Amorphous soft magnetic alloy and inductance component using the same

• US 20070175545A1
• Filed: 02/01/2007
• Published: 08/02/2007
• Est. Priority Date: 02/02/2006
• Status: Abandoned Application

• Current Assignee: Tohoku University National Universities Corporation, NEC Tokin Corporation (Yageo Corporation)
• Original Assignee: Tohoku University National Universities Corporation, NEC Tokin Corporation (Yageo Corporation)
• Inventors: Inoue, Akihisa, Fujiwara, Teruhiko, Matsumoto, Hiroyuki, Yamada, Yasunobu, Urata, Akiri
• Application Number:
  US11/701,342
• Publication Number:
  US 20070175545A1
• Time in Patent Office: Days
• US Class Current: 148/304
• CPC Class Codes: B22F 2003/248 Thermal after-treatment
• CPC Class Codes: B22F 2201/11 Argon
• CPC Class Codes: B22F 2201/20 Use of vacuum
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 3/18 by using pressure rollers
• CPC Class Codes: B22F 3/24 After-treatment of workpieces or articles B22F3/1146 takes precedence
• CPC Class Codes: B22F 9/002 amorphous or microcrystalline
• CPC Class Codes: B22F 9/082 atomising using a fluid using centrifugal force B22F9/10
• CPC Class Codes: C22C 28/00 Alloys based on a metal not provided for in groups C22C5/00 - C22C27/00
• CPC Class Codes: C22C 33/003 making amorphous alloys
• CPC Class Codes: C22C 33/0207 Using a mixture of prealloyed powders or a master alloy mixtures of metal powder in general B22F1/09
• CPC Class Codes: C22C 33/0257 characterised by the range of the alloying elements
• CPC Class Codes: C22C 45/02 with iron as the major constituent
• CPC Class Codes: H01F 1/153 Amorphous metallic alloys, e.g. glassy metals making ferrous amorphous alloys C22C33/003
• CPC Class Codes: H01F 1/15308 based on Fe/Ni H01F1/15325 takes precedence
• CPC Class Codes: H01F 1/15375 using polymers
• CPC Class Codes: H01F 17/062 Toroidal core with turns of coil around it
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 3/14 Constrictions; Gaps, e.g. air-gaps in magnetic shunt paths H01F3/12
• CPC Class Codes: H01F 41/0226 : from amorphous ribbons
• 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

To provide an amorphous soft magnetic alloy having a supercooled liquid region and excellent in amorphous-forming ability and soft magnetic properties, by selecting and optimizing an alloy composition, and to further provide a ribbon, a powder, a high-frequency magnetic core, and a bulk member each using such an amorphous soft magnetic alloy. The amorphous soft magnetic alloy has a composition expressed by a formula of (Fe_1-αTM_α)_100-w-x-y-zP_wB_xL_ySi_z, wherein unavoidable impurities are contained, TM is at least one selected from Co and Ni, L is at least one selected from the group consisting of Al, V, Cr, Y, Zr, Mo, Nb, Ta, and W, 0≦α0.98, 2≦w≦16 at %, 2≦x≦16 at %, 0<y≦10 at %, and 0≦z≦8 at %).

Claims

1. An amorphous soft magnetic alloy having a composition expressed by a formula of (Fe_1-α

TM_α

)_100-w-x-y-zP_wB_xL_ySi_z, wherein unavoidable impurities are contained, TM is at least one selected from Co and Ni, L is at least one selected frown the group consisting of Al, V, Cr, Y Zr, Mo, Nb, Ta, and W. 0≦

α

≦

0.98, 2≦

w≦

16 at %, 2≦

x≦

16 at %, 0<

y≦

10 at %, and 0≦

z≦

8 at %.

