Insulator-coated soft magnetic powder, powder magnetic core, magnetic element, electronic device, and vehicle

Patent metadata

Field	Value
Publication number	US-11348712-B2
Application number	US-201816145304-A
Country	US
Kind code	B2
Filing date	Sep 28, 2018
Priority date	Sep 29, 2017
Publication date	May 31, 2022
Grant date	May 31, 2022

Abstract

An insulator-coated soft magnetic powder includes a plurality of particles each including a core which contains a soft magnetic material, and an insulating layer which is provided on the surface of the core and contains a glass material including Bi2O3 as a main component. The content of an alkali metal in the insulating layer is 5 mol % or less. The glass material further contains at least one of ZnO and B2O3. The content of Bi2O3 in the glass material is 40 mol % or more and 80 mol % or less.

First claim

What is claimed is:

1. An insulator-coated soft magnetic powder, comprising a plurality of particles, each particle including:
a core which contains a soft magnetic material; and
an insulating layer which is provided on an entire outer surface of the core, the insulating layer containing a glass material including Bi 2 O 3 as a main component, an amount of Bi 2 O 3 being 40 mol % or more and 65 mol % or less,
wherein the insulating layer contains 5 mol % or less of an alkali metal.

2. The insulator-coated soft magnetic powder according to claim 1 , wherein the glass material further contains at least one of ZnO and B 2 O 3 .

3. The insulator-coated soft magnetic powder according to claim 1 , wherein the plurality of particles have an average particle diameter of 1 μm or more and 50 μm or less.

4. A powder magnetic core, comprising:
the insulator-coated soft magnetic powder according to claim 1 ;
a binder; and
an organic solvent.

5. A magnetic element, comprising:
the powder magnetic core according to claim 4 ; and
a conductive wire operatively associated with the powder magnetic core.

6. An electronic device, comprising:
the magnetic element according to claim 5 ;
a housing; and
a display.

7. A vehicle, comprising:
the magnetic element according to claim 6
a body; and
a propulsion system.

8. An insulator-coated soft magnetic powder, comprising a plurality of particles, each particle including:
a core which contains a soft magnetic material; and
an insulating layer which is provided on an entire outer surface of the core, the insulating layer containing Bi 2 O 3 as a main component, an amount of the Bi 2 O 3 being 40 mole % or more and 65 mole % or less,
wherein the insulating layer contains 5 mol % or less of an alkali metal.

9. The insulator-coated soft magnetic powder according to claim 8 , wherein the soft magnetic material further comprises an Fe based alloy.

10. The insulator-coated soft magnetic powder according to claim 8 , wherein the insulating layer further contains at least one of ZnO and B 2 O 3 .

11. The insulator-coated soft magnetic powder according to claim 10 , wherein a content of ZnO in the insulating layer is 15 mol % or more and 70 mol % or less with respect to a content of the Bi 2 O 3 .

12. The insulator-coated soft magnetic powder according to claim 10 , wherein a content of B 2 O 3 in the insulating layer is 15 mol % or more and 70 mol % or less with respect to a content of the Bi 2 O 3 .

13. The insulator-coated soft magnetic powder according to claim 10 , wherein the insulating layer contains both the ZnO and the B 2 O 3 and a ratio of a mol % content of the B 2 O 3 to a mol % content of the ZnO is 0.7 or more and 1.1 or less.

14. The insulator-coated soft magnetic powder according to claim 10 , wherein the insulating layer further contains least one of SiO 2 and Al 2 O 3 at a content less than that of the at least one of ZnO and B 2 O 3 .

15. The insulator-coated soft magnetic powder according to claim 8 , wherein the insulating layer has a softening point of 250° C. or higher and 600° C. or lower.

16. The insulator-coated soft magnetic powder according to claim 8 , wherein each insulating particle further includes 10 mass % or less of an electrically non-conductive inorganic material.

17. The insulator-coated soft magnetic powder according to claim 8 , wherein the plurality of particles have an average particle diameter of 0.3 μm or more and 20 μm or less.

18. The insulator-coated soft magnetic powder according to claim 8 , wherein the insulating layer is mechanically adhered to the core.

Assignees

• Seiko Epson Corp

Inventors

• Sato Toshikuni
• Nakamura Atsushi

Classifications

• B22F1/16

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

• B22F1/05

  Metallic powder characterised by the size or surface area of the particles · CPC title

• H01F1/24 Primary

  the particles being insulated · CPC title

• H01F3/08

  made from powder (powder coatings on sheets H01F3/02; on strips or ribbons H01F3/04; on wires H01F3/06) · CPC title

• H01F27/2823

  Wires (H01F27/2866 takes precedence) · CPC title