# US 12,224,092 B2 · Compression molded core, method for manufacturing the compression molded core, inductor including the compression molded core, and electric/electronic equipment mounted with the inductor > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,224,092 B2 - Document ID: US12224092B2 - Status: Granted - Kind: B2 - Application number: 17/227,019 - Filed: 2021-04-09 - Published: 2021-07-29 - Granted: 2025-02-11 - Earliest claimed: 2018-10-30 - Assignees: Alps Alpine Co., Ltd. - Applicants: Alps Alpine Co., Ltd. - Inventors: Akinori Kojima; Ryo Nakabayashi; Keiichiro Sato - Web page: https://patentgrep.com/patent/US12224092B2 ## CPC - H01F 1/08: 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 1/14741: {pressed, sintered or bonded together} - H01F 1/14766: {Fe-Si based alloys} - H01F 1/153: Amorphous metallic alloys, e.g. glassy metals {(making ferrous amorphous alloys C22C33/003)} - H01F 1/15375: {using polymers} - H01F 1/22: pressed, sintered, or bound together - H01F 1/26: by macromolecular organic substances - H01F 17/04: with magnetic core - 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)} - H01F 1/14708: {Fe-Ni based alloys (pure Fe or Ni H01F1/14, H01F1/16 or H01F1/20)} - H01F 1/15308: {based on Fe/Ni (H01F1/15325 takes precedence)} - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES ## Abstract A compression molded core contains a plurality of soft magnetic material powders. A first powder and a second powder in the plurality of powders satisfy D1>D2, 0.23≤(D1−D2)/D1<0.6, D1≤7 μm, and 3 μm≤DT≤5.7 μm. D1 is the median diameter, which is a particle size at which the integrated particle diameter distribution from the small particle size side is 50% in a volume-based particle size distribution measured by a laser diffraction/scattering method, of the first powder and is maximum among median diameters; D2 is the median diameter D2 of the second powder and is minimum among median diameters; and DT is determined using the weight rate R1 of the first powder and the weight rate R2 of the second powder by R1×D1+R2×D2. ## Claims ### Claim 1 A compression molded core comprising a plurality of types of powders each formed of a soft magnetic material, wherein a median diameter of each powder is defined as a particle diameter at which an integrated particle diameter distribution becomes 50% when accumulated from a small particle size side based on a volume-based particle size distribution measured by a laser diffraction/scattering method, wherein the plurality of types of powders include: a first powder made of an amorphous magnetic material and having a first median diameter D1 which is a greatest median diameter among the median diameters of the plurality of types of powders; and a second powder made of a crystalline magnetic material and having a second median diameter D2 which is a smallest median diameter among the median diameters of the plurality of types of powders, the second median diameter D2 being smaller than the first median diameter D1, wherein the first powder has a first weight ratio R1 which is a ratio of a weight of the first powder to a total weight of the first powder and the second powder in the compression molded core, while the second powder has a second weight ratio R2 which is a ratio of a weight of the second powder to the total weight of the first powder and the second powder in the compression molded core, an average median diameter DT being defined as DT=R1×D1+R2×D2, and wherein the second weight ratio R2, the first median diameter D1, the second median diameter D2, and the average median diameter DT satisfy following expressions (1) to (4): 0.4≤R2≤0.7 (1) 0.23≤(D1−D2)/D1<0.3 (2) D1≤5.9 μm (3) 3 μm≤DT≤5.7 μm (4). ### Claim 2 (depends on 1) The compression molded core according to claim 1, wherein the amorphous magnetic material includes an Fe-based amorphous alloy containing at least Fe, P, and C. ### Claim 3 (depends on 2) The compression molded core according to claim 2, wherein the Fe-based amorphous alloy further contains at least Ni, B, and Cr. ### Claim 4 (depends on 1) The compression molded core according to claim 1, wherein the crystalline magnetic material includes at least one of an Fe—Si—Cr alloy and an Fe—Ni alloy. ### Claim 5 (depends on 1) The compression molded core according to claim 1, further comprising: a binding component binding the first powder and the second powder to another material contained in the compression molded core. ### Claim 6 (depends on 5) The compression molded core according to claim 5, wherein the binding component includes a resin material-based component. ### Claim 7 (depends on 6) A method for manufacturing the compression molded core according to claim 6, the method comprising: pressure molding a mixture including the first powder, the second powder, and the binder component, wherein the binder component consists of a resin material. ### Claim 8 (depends on 1) An inductor comprising the compression molded core according to claim 1, a coil, and connection terminals connected to each of ends of the coil, wherein the compression molded core is disposed so as to be at least partially located in an inductive magnetic field generated by a current when the current flows in the coil