# US 12,191,060 B2 · Soft magnetic alloy, soft magnetic alloy ribbon, laminate, and magnetic core

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- Number: US 12,191,060 B2
- Document ID: US12191060B2
- Status: Granted
- Kind: B2
- Application number: 17/893,463
- Filed: 2022-08-23
- Published: 2023-03-16
- Granted: 2025-01-07
- Earliest claimed: 2021-08-25
- Assignees: TDK Corporation
- Applicants: TDK Corporation
- Inventors: Kyotaro Abe; Isao Nakahata; Takuya Tsukahara
- Web page: https://patentgrep.com/patent/US12191060B2

## CPC

- H01F 1/15308: {based on Fe/Ni (H01F1/15325 takes precedence)}
- C22C 45/02: with iron as the major constituent
- H01F 1/15333: {containing nanocrystallites, e.g. obtained by annealing}
- H01F 1/15341: {Preparation processes therefor}
- H01F 3/04: made from strips or ribbons
- H01F 41/0226: {from amorphous ribbons}
- C22C 2202/02: Magnetic
- H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- C22C: ALLOYS (treatment of alloys C21D, C22F)

## Abstract

Provided a soft magnetic alloy ribbon containing Fe and B. Convex portions having an average convex portion height of 7 nm to 130 nm are present on an alloy surface.

## Claims

### Claim 1

A soft magnetic alloy, comprising Fe and B, wherein
the soft magnetic alloy has a structure containing Fe-based nanocrystals,
convex portions having an average convex portion height of 7 nm to 130 nm are present in a continuous pattern shape on an alloy surface, and
an amount of B contained in the convex portions is smaller than an amount of B inside the alloy, and
at a position of a depth of 10 nm from the alloy surface on the convex portions, a sum (B+B−O) of the total amount of boron (B) and oxygen (O) (an amount of B−O) and an amount of B alone in atomic % is ⅓ or less as compared with that inside the alloy.

### Claim 2 (depends on 1)

The soft magnetic alloy according to claim 1, wherein
an area ratio of the convex portions on the alloy surface is 15% or more and 100% or less.

### Claim 3 (depends on 1)

A soft magnetic alloy ribbon, comprising the soft magnetic alloy according to claim 1.

### Claim 4 (depends on 3)

A stacked body having a structure in which the soft magnetic alloy ribbon according to claim 3 is stacked.

### Claim 5 (depends on 1)

A magnetic core, comprising the soft magnetic alloy according to claim 1.

### Claim 6 (depends on 1)

The soft magnetic alloy according to claim 1, wherein the average convex portion height is 10 nm or more and less than 100 nm.

### Claim 7 (depends on 1)

The soft magnetic alloy according to claim 1, wherein the average convex portion height is 35 nm to 97 nm.

### Claim 8 (depends on 1)

The soft magnetic alloy according to claim 1, wherein the average convex portion height is 35 nm to 67 nm.

### Claim 9 (depends on 1)

The soft magnetic alloy according to claim 1, having the formula
(Fe(1-(α+β))X1αX2β)(1-(a+b+c+d+e+f))MaBbPcSidCeSf, in which
X1 is one or more selected from the group consisting of Co and Ni,
X2 is one or more selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O, and a rare earth element,
M is one or more selected from the group consisting of Nb, Hf, Zr, Ta, Mo, W, Ti, and V,
0≤a≤0.140,
0.020≤b≤0.200,
0≤c≤0.150,
0≤d≤0.090,
0≤e≤0.030,
0≤f≤0.030,
α≥0,
β≥0, and
0≤α+β≤0.50 are satisfied.

### Claim 10 (depends on 9)

The soft magnetic alloy according to claim 9, wherein
at least one of a, c, and d is larger than 0.

### Claim 11 (depends on 9)

The soft magnetic alloy according to claim 9, wherein
0.060≤a≤0.080,
0.080≤b≤0.120,
0.030≤c≤0.050,
0≤d≤0.020,
0.001≤e≤0.010.

### Claim 12 (depends on 9)

The soft magnetic alloy according to claim 9, consisting of Fe, Nb, B, P and Si.

### Claim 13

A soft magnetic alloy, having the formula (Fe(1-(α+β))X1αX2β)(1-(a+b+c+d+e+f))MaBbPcSidCeSf, wherein
the soft magnetic alloy has a structure containing Fe-based nanocrystals,
convex portions having an average convex portion height of 7 nm to 130 nm are present in a continuous pattern shape on an alloy surface,
an amount of B contained in the convex portions is smaller than an amount of B inside the alloy,
X1 is one or more selected from the group consisting of Co and Ni,
X2 is one or more selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O, and a rare earth element,
M is one or more selected from the group consisting of Nb, Hf, Zr, Ta, Mo, W, Ti, and V, and
0.060≤a≤0.080,
0.080≤b≤0.120,
0.030≤c≤0.050,
0≤d≤0.020,
0.001≤e≤0.010,
0≤f≤0.030,
α≥0,
β≥0, and
0≤α+β≤0.50 are satisfied.

### Claim 14

A soft magnetic alloy having the formula Fe(1-(a+b+c+d))NbaBbPcSid, wherein
the soft magnetic alloy has a structure containing Fe-based nanocrystals,
convex portions having an average convex portion height of 7 nm to 130 nm are present in a continuous pattern shape on an alloy surface,
an amount of B contained in the convex portions is smaller than an amount of B inside the alloy, and
0≤a≤0.140,
0.020≤b≤0.200,
0≤c≤0.150, and
0≤d≤0.090 are satisfied.