Insulating material-coated soft magnetic powder, dust core, magnetic element, electronic device, and moving body

Patent metadata

Field	Value
Publication number	US-11901101-B2
Application number	US-202217745912-A
Country	US
Kind code	B2
Filing date	May 17, 2022
Priority date	May 18, 2021
Publication date	Feb 13, 2024
Grant date	Feb 13, 2024

Abstract

An insulating material-coated soft magnetic powder includes: a core particle that includes a base portion containing a soft magnetic material containing Fe as a main component and at least one of Si, Cr, and Al, and that includes an oxide film provided on a surface of the base portion and containing an oxide of at least one of Si, Cr, and Al; and an insulating film that is provided on a surface of the core particle and that contains a ceramic, in which a thickness of the insulating film is 5 nm or more and 300 nm or less, and the oxide contained in the oxide film and the ceramic contained in the insulating film are mutually diffused at an interface between the oxide film and the insulating film.

First claim

What is claimed is:

1. An insulating material-coated soft magnetic powder including a plurality of individual particles, each individual particle comprising:
a core particle that includes a base portion containing a soft magnetic material containing Fe as a main component and at least one of Si, Cr, and Al, and that includes an oxide film provided on a surface of the base portion and containing an oxide of at least one of Si, Cr, and Al; and
an insulating film that is provided on a surface of the core particle and that contains a ceramic,
wherein a thickness of the insulating film is 5 nm or more and 300 nm or less as measured from an interface between the insulating film and the oxide film using a scanning transmission electron microscope where an integrated state of the oxide film and the insulating film are confirmed,
the oxide contained in the oxide film and the ceramic contained in the insulating film are mutually diffused at the interface between the oxide film and the insulating film,
the insulating film is formed from melted or sintered insulating particles that collectively define a layer that surrounds the oxide film, and
a majority of the insulating film is occupied by the insulating particles in a melted or sintered state that do not retain a particle shape rather than by insulating particles in the form of a particle that are not melted or sintered.

2. The insulating material-coated soft magnetic powder according to claim 1 , wherein
the ceramic contains at least one of aluminum oxide, silicon oxide, zirconium oxide, boron nitride, and silicon nitride.

3. The insulating material-coated soft magnetic powder according to claim 1 , wherein
each individual particle has an average particle diameter that is 1.0 μm or more and 50.0 μm or less.

4. The insulating material-coated soft magnetic powder according to claim 3 , wherein
S=k{ 6/( d ·ρ)}  (A), and

1.0≤k≤3.2  (B),

where S [m 2 /g] is a specific surface area of each individual particle, ρ [g/m 3 ] s a true density of the core particles, and d [m] is the average particle diameter of the individual particles.

5. The insulating material-coated soft magnetic powder according to claim 1 , wherein
a coercive force is 7.0 [Oe] or less.

6. A dust core comprising:
the insulating material-coated soft magnetic powder according to claim 1 .

7. A magnetic element comprising:
the dust core according to claim 6 .

8. An electronic device comprising:
the magnetic element according to claim 7 .

9. A moving body comprising:
the magnetic element according to claim 7 .

10. The insulating material-coated soft magnetic powder according to claim 1 , wherein the soft magnetic material includes an Fe—Si—B—Nb based alloy.

Assignees

• Seiko Epson Corp

Inventors

• Nakamura Atsushi

Classifications

• H01F1/147 Primary

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

• B22F1/00

  Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties · CPC title

• B22F1/05

  Metallic powder characterised by the size or surface area of the particles · CPC title

• B22F1/052

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

• B22F1/142

  Thermal or thermo-mechanical treatment · CPC title