Magnetic powder and production method thereof, magnetic core and production method thereof, coil component and motor

Patent metadata

Field	Value
Publication number	US-10758982-B2
Application number	US-201715661583-A
Country	US
Kind code	B2
Filing date	Jul 27, 2017
Priority date	Jan 30, 2015
Publication date	Sep 1, 2020
Grant date	Sep 1, 2020

Abstract

A magnetic powder is represented by general formula FeaSibBcPdCue. 71.0≤a≤81.0, 0.14≤b/c≤5, 0≤d≤14, 0<e≤1.4, d≤0.8a−50, e<−0.1(a+d)+10, and a+b+c+d+e=100. A crystallinity is not more than 30% in the case of containing an amorphous phase and a compound phase, and is not more than 60% in the case of not containing a compound phase. The magnetic powder is produced with a gas atomization method. Whereby, it is possible to obtain an alloy magnetic material which has high saturation magnetic flux density and low magnetic loss; and a magnetic core, coil components, and a motor can be realized.

First claim

The invention claimed is:

1. A magnetic powder comprising a principal component represented by a general formula Fe a Si b B c P d Cu e ,
wherein the a, the b, the c, the d, and the e satisfy:
71.0≤ a≤ 81.0,

2.0≤ b≤ 9.0,

0.14≤ b/c≤ 5,

0≤ d≤ 14,

0< e≤ 1.4,
d≤ 0.8 a− 50,
e<− 0.1( a+d )+10, and
a+b+c+d+e= 100, and

further comprising at least an amorphous phase, and a crystalline phase consisting of a compound.

2. The magnetic powder according to claim 1 , wherein saturation magnetic flux density is not less than 1.30 T.

3. A magnetic core, wherein a principal component is formed of the magnetic powder according to claim 1 .

4. The magnetic core according to claim 3 , wherein the magnetic core contains a binder, and the content of the magnetic powder is not less than 60 vol % in terms of volume ratio.

5. A coil component in which a coil conductor is wound around a core part,
wherein the core part is formed of the magnetic core according to claim 4 .

6. A coil component in which a coil conductor is buried in a magnetic part,
wherein a principal component of the magnetic part is formed of the magnetic powder according to claim 1 .

7. The coil component according to claim 6 , wherein the magnetic part contains a binder, and
the content of the magnetic powder in the magnetic part is, in terms of volume ratio, not less than 60 vol % in terms of volume ratio.

8. A motor comprising
a stator core in which a plurality of armature teeth are spaced at regular intervals on the same circumference;
a coil conductor wound around the armature teeth; and
a rotor core arranged rotatably inside the stator core,
wherein a principal component of at least one of the stator core and the rotor core is formed of the magnetic powder according to claim 1 .

9. The magnetic powder according to claim 1 , wherein the b, the c, and the d further satisfy:
1.29≤ b/c≤ 5.00, and

6.0≤ d≤ 14.

10. The magnetic powder according to claim 1 , wherein the a, the b, the c, the d, and the e further satisfy:
74.7≤ a≤ 81.0,

4.0≤ b≤ 9.0,

1.9≤ c≤ 7.0,

7.5≤ d≤ 13.0, and

0.1≤ e≤ 1.3.

11. The magnetic powder according to claim 10 , wherein the a and the d further satisfy:
9.8≤0.8 a− 50≤14.8, and

0.6≤−0.1( a+d )+10≤1.7.

12. The magnetic powder according to claim 1 , wherein the b further satisfies:
2.0≤ b≤ 6.0.

13. A magnetic powder consisting essentially of:
a principal component represented by a general formula Fe a Si b B c P d Cu e ,
wherein the a, the b, the c, the d, and the e satisfy:
71.0≤ a≤ 81.0,

2.0≤ b≤ 9.0,

0.14≤ b/c≤ 5,

6.0≤ d≤ 14,

0≤ e≤ 1.4,

d≤ 0.8 a− 50,
e<− 0.1( a+d )+10, and
a+b+c+d+e= 100.

14. The magnetic powder according to claim 13 , wherein the a, the b, the c, the d, and the e further satisfy:
74.6≤ a≤ 81.0,

4.0≤ b≤ 6.0,

1.9≤ c≤ 7.0,

1.29≤ b/c≤ 5.00,

7.5≤ d≤ 13.0,

0.1≤ e≤ 1.3,

9.8≤0.8 a− 50≤14.8, and

0.6≤−0.1( a+d )+10≤1.7.

Assignees

• Murata Manufacturing Co
• Tohoku Magnet Inst Co Ltd

Inventors

• Takahashi Toru
• Makino Akihiro
• Yodoshi Noriharu

Classifications

• B22F3/00 Primary

  Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor {; Presses and furnaces} · CPC title

• B22F9/082 Primary

  atomising using a fluid (using centrifugal force B22F9/10) · CPC title

• B22F1/08

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

• H01F1/14

  metals or alloys · CPC title

• H01F1/22

  pressed, sintered, or bound together · CPC title