2. An amorphous soft magnetic alloy according to claim 1, wherein a crystallization start temperature (Tx) is 550°

C. or less, a glass transition temperature (Tg) is 520°

C. or less, and a supercooled liquid region represented by Δ

Tx=Tx-Tg is 20°

C. or more.

3. An amorphous soft magnetic alloy according to claim 1, wherein a saturation magnetic flux density is 1.2 T or more.

4. An amorphous soft magnetic alloy according to claim 1, wherein a Curie temperature is 240°

C. or more.

5. An amorphous soft magnetic alloy member made of the amorphous soft magnetic alloy according to claim 1, wherein said amorphopus soft magnetic alloy member has a thickness of 0.5 mm or more and a cross-sectional area of 0.15 mm² or more.

6. An amorphous soft magnetic alloy ribbon made of the amorphous soft magnetic alloy according to claim 1, wherein said amorphous soft magnetic alloy ribbon has a thickness of 1 to 200 μ

m.

7. An amorphous soft magnetic alloy ribbon according to claim 6, wherein said amorphous soft magnetic alloy ribbon has a magnetic permeability of 5000 or more at a frequency of 1 kHz.

8. An amorphous soft magnetic alloy powder made of the amorphous soft magnetic alloy according to claim 1, wherein said amorphous soft magnetic alloy powder has a particle size of 200 μ

m or less (excluding zero).

9. An amorphous soft magnetic alloy powder according to claim 8, wherein said amorphous soft magnetic alloy powder contains at least one of an amorphous soft magnetic alloy powder produced by water atomization and an amorphous soft magnetic alloy powder produced by gas atomization, and 50% or more in number of particles of the powder have a particle size greater than 3 μ

m.

10. An amorphous soft magnetic alloy powder according to claim 8, wherein said amorphous soft magnetic alloy powder contains at least one of an amorphous soft magnetic alloy powder produced by water atomization and an amorphous soft magnetic alloy powder produced by gas atomization, is adapted to pass through a sieve having a mesh size of 250 μ

m, and has a particle size with a center diameter of 200 μ

m or less.

11. An amorphous soft magnetic alloy powder according to claim 8, wherein said amorphous soft magnetic alloy powder contains at least one of an amorphous soft magnetic alloy powder produced by water atomization and an amorphous soft magnetic alloy powder produced by gas atomization, is adapted to pass through a sieve having a mesh size of 150μ

m, and has a particle size with a center diameter of 100 μ

m or less.

12. An amorphous soft magnetic alloy powder according to claim 8, wherein said amorphous soft magnetic alloy powder contains at least one of an amorphous soft magnetic alloy powder produced by water atomization and an amorphous soft magnetic alloy powder produced by gas atomization, is adapted to pass through a sieve having a mesh size of 45 μ

m, and has a particle size with a center diameter of 30 μ

m or less.

13. An amorphous soft magnetic alloy powder according to claim 8, wherein said amorphous soft magnetic alloy powder contains at least one of an amorphous soft magnetic alloy powder produced by water atomization and an amorphous soft magnetic alloy powder produced by gas atomization, is adapted to pass through a sieve having a mesh size of 45 μ

m, and has a particle size with a center diameter of 20 μ

m or less.

14. An amorphous soft magnetic alloy powder according to claim 8, wherein said amorphous soft magnetic alloy powder has an aspect ratio of 1 to 2.

15. A magnetic core formed by machining the amorphous soft magnetic alloy member according to claim 5.

16. A magnetic core formed by annularly winding the amorphous soft magnetic alloy ribbon according to claim 6.

17. A magnetic core according to claim 16, formed by annularly winding said amorphous soft magnetic alloy ribbon through an insulator.

18. A magnetic core formed by laminating substantially same-shaped pieces of the amorphous soft magnetic alloy ribbon according to claim 6.

19. A magnetic core according to claim 18 formed by laminating said substantially same-shaped pieces of said amorphous soft magnetic alloy ribbon through insulators interposed therebetween.

20. A magnetic core formed by molding a mixture of a material powder comprising the amorphous soft magnetic alloy powder according to claim 8 and a binder added thereto in an amount of 10% or less by mass.

