# US 10,767,249 B2 · Magnetic powder and production method thereof, magnetic core and production method thereof, coil component and motor > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,767,249 B2 - Document ID: US10767249B2 - Status: Granted - Kind: B2 - Application number: 15/661,520 - Filed: 2017-07-27 - Published: 2017-11-09 - Granted: 2020-09-08 - Earliest claimed: 2015-01-30 - Assignees: Murata Manufacturing Co., Ltd.; Tohoku Magnet Institute Co., Ltd. - Applicants: Murata Manufacturing Co., Ltd.; Tohoku Magnet Institute Co., Ltd. - Inventors: Toru Takahashi; Kazuhiro Henmi; Akihiro Makino; Noriharu Yodoshi - Web page: https://patentgrep.com/patent/US10767249B2 ## CPC - C22C 38/02: containing silicon - B22F 3/00: Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor {; Presses and furnaces} - B22F 3/02: Compacting only - B22F 3/24: After-treatment of workpieces or articles {(B22F3/1146 takes precedence)} - B22F 9/08: by casting, e.g. through sieves or in water, by atomising or spraying (using electric discharge B22F9/14) - B22F 9/082: {atomising using a fluid (using centrifugal force B22F9/10)} - C22C 38/00: Ferrous alloys, e.g. steel alloys (cast-iron alloys C22C37/00) - C22C 38/002: {containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60} - C22C 45/02: with iron as the major constituent - H01F 1/153: Amorphous metallic alloys, e.g. glassy metals {(making ferrous amorphous alloys C22C33/003)} - H01F 1/22: pressed, sintered, or bound together - H01F 3/08: made from powder (powder coatings on sheets H01F3/02; on strips or ribbons H01F3/04; on wires H01F3/06) - 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)} - H02K 1/02: characterised by the magnetic material - B22F 1/08: Metallic powder characterised by particles having an amorphous microstructure - B22F 2003/248: {Thermal after-treatment} - B22F 2009/0824: {with a specific atomising fluid} - B22F 2009/0848: {Melting process before atomisation} - B22F 2301/35: Iron - C22C 2200/02: Amorphous - C22C 2202/02: Magnetic - C22C: ALLOYS (treatment of alloys C21D, C22F) - 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 - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES - H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53}) ## Abstract A magnetic powder is represented by general formula Fea(SibBcPd)100-a, and is produced with a gas atomization method. When the value of a and the value of b in the general formula is represented (a, b), (a, b) is within a predetermined region V1. Similarly, (a, c) and (a, d) are within a predetermined region, respectively. Whereby, it is possible to obtain an alloy magnetic powder which has high saturation magnetic flux density, low magnetic loss, and is spherical and easy to handle; and a magnetic core, a variety of coil components, and a motor can be realized by using the magnetic material. ## Claims ### Claim 1 A magnetic powder comprising a principal component represented by a general formula Fea-eMe(Sib(B1-αCα)cPd)100-a, wherein M is one or more selected from the group consisting of Ni and Co, e is 0 to 12.0, α is 0, and b+c+d=1.00, when representing as (a, b) the a and the b, (a, b) is within a region surrounded by A1 (71.0, 0.19), B1 (79.6, 0), C1 (80.0, 0), D1 (81.0, 0.17), E1 (81.0, 0.44), F1 (79.6, 0.78) and G1 (71.0, 0.38), when representing as (a, c) the a and the c, (a, c) is within a region surrounded by A2 (71.0, 0.48), B2 (78.1, 0), C2 (79.6, 0), D2 (81.0, 0.18), E2 (81.0, 0.26), F2 (79.1, 0.75) and G2 (71.0, 0.72), and when representing as (a, d) the a and the d, (a, d) is within a region surrounded by A3 (71.0, 0.08), B3 (71.9, 0), C3 (79.1, 0), D3 (81.0, 0.36), E3 (81.0, 0.62), F3 (77.2, 0.67) and G3 (71.0, 0.23). ### Claim 2 (depends on 1) The magnetic powder according to claim 1, wherein e=0. ### Claim 3 (depends on 2) The magnetic powder according to claim 2, wherein the a is 77.0 to 81.0, the b is 0.1 to 0.78, the c is 0 to 0.75, and the d is 0.05 to 0.67. ### Claim 4 (depends on 2) The magnetic powder according to claim 2, wherein the c is 0 to 0.30. ### Claim 5 (depends on 1) The magnetic powder according to claim 1, wherein crystallinity measured by an X-ray diffraction method is at least 0% and not more than 30%. ### Claim 6 (depends on 1) The magnetic powder according to claim 1, wherein saturation magnetic flux density is not less than 1.30 T. ### Claim 7 (depends on 1) A magnetic core, wherein a principal component is formed of the magnetic powder according to claim 1. ### Claim 8 (depends on 7) The magnetic core according to claim 7, wherein the magnetic core contains a binder, and the content of the magnetic powder is not less than 60 vol % in terms of volume ratio. ### Claim 9 (depends on 7) A coil component in which a coil conductor is wound around a core part, wherein the core part is formed of the magnetic core according to claim 7. ### Claim 10 (depends on 1) A coil component in which a coil conductor is buried in a magnetic part, wherein a principal component of the magnetic part is formed of the magnetic powder according to claim 1. ### Claim 11 (depends on 10) The coil component according to claim 10, wherein the magnetic part contains a binder, and the content of the magnetic powder in the magnetic part is not less than 60 vol % in terms of volume ratio. ### Claim 12 (depends on 1) A motor comprising a stator core in which a plurality of armature teeth are spaced at regular intervals on the same circumference; a coil conductor wound around the armature teeth; and a rotor core arranged rotatably inside the stator core, wherein the principal component of at least one of the stator core and the rotor core is formed of the magnetic powder according to claim 1. ### Claim 13 (depends on 1) The magnetic powder according to claim 1, wherein the a is 77.0 to 81.0, the b is 0.1 to 0.78, the c is 0 to 0.75, and the d is 0.05 to 0.67. ### Claim 14 (depends on 1) The magnetic powder according to claim 1, wherein the c is 0 to 0.30. ### Claim 15 (depends on 1) The magnetic powder according to claim 1, wherein the magnetic powder is produced with a gas atomization method. ### Claim 16 A magnetic powder consisting essentially of: a principal component represented by a general formula Fea-eMe(Sib(B1-αCα)cPd)100-a, in which M is one or more selected from the group consisting of Ni and Co, e is 0 to 12.0, α is 0, and b+c +d=1.00, when representing as (a, b) the a and the b, (a, b) is within a region surrounded by A1 (71.0, 0.19), B1 (79.6, 0), C1 (80.0, 0), D1 (81.0, 0.17), E1 (81.0, 0.44), F1 (79.6, 0.78) and G1 (71.0, 0.38), when representing as (a, c) the a and the c, (a, c) is within a region surrounded by A2 (71.0, 0.48), B2 (78.1, 0), C2 (79.6, 0), D2 (81.0, 0.18), E2 (81.0, 0.26), F2 (79.1, 0.75) and G2 (71.0, 0.72), and when representing as (a, d) the a and the d, (a, d) is within a region surrounded by A3 (71.0, 0.08), B3 (71.9, 0), C3 (79.1, 0), D3 (81.0, 0.36), E3 (81.0, 0.62), F3 (77.2, 0.67) and G3 (71.0, 0.23). ### Claim 17 (depends on 16) The magnetic powder according to claim 16, wherein a is 77.0 to 81.0, b is 0.1 to 0.78, c is 0 to 0.30, d is 0.05 to 0.67, and e is 0.