Dust core and magnetic component

Patent metadata

Field	Value
Publication number	US-2023317334-A1
Application number	US-202318128273-A
Country	US
Kind code	A1
Filing date	Mar 30, 2023
Priority date	Mar 31, 2022
Publication date	Oct 5, 2023
Grant date	—

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

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

2 . The dust core according to claim 1 , wherein 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 the dust core.

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

4 . The dust core according to claim 1 , wherein 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.

5 . The dust core according to claim 4 , wherein the insulation layer includes an oxide of Si.

6 . The dust core according to claim 4 , wherein the insulation layer includes Ti and an oxide of Si.

7 . The dust core according to claim 4 , wherein the core particle includes Fe.

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

9 . 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.

10 . The dust core according to claim 9 , wherein the resin including Si is a methyl-based silicone resin.

11 . The dust core according to claim 9 , 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.

12 . 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 %.

13 . The dust core according to claim 4 , wherein a thickness of the insulation layer is in a range of 5 nm or more and 500 nm or less.

14 . The dust core according to claim 4 , wherein a layer other than the insulation layer exists between the insulation layer and the surface of the core particle.

15 . The dust core according to claim 14 , wherein the layer other than the insulation layer has a thickness of 20 nm or less.

16 . The dust core according to claim 6 , 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.

17 . The dust core according to claim 6 , wherein the oxide of Si is SiO 2 or a composite oxide which includes Si.

18 . The dust core according to claim 7 , wherein the core particle further includes Si, Ni, or Co.

Assignees

• Tdk Corp

Inventors

• Nakazawa Ryoma

Classifications

• H01F1/24 Primary

  the particles being insulated · CPC title

• H01F27/255

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

• B22F9/082

  atomising using a fluid (using centrifugal force B22F9/10) · CPC title

• B22F1/145

  Chemical treatment, e.g. passivation or decarburisation · CPC title

• B22F1/142

  Thermal or thermo-mechanical treatment · CPC title