SOFT MAGNETIC MATERIAL, COMPACT, DUST CORE, ELECTROMAGNETIC COMPONENT, METHOD OF PRODUCING SOFT MAGNETIC MATERIAL, AND METHOD OF PRODUCING DUST CORE

• US 20110227690A1
• Filed: 06/29/2010
• Published: 09/22/2011
• Est. Priority Date: 06/30/2009
• Status: Abandoned Application

• Current Assignee: Sumitomo Electric Industries Limited (Sumitomo Corporation)
• Original Assignee: Sumitomo Electric Industries Limited (Sumitomo Corporation)
• Inventors: Sakamoto, Toshihiro, Watanabe, Asako
• Application Number:
  US13/131,746
• Publication Number:
  US 20110227690A1
• Time in Patent Office: Days
• US Class Current: 336/221
• CPC Class Codes: B22F 1/08 Metallic powder characterised by particles having an amorphous microstructure
• CPC Class Codes: B22F 1/103 containing an organic binding agent comprising a mixture of, or obtained by reaction of, two or more components other than a solvent or a lubricating agent
• 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: C22C 38/00 Ferrous alloys, e.g. steel alloys cast-iron alloys C22C37/00
• 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

Abstract

A soft magnetic material includes a plurality of magnetic particles, a binder, and a lubricant. The binder binds the plurality of magnetic particles. The lubricant is contained in the aggregate of the bound magnetic particles, and has a melting point less than or equal to 100° C. The method of producing a soft magnetic material includes the steps of forming an additive by mixing a binder and a lubricant including fatty acid monoamide, and binding the plurality of magnetic particles by the additive.

Claims

1. A soft magnetic material comprising:

a plurality of magnetic particles,

a binder binding said plurality of magnetic particles, and

a lubricant contained in an aggregate of bound magnetic particles, and having a melting point less than or equal to 100°

C.

2. The soft magnetic material according to claim 1, wherein said lubricant includes fatty acid monoamide or fatty acid monoester.

3. The soft magnetic material according to claim 1, wherein said lubricant includes unsaturated fatty acid monoamide or unsaturated fatty acid monoester.

4. A compact, produced by applying pressure-formation to the soft magnetic material defined in claim 1.

5. A dust core, produced by applying heat treatment to the compact defined in claim 4.

6. An electromagnetic component comprising:

a dust core defined in claim 5, and

a coil wound around said dust core.

7. A method of producing a soft magnetic material, comprising the steps of:

forming an additive by mixing a binder and a lubricant having a melting point less than or equal to 100°

C., and

binding a plurality of magnetic particles by said additive.

8. The method of producing a soft magnetic material according to claim 7, wherein said lubricant including fatty acid monoamide or fatty acid monoester is employed in said step of forming an additive.

9. The method of producing a soft magnetic material according to claim 7, wherein said lubricant including unsaturated fatty acid monoamide or unsaturated fatty acid monoester is employed in said step of forming an additive.

10. A method of producing a dust core, comprising the steps of:

producing a soft magnetic material by the method of producing a soft magnetic material defined in claim 7,

forming a compact by applying pressure-formation to said soft magnetic material, and

heat-treating said compact.

11. The method of producing a dust core according to claim 10, wherein pressure-formation is applied at a temperature higher than a melting point of said lubricant in said step of forming a compact.