Insulator-coated magnetic alloy powder particle, powder magnetic core, and coil part

Patent metadata

Field	Value
Publication number	US-11948730-B2
Application number	US-202017082372-A
Country	US
Kind code	B2
Filing date	Oct 28, 2020
Priority date	Oct 30, 2019
Publication date	Apr 2, 2024
Grant date	Apr 2, 2024

Abstract

An insulator-coated magnetic alloy powder particle includes a magnetic alloy powder particle and an insulator that coats a surface of the magnetic alloy powder particle and that has a plurality of protrusions at a surface thereof, wherein the insulator includes a first insulator in a particulate form enclosed in the protrusion, and a second insulator in a film form that coats at least a part of a surface of the first insulator.

First claim

What is claimed is:

1. An insulator-coated magnetic alloy powder particle, comprising:
a magnetic alloy powder particle; and
an insulator that coats a surface of the magnetic alloy powder particle and that has a plurality of protrusions at a surface thereof, wherein
the insulator includes:
a first insulator in a film form that coats the coats the surface of the magnetic alloy powder particle,
a second insulator in a particulate form, wherein
the first insulator is between the magnetic alloy powder particle and the second insulator, and
the second insulator is enclosed in each of the plurality of protrusions, and

a third insulator in a film form that coats at least a part of a surface of the second insulator and specific regions of the first insulator, wherein
the second insulator is between the first insulator and the third insulator,
the specific regions of the first insulator correspond to regions that are not in contact with the second insulator,
the third insulator protrudes in a region that coats the second insulator,
the protrusion of the third insulator corresponds to the plurality of protrusions, and
a number of protrusions of the plurality of protrusions corresponds to a number of particles of the second insulator at the surface of the magnetic alloy powder particle.

2. The insulator-coated magnetic alloy powder particle according to claim 1 , wherein the third insulator has a film thickness of 2 nm or more and 20 nm or less.

3. The insulator-coated magnetic alloy powder particle according to claim 1 , wherein the third insulator has a volume resistivity of 1×10 14 Ω·cm or more and 1×10 17 Ω·cm or less.

4. The insulator-coated magnetic alloy powder particle according to claim 1 , wherein the second insulator has an average particle diameter of 4 nm or more and 40 nm or less.

5. The insulator-coated magnetic alloy powder particle according to claim 1 , wherein the second insulator has a relative permittivity of 2 or more and 4 or less.

6. The insulator-coated magnetic alloy powder particle according to claim 1 , wherein one particle of the second insulator is present per 43 nm 2 to 10000 nm 2 surface area of the magnetic alloy powder particle.

7. A powder magnetic core, formed by compacting the insulator-coated magnetic alloy powder particles according to claim 1 .

8. A coil part, comprising the powder magnetic core according to claim 7 .

9. A powder magnetic core, formed by compacting
magnetic alloy powder particles, and
an insulator that coats surfaces of the magnetic alloy powder particles, wherein
the insulator includes:
a first insulator in a film form that coats the surfaces of the magnetic alloy powder particles,
a second insulator in a particulate form, wherein
the first insulator is between the magnetic alloy powder particles and the second insulator, and
the second insulator is enclosed in each of a plurality of protrusions, and

a third insulator in a film form that coats at least a part of a surface of the second insulator and specific regions of the first insulator,

the specific regions of the first insulator correspond to regions that are not in contact with the second insulator,
the third insulator protrudes in a region that coats the second insulator,
the protrusion of the third insulator corresponds to the plurality of protrusions,
a number of protrusions of the plurality of protrusions corresponds to a number of particles of the second insulator at the surface of the magnetic alloy powder particles, and
a void surrounded by the second insulator or the third insulator is included.

10. A coil part, comprising the powder magnetic core according to claim 9 .

Assignees

• Seiko Epson Corp

Inventors

• Matsumoto Yasutaka

Classifications

• H01F3/08 Primary

  made from powder (powder coatings on sheets H01F3/02; on strips or ribbons H01F3/04; on wires H01F3/06) · CPC title

• B22F1/102

  Metallic powder coated with organic material · CPC title

• B22F1/16

  Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10) · CPC title

• H01F1/24

  the particles being insulated · CPC title

• B22F2301/15

  Nickel or cobalt · CPC title