Composite particle of soft-magnetic metallic material, method for producing composite particle, powder core, magnetic element, and portable electronic device

Patent metadata

Field	Value
Publication number	US-9767956-B2
Application number	US-201314084011-A
Country	US
Kind code	B2
Filing date	Nov 19, 2013
Priority date	Nov 20, 2012
Publication date	Sep 19, 2017
Grant date	Sep 19, 2017

Abstract

A composite particle includes: a particle composed of a soft magnetic metallic material, and a coating layer composed of a soft magnetic metallic material having a different composition from that of the particle and fusion-bonded to the particle so as to cover the particle, wherein when the Vickers hardness of the particle is represented by HV1 and the Vickers hardness of the coating layer is represented by HV2, HV1 and HV2 satisfy the following relationship: 100≦HV1−HV2, and when half of the projected area circle equivalent diameter of the particle is represented by r and the average thickness of the coating layer is represented by t, r and t satisfy the following relationship: 0.05≦t/r≦1.

First claim

What is claimed is:

1. A composite particle, comprising:
a particle composed of a soft magnetic metallic material;
a coating layer composed of a plurality of coating particles that are each formed of a soft magnetic metallic material having a different composition from that of the particle and fusion-bonded to the particle; and
an insulating layer between the particle and the coating layer, wherein
when a Vickers hardness of the particle is represented by HV1 and a Vickers hardness of the coating layer is represented by HV2, HV1 and HV2 satisfy: 100≦HV1−HV2, and
when half of a projected area circle equivalent diameter of the particle is represented by r and an average thickness of the coating layer is represented by t, r and t satisfy: 0.05≦t/r≦1.

2. The composite particle according to claim 1 , wherein HV1 and HV2 satisfy: 250≦HV1≦1200 and 100≦HV2≦250, respectively.

3. The composite particle according to claim 1 , wherein
the soft magnetic metallic material constituting the particle and the soft magnetic metallic material constituting the coating layer are each a crystalline metallic material, and
an average crystal grain size in the particle as measured by X-ray diffractometry is 0.2 times or more and 0.95 times or less than an average crystal grain size in the coating layer as measured by X-ray diffractometry.

4. The composite particle according to claim 1 , wherein the soft magnetic metallic material constituting the particle is an amorphous metallic material or a nanocrystalline metallic material, and the soft magnetic metallic material constituting the coating layer is a crystalline metallic material.

5. The composite particle according to claim 1 , wherein the soft magnetic metallic material constituting the particle is an Fe—Si-based material.

6. The composite particle according to claim 5 , wherein the soft magnetic metallic material constituting the coating layer is any of pure Fe, an Fe—B-based material, an Fe—Cr-based material, and an Fe—Ni-based material.

7. The composite particle according to claim 1 , wherein the coating layer covers an entire surface of the particle.

8. A method for producing a composite particle, comprising:
forming a coating layer by fusion-bonding coating particles to a surface of a particle through mechanical pressure welding, the coating particles having a smaller diameter than the particle, wherein
an insulating layer is located between the particle and the coating layer,
the particle is composed of a soft magnetic metallic material and the coating layer is composed of a soft magnetic metallic material having a different composition from that of the particle and is fusion-bonded to the particle,
when a Vickers hardness of the particle is represented by HV1 and a Vickers hardness of the coating layer is represented by HV2, HV1 and HV2 satisfy: 100≦HV1−HV2,
when half of a projected area circle equivalent diameter of the particle is represented by r and an average thickness of the coating layer is represented by t, r and t satisfy: 0.05≦t/r≦1.

9. The method for producing a composite particle according to claim 8 , wherein the coating particles are fusion-bonded to the particle so as to entirely cover the surface of the particle.

10. A powder core, comprising:
a compressed powder body obtained by compression-molding composite particles each including a particle composed of a soft magnetic metallic material and a coating layer composed of a plurality of coating particles each formed of a soft magnetic metallic material having a different composition from that of the particle and fusion-bonded to the particle so as to cover the particle and a binding material which binds the composite particles, an insulating layer between located between the particle and the coating layer, wherein
when a Vickers hardness of the particle is represented by HV1 and a Vickers hardness of the coating layer is represented by HV2, HV1 and HV2 satisfy: 100≦HV1−HV2, and
when half of a projected area circle equivalent diameter of the particle is represented by r and an average thickness of the coating layer is represented by t, r and t satisfy: 0.05≦t/r≦1.

11. A magnetic element, comprising the powder core according to claim 10 .

12. A portable electronic device, comprising the magnetic element according to claim 11 .

Assignees

• Seiko Epson Corp

Inventors

• Otsuka Isamu
• Maeta Yu
• Sato Toshikuni

Classifications

• H01F1/14733

  in the form of particles · CPC title

• H01F1/14766

  Fe-Si based alloys · CPC title

• H01F1/24 Primary

  the particles being insulated · CPC title

• C23C10/30

  using a layer of powder or paste on the surface (using liquid suspensions of solids C23C10/18) · CPC title

• H01F41/005 Primary

  Impregnating or encapsulating (insulating of windings H01F41/12) · CPC title