Composite magnetic particle including metal magnetic particle

Patent metadata

Field	Value
Publication number	US-11538612-B2
Application number	US-202016831288-A
Country	US
Kind code	B2
Filing date	Mar 26, 2020
Priority date	Mar 28, 2019
Publication date	Dec 27, 2022
Grant date	Dec 27, 2022

Abstract

A composite magnetic body according to one aspect of the present invention includes a first metal magnetic particle covered with a first resin portion made of a first resin material and a second metal magnetic particle having a smaller particle size than the first metal magnetic particle, where the second metal magnetic particle is bound to the first metal magnetic particle via a second resin portion made of a second resin material and the second resin material has a larger molecular weight than the first resin material.

First claim

What is claimed is:

1. A composite magnetic particle comprising:
a first metal magnetic particle covered with a first resin portion made of a first resin material; and
a second metal magnetic particle having a smaller particle size than the first metal magnetic particle, the second metal magnetic particle being bound to the first metal magnetic particle via a second resin portion made of a second resin material, the second resin material having a larger molecular weight than the first resin material.

2. The composite magnetic particle according to claim 1 , wherein the molecular weight of the second resin material is equal to or more than twice as large as the molecular weight of the first resin material.

3. The composite magnetic particle according to claim 1 , wherein the entire surface of the first metal magnetic particle is covered with the first resin portion.

4. A magnetic base body containing the composite magnetic particle according to claim 1 .

5. A magnetic base body comprising:
a plurality of first metal magnetic particles each covered with a first resin portion made of a first resin material; and
a plurality of second metal magnetic particles having a second average particle size smaller than a first average particle size, the first average particle size being an average particle size of the plurality of first metal magnetic particles,
wherein each of the second metal magnetic particles is covered with a second resin portion made of a second resin material and bound to at least one of the first metal magnetic particles via at least one selected from the group consisting of the first resin portion and the second resin portion, and
wherein, in a case where a cross-section of the magnetic base body is measured using a scanning electron microscope (SEM) with a magnification ratio of 2000, pairs of adjacent ones of the first metal magnetic particles are observed and 15% or less of the pairs have no second metal magnetic particle between the adjacent first metal magnetic particles.

6. An electronic component comprising the magnetic base body according to claim 4 .

7. The electronic component according to claim 6 , comprising a coil provided in the magnetic base body.

8. A manufacturing method for a composite magnetic particle, the manufacturing method comprising steps of:
coating a surface of a first metal magnetic particle with a first resin portion made of a first resin material; and
binding a second metal magnetic particle having a smaller particle size than the first metal magnetic particle to the first metal magnetic particle via a second resin portion made of a second resin material, the second resin material having a larger molecular weight than the first resin material.

9. The manufacturing method according to claim 8 , wherein the binding step includes steps of:
forming the second resin portion on a surface of the first resin portion; and
mixing together the first metal magnetic particle having the second resin portion formed thereon and the second metal magnetic particle.

10. The manufacturing method according to claim 8 , wherein the binding step includes steps of:
mixing together the first metal magnetic particle having the first resin portion formed thereon and the second metal magnetic particle to produce a particle mixture; and
mixing together the particle mixture and a resin composition made of the second resin material.

11. The manufacturing method according to claim 8 , wherein the molecular weight of the second resin material is equal to or more than twice as large as the molecular weight of the first resin material.

12. The manufacturing method according to claim 8 , wherein the first resin portion accounts for 0.01 wt % to 0.1 wt % relative to the second resin portion of 100 wt %.

Assignees

• Taiyo Yuden Kk

Inventors

• Tanada Atsushi

Classifications

• B22F1/052

  characterised by a mixture of particles of different sizes or by the particle size distribution · CPC title

• H01F17/04 Primary

  with magnetic core · CPC title

• H01F27/2823

  Wires (H01F27/2866 takes precedence) · CPC title

• B22F1/10

  Metallic powder containing lubricating or binding agents; Metallic powder containing organic material · CPC title

• H01F1/26 Primary

  by macromolecular organic substances · CPC title