Amorphous alloy powder core and nano-crystal alloy powder core having good high frequency properties and methods of manufacturing the same

• US 6,827,557 B2
• Filed: 01/07/2002
• Issued: 12/07/2004
• Est. Priority Date: 01/05/2001
• Status: Expired due to Fees

• Current Assignee: Corporation Nanokorea, Il Kyn Kim, Kyu Jin Kim, Miraesojae Co., Ltd.
• Original Assignee: Humanelecs Co., Ltd., Kyu-Jin Kim
• Inventors: Kim, Kyu-Jin
• Primary Examiner(s): JENKINS, DANIEL J
• Application Number:
  US10/041,089
• Publication Number:
  US 20020124914A1
• Time in Patent Office: 1,065 Days
• Field of Search: 419/35, 419/38, 419/39, 419/36, 419/37, 419/31, 419/29, 148/105
• US Class Current: 417/35
• CPC Class Codes: B22F 1/10 Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
• CPC Class Codes: B22F 3/006 Amorphous articles
• CPC Class Codes: B22F 9/007 Transformation of amorphous into microcrystalline state
• CPC Class Codes: C21D 2201/03 Amorphous or microcrystalline structure
• CPC Class Codes: C21D 6/00 Heat treatment of ferrous alloys
• CPC Class Codes: C21D 6/008 containing Si
• CPC Class Codes: C22C 45/02 with iron as the major constituent
• CPC Class Codes: C22F 1/10 of nickel or cobalt or alloys based thereon
• CPC Class Codes: H01F 1/15333 containing nanocrystallites, e.g. obtained by annealing
• CPC Class Codes: H01F 1/15375 using polymers
• 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 method of manufacturing an amorphous alloy core including the steps of mixing an amorphous alloy powder with a solution made by dissolving a polyimide/phenolic resin binder in an organic solvent, evenly coating the binder in liquid phase on the surface of the alloy powder to make a powder of composite particles, molding the power of composite particles, and performing a heating treatment thereon. This invention also discloses a method of manufacturing a nano-crystal alloy core including the steps of (a) mixing an amorphous alloy powder with a solution made by dissolving a polyimide/phenolic resin binder in an organic solvent, evenly coating the binder in the liquid phase on the surface of the alloy powder to make composite particles, molding the composite particles at room temperature, and performing a heating treatment thereon at a temperature higher than the crystallization starting temperature of the alloy; and (b) performing a heating treatment on an amorphous alloy powder at over a crystallization starting temperature to make a nano-crystal phase, mixing a solution made by solving a polyimide/phenolic resin binder in an organic solvent therewith, evenly coating the binder in liquid phase on the surface of the alloy powder to make composite particles, and molding the power of composite particles at 100 to 300° C.

Claims

1. A method of manufacturing an amorphous alloy core comprising the steps of:

mixing an amorphous alloy powder with a solution, the amorphous alloy powder having an average diameter of less than 10 μ

m and selected from the group consisting of Fe—

Si—

B based alloys and Fe—

Al—

B based alloys made by high pressure water injection, the solution made by dissolving a polyimide resin binder ranging from 0.5 to 3.0 wt % of the total mass in an organic solvent, evenly coating the binder in liquid phase on the surface of the alloy powder to make a powder of composite particles;

molding the powder of composite particles at a temperature of 50 to 300°

C. under a pressure of 30 ton/cm²; and

performing a heating treatment at a temperature more than 10°

C. lower than a crystallization starting temperature of said amorphous alloy.

2. A method of manufacturing a nano-crystal alloy core having a saturated magnetic flux density of more than 1.10T and a permeability of more than 0.90, measured between 1 MHz and 0.1 MHz, the method comprising the steps of:

mixing an amorphous alloy powder with a solution, the amornhous alloy powder having an average diameter of less than 10 μ

m and selected from the group consisting of Fe—

Si—

B based alloys and Fe—

Al—

B based allow made by high pressure water injection, the solution made by dissolving a polyamide resin binder ranging from 0.5 to 3.0 wt % of the total mass in an organic solvent, evenly coating the binder in liquid phase on the surface of the alloy powder to make a powder of composite particles;

molding the powder of composite particles at a temperature of 50 to 300°

C. under a pressure of 10 to 30 ton/cm²; and

performing a heating treatment at a temperature less than 100°

C. higher than a crystallization starting temperature of said amorphous alloy.