Soft magnetic alloy powder, dust core, and magnetic component

Patent metadata

Field	Value
Publication number	US-11145448-B2
Application number	US-201916296378-A
Country	US
Kind code	B2
Filing date	Mar 8, 2019
Priority date	Mar 9, 2018
Publication date	Oct 12, 2021
Grant date	Oct 12, 2021

Abstract

A soft magnetic alloy powder includes a plurality of soft magnetic alloy particles of a soft magnetic alloy represented by a composition formula (Fe (1−(α+β)) X1 α X2 β ) (1−(a+b+c+d+e)) M a B b P c Si d C e , wherein X1 represents Co and/or Ni; X2 represents at least one selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O, and rare earth elements; M represents at least one selected from the group consisting of Nb, Hf, Zr, Ta, Mo, W, and V; 0.020≤a≤0.14, 0.020<b≤0.20, 0<c≤0.15, 0≤d≤0.060, 0≤e≤0.040, α≥0, β≥0, and 0≤α+β≤0.50 are satisfied, and wherein the soft magnetic alloy has a nano-heterostructure with initial fine crystals present in an amorphous substance; and the surface of each of the soft magnetic alloy particles is covered with a coating portion including a compound of at least one element selected from the group consisting of P, Si, Bi, and Zn.

First claim

What is claimed is:

1. A soft magnetic alloy powder comprising a plurality of soft magnetic alloy particles of a soft magnetic alloy represented by a composition formula (Fe (1−(α+β)) X1 α X2 β ) (1−(a+b+c+d+e)) M a B b P c Si d C e , wherein
X1 represents at least one selected from the group consisting of Co and Ni;
X2 represents at least one selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O and rare earth elements;
M represents at least one selected from the group consisting of Nb, Hf, Zr, Ta, Mo, W and V;
a, b, c, d, e, α and β satisfy the following relations:
0.020≤a≤0.14,
0.020<b≤0.20,
0<c≤0.15,
0≤d≤0.060,
0≤e≤0.040,
α≥0,
β≥0, and
0≤α+β≤0.50; and wherein
the soft magnetic alloy has a nano-heterostructure with initial fine crystals present in an amorphous substance;
the surface of each of the soft magnetic alloy particles is covered with a coating portion;
the coating portion comprises at least one selected from the group consisting of P 2 O 5 —ZnO—R 2 O—Al 2 O 3 glass where R represents an alkali metal, Bi 2 O 3 —ZnO—B 2 O 3 —SiO 2 glass and BaO—ZnO—B 2 O 3 —SiO 2 —Al 2 O 3 glass;
a thickness of the coating portion is 5 nm or more and 200 nm or less; and
a resistivity of the soft magnetic alloy powder when a pressure of 0.6 t/cm 2 is applied to the soft magnetic alloy powder is 10 4 Ωcm or more.

2. The soft magnetic alloy powder according to claim 1 , wherein the initial fine crystal has an average grain size of 0.3 nm or more and 10 nm or less.

3. A soft magnetic alloy powder comprising a plurality of soft magnetic alloy particles of a soft magnetic alloy represented by a composition formula (Fe (1−(α+β)) X1 α X2 β ) (1−(a+b+c+d+e)) M a B b P c Si d C e , wherein
X1 represents at least one selected from the group consisting of Co and Ni;
X2 represents at least one selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O and rare earth elements;
M represents at least one selected from the group consisting of Nb, Hf, Zr, Ta, Mo, W and V;
a, b, c, d, e, α and β satisfy the following relations:
0.020≤a≤0.14,
0.020<b≤0.20,
0<c≤0.15,
0≤d≤0.060,
0≤e≤0.040,
α≥0,
β≥0, and
0≤α+β≤0.50;
the soft magnetic alloy has an Fe-based nanocrystal;
the surface of each of the soft magnetic alloy particles is covered with a coating portion;
the coating portion comprises at least one selected from the group consisting of P 2 O 5 —ZnO—R 2 O—Al 2 O 3 glass where R represents an alkali metal, Bi 2 O 3 —ZnO—B 2 O 3 —SiO 2 glass and BaO—ZnO—B 2 O 3 —SiO 2 —Al 2 O 3 glass;
a thickness of the coating portion is 5 nm or more and 200 nm or less; and
a resistivity of the soft magnetic alloy powder when a pressure of 0.6 t/cm 2 is applied to the soft magnetic alloy powder is 10 4 Ωcm or more.

4. The soft magnetic alloy powder according to claim 3 , wherein the Fe-based nanocrystal has an average grain size of 5 nm or more and 30 nm or less.

5. A dust core comprising the soft magnetic alloy powder according to claim 1 .

6. A dust core comprising the soft magnetic alloy powder according to claim 3 .

7. A magnetic component comprising the dust core according to claim 5 .

8. A magnetic component comprising the dust core according to claim 6 .

9. The soft magnetic alloy powder according to claim 1 , wherein the resistivity of the soft magnetic alloy powder when a pressure of 0.6 t/cm 2 is applied to the soft magnetic alloy powder is 10 5 Ωcm or more.

10. The soft magnetic alloy powder according to claim 3 , wherein the resistivity of the soft magnetic alloy powder when a pressure of 0.6 t/cm 2 is applied to the soft magnetic alloy powder is 10 5 Ωcm or more.

11. The soft magnetic alloy powder according to claim 1 , wherein the resistivity of the soft magnetic alloy powder when a pressure of 0.6 t/cm 2 is applied to the soft magnetic alloy powder is 10 6 Ωcm or more.

12. The soft magnetic alloy powder according to claim 3 , wherein the resistivity of the soft magnetic alloy powder when a pressure of 0.6 t/cm 2 is applied to the soft magnetic alloy powder is 10 6 Ωcm or more.

13. The soft magnetic alloy powder according to claim 1 , wherein the thickness of the coating portion is 5 nm or more and 150 nm or less.

14. The soft magnetic alloy powder according to claim 1 , wherein the thickness of the coating portion is 5 nm or more and 50 nm or less.

15. The soft magnetic alloy powder according to claim 3 , wherein the thickness of the coating portion is 5 nm or more and 150 nm or less.

16. The soft magnetic alloy powder according to claim 3 , wherein the thickness of the coating portion is 5 nm or more and 50 nm or less.

Assignees

• Tdk Corp

Inventors

• Hosono Masakazu
• Horino Kenji
• Matsumoto Hiroyuki
• Yoshidome Kazuhiro
• Hasegawa Akito
• Amano Hajime
• Nakahata Isao

Classifications

• B22F1/08

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

• B22F1/16

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

• C22C2200/04

  Nanocrystalline · CPC title

• C22C45/008

  with Fe, Co or Ni as the major constituent (C22C45/02, C22C45/04 take precedence) · CPC title

• B22F2304/054

  Particle size between 1 and 100 nm · CPC title