Soft magnetic metal particle, dust core, and magnetic component

Patent metadata

Field	Value
Publication number	US-2023317333-A1
Application number	US-202318127150-A
Country	US
Kind code	A1
Filing date	Mar 28, 2023
Priority date	Mar 31, 2022
Publication date	Oct 5, 2023
Grant date	—

Abstract

A soft magnetic metal particle having a core particle and an insulation layer formed on a surface of the core particle, wherein the insulation layer includes Ti and an oxide of Si, and
an amount ratio of Ti is within a range of 1.0 mol % or more and 30 mol % or less with respect to a total amount of Si and Ti in the insulation layer.

First claim

1 . A soft magnetic metal particle comprising a core particle and an insulation layer formed on a surface of the core particle, wherein
the insulation layer includes Ti and an oxide of Si, and an amount ratio of Ti is within a range of 1.0 mol % or more and 30 mol % or less with respect to a total amount of Si and Ti in the insulation layer.

2 . The soft magnetic metal particle according to claim 1 , wherein the core particle includes Fe.

3 . A dust core including the soft magnetic metal particle according to claim 1 .

4 . A magnetic component including the dust core according to claim 3 .

5 . The soft magnetic metal particle according to claim 2 , wherein the core particle further includes Si, Ni, or Co.

6 . The soft magnetic metal particle according to claim 1 , wherein the insulation layer covers 90% or more of the entire surface of the core particle.

7 . The soft magnetic metal particle according to claim 1 , wherein a layer other than the insulation layer exists between the insulation layer and the surface of the core particle.

8 . The soft magnetic metal particle according to claim 7 , wherein the layer other than the insulation layer has a thickness of 20 nm or less.

9 . The soft magnetic metal particle according to claim 1 , wherein the amount ratio of Ti is within a range of 3.0 mol % or more and 15 mol % or less with respect to the total amount of Si and Ti in the insulation layer.

10 . The soft magnetic metal particle according to claim 1 , wherein the amount ratio of Ti is within a range of 4.0 mol % or more and 10 mol % or less with respect to the total amount of Si and Ti in the insulation layer.

11 . The soft magnetic metal particle according to claim 1 , 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 an amount of Ti.

12 . The soft magnetic metal particle 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.

13 . The soft magnetic metal particle according to claim 12 , wherein the thickness of the insulation layer is in a range of 10 nm or more and 200 nm or less.

14 . The soft magnetic metal particle according to claim 1 , wherein the oxide of Si is SiO 2 or a composite oxide which includes Si.

15 . The soft magnetic metal particle according to claim 1 , wherein Ti in the insulation layer is in a form of a substance of Ti or a compound including Ti.

16 . The soft magnetic metal particle according to claim 15 , wherein the compound including Ti is an organometallic compound including Ti, an oxide of Ti, or a composite oxide including Ti.

17 . The dust core according to claim 3 , further comprising a grain boundary phase, wherein the grain boundary phase comprises silicone resin, an epoxy resin, an imide resin, and/or Si—O-based oxides.

18 . The dust core according to claim 17 , wherein the grain boundary phase comprises a methyl-based silicone resin, cresol novolac, or bismaleimide.

19 . The dust core according to claim 17 , wherein an amount of the soft magnetic metal particle in the dust core is within a range of 90 wt % to 99.9 wt %.

20 . The dust core according to claim 17 , wherein the grain boundary phase comprises Ti.

Assignees

• Tdk Corp

Inventors

• Nakazawa Ryoma

Classifications

• H01F1/24 Primary

  the particles being insulated · CPC title

• H01F1/33

  mixtures of metallic and non-metallic particles; metallic particles having oxide skin · CPC title

• H01F3/08 Primary

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

• H01F1/14783

  with insulating coating · CPC title

• H01F27/255

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