Mixed magnetic powders and the electronic device using the same

Patent metadata

Field	Value
Publication number	US-10144995-B2
Application number	US-201815989206-A
Country	US
Kind code	B2
Filing date	May 25, 2018
Priority date	Sep 24, 2014
Publication date	Dec 4, 2018
Grant date	Dec 4, 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. A magnetic powder for mixing with a corresponding magnetic powder to make a magnetic body, wherein each of said magnetic powder and said corresponding magnetic powder is made of a soft magnetic material, and the average particle diameter of said magnetic powder is greater than that of said corresponding magnetic powder, wherein the ratio of the D50 of said magnetic powder to the D50 of said corresponding magnetic powder is in the range of 5 to 12, wherein said magnetic powder weighs 50 to 90 percent of the total weight of said magnetic powder and said corresponding magnetic powder, and said corresponding magnetic powder weighs 10 to 50 percent of the total weight of said magnetic powder and said corresponding magnetic powder, wherein the D50 of said magnetic powder is in the range of 17 to 36 um, the D10 of said magnetic powder is in the range of 8 to 26 um, and the D90 of said magnetic powder is in the range of 30 to 52 um, for pairing with a corresponding D50, D10 and D90 of said corresponding magnetic powder to increase the density of the magnetic body.

2. The magnetic powder according to claim 1 , wherein each of said magnetic powder and said corresponding magnetic powder is made of amorphous alloy.

3. The magnetic powder according to claim 1 , wherein said magnetic powder weighs 60 to 80 percent of the total weight of said magnetic powder and said corresponding magnetic powder and said corresponding magnetic powder weighs 20 to 40 percent of the total weight of said magnetic powder and said corresponding magnetic powder.

4. The magnetic powder according to claim 1 , wherein said magnetic powder weighs 60 to 70 percent of the total weight of said magnetic powder and said corresponding magnetic powder and said corresponding magnetic powder weighs 30 to 40 percent of the total weight of said magnetic powder and said corresponding magnetic powder.

5. The magnetic powder according to claim 1 , wherein the D50 of said magnetic powder is in the range of 20 to 34 um and the D50 of said corresponding magnetic powder is in the range of 1.8 to 3.2 um.

6. The magnetic powder according to claim 1 , wherein the D50 of said magnetic powder is in the range of 17 to 20 um and the D50 of said corresponding magnetic powder is in the range of 1.0 to 1.8 um.

7. The magnetic powder according to claim 1 , wherein the ratio of the D50 of said magnetic powder to the D50 of said corresponding magnetic powder is in the range of 6 to 9.

8. The magnetic powder according to claim 1 , wherein the ratio of the D50 of said magnetic powder to the D50 of said corresponding magnetic powder is in the range of 10 to 12.

9. The magnetic powder according to claim 1 , wherein each of said magnetic powder and said corresponding magnetic powder is made of iron powders.

10. The magnetic powder according to claim 1 , wherein said magnetic powder is made of amorphous alloy powder, wherein said magnetic powder comprises 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.

11. The magnetic powder according to claim 1 , wherein the ratio of the number of particles of said magnetic powder at D50 to the number of particles of said magnetic powder at D10 is greater than 2, and the ratio of the number of particles of said magnetic powder at D50 to the number of particles of said magnetic powder at D90 is greater than 1.

12. The magnetic powder according to claim 1 , wherein the ratio of the number of particles of said magnetic powder at D50 to the number of particles of said magnetic powder at D10 is greater than 3, and the ratio of the number of particles of said magnetic powder at D50 to the number of particles of said magnetic powder at D90 is greater than 1.5.

13. A method for making a magnetic body, said method comprising:
forming a first magnetic powder;
forming 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; and
mixing the first magnetic powder and the second magnetic powder for making the magnetic body, wherein the D50 of the first magnetic powder is in the range of 17 to 36 um, the D10 of the first magnetic powder is in the range of 8 to 26 um, and the D90 of the first magnetic powder is in the range of 30 to 52 um, for pairing with a corresponding D50, D10 and D90 of the second magnetic powder to increase the density of the magnetic body.

14. The method according to claim 13 , wherein each of the first magnetic powder and the second magnetic powder is made of amorphous alloy.

15. The method according to claim 13 , wherein the ratio of the D50 of the first magnetic powder to the D50 of the second magnetic powder is in the range of 6 to 9.

16. The method according to claim 13 , 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 2, 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.

17. The method according to claim 13 , 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.

18. The method according to claim 13 , wherein each of the first magnetic powder and the second magnetic powder is made of iron powders.

19. An electronic device, comprising:
a magnetic body, comprising:
a first magnetic powder; and
a second magnetic powder, mixed with the first 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, the D10 of the first magnetic powder is in the range of 8 to 26 um, and the D90 of the first magnetic powder is in the range of 30 to 52 um, for pairing with a corresponding D50, D10 and D90 of the second magnetic powder to increase the density of the magnetic body; and
a wire, disposed in the magnetic body.

20. The electronic device according to claim 19 , wherein the electronic device is an inductor.

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

• C22C38/34

  with more than 1.5% by weight of silicon · CPC title

• C22C38/02

  containing silicon · CPC title

• C22C2200/02

  Amorphous · CPC title