Dust core and magnetic component

Patent metadata

Field	Value
Publication number	US-12505941-B2
Application number	US-202318128273-A
Country	US
Kind code	B2
Filing date	Mar 30, 2023
Priority date	Mar 31, 2022
Publication date	Dec 23, 2025
Grant date	Dec 23, 2025

Abstract

A dust core including soft magnetic metal particles and a grain boundary phase, wherein the grain boundary phase includes Si and Ti.

First claim

What is claimed is:

1 . A dust core comprising soft magnetic metal particles and a grain boundary phase, wherein
the grain boundary phase includes Si and Ti, at least one soft magnetic metal particle of the soft magnetic metal particles comprises a core particle and an insulation layer formed on a surface of the core particle, a layer other than the insulation layer exists between the insulation layer and the surface of the core particle, a content of Ti in the grain boundary phase is higher than that in the insulation layer, the layer other than the insulation layer includes a phosphoric acid compound, an amount ratio of Ti in the grain boundary phase is within a range of 100 ppm or more and 3000 ppm or less by mass with respect to a total weight of the dust core, and an initial permeability μi of the dust core is 50.0 or more.

2 . The dust core according to claim 1 , wherein at least one soft magnetic metal particle of the soft magnetic metal particles includes Fe.

3 . The dust core according to claim 1 , wherein the insulation layer includes an oxide of Si.

4 . The dust core according to claim 1 , wherein an amount of the soft magnetic metal particles in the dust core is within a range of 90 wt % to 99.9 wt %.

5 . The dust core according to claim 1 , wherein a thickness of the insulation layer is in a range of 5 nm or more and 500 nm or less.

6 . The dust core according to claim 1 , wherein the layer other than the insulation layer has a thickness of 20 nm or less.

7 . The dust core according to claim 1 , wherein the grain boundary phase further includes a resin including Si, and Ti is mixed with the resin including Si.

8 . The dust core according to claim 7 , wherein the resin including Si is a methyl-based silicone resin.

9 . The dust core according to claim 7 , wherein the grain boundary phase further includes an epoxy resin, an imide resin, Si—O-based oxides, Ca—O-based oxides, Ba—O-based oxides, and/or Bi—O-based oxides.

10 . The dust core according to claim 1 , wherein the insulation layer includes Ti and an oxide of Si.

11 . The dust core according to claim 10 , wherein the insulation layer further includes at least one element selected from the group consisting of Ba, Ca, Mg, Al, Zr, Ni, Mn, and Zn, and a total amount ratio of the at least one element is 1 mol % or less with respect to a total amount of Ti in the insulation layer.

12 . The dust core according to claim 10 , wherein the oxide of Si is SiO 2 or a composite oxide which includes Si.

13 . The dust core according to claim 1 , wherein the core particle includes Fe.

14 . The dust core according to claim 13 , wherein the core particle further includes Si, Ni, or Co.

15 . A magnetic component including the dust core according to claim 1 .

16 . A dust core comprising soft magnetic metal particles and a grain boundary phase, wherein
the grain boundary phase includes Si and Ti, at least one soft magnetic metal particle of the soft magnetic metal particles comprises a core particle and an insulation layer formed on a surface of the core particle, the insulation layer includes Ti and an oxide of Si, the insulation layer includes a simple substance of Ti and/or an organometallic compound including Ti, a content of Ti in the grain boundary phase is higher than that in the insulation layer, an amount ratio of Ti in the grain boundary phase is within a range of 100 ppm or more and 3000 ppm or less by mass with respect to a total weight of the dust core, and an initial permeability μi of the dust core is 50.0 or more.

17 . The dust core according to claim 16 , wherein at least one soft magnetic metal particle of the soft magnetic metal particles includes Fe.

18 . A magnetic component including the dust core according to claim 16 .

19 . A dust core comprising soft magnetic metal particles and a grain boundary phase, wherein
the grain boundary phase includes Si and Ti, at least one soft magnetic metal particle of the soft magnetic metal particles comprises a core particle and an insulation layer formed on a surface of the core particle, the insulation layer includes Ti and an oxide of Si, the insulation layer includes a simple substance of Ti and/or an organometallic compound including Ti, the average value of Ti/(Si+Ti) in the insulation layer of all soft magnetic metal particles contained in the soft magnetic metal particles in the dust core is 1.3 mol % or higher, a content of Ti in the grain boundary phase is higher than that in the insulation layer, and an amount ratio of Ti in the grain boundary phase is within a range of 100 ppm or more and 3000 ppm or less by mass with respect to a total weight of the dust core.

20 . A magnetic component including the dust core according to claim 19 .

Assignees

• Tdk Corp

Inventors

• Nakazawa Ryoma

Classifications

• B22F1/16

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

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title

• B22F2302/256

  Silicium oxide (SiO2) · CPC title

• B22F2304/10

  Micron size particles, i.e. above 1 micrometer up to 500 micrometer · CPC title

• B22F2301/35

  Iron · CPC title