High permeability soft magnetic composites
First Claim
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1. A method for making a magnetic composite material, comprising:
- providing a high compressibility powder with a first average particle size;
providing a high permeability powder with a second average particle size;
mixing the two powders;
coating the high compressibility powder, the high permeability powder, both the high compressibility powder and the high permeability powder, or the powder mixture with an agent; and
compacting the powder mixture.
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Abstract
Soft magnetic composites having a high compressibility and a high permeability are described. These two characteristics are obtained by combining high compressibility iron powder to high permeability powders. The iron powder is of a high compressibility and in a size range and proportion that results in a powder mass amenable to compaction by industrially viable and cost-effective compaction process such as uniaxial cold compaction. The high compressibility iron powder helps achieve high relative density and also allows easy path for the passage of magnetic flux.
26 Citations
59 Claims
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1. A method for making a magnetic composite material, comprising:
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providing a high compressibility powder with a first average particle size;
providing a high permeability powder with a second average particle size;
mixing the two powders;
coating the high compressibility powder, the high permeability powder, both the high compressibility powder and the high permeability powder, or the powder mixture with an agent; and
compacting the powder mixture. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method for making a magnetic composite material, comprising:
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providing a high compressibility powder with a first average particle size;
providing a high permeability powder with a second average particle size;
mixing the two powders;
coating the high compressibility powder, the high permeability powder, both the high compressibility powder and the high permeability powder, or the powder mixture with an agent;
compacting the powder mixture; and
annealing the compacted powder mixture. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22)
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23. A method for making a magnetic composite material, comprising:
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providing iron powder with a first average particle size;
providing a high permeability powder with a second average particle size;
mixing the two powders;
coating the high compressibility powder, the high permeability powder, both the high compressibility powder and the high permeability powder, or the powder mixture with an agent comprising silicone;
compacting the powder mixture; and
annealing the compacted powder mixture. - View Dependent Claims (24)
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25. A magnetic composite material made by the method comprising:
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providing a high compressibility powder with a first average particle size;
providing a high permeability powder with a second average particle size;
mixing the two powders;
coating the high compressibility powder, the high permeability powder, both the high compressibility powder and the high permeability powder, or the powder mixture with an agent; and
compacting the powder mixture.
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26. A magnetic composite material made by the method comprising:
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providing a high compressibility powder with a first average particle size;
providing a high permeability powder with a second average particle size;
mixing the two powders;
coating the high compressibility powder, the high permeability powder, both the high compressibility powder and the high permeability powder, or the powder mixture with an agent;
compacting the powder mixture; and
annealing the compacted powder mixture.
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27. A magnetic composite material made by the method comprising:
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providing iron powder with a first average particle size;
providing a high permeability powder with a second average particle size;
mixing the two powders;
coating the high compressibility powder, the high permeability powder, both the high compressibility powder and the high permeability powder, or the powder mixture with an agent comprising silicone;
compacting the powder mixture; and
annealing the compacted powder mixture.
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28. An un-compacted magnetic composite material, comprising:
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a high compressibility powder having a first average particle size; and
a high permeability powder having a second average particle size;
wherein the high compressibility powder, the high permeability powder, or both are coated with an agent comprising silicone. - View Dependent Claims (29, 30, 31, 32, 33)
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34. A magnetic composite material, comprising:
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a high compressibility powder having a first average particle size; and
a high permeability powder having a second average particle size;
wherein the material has a relative density of least about 80% and wherein the high compressibility powder, the high permeability powder, or both are coated with an agent. - View Dependent Claims (35, 36, 37, 38, 39, 40, 41, 42)
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43. A magnetic composite material, comprising:
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a high compressibility powder having a first average particle size; and
a high permeability powder having a second average particle size;
wherein the material has a relative density of about 95 to about 97% and wherein the high compressibility powder, the high permeability powder, or both are coated with an agent. - View Dependent Claims (44, 45, 46, 47, 48, 49, 50)
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51. A magnetic composite material, comprising:
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a high compressibility powder comprising iron having a first average particle size; and
a high permeability powder having a second average particle size;
wherein the material has a relative density of about 95 to about 97% and wherein the high compressibility powder, the high permeability powder, or both are coated with an agent comprising silica. - View Dependent Claims (52, 53, 54, 55, 56)
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57. A device containing a magnetic composite material comprising:
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a high compressibility powder having a first average particle size; and
a high permeability powder having a second average particle size;
wherein the material has a relative density of least about 80% and wherein the high compressibility powder, the high permeability powder, or both are coated with an agent.
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58. A device containing a magnetic composite material comprising:
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a high compressibility powder having a first average particle size; and
a high permeability powder having a second average particle size;
wherein the material has a relative density of about 95 to about 97% and wherein the high compressibility powder, the high permeability powder, or both are coated with an agent.
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59. A device containing a magnetic composite material comprising:
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a high compressibility powder comprising iron having a first average particle size; and
a high permeability powder having a second average particle size;
wherein the material has a relative density of about 95 to about 97% and wherein the high compressibility powder, the high permeability powder, or both are coated with an agent comprising silica.
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Specification