# US 12,002,608 B2 · Ferromagnetic powder composition

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- Number: US 12,002,608 B2
- Document ID: US12002608B2
- Status: Granted
- Kind: B2
- Application number: 17/058,942
- Filed: 2019-05-28
- Published: 2021-07-08
- Granted: 2024-06-04
- Earliest claimed: 2018-05-30
- Assignees: HöGanäS AB (Publ)
- Applicants: Höganäs AB (Publ)
- Inventors: Zhou Ye
- Web page: https://patentgrep.com/patent/US12002608B2

## CPC

- H01F 1/24: the particles being insulated
- B22F 1/102: Metallic powder coated with organic material
- B22F 1/16: Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10)
- H01F 1/1475: {the particles being insulated}
- H01F 1/14766: {Fe-Si based alloys}
- H01F 3/08: made from powder (powder coatings on sheets H01F3/02; on strips or ribbons H01F3/04; on wires H01F3/06)
- H01F 27/24: Magnetic cores
- H01F 27/255: made from particles (H01F27/26 takes precedence)
- 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 2998/10: Processes characterised by the sequence of their steps
- C22C 2202/02: Magnetic
- 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

The present invention relates to an electrically insulated iron-based soft magnetic powder composition, a soft magnetic composite component obtainable from the powder composition and a process for producing the same. Specifically, the invention concerns a soft magnetic powder composition for the preparation of soft magnetic components working at high frequencies, the components being suitable for use e.g. as inductors or reactors for power electronics.

## Claims

### Claim 1

A composition comprising particles A and particles B, each of the particles A and B comprising a core, the core of the particles A being a soft magnetic iron based core, and the core of the particles B being formed from an Fe—Si alloy,
wherein an amount of a total of the particles A and B relative to a total weight of the composition is 85% by weight or more,
wherein the core of the particles B consists of Fe, Si, and less than 2% of other elements,
wherein the surface of each core of the particles A and B is coated with a phosphorus-containing insulating layer A1 and B1, respectively,
and wherein the particles A having the insulating coating layer A1 are provided with a further layer A2 on top of the layer A1, the layer A2 being formed from a compound of formula (I), or a reaction product of formula (I):
M(OR1)x(R2)y Formula (I)
wherein M is selected from Si, Ti, Al, or Zr;
R1 is a straight or branched alkyl group having 4 or less carbon atoms;
R2 is an organic group optionally containing a functional group, and
x+y are integers denoting the number of groups OR1 and R2, respectively, and if M is Si, Zr or Ti, x is chosen from 1, 2 and 3, and y is chosen from 1, 2 and 3, with the proviso that (x+y)=4; and
if M is Al, then x is chosen from 1 and 2, and y is chosen from 1 and 2, with the proviso that (x+y)=3;
wherein the reaction product is a product obtained by a reaction of one molecule of a compound of formula (I) with one or more molecules of a compound of formula (I) and/or with the layer A1; and
wherein the particles A further comprise particles C that are adhered to the layer A2 or which are incorporated into the layer A2, the particles C being particles of a material having Mohs hardness of 3.5 or less.

### Claim 2 (depends on 1)

The composition according to claim 1, wherein the particles B are provided with a layer B2 on the layer B1, the layer B2 being formed from a compound of formula (I), or a reaction product of formula (I):
M(OR1)x(R2)y Formula (I)
wherein M is selected from Si, Ti, Al, or Zr;
R1 is a straight or branched alkyl group having 4 or less carbon atoms;
R2 is an organic group optionally containing a functional group, and
x+y are integers denoting the number of groups OR1 and R2, respectively, and if M is Si, Zr or Ti, x is chosen from 1, 2 and 3, and y is chosen from 1, 2 and 3, with the proviso that (x+y)=4; and
if M is Al, then x is chosen from 1 and 2, and y is chosen from 1 and 2, with the proviso that (x+y)=3,
and wherein optionally the particles B contain particles C that are adhered to or incorporated into the layer B2.

### Claim 3 (depends on 1)

The composition according to claim 1, wherein said powder composition further comprises a lubricant.

### Claim 4 (depends on 1)

The composition according to claim 1, wherein the layer A2 and/or B2 is formed from a compound of formula (I), or wherein the layer A2 and/or B2 is formed from a reaction product of a compound of formula (I), wherein the number of metal atoms M in one molecule is from 2-20.

### Claim 5 (depends on 1)

The composition according to claim 1, wherein R2 includes one or more of the following functional groups: amine, diamine, amide, imide, epoxy, mercapto, disulfido, chloroalkyl, hydroxyl, ethylene oxide, ureido, urethane, isocyanato, acrylate, glyceryl acrylate, carboxyl, carbonyl, and aldehyde.

### Claim 6 (depends on 1)

The composition according to claim 1, wherein the compound of formula (I) or a reaction product thereof is an oligomer of the compound of formula (I), and wherein the oligomer is selected from alkoxy-terminated amino-silsesquioxanes, amino-siloxanes, oligomeric 3-aminopropyl-alkoxy-silane, 3-aminopropyl/propyl-alkoxy-silane, N-aminoethyl-3-aminopropyl-alkoxy-silane, or N-aminoethyl-3-aminopropyl/methyl-alkoxy-silane, or mixtures thereof.

### Claim 7 (depends on 1)

The composition according to claim 1, wherein the particles C include bismuth or bismuth (III) oxide.

### Claim 8 (depends on 1)

The composition according to claim 1, wherein the weight ratio of particles A and B (A:B) is from 95:5 to 50:50.

### Claim 9 (depends on 1)

The composition according to claim 1, wherein the core particles of the particles A have an apparent density of 3.3-3.7 g/mL.

### Claim 10 (depends on 1)

The composition according to claim 1, wherein layer A2 comprises a compound of formula (I), a dimer, and/or an oligomer thereof.

### Claim 11 (depends on 1)

The composition according to claim 1, wherein the reaction product is a polycondensate of two or more compounds of Formula (I) wherein the compounds may be the same or different from each other.

### Claim 12 (depends on 1)

A method for producing a compacted and heat-treated component, comprising the steps of
a) providing a composition as defined in claim 1,
b) compacting the composition, optionally mixed with a lubricant, in a uniaxial press movement in a die,
c) ejecting the compacted component from the die, and
d) optionally heat-treating the ejected component in a non-reducing atmosphere at a temperature of up to 800° C.

### Claim 13 (depends on 1)

Component, obtainable by compacting a composition as defined in claim 1.

### Claim 14 (depends on 13)

Component according to claim 13, which is an inductor core.

### Claim 15 (depends on 14)

Inductor core according to claim 14, having a resistivity ρ of 3,000 μΩm or higher; a saturation magnetic flux density Bs of 1.1 T or higher; a core loss of 21 W/kg or less at a frequency of 10 kHz and an induction of 0.1 T; a coercivity at 10 000 A/m of 240 A/m or less; and a DC-bias of not less than 50% at 4 000 A/m.