21. A magnetic core according to claim 20 wherein a mixing ratio of said binder in said mixture is 5% or less by mass, a space factor of said material powder in said magnetic core is 70% or more, a magnetic flux density is 0.4 T or more in applying a magnetic field of 1.6×

10⁴ A/m, and a resistivity is 1 Ω

·

cm or more.

22. A magnetic core according to claim 20, wherein a mixing ratio of said binder in said mixture is 3% or less by mass, a molding temperature is equal to or higher than a softening point of said binder, a space factor of said material powder in said magnetic core is 80% or more, a magnetic flux density is 0.6 T or more in applying a magnetic field of 1.6×

10⁴ A/m, and a resistivity is 0.1 Ω

·

cm or more.

23. A magnetic core according to claim 20, wherein a mixing ratio of said binder in said mixture is 1% or less by mass, a molding temperature is in a supercooled liquid region of said amorphous soft magnetic alloy powder, a space factor of said material powder in said magnetic core is 90% or more, a magnetic flux density is 0.9 T or more in applying a magnetic field of 1.6×

10⁴ A/m, and a resistivity is 0.01 Ω

·

cm or more.

24. A magnetic core according to claim 20, wherein said material powder contains a soft magnetic alloy powder in an amount of 5 to 50% by volume, said soft magnetic alloy powder having a smaller center particle size and a lower hardness as compared with said amorphous soft magnetic alloy powder.

25. A magnetic core according to claim 15, wherein said magnetic core is formed by heat treatment in a temperature region equal to or higher than a Curie temperature and equal to or lower than a crystallization start temperature of said amorphous soft magnetic alloy.

26. An inductance component formed by applying a coil with at least one turn to the magnetic core according to claim 15.

27. An inductance component formed by integrally molding the magnetic core according to claim 20 and a coil, wherein said coil is formed by winding a linear conductor by at least one turn and is disposed in said magnetic core.

28. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprised of the amorphous soft magnetic alloy powder according to claim 10 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 10 kHz or more is 20 or more.

29. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprised of the amorphous soft magnetic alloy powder according to claim 11 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 100 kHz or more is 25 or more.

30. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprised of the amorphous soft magnetic alloy powder according to claim 12 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 500 kHz or more is 40 or more.

31. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprising the amorphous soft magnetic alloy powder according to claim 13 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 1 MHz or more is 50 or more.

32. An inductance component according to claim 28, wherein said coil is formed by winding a linear conductor by at least one turn and is disposed in said magnetic core, and said magnetic core and said coil are integrally molded.

33. An inductance component according to claim 26, wherein said magnetic core is formed with a gap.

34. An inductance component according to claim 26, wherein said magnetic core is formed by heat treatment in a temperature region equal to or higher than a Curie temperature and equal to or lower than a crystallization start temperature of said amorphous soft magnetic alloy.

35. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprised of the amorphous soft magnetic alloy powder according to claim 14 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 10 kHz or more is 20 or more.

36. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprised of the amorphous soft magnetic alloy powder according to claim 14 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 100 kHz or more is 25 or more.

37. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprised of the amorphous soft magnetic alloy powder according to claim 14 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 500 kHz or more is 40 or more.

38. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprising the amorphous soft magnetic alloy powder according to claim 14 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 1 MHz or more is 50 or more.

39. An inductance component according to claim 35, wherein said coil is formed by winding a linear conductor by at least one turn and is disposed in said magnetic core, and said magnetic core and said coil are integrally molded.

40. An amorphous soft magnetic alloy having a composition expressed by a formula of (Fe_1-α

TM_α

)_100-w-x-y-zP_wB_xL_ySi_zTi_pC_qMn_rCu_s, wherein unavoidable impurities are contained, TM is at least one selected from Co and Ni, L is at least one selected from the group consisting of Al, Cr, Zr, Mo, and Nb, 0≦

α

≦

0.3, 2≦

w≦

18 at %, 2≦

x≦

5 at %, 0≦

y≦

10 at %, 0≦

z≦

4 at %, and p, q, r, and s each represents an addition ratio given that the total mass of Fe, TM, P, B, L, and Si is 100, and are defined as 0≦

p≦

0.3, 0≦

q≦

0.5, 0≦

r≦

2, and 0≦

s≦

1.

