Metal magnetic powder and method for manufacturing same, as well as coil component and circuit board

Patent metadata

Field	Value
Publication number	US-11823825-B2
Application number	US-202117370765-A
Country	US
Kind code	B2
Filing date	Jul 8, 2021
Priority date	Jul 31, 2020
Publication date	Nov 21, 2023
Grant date	Nov 21, 2023

Abstract

A metal magnetic powder is constituted by metal magnetic grains that each include: a metal phase where the percentage of Fe at its center part is 98 percent by mass or higher, while the mass percentage of Fe at its contour part is lower than that at the center part; and an oxide film covering the metal phase, so as to inhibit oxidation of Fe contained in the metal phase, despite the high content percentage of Fe in the metal phase.

First claim

I claim:

1. A metal magnetic powder constituted by metal magnetic grains, each comprising:
a metal phase where a mass percentage of Fe relative to all metal elements contained at its center part is 98 percent or higher, and a mass percentage of Fe relative to all metal elements contained at its contour part is lower than that at the center part, said metal phase being a part of each magnetic grain where an oxygen abundance ratio is 15 atomic percent or lower; and
an oxide film covering the metal phase,
wherein the metal phase further contains at least one type of element selected from Si, Cr, Al, Ti, Zr, and Mg.

2. The metal magnetic powder according to claim 1 , wherein the percentage of Fe at the contour part is lower by 1 to 20 percent by mass than that at the center part.

3. The metal magnetic powder according to claim 1 , wherein the percentage of Fe at the contour part is lower by 5 to 18 percent by mass than that at the center part.

4. The metal magnetic powder according to claim 1 , wherein the percentage of Fe at the contour part is 80 to 85 percent by mass.

5. The metal magnetic powder according to claim 1 , wherein a total of percentages of Si, Cr, Al, Ti, Zr, and Mg at the contour part is higher by at least 5 percent by mass than a total of corresponding percentages at the center part.

6. The metal magnetic powder according to claim 1 , wherein a part containing more Fe than a total of mass percentages of Si, Cr, Al, Ti, Zr, and Mg is formed in the oxide film.

7. A coil component, comprising:
a magnetic body in which metal magnetic grains constituting the metal magnetic powder according to claim 1 are joined together via a resin or oxide; and
conductors placed inside, or on a surface of, the magnetic body.

8. A circuit board on which the coil component according to claim 7 is installed.

9. The metal magnetic powder according to claim 1 , wherein a total of percentages of Si, Cr, Al, Ti, Zr, and Mg at the contour part is higher than a total of corresponding percentages at the center part, and a total of corresponding percentages at an intermediate part located between the center part and the contour part in a radial direction of each magnetic grain is between the total of corresponding percentages at the center part and the total of corresponding percentages at the contour part.

Assignees

• Taiyo Yuden Kk

Inventors

• Orimo Yoko

Classifications

• H01F1/147 Primary

  Alloys characterised by their composition {(treatment thereof for enhancing their electromagnetic properties C21D8/12)} · CPC title

• B22F1/06

  Metallic powder characterised by the shape of the particles (nanosized particles B22F1/054) · CPC title

• B22F1/142

  Thermal or thermo-mechanical treatment · CPC title

• C22C38/34 Primary

  with more than 1.5% by weight of silicon · CPC title

• H01F27/255

  made from particles (H01F27/26 takes precedence) · CPC title