# US 10,121,586 B2 · Method for manufacturing Fe-based amorphous metal powder and method for manufacturing amorphous soft magnetic cores using same

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- Number: US 10,121,586 B2
- Document ID: US10121586B2
- Status: Granted
- Kind: B2
- Application number: 14/762,021
- Filed: 2014-01-21
- Published: 2015-12-10
- Granted: 2018-11-06
- Earliest claimed: 2013-01-24
- Assignees: Amogreentech Co., Ltd.
- Applicants: Amogreentech Co., Ltd.
- Inventors: Byoung Ki Lee; Se Joong Yoon; Mi Rae Kim
- Web page: https://patentgrep.com/patent/US10121586B2

## CPC

- 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)}
- B22F 1/052: characterised by a mixture of particles of different sizes or by the particle size distribution
- B22F 1/08: Metallic powder characterised by particles having an amorphous microstructure
- B22F 3/006: {Amorphous articles}
- B22F 3/02: Compacting only
- B22F 3/24: After-treatment of workpieces or articles {(B22F3/1146 takes precedence)}
- B22F 9/008: {Rapid solidification processing}
- B22F 9/04: starting from solid material, e.g. by crushing, grinding or milling ({C22C1/1084 takes precedence}; crushing, grinding or milling, in general, see the relevant subclasses, e.g. B02C)
- H01F 1/14766: {Fe-Si based alloys}
- B22F 2009/048: {by pulverising a quenched ribbon}
- B22F 2998/10: Processes characterised by the sequence of their steps
- C22C 33/0278: {with at least one alloying element having a minimum content above 5%}
- C22C 2200/00: Crystalline structure
- C22C 2202/02: Magnetic
- H01F 1/15308: {based on Fe/Ni (H01F1/15325 takes precedence)}
- H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- C22C: ALLOYS (treatment of alloys C21D, C22F)

## Abstract

A manufacturing method of an amorphous soft magnetic core using a Fe-based amorphous metallic powder includes size-sorting an amorphous metallic powder obtained by pulverizing an amorphous ribbon prepared by a rapid solidification process (RSP) and then using the amorphous metallic powder having a particle size distribution so as to comprise 10 to 85 wt. % of powder having a particle size of 75 to 100 μm, 10 to 70 wt. % of powder having a particle size of 50 to 75 μm, and 5 to 20 wt. % of powder having a particle size of 5 to 50 μm to manufacture an amorphous soft magnetic core with excellent high-current DC bias characteristic and good core loss characteristic.

## Claims

### Claim 1

A method for manufacturing an amorphous soft magnetic core, comprising:
preparing a composite powder;
adding a binder to the composite powder and molding the composite powder and the binder to obtain a molded core material; and
annealing the molded core material,
wherein the preparing consists of:
preparing a Fe-based amorphous metallic ribbon;
pulverizing the amorphous metallic ribbon to obtain an amorphous metallic powder;
size-sorting the amorphous metallic powder to obtain size-sorted amorphous metallic powders; and
mixing, among the size-sorted amorphous metallic powders, a size-sorted amorphous metallic powder having a particle size of 5 to 100 μm to obtain the composite powder, wherein the composite powder consists of: 40 to 85 wt. % of powder having a particle size of 75 to 100 μm, 10 to 50 wt. % of powder having a particle size of 50 to 75 μm, and 5 to 20 wt. % of powder having a particle size of 5 to 50 μm.

### Claim 2 (depends on 1)

The method as claimed in claim 1, wherein the binder comprises 0.5 to 3 wt. % of any one selected from the group consisting of phenol, polyimide, and epoxy.

### Claim 3 (depends on 1)

The method as claimed in claim 1, wherein the annealing is performed at a temperature of 300 to 500° C. under an atmospheric condition for 0.3 to 4.3 hours.

### Claim 4

A method for manufacturing an amorphous metallic powder for an amorphous soft magnetic core, consisting of:
preliminarily heat-treating a Fe-based amorphous metallic ribbon prepared by a rapid solidification process (RSP);
pulverizing the amorphous metallic ribbon to obtain an amorphous metallic powder; and
size-sorting the amorphous metallic powder to obtain size-sorted amorphous metallic powders; and
mixing, among the size-sorted amorphous metallic powders, a size-sorted amorphous metallic powder having a particle size of 5 to 100 μm to obtain a composite powder, wherein the composite powder consists of: 40 to 85 wt. % of powder having a particle size of 75 to 100 μm, 10 to 50 wt. % of powder having a particle size of 50 to 75 μm, and 5 to 20 wt. % of powder having a particle size of 5 to 50 μm.

### Claim 5 (depends on 4)

The method as claimed in claim 4, wherein the amorphous metallic powder is used for a soft magnetic core having an improved DC bias characteristic.

### Claim 6 (depends on 1)

The method as claimed in claim 1, after the annealing, further comprising: coating the molded core material with an insulating resin.