Soft magnetic powder, pressed powder body, and magnetic component

Patent metadata

Field	Value
Publication number	US-11894169-B2
Application number	US-201916413848-A
Country	US
Kind code	B2
Filing date	May 16, 2019
Priority date	May 21, 2018
Publication date	Feb 6, 2024
Grant date	Feb 6, 2024

Abstract

Disclosed is a soft magnetic powder including a main component represented by composition formula: (Fe(1−(α+β))X1αX2β)(1−(a+b+c+d+e+f))MaBbPcSidCeSf. X1 represents one or more selected from the group consisting of Co and Ni; X2 represents one or more selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, and rare earth elements; and M represents one or more selected from the group consisting of Nb, Hf, Zr, Ta, Mo, W, Ti, and V. The following relations are satisfied: 0≤a≤0.140; 0.020<b≤0.200; 0<c≤0.150; 0≤d≤0.060; 0≤e≤0.030; 0≤f≤0.010; α≥0; β≥0; and 0≤α+β≤0.50. An oxygen content ratio in the soft magnetic powder is from 300 ppm to 3,000 ppm as a mass ratio.

First claim

What is claimed is:

1. A soft magnetic powder comprising a main component represented by the following composition formula, by atomic ratio:
(Fe (1−(α+β)) X1 α X2 β ) (1−(a+b+c+d+e+f)) M a B b P c Si d C e S f ,
wherein X1 represents one or more selected from the group consisting of Co and Ni,
X2 represents one or more selected from the group consisting of Al, Zn, Sn, Cu, Cr, Bi, La, and Y,
M represents Nb,
0.040≤a≤0.140;
0.025<b≤0.200;
0.001<c≤0.150;
0≤d≤0.060;
0≤e≤0.030;
0≤f≤0.010;
0≤α{1−(a+b+c+d+e+f)}≥0.400;
0≤β{1−(a+b+c+d+e+f)}≥0.030;
0≤α+β≤0.50,
an oxygen content ratio in the soft magnetic powder is from 321 ppm to 2,831 ppm as a mass ratio, and
coercivity Hc is 3.2 Oe or less.

2. The soft magnetic powder according to claim 1 , wherein the soft magnetic powder is amorphous.

3. The soft magnetic powder according to claim 1 , wherein the soft magnetic powder comprises an amorphous phase and microcrystals, and a nanohetero structure with the microcrystals existing in the amorphous phase is contained.

4. The soft magnetic powder according to claim 3 , wherein the microcrystals have an average particle size of 0.3 to 10 nm.

5. The soft magnetic powder according to claim 1 , wherein a structure comprised of Fe-based nanocrystals is contained.

6. The soft magnetic powder according to claim 5 , wherein the Fe-based nanocrystals have an average particle size of from 3 nm to 50 nm.

7. The soft magnetic powder according to claim 1 , wherein a Fe composition network phase in which regions having a higher Fe content proportion than the Fe content proportion included in the entirety of the soft magnetic powder are connected is contained,
the Fe composition network phase has maximum points of 400,000 or more points/μm 3 of the Fe content proportion, at which the Fe content proportion becomes locally higher than that of the surroundings, and
the proportion of maximum points of the Fe content proportion having a coordination number of from 1 to 5 is from 80% to 100%, among all of the maximum points of the Fe content proportion.

8. The soft magnetic powder according to claim 7 , wherein a volume proportion occupied by the Fe composition network phase in the entirety of the soft magnetic powder is from 25 vol % to 50 vol %.

9. The soft magnetic powder according to claim 1 , wherein a volume resistivity in a state of being compacted at a pressure of 0.1 t/cm 2 is from 0.5 kΩ·cm to 500 kΩ·cm.

10. A pressed powder body comprising the soft magnetic powder according to claim 1 .

11. A magnetic component comprising the pressed powder body according to claim 10 .

12. The soft magnetic powder according to claim 1 , wherein a volume resistivity in a state of being compacted at a pressure of 0.1 t/cm 2 is 3 kΩ·cm or higher.

13. The soft magnetic powder according to claim 1 , wherein a volume resistivity in a state of being compacted at a pressure of 0.1 t/cm 2 is from 3 kΩ·cm to 500 kΩ·cm.

14. The soft magnetic powder according to claim 1 , wherein 0.060≤b≤0.200, 0.010≤c≤0.150, 0≤e≤0.020, the oxygen content ratio in the soft magnetic powder is from 820 ppm to 1,975 ppm as a mass ratio, and a volume resistivity in a state of being compacted at a pressure of 0.1 t/cm 2 is from 3 kΩ·cm or higher.

Assignees

• Tdk Corp

Inventors

• Yoshidome Kazuhiro
• Matsumoto Hiroyuki
• Horino Kenji
• Mori Satoko
• Hosono Masakazu
• Kajiura Yoshiki

Classifications

• H01F1/15333 Primary

  containing nanocrystallites, e.g. obtained by annealing · CPC title

• C22C38/007

  containing silver · CPC title

• C22C38/008

  containing tin · CPC title

• C22C38/04

  containing manganese · CPC title

• C22C38/06

  containing aluminium · CPC title