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

Patent metadata

Field	Value
Publication number	US-10767249-B2
Application number	US-201715661520-A
Country	US
Kind code	B2
Filing date	Jul 27, 2017
Priority date	Jan 30, 2015
Publication date	Sep 8, 2020
Grant date	Sep 8, 2020

Abstract

A magnetic powder is represented by general formula Fea(SibBcPd)100-a, and is produced with a gas atomization method. When the value of a and the value of b in the general formula is represented (a, b), (a, b) is within a predetermined region V1. Similarly, (a, c) and (a, d) are within a predetermined region, respectively. Whereby, it is possible to obtain an alloy magnetic powder which has high saturation magnetic flux density, low magnetic loss, and is spherical and easy to handle; and a magnetic core, a variety of coil components, and a motor can be realized by using the magnetic material.

First claim

The invention claimed is:

1. A magnetic powder comprising
a principal component represented by a general formula Fe a-e M e (Si b (B 1-α C α ) c P d ) 100-a ,
wherein M is one or more selected from the group consisting of Ni and Co, e is 0 to 12.0, α is 0, and b+c+d=1.00,
when representing as (a, b) the a and the b, (a, b) is within a region surrounded by A 1 ( 71 . 0 , 0 . 19 ), B 1 ( 79 . 6 , 0 ), C 1 ( 80 . 0 , 0 ), D 1 ( 81 . 0 , 0 . 17 ), E 1 ( 81 . 0 , 0 . 44 ), F 1 ( 79 . 6 , 0 . 78 ) and G 1 ( 71 . 0 , 0 . 38 ),
when representing as (a, c) the a and the c, (a, c) is within a region surrounded by A 2 ( 71 . 0 , 0 . 48 ), B 2 ( 78 . 1 , 0 ), C 2 ( 79 . 6 , 0 ), D 2 ( 81 . 0 , 0 . 18 ), E 2 ( 81 . 0 , 0 . 26 ), F 2 ( 79 . 1 , 0 . 75 ) and G 2 ( 71 . 0 , 0 . 72 ), and
when representing as (a, d) the a and the d, (a, d) is within a region surrounded by A 3 ( 71 . 0 , 0 . 08 ), B 3 ( 71 . 9 , 0 ), C 3 ( 79 . 1 , 0 ), D 3 ( 81 . 0 , 0 . 36 ), E 3 ( 81 . 0 , 0 . 62 ), F 3 ( 77 . 2 , 0 . 67 ) and G 3 ( 71 . 0 , 0 . 23 ).

2. The magnetic powder according to claim 1 , wherein e=0.

3. The magnetic powder according to claim 2 , wherein the a is 77.0 to 81.0, the b is 0.1 to 0.78, the c is 0 to 0.75, and the d is 0.05 to 0.67.

4. The magnetic powder according to claim 2 , wherein the c is 0 to 0.30.

5. The magnetic powder according to claim 1 , wherein crystallinity measured by an X-ray diffraction method is at least 0% and not more than 30%.

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

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

8. The magnetic core according to claim 7 , 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.

9. 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 7 .

10. 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 .

11. The coil component according to claim 10 , wherein the magnetic part contains a binder, and
the content of the magnetic powder in the magnetic part is not less than 60 vol % in terms of volume ratio.

12. 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 the principal component of at least one of the stator core and the rotor core is formed of the magnetic powder according to claim 1 .

13. The magnetic powder according to claim 1 , wherein the a is 77.0 to 81.0, the b is 0.1 to 0.78, the c is 0 to 0.75, and the d is 0.05 to 0.67.

14. The magnetic powder according to claim 1 , wherein the c is 0 to 0.30.

15. The magnetic powder according to claim 1 , wherein the magnetic powder is produced with a gas atomization method.

16. A magnetic powder consisting essentially of: a principal component represented by a general formula Fe a-e M e (Si b (B 1-α C α ) c P d ) 100-a , in which M is one or more selected from the group consisting of Ni and Co, e is 0 to 12.0, α is 0, and b+c +d=1.00,
when representing as (a, b) the a and the b, (a, b) is within a region surrounded by A 1 ( 71 . 0 , 0 . 19 ), B 1 ( 79 . 6 , 0 ), C 1 ( 80 . 0 , 0 ), D 1 ( 81 . 0 , 0 . 17 ), E 1 ( 81 . 0 , 0 . 44 ), F 1 ( 79 . 6 , 0 . 78 ) and G 1 ( 71 . 0 , 0 . 38 ),
when representing as (a, c) the a and the c, (a, c) is within a region surrounded by A 2 ( 71 . 0 , 0 . 48 ), B 2 ( 78 . 1 , 0 ), C 2 ( 79 . 6 , 0 ), D 2 ( 81 . 0 , 0 . 18 ), E 2 ( 81 . 0 , 0 . 26 ), F 2 ( 79 . 1 , 0 . 75 ) and G 2 ( 71 . 0 , 0 . 72 ), and
when representing as (a, d) the a and the d, (a, d) is within a region surrounded by A 3 ( 71 . 0 , 0 . 08 ), B 3 ( 71 . 9 , 0 ), C 3 ( 79 . 1 , 0 ), D 3 ( 81 . 0 , 0 . 36 ), E 3 ( 81 . 0 , 0 . 62 ), F 3 ( 77 . 2 , 0 . 67 ) and G 3 ( 71 . 0 , 0 . 23 ).

17. The magnetic powder according to claim 16 , wherein a is 77.0 to 81.0, b is 0.1 to 0.78, c is 0 to 0.30, d is 0.05 to 0.67, and e is 0.

Assignees

• Murata Manufacturing Co
• Tohoku Magnet Inst Co Ltd

Inventors

• Takahashi Toru
• Henmi Kazuhiro
• Makino Akihiro
• Yodoshi Noriharu

Classifications

• B22F1/08

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

• B22F3/00

  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

• H01F1/153

  Amorphous metallic alloys, e.g. glassy metals {(making ferrous amorphous alloys C22C33/003)} · CPC title

• H01F1/22

  pressed, sintered, or bound together · CPC title

• B22F9/08

  by casting, e.g. through sieves or in water, by atomising or spraying (using electric discharge B22F9/14) · CPC title