0.5˜1 wt % C, 6.2˜7.2 wt % Si, 0˜3.0 wt % Cr, 2.2˜2.8 wt % B, and the rest is Fe, wherein 0% is less than 5000 ppm, and wherein the second magnetic power comprising 0.5˜1 wt % C, 5.7˜7.7 wt % Si, 0˜3.0 wt % Cr, 2.0˜3.0 wt % B, and the rest is Fe, wherein 0% is less than 10000 ppm.

14. An electronic device, comprising:
a magnetic body, comprising:
a first magnetic powder; and
a second magnetic powder, wherein each of the first magnetic powder and the second magnetic powder is made of a soft magnetic material, and the average particle diameter of the first magnetic powder is greater than that of the second magnetic powder, wherein the ratio of the D50 of the first magnetic powder to the D50 of the second magnetic powder is in the range of 5 to 12, wherein the first magnetic powder weighs 50 to 90 percent of the total weight of the first magnetic powder and the second magnetic powder, and the second magnetic powder weighs 10 to 50 percent of the total weight of the first magnetic powder and the second magnetic powder, wherein the D50 of the first magnetic powder is in the range of 17 to 36 um and the D50 of the second magnetic powder is in the range of 1.0 to 3.5 um; the D10 of the first magnetic powder is in the range of 8 to 26 um and the D10 of the second magnetic powder is in the range of 0.5 to 1.7 um; and the D90 of the first magnetic powder is in the range of 30 to 52 um and the D90 of the second magnetic powder is in the range of 2.8 to 5.6 um; and
a wire, disposed in the magnetic body.

15. The electronic device according to claim 14 , wherein each of the first magnetic powder and the second magnetic powder is made of iron.

16. The electronic device according to claim 14 , wherein each of the first magnetic powder and the second magnetic powder is made of metal alloy.

17. The electronic device according to claim 14 , wherein each of the first magnetic powder and the second magnetic powder is made of amorphous alloy.

18. The electronic device according to claim 14 , wherein said electronic device is an inductor.

19. Mixed magnetic powders for making a magnetic body, comprising:
a first magnetic powder; and
a second magnetic powder, wherein each of the first magnetic powder and the second magnetic powder is made of a soft magnetic material, and the average particle diameter of the first magnetic powder is greater than that of th

Assignees

• Cyntec Co Ltd

Inventors

• Lin Lu-Kuei
• Chien Shih-Feng
• Wu Po-I

Classifications

• B22F1/052

  characterised by a mixture of particles of different sizes or by the particle size distribution · CPC title

• B22F1/08

  Metallic powder characterised by particles having an amorphous microstructure · CPC title

• C22C38/02

  containing silicon · CPC title

• H01F2017/048

  with encapsulating core, e.g. made of resin and magnetic powder · CPC title

• C22C45/02

  with iron as the major constituent · CPC title