Magnetic powder, magnetic compact, and inductor

Patent metadata

Field	Value
Publication number	US-2022102052-A1
Application number	US-202117486850-A
Country	US
Kind code	A1
Filing date	Sep 27, 2021
Priority date	Sep 30, 2020
Publication date	Mar 31, 2022
Grant date	—

Abstract

A magnetic powder contains first magnetic particles, second magnetic particles having a particle size larger than a particle size of the first magnetic particles, and resin. At least one portion of each of the second magnetic particles is covered by the resin and the first magnetic particles. Coverage (L1/L2)≥0.42 holds, where L1 is a sum of particle sizes of the first magnetic particles covering the second magnetic particle and L2 is a perimeter of the second magnetic particle.

First claim

What is claimed is:

1 . A magnetic powder containing:
first magnetic particles; second magnetic particles having a particle size larger than a particle size of the first magnetic particles; and resin, wherein at least a portion of each of the second magnetic particles is covered by the resin and the first magnetic particles, and where L1 is a sum of particle sizes of the first magnetic particles covering the second magnetic particle and L2 is a perimeter of the second magnetic particle, the following expression is satisfied coverage (L1/L2)≥0.42.

2 . The magnetic powder according to claim 1 , wherein
the coverage (L1/L2)≥0.50 is satisfied.

3 . The magnetic powder according to claim 1 , wherein
the magnetic powder has a bottom value at which a particle frequency is smallest among a plurality of peak values in a particle size distribution indicating a relationship between the particle frequency and a particle size, the particle size of the first magnetic particles is less than the bottom value, and the particle size of the second magnetic particles is larger than the bottom value.

4 . The magnetic powder according to claim 3 , wherein
the L1 is the sum of the particle sizes of the first magnetic particles of which at least a portion is included within a distance given by (particle size D1)/2 from an outline of the second magnetic particle, where D1 is a particle size at the highest particle frequency in a particle size range less than the bottom value of the particle frequency in the particle size distribution.

5 . The magnetic powder according to claim 1 , wherein
the first magnetic particles and the second magnetic particles are magnetic metal particles.

6 . The magnetic powder according to claim 5 , wherein
the magnetic metal particles contain at least one selected from the group consisting of Fe; an alloy containing Fe and Ni; an alloy containing Fe and Co; an alloy containing Fe and Si; an alloy containing Fe, Si, and Cr; an alloy containing Fe, Si, and Al; an alloy containing Fe, Si, B, and Cr; and an alloy containing Fe, P, Cr, Si, B, Nb, and C.

7 . The magnetic powder according to claim 1 , wherein
the resin is a thermosetting resin.

8 . The magnetic powder according to claim 1 , wherein
the resin is uncured.

9 . The magnetic powder according to claim 2 , wherein
the magnetic powder has a bottom value at which a particle frequency is smallest among a plurality of peak values in a particle size distribution indicating a relationship between the particle frequency and a particle size, the particle size of the first magnetic particles is less than the bottom value, and the particle size of the second magnetic particles is larger than the bottom value.

10 . The magnetic powder according to claim 2 , wherein
the first magnetic particles and the second magnetic particles are magnetic metal particles.

11 . The magnetic powder according to claim 3 , wherein
the first magnetic particles and the second magnetic particles are magnetic metal particles.

12 . The magnetic powder according to claim 2 , wherein
the resin is a thermosetting resin.

13 . The magnetic powder according to claim 2 , wherein
the resin is uncured.

14 . A magnetic compact containing:
first magnetic particles; second magnetic particles having a particle size larger than a particle size of the first magnetic particles; and resin, wherein each of the second magnetic particles is surrounded by the first magnetic particles, and where L1 is a sum of particle sizes of the first magnetic particles surrounding the second magnetic particle and L2 is a perimeter of the second magnetic particle, the following expression is satisfied coverage (L1/L2)≥0.95.

15 . The magnetic compact according to claim 14 , wherein
the coverage (L1/L2)≥1.09 is satisfied.

16 . The magnetic compact according to claim 14 , wherein
the magnetic compact has a bottom value at which a particle frequency is smallest among a plurality of peak values in a particle size distribution indicating a relationship between the particle frequency and a particle size, the particle size of the first magnetic particles is less than the bottom value and, the particle size of the second magnetic particles is larger than the bottom value.

17 . The magnetic compact according to claim 16 , wherein
the L1 is the sum of the particle sizes of the first magnetic particles of which at least a portion is included within a distance given by (particle size D1)/2 from an outline of the second magnetic particle, where D1 is a particle size at the highest particle frequency in a particle size range less than the bottom value of the particle frequency in the particle size distribution.

18 . An inductor comprising:
a coil conductor; and the magnetic compact according to claim 14 defines a winding core of the coil conductor.

19 . The magnetic compact according to claim 15 , wherein
the magnetic compact has a bottom value at which a particle frequency is smallest among a plurality of peak values in a particle size distribution indicating a relationship between the particle frequency and a particle size, the particle size of the first magnetic particles is less than the bottom value and, the particle size of the second magnetic particles is larger than the bottom value.

20 . An inductor comprising:
a coil conductor; and the magnetic compact according to claim 15 defines a winding core of the coil conductor.

Assignees

• Murata Manufacturing Co

Inventors

• Ishida Keiichi
• Kimura Yoshinobu
• Hattori Yoshihiko
• Muneuchi Keita
• Fujisawa Nobuyuki

Classifications

• H01F1/26

  by macromolecular organic substances · CPC title

• H01F27/2847

  Sheets; Strips (H01F27/2866 takes precedence) · CPC title

• H01F17/04 Primary

  with magnetic core · CPC title

• H01F2017/048

  with encapsulating core, e.g. made of resin and magnetic powder · CPC title

• H01F27/255 Primary

  made from particles (H01F27/26 takes precedence) · CPC title