Soft magnetic material powder and manufacturing method thereof, and magnetic core and manufacturing method thereof

Patent metadata

Field	Value
Publication number	US-10685768-B2
Application number	US-201715434488-A
Country	US
Kind code	B2
Filing date	Feb 16, 2017
Priority date	Oct 10, 2014
Publication date	Jun 16, 2020
Grant date	Jun 16, 2020

Abstract

A soft magnetic material powder includes soft magnetic material particles, the soft magnetic material particles each include a core formed from an Fe-based soft magnetic material and an insulating film covering the surface of the core, and the insulating film contains an inorganic oxide and a water soluble polymer. A magnetic core includes soft magnetic material particles and a binder bonding the soft magnetic material particles to each other, the soft magnetic material particles each include a core containing an Fe-based soft magnetic material and an insulating film covering the surface of the core, and the insulating film contains an inorganic oxide and a water soluble polymer.

First claim

The invention claimed is:

1. A soft magnetic material powder comprising:
soft magnetic material particles,
wherein the soft magnetic material particles each include:
a core containing an Fe-based soft magnetic material;
an insulating film covers the surface of the core,
the insulating film contains an inorganic oxide and a water soluble polymer, and
the inorganic oxide and water soluble polymer are formed in the same film layer.

2. The soft magnetic material powder according to claim 1 ,
wherein the water soluble polymer is at least one selected from the group consisting of a poly(vinyl pyrrolidone), a poly(ethylene imine), a carboxymethyl cellulose, a gelatin, a poly(acrylic acid), a poly(ethylene glycol), and a poly(vinyl alcohol).

3. The soft magnetic material powder according to claim 1 ,
wherein the water soluble polymer is a poly(vinyl pyrrolidone) and is contained in a range of 0.01 to 1 percent by weight with respect to 100 percent by weight of the Fe-based soft magnetic material.

4. The soft magnetic material powder according to claim 1 ,
wherein the inorganic oxide is at least one selected from the group consisting of TiO 2 , SiO 2 , Al 2 O 3 , and ZrO.

5. The soft magnetic material powder according to claim 1 ,
wherein the inorganic oxide is SiO 2 and is contained in a range of 0.01 to 5 percent by weight with respect to 100 percent by weight of the Fe-based soft magnetic material.

6. The soft magnetic material powder according to claim 1 ,
wherein the Fe-based soft magnetic material is at least one selected from the group consisting of Fe, FeNi, FeCo, FeSi, FeSiCr, FeSiAl, and FeSiBCr.

7. A magnetic core comprising the soft magnetic material powder according to claim 1 .

8. A magnetic core comprising:
soft magnetic material particles; and
a binder which bonds the soft magnetic material particles to each other,
wherein the soft magnetic material particles each include:
a core containing an Fe-based soft magnetic material;
an insulating film covers the surface of the core,
the insulating film contains an inorganic oxide and a water soluble polymer, and
the inorganic oxide and water soluble polymer are formed in the same film layer.

9. A magnetic core comprising:
soft magnetic material particles; and
a binder which bonds the soft magnetic material particles to each other,
wherein the soft magnetic material particles each include:
a core formed from an Fe-based soft magnetic material; and
a Si-containing insulating film covering the surface of the core,
the Fe-based soft magnetic material includes Fe and Cr, and
the insulating film contains an inorganic oxide in which the amount of Si is larger than that of Cr.

10. A method for manufacturing a magnetic core, the method comprising:
mixing the soft magnetic material powder according to claim 1 and a thermosetting resin functioning as a binder to form a mixture; and
heat-curing the thermosetting resin of the mixture to obtain a magnetic core.

11. A method for manufacturing a magnetic core, the method comprising:
mixing the soft magnetic material powder according to claim 1 and a thermosetting resin functioning as a binder to form a mixture; and
after the thermosetting resin is cured by heating the mixture, performing an annealing treatment to obtain a magnetic core.

12. An electronic component comprising the magnetic core according to claim 7 .

Assignees

• Murata Manufacturing Co

Inventors

• Ishida Yuya

Classifications

• B22F1/16

  Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10) · CPC title

• B22F1/102

  Metallic powder coated with organic material · CPC title

• H01F1/33

  mixtures of metallic and non-metallic particles; metallic particles having oxide skin · CPC title

• H01F1/26

  by macromolecular organic substances · CPC title

• H01F1/147 Primary

  Alloys characterised by their composition {(treatment thereof for enhancing their electromagnetic properties C21D8/12)} · CPC title