Dust core

Patent metadata

Field	Value
Publication number	US-11545287-B2
Application number	US-201715694509-A
Country	US
Kind code	B2
Filing date	Sep 1, 2017
Priority date	Sep 2, 2016
Publication date	Jan 3, 2023
Grant date	Jan 3, 2023

Abstract

A dust core including a metal magnetic powder and a resin, in which the metal magnetic powder shows a particle diameter of more than 0 μm and 200 μm or less, a number percentage of 5.0% or more of metal magnetic particles among the metal magnetic particles composing the metal magnetic powder are at least partially surface-coated with an inorganic compound including an alkaline earth metal, in a coating part coating the metal magnetic particles, an amount of the alkaline earth metal is 10.0 mass % or more, when a total amount of a metal element included in the coating part is 100 mass %, is provide. The dust core is superior in a corrosion-resistance.

First claim

The invention claimed is:

1. A dust core comprising a metal magnetic powder and a resin, wherein
the metal magnetic powder shows a particle diameter of more than 0 μm and 200 μm or less,
when d10 is a 10% particle diameter from smaller size in a cumulative particle size distribution of the metal magnetic powder, d10 is 1.9 μm or more and 24.9 μm or less,
a number percentage of metal magnetic particles at least partially surface-coated with an inorganic compound including an alkaline earth metal is 5.0% or more among all of metal magnetic particles in the metal magnetic powder,
in a coating part coating the metal magnetic particles, an amount of the alkaline earth metal is 10.0 mass% or more, when a total amount of a metal element included in the coating part is 100 mass%,
each of the metal magnetic particles at least partially surface-coated has the coating part, and
the metal magnetic powder includes metal magnetic particles having a particle diameter of 25.0 μm or more,
a number percentage of metal magnetic particles having a particle diameter of 25.0 μm or more and coated with the inorganic compound including the alkaline earth metal is 50.0% or less among the metal magnetic particles having a particle diameter of 25.0 μm or more in the metal magnetic powder.

2. The dust core according to claim 1 , wherein the alkaline earth metal is Mg.

3. The dust core according to claim 1 , wherein the metal magnetic powder includes metal magnetic particles having a particle diameter of 10.0 μm or less,
a number percentage of metal magnetic particles having a particle diameter of 10.0 μm or less and coated with the inorganic compound including the alkaline earth metal is 60.0% or more among the metal magnetic particles having a particle diameter of 10.0 μm or less in the metal magnetic powder.

4. The dust core according to claim 1 , wherein the metal magnetic powder includes metal magnetic particles having a particle diameter of 5.0 μm or less,
a number percentage of the metal magnetic particles having a particle diameter of 5.0 μm or less and coated with the inorganic compound including the alkaline earth metal is 80.0% or more among the metal magnetic particles having a particle diameter of 5.0 μm or less in the metal magnetic powder.

5. The dust core according to claim 1 , wherein the metal magnetic particles coated with the inorganic compound including the alkaline earth metal show
0.0050<Sc/Sm<0.1000
when
Sm is a cross-sectional area of the metal magnetic particles, and
Sc is a cross-sectional area of a part where the metal magnetic particles are coated with the inorganic compound including the alkaline earth metal.

6. The dust core according to claim 1 , wherein
among all of the metal magnetic particles in the metal magnetic powder,
the metal magnetic particles, other than the metal magnetic particles coated with the inorganic compound including the alkaline earth metal, are at least partially surface-coated with an insulating material except for the inorganic compound including the alkaline earth metal.

7. The dust core according to claim 6 , wherein the insulating material is an oxide including Si.

8. The dust core according to claim 1 , wherein the metal magnetic particles composing the metal magnetic powder include Fe or Fe and Si.

9. The dust core according to claim 1 , wherein the number percentage of metal magnetic particles that are at least partially surface-coated with an inorganic compound including an alkaline earth metal is 7.5% or more among all of the metal magnetic particles in the metal magnetic powder.

10. The dust core according to claim 1 , wherein the number percentage of metal magnetic particles that are at least partially surface-coated with an inorganic compound including an alkaline earth metal is 10.0% or more among all of the metal magnetic particles in the metal magnetic powder.

11. The dust core according to claim 1 , wherein in a coating part coating the metal magnetic particles, an amount of the alkaline earth metal is 25.0 mass% or more, when a total amount of a metal element included in the coating part is 100 mass%.

12. The dust core according to claim 5 , wherein 0.0055<Sc/Sm<0.0950.

13. The dust core according to claim 5 , wherein 0.0300<Sc/Sm<0.0750.

14. The dust core according to claim 1 , which has a rust area ratio of 15% or less.

15. The dust core according to claim 1 , which has a rust area ratio of 10% or less.

16. The dust core according to claim 1 , which has a rust area ratio of 7.5% or less.

17. The dust core according to claim 1 , which has a rust area ratio of 5.0% or less.

Assignees

• Tdk Corp

Inventors

• Nakazawa Ryoma
• FUTAMATA Yousuke
• Takahashi Takeshi

Classifications

• C22C45/02

  with iron as the major constituent · CPC title

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title

• B29K2995/0008

  Magnetic or paramagnetic · CPC title

• C22C38/00

  Ferrous alloys, e.g. steel alloys (cast-iron alloys C22C37/00) · CPC title

• C22C38/06

  containing aluminium · CPC title