Dust core

Patent metadata

Field	Value
Publication number	US-12110577-B2
Application number	US-202017421201-A
Country	US
Kind code	B2
Filing date	Mar 11, 2020
Priority date	Mar 22, 2019
Publication date	Oct 8, 2024
Grant date	Oct 8, 2024

Abstract

The iron loss of a dust core is reduced. A dust core ( 1 ) includes soft magnetic metal particles ( 3 ) having an average particle size of 5 μm or more and 30 μm or less, and a particle boundary phase ( 6 ). The particle boundary phase ( 6 ) includes a polycrystalline compound containing Al (aluminum). When a sectional structure of the dust core ( 1 ) is observed, an area percentage of α-Al 2 O 3 in the particle boundary phase ( 6 ) is 75% or less. An average thickness Ta of the particle boundary phase ( 6 ) is 10 nm or more and 300 nm or less. According to the present invention, the iron loss is reduced.

First claim

What is claimed is:

1. A dust core comprising soft magnetic metal particles and a particle boundary phase, the soft magnetic metal particles having an average particle size of 5 μm or more and 30 μm or less,
wherein the particle boundary phase includes a polycrystalline compound containing Al (aluminum),
when a sectional structure of the dust core is observed, an area percentage of α-Al 2 O 3 in the particle boundary phase is 75% or less,
when the sectional structure of the dust core is observed in a first field of view of a 150 μm×150 μm square, and when, in a region where the particle boundary phase is located in an H-letter shape, two intersecting points where two vertical lines and one horizontal line that constitute the H letter intersect are connected with a straight line, and a perpendicular bisector of the straight line is drawn, a crossing width at a position where the perpendicular bisector crosses the particle boundary phase is defined as a thickness Tn of the particle boundary phase, and
when the thickness of the particle boundary phase is measured at five positions to respectively determine Tn (where n is an integer of 1 to 5), and an average thickness Ta which is an average of Tn (where n is an integer of 1 to 5) is calculated,
the average thickness Ta is 10 nm or more and 300 nm or less.

2. The dust core according to claim 1 , wherein
when a ratio of an amount of Al to an amount of oxygen in the particle boundary phase is measured, Al:O (molar ratio) is 2.0:2.5 to 2.0:2.9.

3. The dust core according to claim 1 ,
wherein when the sectional structure of the dust core is observed in a second field of view of a 100 μm×100 μm square, the particle boundary phase is continuously formed from a start point at which the particle boundary phase is present on one side of the square defining the second field of view to a side opposing the one side of the square, and the dust core has five or more continuous layers that are different from each other, and
an average length of paths of the continuous layers from the one side to the opposing side is 115 μm or more.

4. The dust core according to claim 1 ,
wherein when the sectional structure of the dust core is observed in a third field of view of a 100 μm×100 μm square, and an area percentage P (%) of pores in the third field of view is determined,
a difference between P 1 and P 2 is 3% or less,
where P 1 represents a maximum value of the area percentage P, and P 2 represents a minimum value of the area percentage P.

5. The dust core according to claim 1 ,
wherein when the sectional structure of the dust core is observed, an area percentage S(Al) of the polycrystalline compound containing Al (aluminum) in the particle boundary phase is 85% or more and 100% or less, and
when, in the area percentage S(Al), an area percentage S(α) of α-Al 2 O 3 is represented by A %, an area percentage S(γ) of γ-Al 2 O 3 is represented by B %, and an area percentage S(o) of Al 2 O 3 having another crystal structures is represented by C %, 80≤A+B≤100 (where 0≤A≤40, 40≤B≤100) and 0≤C≤20 (A+B+C=100).

Assignees

• Ngk Spark Plug Co
• Niterra Co Ltd

Inventors

• Watanabe Hiroshi
• Mori Satoshi
• Fujii Manami
• Takaoka Katsuya
• Takeuchi Hiroki
• Kozuka Hisashi

Classifications

• B22F1/00

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

• B22F1/105

  containing inorganic lubricating or binding agents, e.g. metal salts · CPC title

• B22F1/052 Primary

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

• H01F1/20

  in the form of particles, e.g. powder (H01F1/147 takes precedence) · CPC title