41. An amorphous soft magnetic alloy according to claim 40, wherein a crystallization start temperature (Tx) is 550°

C. or less, a glass transition temperature (Tg) is 520°

C. or less, and a supercooled liquid region represented by Δ

Tx=Tx-Tg is 20°

C. or more.

42. An amorphous soft magnetic alloy according to claim 40, wherein a saturation magnetic flux density is 1.2 T or more.

43. An amorphous soft magnetic alloy according to claim 40, wherein a Curie temperature is 240°

C. or more.

44. An amorphous soft magnetic alloy member made of the amorphous soft magnetic alloy according to claim 40, wherein said amorphopus soft magnetic alloy member has a thickness of 0.5 mm or more and a cross-sectional area of 0.15 mm² or more.

45. An amorphous soft magnetic alloy ribbon made of the amorphous soft magnetic alloy according to claim 40, wherein said amorphous soft magnetic alloy ribbon has a thickness of 1 to 200 μ

m.

46. An amorphous soft magnetic alloy ribbon according to claim 45, wherein said amorphous soft magnetic alloy ribbon has a magnetic permeability of 5000 or more at a frequency of 1 kHz.

47. An amorphous soft magnetic alloy powder made of the amorphous soft magnetic alloy according to claim 40, wherein said amorphous soft magnetic alloy powder has a particle size of 200 μ

m or less (excluding zero).

48. An amorphous soft magnetic alloy powder according to claim 47, wherein said amorphous soft magnetic alloy powder contains at least one of an amorphous soft magnetic alloy powder produced by water atomization and an amorphous soft magnetic alloy powder produced by gas atomization, and 50% or more in number of particles of the powder have a particle size greater than 3 μ

m.

49. An amorphous soft magnetic alloy powder according to claim 47, wherein said amorphous soft magnetic alloy powder contains at least one of an amorphous soft magnetic alloy powder produced by water atomization and an amorphous soft magnetic alloy powder produced by gas atomization, is adapted to pass through a sieve having a mesh size of 250 μ

m, and has a particle size with a center diameter of 200 μ

m or less.

50. An amorphous soft magnetic alloy powder according to claim 47, wherein said amorphous soft magnetic alloy powder contains at least one of an amorphous soft magnetic alloy powder produced by water atomization and an amorphous soft magnetic alloy powder produced by gas atomization, is adapted to pass through a sieve having a mesh size of 150 μ

m, and has a particle size with a center diameter of 100 μ

m or less.

51. An amorphous soft magnetic alloy powder according to claim 47, wherein said amorphous soft magnetic alloy powder contains at least one of an amorphous soft magnetic alloy powder produced by water atomization and an amorphous soft magnetic alloy powder produced by gas atomization, is adapted to pass through a sieve having a mesh size of 45 μ

m, and has a particle size with a center diameter of 30 μ

m or less.

52. An amorphous soft magnetic alloy powder according to claim 47, wherein said amorphous soft magnetic alloy powder contains at least one of an amorphous soft magnetic alloy powder produced by water atomization and an amorphous soft magnetic alloy powder produced by gas atomization, is adapted to pass through a sieve having a mesh size of 45 μ

m, and has a particle size with a center diameter of 20 μ

m or less.

53. An amorphous soft magnetic alloy powder according to claim 47, wherein said amorphous soft magnetic alloy powder has an aspect ratio of 1 to 2.

54. A magnetic core formed by machining the amorphous soft magnetic alloy member according to claim 44.

55. A magnetic core formed by annularly winding the amorphous soft magnetic alloy ribbon according to claim 45.

56. A magnetic core according to claim 55, formed by annularly winding said amorphous soft magnetic alloy ribbon through an insulator.

57. A magnetic core formed by laminating substantially same-shaped pieces of the amorphous soft magnetic alloy ribbon according to claim 45.

58. A magnetic core according to claim 57, formed by laminating said substantially same-shaped pieces of said amorphous soft magnetic alloy ribbon through insulators interposed therebetween.

