# US 10,770,209 B2 · Soft magnetic powder, magnetic core, method for manufacturing soft magnetic powder, and method for manufacturing magnetic core

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 10,770,209 B2
- Document ID: US10770209B2
- Status: Granted
- Kind: B2
- Application number: 15/772,912
- Filed: 2016-11-09
- Published: 2018-11-01
- Granted: 2020-09-08
- Earliest claimed: 2015-11-27
- Assignees: Autonetworks Technologies, Ltd.; Sumitomo Wiring Systems, Ltd.; Sumitomo Electric Industries, Ltd.
- Applicants: AutoNetworks Technologies, Ltd.; Sumitomo Wiring Systems, Ltd.; Sumitomo Electric Industries, Ltd.
- Inventors: Shintaro Nanbara; Kazushi Kusawake; Takashi Takada
- Web page: https://patentgrep.com/patent/US10770209B2

## CPC

- H01F 1/14766: {Fe-Si based alloys}
- B22F 1/142: Thermal or thermo-mechanical treatment
- B22F 1/16: Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10)
- C22C 33/0278: {with at least one alloying element having a minimum content above 5%}
- C22C 38/00: Ferrous alloys, e.g. steel alloys (cast-iron alloys C22C37/00)
- C22C 38/02: containing silicon
- H01F 1/26: by macromolecular organic substances
- 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)}
- B22F 3/02: Compacting only
- B22F 2301/35: Iron
- B22F 2998/10: Processes characterised by the sequence of their steps
- C22C 2202/02: Magnetic
- H01F 27/255: made from particles (H01F27/26 takes precedence)
- H01F 37/00: Fixed inductances not covered by group H01F17/00
- 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

Provided is soft magnetic powder constituted by an Fe alloy containing Si, in which soft magnetic particles of the soft magnetic powder include a SiO2 layer formed on a surface of the particles, and a surface layer formed directly on the SiO2 layer. The surface layer includes a first material that constitutes a matrix and a second material that is dispersed in the matrix. The first material is silicone or phosphate, and the second material is silicone or phosphate and is different from the first material.

## Claims

### Claim 1

A magnetic core constituted by a composite material containing soft magnetic powder and resin,
wherein the soft magnetic powder is constituted by an Fe alloy containing Si, wherein soft magnetic particles of the soft magnetic powder include a SiO2 layer formed on a surface of the particles, and a surface layer formed directly on the SiO2 layer, the surface layer includes a first material that constitutes a matrix and a second material that is dispersed in the matrix, and the first material is silicone or phosphate, and the second material is silicone or phosphate and is different from the first material;
wherein a volume percentage of the soft magnetic powder in the composite material is 50% or more and 85% or less, and
Bs/μm is 0.056 or more, where Bs is a saturation flux density of the composite material and μm is a maximum magnetic permeability.

### Claim 2 (depends on 1)

The magnetic core according to claim 1, wherein the resin is polyphenylene sulfide.

### Claim 3 (depends on 1)

The magnetic core according to claim 1, wherein an average thickness of the SiO2 layer is 5 nm or more and 200 nm or less.

### Claim 4 (depends on 1)

The magnetic core according claim 1, wherein an average thickness of the surface layer is 0.5 μm or more and 10 μm or less.

### Claim 5 (depends on 2)

The magnetic core according claim 2, wherein an average thickness of the surface layer is 0.5 μm or more and 10 μm or less.

### Claim 6 (depends on 1)

The magnetic core according to claim 1, wherein the Si content in the Fe alloy is 4.5 mass % or more and 8.0 mass % or less.

### Claim 7 (depends on 2)

The magnetic core according to claim 2, wherein the Si content in the Fe alloy is 4.5 mass % or more and 8.0 mass % or less.

### Claim 8 (depends on 5)

The magnetic core according to claim 5, wherein the Si content in the Fe alloy is 4.5 mass % or more and 8.0 mass % or less.

### Claim 9

A magnetic core constituted by a composite material containing soft magnetic powder and resin,
wherein the soft magnetic powder is constituted by an Fe alloy containing Si, wherein soft magnetic particles of the soft magnetic powder include a SiO2 layer formed on a surface of the particles, and a surface layer formed directly on the SiO2 layer, the surface layer includes a first material that constitutes a matrix and a second material that is dispersed in the matrix, and the first material is phosphate, and the second material is silicone,
a volume percentage of the soft magnetic powder in the composite material is 50% or more and 85% or less, and Bs/μm is 0.056 or more, where Bs is a saturation flux density of the composite material and μm is a maximum magnetic permeability.

### Claim 10

A magnetic core constituted by a composite material containing soft magnetic powder and resin,
wherein the soft magnetic powder is constituted by an Fe alloy containing Si, wherein soft magnetic particles of the soft magnetic powder include a SiO2 layer formed on a surface of the particles, and a surface layer formed directly on the SiO2 layer, the surface layer includes a first material that constitutes a matrix and a second material that is dispersed in the matrix, and the first material is silicone or phosphate, and the second material is silicone or phosphate and is different from the first material, wherein an average thickness of the SiO2 layer is 5 nm or more and 200 nm or less;
a volume percentage of the soft magnetic powder in the composite material is 50% or more and 85% or less, and
Bs/μm is 0.056 or more, where Bs is a saturation flux density of the composite material and μm is a maximum magnetic permeability.

### Claim 11

A magnetic core constituted by a composite material containing soft magnetic powder and resin, wherein the soft magnetic powder is constituted by an Fe alloy containing Si, wherein soft magnetic particles of the soft magnetic powder include a SiO2 layer formed on a surface of the particles, and a surface layer formed directly on the SiO2 layer, the surface layer includes a first material that constitutes a matrix and a second material that is dispersed in the matrix, and the first material is silicone or phosphate, and the second material is silicone or phosphate and is different from the first material, wherein an average thickness of the surface layer is 0.5 μm or more and 10 μm or less,
a volume percentage of the soft magnetic powder in the composite material is 50% or more and 85% or less, and
Bs/μm is 0.056 or more, where Bs is a saturation flux density of the composite material and μm is a maximum magnetic permeability.

### Claim 12

A magnetic core constituted by a composite material containing soft magnetic powder and resin,
wherein the soft magnetic powder is constituted by an Fe alloy containing Si, wherein soft magnetic particles of the soft magnetic powder include a SiO2 layer formed on a surface of the particles, and a surface layer formed directly on the SiO2 layer, the surface layer includes a first material that constitutes a matrix and a second material that is dispersed in the matrix, and the first material is silicone or phosphate, and the second material is silicone or phosphate and is different from the first material, wherein an average thickness of the surface layer is 0.5 μm or more and 10 μm or less, wherein the Si content in the Fe alloy is 4.5 mass % or more and 8.0 mass % or less,
a volume percentage of the soft magnetic powder in the composite material is 50% or more and 85% or less, and
Bs/μm is 0.056 or more, where Bs is a saturation flux density of the composite material and μm is a maximum magnetic permeability.