Plurality of flaky magnetic metal particles, pressed powder material, and rotating electric machine

Patent metadata

Field	Value
Publication number	US-10774404-B2
Application number	US-201715693704-A
Country	US
Kind code	B2
Filing date	Sep 1, 2017
Priority date	Mar 13, 2017
Publication date	Sep 15, 2020
Grant date	Sep 15, 2020

Abstract

Provided is a plurality of flaky magnetic metal particles of the embodiments, each flaky magnetic metal particle having a flat surface provided with either or both of a plurality of concavities and a plurality of convexities arranged in a first direction, each concavity or convexity having a width of 0.1 μm or more, a length of 1 μm or more, and an aspect ratio of 2 or higher; and at least one first element selected from the group consisting of iron (Fe), cobalt (Co), and nickel (Ni), the flaky magnetic metal particles having an average thickness of between 10 nm and 100 μm inclusive and an average aspect ratio of between 5 and 10,000 inclusive.

First claim

What is claimed is:

1. A plurality of flaky magnetic metal particles, each flaky magnetic metal particle comprising a flat surface; and a magnetic metal phase containing at least one first element selected from the group consisting of Fe, Co, and Ni,
the flaky magnetic metal particles having an average thickness of between 10 nm and 100 μm inclusive and an average aspect ratio of between 5 and 10,000 inclusive, and having a difference in coercivity on the basis of direction within the flat surface, wherein the proportion of the difference in coercivity on the basis of direction within the flat surface is 1% or higher.

2. The flaky magnetic metal particles according to claim 1 , wherein the crystal grain size of the magnetic metal phase is 10 nm or less.

3. The flaky magnetic metal particles according to claim 1 , wherein the magnetic metal phase contains at least one additive element selected from the group consisting of boron (B), silicon (Si), aluminum (Al), carbon (C), titanium (Ti), zirconium (Zr), hafnium (Hf), niobium (Nb), tantalum (Ta), molybdenum (Mo), chromium (Cr), copper (Cu), tungsten (W), phosphorus (P), nitrogen (N), gallium (Ga), and yttrium (Y).

4. The flaky magnetic metal particles according to claim 1 , wherein the flat surface has either or both of a plurality of concavities and a plurality of convexities arranged in a first direction, each concavity or convexity having a width of 0.1 μm or more, a length of 1 μm or more, and an aspect ratio of 2 or higher, and wherein the plurality of concavities and the plurality of convexities are confined by a perimeter of the flat surface.

5. The flaky magnetic metal particles according to claim 1 , wherein the lattice strain of the flaky magnetic metal particles is between 0.01% and 10% inclusive.

6. The flaky magnetic metal particles according to claim 1 , wherein the flaky magnetic metal particles having a body-centered cubic crystal structure.

7. The flaky magnetic metal particles according to claim 1 , wherein the flat surface has the (110) plane orientation or the (111) plane orientation.

8. The flaky magnetic metal particles according to claim 1 , wherein the ratio of the maximum length with respect to the minimum length within the flat surface is between 1 and 5 inclusive on the average, and
each of the flaky magnetic metal particles further comprises a plurality of small magnetic metal particles on the flat surface, the number of the small magnetic metal particles disposed on the flat surface being 5 or more on the average, and the small magnetic metal particles containing at least one of the first elements and having an average particle size of between 10 nm and 1 μm inclusive.

9. The flaky magnetic metal particles according to claim 1 , wherein at least a portion of the surface of the flaky magnetic metal particles is coated with a coating layer having a thickness of between 0.1 nm and 1 μm inclusive and containing at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F).

10. A pressed powder material comprising:
a plurality of flaky magnetic metal particles, each flaky magnetic metal particle having a flat surface and a magnetic metal phase containing at least one first element selected from the group consisting of Fe, Co, and Ni, the flay magnetic metal particles having an average thickness of between 10 nm and 100 μm inclusive and an average aspect ratio of between 5 and 10,000 inclusive; and
an interposed phase existing between the flaky magnetic metal particles and containing at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F),
the flat surfaces of the flaky magnetic metal particles in the pressed powder material being oriented parallel to a plane of the pressed powder material, and the pressed powder material having a difference in coercivity on the basis of direction within the plane wherein the proportion of the difference in coercivity on the basis of direction within the plane of the pressed powder material is 1% or higher.

11. The pressed powder material according to claim 10 , wherein the crystal grain size of the magnetic metal phase is 10 nm or less.

12. The pressed powder material according to claim 10 , wherein the magnetic metal phase contains at least one additive element selected from the group consisting of B, Si, Al, C, Ti, Zr, Hf, Nb, Ta, Mo, Cr, Cu, W, P, N, Ga, and Y.

13. The pressed powder material according to claim 10 , wherein the flat surfaces of the flaky magnetic metal particles have either or both of a plurality of concavities and a plurality of convexities arranged in a first direction, each concavity or convexity having a width of 0.1 μm or more, a length of 1 μm or more, and an aspect ratio of 2 or higher.

14. The pressed powder material according to claim 10 , wherein the lattice strain of the flaky magnetic metal particles is between 0.01% and 10% inclusive.

15. The pressed powder material according to claim 10 , wherein the flaky magnetic metal particles have a body-centered cubic crystal structure.

16. The pressed powder material according to claim 10 , wherein the flat surfaces of the flaky magnetic metal particles have the (110) plane orientation or the (111) plane orientation.

17. The pressed powder material according to claim 10 , wherein the ratio of the maximum length with respect to the minimum length within the flat surface of a flaky magnetic metal particle is between 1 and 5 inclusive on the average, and each of the flaky magnetic metal particles further include a plurality of small magnetic metal particles on the flat surface, the number of the small magnetic metal particles disposed on the flat surface being 5 or more on the average, and the small magnetic metal particles containing at least one of the first elements and having an average particle size of between 10 nm and 1 μm inclusive.

18. A rotating electric machine comprising the pressed powder material according to claim 10 .

Assignees

• Toshiba Kk

Inventors

• Suetsuna Tomohiro
• Kinouchi Hiroaki
• Kawamoto Takahiro

Classifications

• C21D8/02

  during manufacturing of plates or strips (C21D8/12 takes precedence) · CPC title

• H01F1/26

  by macromolecular organic substances · CPC title

• H01F41/0246

  Manufacturing of magnetic circuits by moulding or by pressing powder (magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36) · CPC title

• H02K15/00

  Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines · CPC title

• H02K1/02

  characterised by the magnetic material · CPC title