Soft magnetic alloy powder, soft magnetic sintered body, and coil-type electronic component

Patent metadata

Field	Value
Publication number	US-12440892-B2
Application number	US-202017760951-A
Country	US
Kind code	B2
Filing date	Sep 25, 2020
Priority date	Sep 26, 2019
Publication date	Oct 14, 2025
Grant date	Oct 14, 2025

Abstract

A soft magnetic metal powder or the like from which a soft magnetic metal fired body can be provided has a high magnetic permeability μ and a specific resistance ρ and is contained in a coil-type electronic component having sufficiently high inductance L and Q value and unlikely to be plating-extended and short-circuited. A soft magnetic metal powder contains soft magnetic metal particles containing at least Fe and Ni. Said soft magnetic metal powder further contains P, Si, Cr and/or M. M is at least one selected from among B, Co, Mn, Ti, Zr, Hf, Nb, Ta, Mo, Mg, Ca, Sr, Ba, Zn, Al, and rare earth elements. The content of each element is within a predetermined range.

First claim

What is claimed is:

1. A soft magnetic metal powder comprising soft magnetic metal particles each constituted by a Fe—Ni—Si-M based alloy, wherein
the Fe—Ni—Si-M based alloy further includes P;
M is one or more selected from B, Co, Mn, Ti, Zr, Hf, Nb, Ta, Mo, Mg, Ca, Sr, Ba, Zn and rare earth elements; and
the Fe—Ni—Si-M based alloy includes 15.0 mass % or more and 55.0 mass % or less of Ni, 2.0 mass % or more and 6.0 mass % or less of Si, 2.0 mass % or more and 40.0 mass % or less of M, and 100 ppm or more and 5000 ppm or less of P with respect to 100 mass % of a total amount of Fe, Ni, Si, and M.

2. The soft magnetic metal powder according to claim 1 , wherein M is Co.

3. The soft magnetic metal powder according to claim 1 , wherein an average particle size (D50) of the soft magnetic metal powder is 1.5 μm or more and 15.0 μm or less.

4. A soft magnetic sintered body comprising the soft magnetic metal powder according to claim 1 .

5. A coil type electronic component comprising a magnetic element and a coil conductor embedded in the magnetic element, wherein
the magnetic element comprises the soft magnetic metal sintered body according to claim 4 .

6. The coil type electronic component according to claim 5 , wherein the soft magnetic metal particles are each covered with a coating film, and
the coating film has a layer including Si or oxides of Si contacting the soft magnetic particle.

7. The coil type electronic component according to claim 6 , wherein the layer of the coating film contacting the soft magnetic metal particle further includes P.

8. The coil type electronic component according to claim 6 , wherein an average thickness of the coating film is within a range of 5 nm or more and 60 nm or less.

9. The coil type electronic component according to claim 5 , wherein the magnetic element includes the soft magnetic metal particles and a resin; and
a space formed between the soft magnetic metal particles are filled with the resin.

10. The coil type electronic component according to claim 9 , wherein the resin is a phenol resin or an epoxy resin.

11. A soft magnetic metal powder comprising soft magnetic metal particles each constituted by a Fe—Ni based alloy, wherein
the Fe—Ni based alloy further includes Cr;
the Fe—Ni based alloy further includes Si and Co;
the Fe—Ni based alloy includes 15.0 mass % or more and 80.0 mass % or less of Ni, 0.5 mass % or more and 1.5 mass % or less of Cr, and 1.0 mass % or more and 50.0 mass % or less of Co, 1.0 mass % or more and 6.0 mass % or less of Si, 0.5 mass % or less of O, 100 ppm or more and 5000 ppm or less of P, and 0.15 mass % or less of elements other than Fe, Ni, Si, Co, Cr, P and O with respect to 100 mass % of a total amount of Fe, Ni, Si, Co, and Cr.

12. The soft magnetic metal powder according to claim 11 , wherein the Fe—Ni based alloy includes 2.5 mass % or more and 5.5 mass % or less of Si with respect to 100 mass % of a total amount of Fe, Ni, Si, M, and Cr.

Assignees

• Tdk Corp

Inventors

• Suzuki Takashi
• Sakurai Yu
• Itoh Hideyuki
• Kakuda Kouichi
• Wada Ryuichi
• Enomoto Nami
• Nagai Yusuke
• Kawasaki Kunihiko
• Kondo Shinichi
• ISHIMA Yuya

Classifications

• C22C19/057

  with the maximum Cr content being less 10% · CPC title

• C22C19/03

  based on nickel · CPC title

• C22C38/08

  containing nickel {(C22C38/105 takes precedence)} · CPC title

• B22F1/10

  Metallic powder containing lubricating or binding agents; Metallic powder containing organic material · CPC title

• H01F27/28

  Coils; Windings; Conductive connections · CPC title