Magnetic core and method of manufacturing the same

• US 6,284,060 B1
• Filed: 09/04/1998
• Issued: 09/04/2001
• Est. Priority Date: 04/18/1997
• Status: Expired due to Term

• Current Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Original Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Inventors: Matsutani, Nobuya, Mido, Yuji
• Primary Examiner(s): Sheehan, John P.
• Application Number:
  US09/148,116
• Time in Patent Office: 1,096 Days
• Field of Search: 252/62.54, 252/62.55, 148/300, 148/307, 148/310, 148/301, 148/302, 148/303, 148/304, 148/306, 752/30, 752/28, 752/46
• US Class Current: 148/300
• CPC Class Codes: H01F 1/24 the particles being insulated
• CPC Class Codes: H01F 1/26 by macromolecular organic substances
• 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 magnetic core of a compressed compact comprises a mixture of magnetic powder and a spacing material, wherein the distance between adjacent magnetic powder particles is controlled by the spacing material. In this constitution, a magnetic core low in core loss, high in magnetic permeability, and excellent in direct-current superposing characteristic is realized.

Claims

1. A magnetic core comprising a mixture of magnetic powder and a spacing material, wherein the distance between adjacent particles of said magnetic powder is controlled by said spacing material and wherein the distance between adjacent magnetic particles is represented by δ

and the mean particle size of magnetic powder is represented by d, and the relationship of 10<sup>−

3</sup>≦

δ

/d≦

10<sup>−

1</sup> is satisfied in 70% or more of the magnetic powder, said magnetic powder comprising a soft magnetic material.

2. A magnetic core of claim 1, wherein the mean particle size of said magnetic powder is 1-100 microns.

3. A magnetic core of claim 1, wherein said spacing material is an inorganic matter with mean particle size of 0.01-10 microns.

4. A magnetic core of claim 1, wherein said spacing material is composed of an organic matter expressed in the formula:

where X is an alkoxy silyl group, Y is an organic functional group, and Z is an organic unit, and each of l, m, n and o is an integer not less than zero.

5. A magnetic core of claim 1, wherein said spacing material is a metal powder with mean particle size of 0.1-20 microns.

6. The magnetic core of claim 1, wherein said spacing material is composed of at least two types out of (a) an inorganic matter powder, which is at least one inorganic matter selected from the group consisting of Al₂O₃, MgO, TiO₂, ZrO, SiO₂, and CaO, (b) an organic matter powder which is at least one organic matter selected from the group consisting of silicon resins, fluorocarbon resins, benzoguanamine resins and the following organic compound:

where X is an alkoxy silyl group, Y is an organic functional group, and Z is an organic unit, and each of l, m, n and o is an integer not less than zero and (c) a metal powder.