Method for manufacturing magnetic body and coil component containing magnetic body

Patent metadata

Field	Value
Publication number	US-11488773-B2
Application number	US-202017121526-A
Country	US
Kind code	B2
Filing date	Dec 14, 2020
Priority date	Dec 26, 2019
Publication date	Nov 1, 2022
Grant date	Nov 1, 2022

Abstract

When manufacturing a magnetic body whose primary component is Ni—Zn ferrite, an iron oxide powder whose Mn content is 0.20 to 0.85 percent by mass is used as a raw material powder, or, in addition to using an iron oxide powder whose Mn content is 0.20 percent by mass or higher as a raw material powder, a mol ratio of Ni to Zn (Ni/Zn) in the ferrite material is determined based on the Mn content in the iron oxide powder and the raw material powders are compounded in such a way that the mol ratio is achieved. The magnetic body does not contain any additives as essential components other than the primary components of the Ni—Zn ferrite material. A coil component using the magnetic body has excellent direct-current superimposition property and magnetic permeability.

First claim

We claim:

1. A method for manufacturing a magnetic body made of a ferrite material containing Fe, Ni, and Zn, comprising:
preparing a calcinated powdery material for obtaining the ferrite material, using an iron oxide powder whose Mn content is 0.20 to 0.85 percent by mass as a raw material powder;
obtaining a compact by compressing the calcinated powdery material; and
sintering the compact to obtain the magnetic body.

2. The method for manufacturing a magnetic body according to claim 1 , wherein the ferrite material contains Fe, Zn, and Ni at following ratios in terms of Fe 2 O 3 , ZnO, and NiO:
64.4 to 67.4 percent by mass of Fe 2 O 3 ;
10.4 to 25.6 percent by mass of ZnO; and
9.4 to 23.8 percent by mass of NiO.

3. The method for manufacturing a magnetic body according to claim 1 , wherein the ferrite material further contains Cu.

4. The method for manufacturing a magnetic body according to claim 3 , wherein the ferrite material contains Fe, Zn, Ni, and Cu at following ratios in terms of Fe 2 O 3 , ZnO, NiO, and CuO:
58.9 to 66.9 percent by mass of Fe 2 O 3 ;
9.5 to 25.4 percent by mass of ZnO;
8.6 to 23.6 percent by mass of NiO; and
0.6 to 8.6 percent by mass of CuO.

5. A method for manufacturing a magnetic body made of a ferrite material containing Fe, Ni, and Zn, comprising:
providing an iron oxide powder whose Mn content is 0.20 percent by mass or higher as a raw material powder;
determining a mol ratio of Ni to Zn (Ni/Zn) in the ferrite material based on the Mn content of the iron oxide powder;
preparing other raw material powders containing Ni and Zn in a manner achieving the mol ratio in the ferrite material;
preparing a calcinated powder material for obtaining the ferrite material, using the iron oxide power and the other raw material powders;
obtaining a compact by compressing the calcinated powdery material; and
sintering the compact to obtain the magnetic body.

6. The method for manufacturing a magnetic body according to claim 5 , wherein the Mn content in the iron oxide powder is 0.85 percent by mass or lower.

7. The method for manufacturing a magnetic body according to claim 5 , wherein the ferrite material contains Fe, Zn, and Ni at following ratios in terms of Fe 2 O 3 , ZnO, and NiO:
64.4 to 67.4 percent by mass of Fe 2 O 3 ;
10.4 to 25.6 percent by mass of ZnO; and
9.4 to 23.8 percent by mass of NiO.

8. The method for manufacturing a magnetic body according to claim 5 , wherein the ferrite material further contains Cu.

9. The method for manufacturing a magnetic body according to claim 8 , wherein the ferrite material contains Fe, Zn, Ni, and Cu at following ratios in terms of Fe 2 O 3 , ZnO, NiO, and CuO:
58.9 to 66.9 percent by mass of Fe 2 O 3 ;
9.5 to 25.4 percent by mass of ZnO;
8.6 to 23.6 percent by mass of NiO; and
0.6 to 8.6 percent by mass of CuO.

10. A coil component comprising a combination of a magnetic body obtained per the method for manufacturing a magnetic body according to claim 1 , and a conductor.

11. A coil component comprising a combination of a magnetic body obtained per the method for manufacturing a magnetic body according to claim 5 , and a conductor.

Assignees

• Taiyo Yuden Kk

Inventors

• Asako Norihiro
• Yazawa Kenji
• Aoki Makoto
• Kobayashi Tomomi

Classifications

• C04B35/265

  Compositions containing one or more ferrites of the group comprising manganese or zinc and one or more ferrites of the group comprising nickel, copper or cobalt · CPC title

• C04B2235/3284

  Zinc oxides, zincates, cadmium oxides, cadmiates, mercury oxides, mercurates or oxide forming salts thereof · CPC title

• H01F27/28

  Coils; Windings; Conductive connections · CPC title

• H01F41/0246 Primary

  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

• C04B2235/3281

  Copper oxides, cuprates or oxide-forming salts thereof, e.g. CuO or Cu2O · CPC title