Amorphous alloy powder core and nano-crystal alloy powder core having good high frequency properties and methods of manufacturing the same

• US 20020124914A1
• Filed: 01/07/2002
• Published: 09/12/2002
• Est. Priority Date: 01/05/2001
• Status: Active Grant

• Current Assignee: Corporation Nanokorea, Il Kyn Kim, Kyu Jin Kim, Miraesojae Co., Ltd.
• Original Assignee: Humanelecs Co., Ltd., Kim Kyu-Jin
• Inventors: Kim, Kyu-Jin
• Granted Patent: US 6,827,557 B2
• Time in Patent Office: Days
• US Class Current: 148/403
• CPC Class Codes: B22F 1/10 Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
• CPC Class Codes: B22F 3/006 Amorphous articles
• CPC Class Codes: B22F 9/007 Transformation of amorphous into microcrystalline state
• CPC Class Codes: C21D 2201/03 Amorphous or microcrystalline structure
• CPC Class Codes: C21D 6/00 Heat treatment of ferrous alloys
• CPC Class Codes: C21D 6/008 containing Si
• CPC Class Codes: C22C 45/02 with iron as the major constituent
• CPC Class Codes: C22F 1/10 of nickel or cobalt or alloys based thereon
• CPC Class Codes: H01F 1/15333 containing nanocrystallites, e.g. obtained by annealing
• CPC Class Codes: H01F 1/15375 using polymers
• CPC Class Codes: H01F 41/0246 Manufacturing of magnetic circuits by moulding or by pressing powder magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36

Abstract

A method of manufacturing an amorphous alloy core including the steps of mixing an amorphous alloy powder with a solution made by dissolving a polyimide/phenolic resin binder in an organic solvent, evenly coating the binder in liquid phase on the surface of the alloy powder to make a powder of composite particles, molding the power of composite particles, and performing a heating treatment thereon. This invention also discloses a method of manufacturing a nano-crystal alloy core including the steps of (a) mixing an amorphous alloy powder with a solution made by dissolving a polyimide/phenolic resin binder in an organic solvent, evenly coating the binder in the liquid phase on the surface of the alloy powder to make composite particles, molding the composite particles at room temperature, and performing a heating treatment thereon at a temperature higher than the crystallization starting temperature of the alloy; and (b) performing a heating treatment on an amorphous alloy powder at over a crystallization starting temperature to make a nano-crystal phase, mixing a solution made by solving a polyimide/phenolic resin binder in an organic solvent therewith, evenly coating the binder in liquid phase on the surface of the alloy powder to make composite particles, and molding the power of composite particles at 100 to 300° C.

Claims

1. A method of manufacturing an amorphous alloy core comprising the steps of:

mixing an amorphous alloy powder with a solution made by dissolving a polyimide/phenolic resin binder in an organic solvent, evenly coating the binder in liquid phase on the surface of the alloy powder to make a powder of composite particles;

molding the power of composite particles; and

performing a heating treatment thereon.

2. A method according to claim 1, wherein the amorphous alloy powder is selected from the group consisting of Fe—

Si—

B based alloys, Fe—

Al—

B based alloys, and Co—

Fe—

Si—

B based alloys.

3. A method according to claim 1, wherein the amount of the binder is 0.5 to 3.0 wt % of the total mass.

4. A method according to claim 1, wherein the molding is performed at from about room temperature to about 200°

C. under a pressure of 10 to 50 ton/cm².

5. A method according to claim 1, wherein the heating treatment is performed at 150 to 500°

C.

6. A method according to claim 1, further comprising the step of performing a heating treatment on the amorphous alloy powder at less than 500°

C. before mixing the amorphous alloy powder in the solution made by dissolving the polyimide resin or phenolic resin in the organic solvent.

7. An amorphous alloy core having a saturated magnetic flux density of more than 0.80T and a permeability of more than 0.90, measured in 1 MHz and 0.1 MHz.

8. An amorphous alloy core according to claim 7, wherein the amorphous alloy core is made by evenly coating a polyimide-based or phenol-based binder on an amorphous alloy powder, and performing a compression molding at less than 200°

C.

9. A method of manufacturing a nano-crystal alloy core comprising the steps of:

mixing an amorphous alloy powder with a solution made by dissolving a polyimide/phenolic resin binder in an organic solvent, evenly coating the binder in liquid phase on the surface of the alloy powder to make a powder of composite particles;

molding the power of composite particles at room temperature; and

performing a heating treatment thereon at over a crystallization starting temperature.

10. A method according to claim 9, wherein the amorphous alloy powder is selected from the group consisting of Fe—

Si—

B based alloys and Fe—

Al—

B based alloys.

11. A method according to claim 9, wherein the heating treatment is performed at less than 100°

C. higher than the crystallization starting temperature of said amorphous alloy.

13. A method according to claim 12, wherein the amorphous alloy powder is selected from the group consisting of Fe—

Si—

B based alloys and Fe—

Al—

B based alloys.

14. A method according to claim 12, wherein the heating treatment is performed at less than 100°

C. higher than the crystallization starting temperature of said amorphous alloy.

12. A method of manufacturing a nano-crystal alloy core comprising:

performing a heating treatment on an amorphous alloy powder at over a crystallization starting temperature to make a nano-crystal phase, mixing a solution made by dissolving a polyimide/phenolic resin binder in an organic solvent therewith, evenly coating the binder in liquid phase on the surface of the alloy powder to make a powder of composite particles; and

molding the power of composite particles at 100 to 300°

C.

15. A nano-crystal alloy core having a saturated magnetic flux density of more than 1.10T and a permeability of more than 0.90, measured in 1 MHz and 0.1 MHz.

16. A method of manufacturing an amorphous alloy core or nano-crystal alloy core by mixing an alloy powder with a solution made by dissolving a resin selected from the group consisting of a polyimide resin and a phenolic resin in an organic solvent.