Soft Magnetic Material, Powder Magnetic Core, Method for Manufacturing Soft Magnetic Material, and Method for Manufacturing Powder Magnetic Core

• US 20080044679A1
• Filed: 07/19/2006
• Published: 02/21/2008
• Est. Priority Date: 09/21/2005
• Status: Active Grant

• Current Assignee: Sumitomo Electric Industries Limited (Sumitomo Corporation)
• Original Assignee: Sumitomo Electric Industries, Inc.
• Inventors: Mochida, Yasushi, Maeda, Toru, Maeda, Kazuyuki, Mimura, Koji
• Granted Patent: US 7,622,202 B2
• Time in Patent Office: Days
• US Class Current: 428/546
• CPC Class Codes: B22F 1/16 Metallic particles coated with a non-metal coated with lubricating or binding agents or with organic material B22F1/10
• CPC Class Codes: B22F 2003/145 by warm compacting, below debindering temperature
• CPC Class Codes: B22F 2003/248 Thermal after-treatment
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: C22C 2202/02 Magnetic
• CPC Class Codes: C22C 33/02 by powder metallurgy working metallic powder B22F
• CPC Class Codes: H01F 1/24 the particles being insulated
• CPC Class Codes: H01F 1/26 by macromolecular organic substances
• CPC Class Codes: H01F 1/33 mixtures of metallic and non-metallic particles; metallic particles having oxide skin
• CPC Class Codes: H01F 3/08 made from powder powder coatings on sheets H01F3/02; on strips or ribbons H01F3/04; on wires H01F3/06
• 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
• CPC Class Codes: Y10T 428/12014 having metal particles
• CPC Class Codes: Y10T 428/2995 Silane, siloxane or silicone coating
• CPC Class Codes: Y10T 428/32 Composite [nonstructural laminate] of inorganic material having metal-compound-containing layer and having defined magnetic layer
• CPC Class Codes: Y10T 428/325 Magnetic layer next to second metal compound-containing layer

Abstract

A soft magnetic material includes a plurality of composite magnetic particles (40) each including a metal magnetic particle (10) and an insulation coating (20) covering the surface of the metal magnetic particle (10), wherein the insulation coating (20) contains Si (silicon), and 80% or more of Si contained in the insulation coating constitutes a silsesquioxane skeleton. Therefore, it is possible to effectively decrease a hysteresis loss while suppressing an increase in eddy-current loss.

Claims

1. A soft magnetic material comprising a plurality of composite magnetic particles (40) each including a metal magnetic particle (10) and an insulation coating (20) covering the surface of the metal magnetic particle, wherein the insulation coating contains Si, and 80% or more of Si contained in the insulation coating constitutes a silsesquioxane skeleton.

2. The soft magnetic material according to claim 1, wherein the average thickness of the insulation coating (20) is 10 nm to 1 μ

m.

3. The soft magnetic material according to claim 1, wherein each of the plurality of composite magnetic particles (40) further includes an undercoating (30) formed between the metal magnetic particle and the insulation coating, wherein the undercoating is composed of an insulating amorphous compound.

4. The soft magnetic material according to claim 3, wherein the undercoating (30) includes an amorphous compound of a phosphate of at least one selected from the group consisting of Al, Si, Mg, Y, Ca, Zr, and Fe, an amorphous compound of a borate thereof, or an amorphous compound of an oxide thereof.

5. The soft magnetic material according to claim 3, wherein the average thickness of the undercoating (30) is 10 nm to 1 μ

m.

6. A powder magnetic core manufactured using the soft magnetic material according to claim 1.

7. A powder magnetic core comprising a plurality of composite magnetic particles (40) each including a metal magnetic particle (10) and an insulation coating (20) covering the surface of the metal magnetic particle,

wherein the insulation coating contains Si, and 80% or more of Si contained in the insulation coating constitutes a silsesquioxane skeleton and a silica skeleton represented by (Si—

O_x)_n wherein x>

1.5.

8. A method for manufacturing a soft magnetic material comprising a step of forming an insulation coating (20) on a metal magnetic particle (10),

wherein 80% or more of Si contained in the insulation coating constitutes a silsesquioxane skeleton.

9. A method for manufacturing a powder magnetic core comprising:

a pressure molding step of pressure-molding the soft magnetic material manufactured by the method for manufacturing the soft magnetic material according to claim 8;

and

a step of thermally curing the insulation coating (20) after the pressure molding step.

10. A method for manufacturing a powder magnetic core comprising a pressure molding step of pressure-molding, in a heated mold, the soft magnetic material manufactured by the method for manufacturing the soft magnetic material according to claim 8 and, at the same time, thermally curing the insulation coating (20).