Soft magnetic alloy and magnetic component

Patent metadata

Field	Value
Publication number	US-11495377-B2
Application number	US-201916971338-A
Country	US
Kind code	B2
Filing date	Feb 15, 2019
Priority date	Feb 21, 2018
Publication date	Nov 8, 2022
Grant date	Nov 8, 2022

Abstract

Provided is a soft magnetic alloy which has high saturation flux density and low coercivity and is represented by the compositional formula (Fe (1−(α+β)) X1 α X2 β ) (1−(a+b+c+d+e+f)) M a P b Si c Cu d X3 e B f , wherein X1 is at least one element selected from the group consisting of Co and Ni, X2 is at least one element selected from the group consisting of Ti, V, Mn, Ag, Zn, Al, Sn, As, Sb, Bi, and rare earth elements, X3 is at least one element selected from the group consisting of C and Ge, and M is at least one element selected from the group consisting of Zr, Nb, Hf, Ta, Mo, and W, and wherein 0.030≤a≤0.120, 0.010≤b≤0.150, 0≤c≤0.050, 0≤d≤0.020, 0≤e≤0.100, 0≤f≤0.030, α≥0, β≥0, and 0≤α+β≤0.55.

First claim

What is claimed is:

1. A soft magnetic alloy represented by a compositional formula (Fe (1−(α+β)) X1 α X2 β ) (1−(a+b+c+d++e+f) M a P b Si c Cu d X3 e B f having a structure including Fe-based nanocrystals, in which
X1 represents one or more selected from a group consisting of Co and Ni,
X2 represents one or more selected from a group consisting of V, Mn, Zn, Al, Sn, and La,
X3 represents one or more selected from a group consisting of C and Ge,
M represents one or more selected from a group consisting of Zr, Nb, Hf, Ta, Mo, and W,
030≤a≤0.120,
0.010≤b≤0.150,
0≤c≤0.050,
0≤d≤0.020,
0≤e≤0.100,
0≤f≤0.020,
0≤α{1−(a+b+c+d+e+f)}≤0.500,
0≤β{1−(a+b+c+d+e+f)}≤0.30,
0≤α+β≤0.55 are satisfied, and
an average grain size of the Fe-based nanocrystals is 5 to 30 nm.

2. The soft magnetic alloy according to claim 1 , wherein b ≥c is satisfied.

3. The soft magnetic alloy according to claim 1 , wherein 0≤f≤0.010 is satisfied.

4. The soft magnetic alloy according to claim 1 , wherein 0≤f<0.001 is satisfied.

5. The soft magnetic alloy according to claim 1 , wherein 0.730≤1−(a+b+c+d+e+f)≤0.930 is satisfied.

6. The soft magnetic alloy according to claim 1 , wherein 0≤α{1−(a+b+c+d+e+f)}≤0.40 is satisfied.

7. The soft magnetic alloy according to claim 1 , wherein α=0 is satisfied.

8. The soft magnetic alloy according to claim 1 , wherein β=0 is satisfied.

9. The soft magnetic alloy according to claim 1 , wherein α=β=0 is satisfied.

10. The soft magnetic alloy according to claim 1 having a thin ribbon form, wherein a thickness of the thin ribbon is 5 to 30 μm.

11. The soft magnetic alloy according to claim 1 having a powder form.

12. A magnetic component comprising the soft magnetic alloy according to claim 1 .

13. A soft magnetic alloy represented by a compositional formula (Fe (1−(α+β)) X1 α X2 β ) (1−(a+b+c+d++e+f) M a P b Si c Cu d X3 e B f having a nano-hetero structure in which fine crystals are in an amorphous material, in which
X1 represents one or more selected from a group consisting of Co and Ni,
X2 represents one or more selected from a group consisting of V, Mn, Zn, Al, Sn, and La,
X3 represents one or more selected from a group consisting of C and Ge,
M represents one or more selected from a group consisting of Zr, Nb, Hf, Ta, Mo, and W,
030≤a≤0.120,
0.010≤b≤0.150,
0≤c≤0.050,
0≤d≤0.020,
0≤e≤0.100,
0≤f≤0.020,
0≤α{1−(a+b+c+d+e+f)}≤0.500,
0≤β{1−(a+b+c+d+e+f)}≤0.30, and
0≤α+β≤0.55 are satisfied, and an average grain size of the fine crystals is 0.3 to 10 nm.

14. A soft magnetic alloy represented by a compositional formula (Fe (1−(α+β)) X1 α X2 β ) (1−(a+b+c+d++e+f) M a P b Si c Cu d X3 e B f , in which
X1 represents one or more selected from a group consisting of Co and Ni,
X2 represents one or more selected from a group consisting of V, Mn, Zn, Al, Sn, and La,
X3 represents one or more selected from a group consisting of C and Ge,
M represents one or more selected from a group consisting of Zr, Nb, Hf, Ta, Mo, and W,
0.030≤a≤0.120,
0.010≤b≤0.150,
0≤c≤0.050,
0≤d≤0.020,
0≤e≤0.100,
0≤f≤0.020,
0≤α{1−(a+b+c+d+e+f)}≤0.500,
0≤β{1−(a+b+c+d+e+f)}≤0.030, and
0≤α+β≤0.55 are satisfied, and the alloy is in amorphous form.

Assignees

• Tdk Corp

Inventors

• Amano Hajime
• Harada Akihiro
• Horino Kenji
• Matsumoto Hiroyuki
• Yoshidome Kazuhiro
• Hasegawa Akito
• Ara Kensuke
• Hosono Masakazu

Classifications

• C22C45/008 Primary

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

• C22C45/02

  with iron as the major constituent · CPC title

• H01F1/15308

  based on Fe/Ni (H01F1/15325 takes precedence) · CPC title

• B22F9/02

  using physical processes · CPC title

• C22C2200/02

  Amorphous · CPC title