Magnetic core using amorphous soft magnetic alloy

• US 7,501,925 B2
• Filed: 09/28/2007
• Issued: 03/10/2009
• Est. Priority Date: 09/29/2006
• Status: Active Grant

• Current Assignee: Alps Alpine Co., Ltd.
• Original Assignee: ALPS Electric Company Limited (Alps Alpine Co., Ltd.)
• Inventors: Naito, Yutaka, Aoki, Kazuo, Abe, Masatomi, Kaneko, Kazuya
• Primary Examiner(s): Sheehan; John P.
• Application Number:
  US11/864,404
• Publication Number:
  US 20080078474A1
• Time in Patent Office: 529 Days
• Field of Search: None
• US Class Current: 336/233
• CPC Class Codes: C22C 2200/02 Amorphous
• CPC Class Codes: C22C 2202/02 Magnetic
• 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 33/0228 comprising other non-metallic compounds or more than 5% of graphite
• CPC Class Codes: H01F 1/15308 based on Fe/Ni H01F1/15325 takes precedence
• CPC Class Codes: H01F 1/15366 using a binder

Abstract

A magnetic core made of a mixed material including powder of an amorphous soft magnetic iron alloy and about 10% by volume or more of nonmagnetic inorganic powder, the amorphous soft magnetic iron alloy being expressed by the following composition:
Fe_{100-a-b-x-y-z-w-t}CO_aNi_bM_xP_yC_zB_wSi_t

wherein M is one or two or more elements selected from among Cr, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd and Au, and a, b, x, y, z, w and t represent composition ratios satisfying 0 atom %≦x≦3 atom %, 2 atom %≦y≦15 atom %, 0 atom %<z≦8 atom %, 1 atom %≦w≦12 atom %, 0.5 atom %≦t≦8 atom %, 0 atom %≦a≦20 atom %, 0 atom %≦b≦5 atom %, and 70 atom %≦(100-a-b-x-y-z-w-t)≦80 atom %.

Claims

1. A magnetic core made of a mixed material including powder of an amorphous soft magnetic iron alloy and about 10% by volume or more of a ceramic material powder, the mixed material including a binder for compacting the mixed material into a predetermined shape, the amorphous soft magnetic iron alloy being expressed by the following composition:

Fe_{100-a-b-x-y-z-w-t}CO_aNi_bM_xP_yC_zB_wSi_t

wherein M is one or two or more elements selected from among Cr, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd and Au, and a, b, x, y, z, w and t represent composition ratios satisfying 0 atom %≦

x≦

3 atom %, 2 atom %≦

y≦

15 atom %, 0 atom %<

z≦

8 atom %, 1 atom %≦

w≦

12 atom %, 0.5 atom %≦

t≦

8 atom %, 0 atom %≦

a≦

20 atom %, 0 atom %≦

b≦

5 atom %, and 70 atom %≦

(100-a-b-x-y-z-w-t)≦

80 atom %.

2. The magnetic core according to claim 1, wherein a proportion of the ceramic material powder in the mixed material is about 20% by volume to about 50% by volume.

3. The magnetic core according to claim 2, wherein an average particle size of the ceramic material powder is about 1.0 μ

m to about 30 μ

m.

4. The magnetic core according to claim 1, wherein the magnetic core has micro-gaps that are smaller in size than a size of magnetic particles in the magnetic core such that a magnetic path in the magnetic core is magnetically continuous.

5. A magnetic core made of a mixed material including powder of an amorphous soft magnetic iron alloy and about 10% by volume or more of a ceramic material powder, the mixed material including a binder for compacting the mixed material into a predetermined shape, the amorphous soft magnetic iron alloy being expressed by the following composition:

Fe_{100-a-b-x-y-z-w-t}CO_aNi_bM_xP_yC_zB_wSi_t

wherein M is one or two or more elements selected from among Cr, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd and Au, and a, b, x, y, z, w and t represent composition ratios satisfying 0 atom %≦

x≦

3 atom %, 2 atom %≦

y≦

15 atom %, 0 atom %<

z≦

8 atom %, 1 atom %≦

w≦

12 atom %, 0.5 atom %≦

t≦

8 atom %, 0 atom %≦

a≦

20 atom %, 0 atom %≦

b≦

5 atom %, and 70 atom %≦

(100-a-b-x-y-z-w-t)≦

80 atom %,

wherein a proportion of the ceramic material powder in the mixed material is about 20% by volume to about 50% by volume,

wherein an average particle size of the ceramic material powder is about 1.0 μ

m to about 30 μ

m, and

wherein the magnetic core has micro-gaps that are smaller in size than a size of magnetic particles in the magnetic core such that a magnetic path in the magnetic core is magnetically continuous.