59. A magnetic core formed by molding a mixture of a material powder comprising the amorphous soft magnetic alloy powder according to claim 47 and a binder added thereto in an amount of 10% or less by mass.

60. A magnetic core according to claim 59, wherein a mixing ratio of said binder in said mixture is 5% or less by mass, a space factor of said material powder in said magnetic core is 70% or more, a magnetic flux density is 0.4 T or more in applying a magnetic field of 1.6×

10⁴ A/m, and a resistivity is 1 Ω

·

cm or more.

61. A magnetic core according to claim 59, wherein a mixing ratio of said binder in said mixture is 3% or less by mass, a molding temperature is equal to or higher than a softening point of said binder, a space factor of said material powder in said magnetic core is 80% or more, a magnetic flux density is 0.6 T or more in applying a magnetic field of 1.6×

10⁴ A/m, and a resistivity is 0.1 Ω

·

cm or more.

62. A magnetic core according to claim 59, wherein a mixing ratio of said binder in said mixture is 1% or less by mass, a molding temperature is in a supercooled liquid region of said amorphous soft magnetic alloy powder, a space factor of said material powder in said magnetic core is 90% or more, a magnetic flux density is 0.9 T or more in applying a magnetic field of 1.6×

10⁴ A/m, and a resistivity is 0.01 Ω

·

cm or more.

63. A magnetic core according to claim 59, wherein said material powder contains a soft magnetic alloy powder in an amount of 5 to 50% by volume, said soft magnetic alloy powder having a smaller center particle size and a lower hardness as compared with said amorphous soft magnetic alloy powder.

64. A magnetic core according to claim 54, wherein said magnetic core is formed by heat treatment in a temperature region equal to or higher than a Curie temperature and equal to or lower than a crystallization start temperature of said amorphous soft magnetic alloy.

65. An inductance component formed by applying a coil with at least one turn to the magnetic core according to claim 54.

66. An inductance component formed by integrally molding the magnetic core according to claim 59 and a coil, wherein said coil is formed by winding a linear conductor by at least one turn and is disposed in said magnetic core.

67. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprised of the amorphous soft magnetic alloy powder according to claim 49 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 10 kHz or more is 20 or more.

68. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprised of the amorphous soft magnetic alloy powder according to claim 50 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 100 kHz or more is 25 or more.

69. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprised of the amorphous soft magnetic alloy powder according to claim 51 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 500 kHz or more is 40 or more.

70. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprising the amorphous soft magnetic alloy powder according to claim 52 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 1 MHz or more is 50 or more.

71. An inductance component according to claim 67, wherein said coil is formed by winding a linear conductor by at least one turn and is disposed in said magnetic core, and said magnetic core and said coil are integrally molded.

72. An inductance component according to claim 65, wherein said magnetic core is formed with a gap.

73. An inductance component according to claim 65, wherein said magnetic core is formed by heat treatment in a temperature region equal to or higher than a Curie temperature and equal to or lower than a crystallization start temperature of said amorphous soft magnetic alloy.

74. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprised of the amorphous soft magnetic alloy powder according to claim 53 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 10 kHz or more is 20 or more.

75. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprised of the amorphous soft magnetic alloy powder according to claim 53 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 100 kHz or more is 25 or more.

76. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprised of the amorphous soft magnetic alloy powder according to claim 53 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 500 kHz or more is 40 or more.

77. An inductance component formed by applying a coil with at least one turn to a magnetic core formed by molding a mixture of a material powder comprising the amorphous soft magnetic alloy powder according to claim 53 and a binder added thereto in an amount of 5% or less by mass, a space factor of said material powder in said magnetic core being 50% or more, wherein a peak value of Q (1/tan δ

) of said inductance component in a frequency band of 1 MHz or more is 50 or more.

78. An inductance component according to claim 74, wherein said coil is formed by winding a linear conductor by at least one turn and is disposed in said magnetic core, and said magnetic core and said coil are integrally molded.