through the connection terminals. ### Claim 9 (depends on 8) The inductor according to claim 8, wherein an initial permeability μ(0) measured at a condition of 1 MHZ, a relative magnetic permeability μ(8) measured at a condition of 1 MHz when an external magnetic field is 8 kA/m, and an iron loss Pcv (unit: kW/m3) measured at a condition of applying a magnetic field having an effective maximum magnetic flux density of 15 mT at a frequency of 2 MHz satisfy a following expression (I): μ(0)×μ(8)/Pcv>3.2 kW−1m3 (I). ### Claim 10 (depends on 8) Electric/electronic equipment mounted with the inductor according to claim 8, wherein the inductor is connected to a substrate with the connection terminals. ### Claim 11 A compression molded core comprising a plurality of types of powders each formed of a soft magnetic material, wherein a median diameter of each powder is defined as a particle diameter at which an integrated particle diameter distribution becomes 50% when accumulated from a small particle size side based on a volume-based particle size distribution measured by a laser diffraction/scattering method, wherein the plurality of types of powders include: a first powder made of an amorphous magnetic material and having a first median diameter D1 which is a greatest median diameter among the median diameters of the plurality of types of powders; and a second powder made of a crystalline magnetic material and having a second median diameter D2 which is a smallest median diameter among the median diameters of the plurality of types of powders, the second median diameter D2 being smaller than the first median diameter D1, wherein the first powder has a first weight ratio R1 which is a ratio of a weight of the first powder to a total weight of the first powder and the second powder in the compression molded core, while the second powder has a second weight ratio R2 which is a ratio of a weight of the second powder to the total weight of the first powder and the second powder in the compression molded core, an average median diameter DT being defined as DT=R1×D1+R2×D2, and wherein the second weight ratio R2, the first median diameter D1, the second median diameter D2, and the average median diameter DT satisfy following expressions (1) to (5): 0.4≤R2≤0.7 (1) 0.3≤(D1−D2)/D1≤0.59 (2) D1≤7 μm (3) 3 μm≤DT≤5.7 μm (4) D2≤3.9 μm (5). ### Claim 12 (depends on 11) The compression molded core according to claim 11, wherein the amorphous magnetic material includes an Fe-based amorphous alloy containing at least Fe, P, and C, and the crystalline magnetic material includes at least one of an Fe—Si—Cr alloy and an Fe—Ni alloy, and wherein the compression molded core further comprises: a resin-based binding component binding the first powder and the second powder to another material contained in the compression molded core. ### Claim 13 (depends on 12) The compression molded core according to claim 12, wherein the Fe-based amorphous alloy further contains at least Ni, B, and Cr. ### Claim 14 (depends on 11) An inductor comprising the compression molded core according to claim 11, a coil, and connection terminals connected to each of ends of the coil, wherein the compression molded core is disposed so as to be at least partially located in an inductive magnetic field generated by a current when the current flows in the coil through the connection terminals. ### Claim 15 (depends on 14) The inductor according to claim 14, wherein an initial permeability μ(0) measured at a condition of 1 MHz, a relative magnetic permeability μ(8) measured at a condition of 1 MHz when an external magnetic field is 8 kA/m, and an iron loss Pcv (unit: kW/m3) measured at a condition of applying a magnetic field having an effective maximum magnetic flux density of 15 mT at a frequency of 2 MHz satisfy a following expression (I): μ(0)×μ(8)/Pcv>3.2 kW−1m3 (I). ### Claim 16 A compression molded core comprising a plurality of types of powders each formed of a soft magnetic material, wherein a median diameter of each powder is defined as a particle diameter at which an integrated particle diameter distribution becomes 50% when accumulated from a small particle size side based on a volume-based particle size distribution measured by a laser diffraction/scattering method, wherein the plurality of types of powders include: a first powder made of an amorphous magnetic material and having a first median diameter D1 which is a greatest median diameter among the median diameters of the plurality of types of powders; and a second powder made of a crystalline magnetic material and having a second median diameter D2 which is a smallest median diameter among the median diameters of the plurality of types of powders, the second median diameter D2 being smaller than the first median diameter D1, wherein the first powder has a first weight ratio R1 which is a ratio of a weight of the first powder to a total weight of the first powder and the second powder in the compression molded core, while the second powder has a second weight ratio R2 which is a ratio of a weight of the second powder to the total weight of the first powder and the second powder in the compression molded core, an average median diameter DT being defined as DT=R1×D1+R2×D2, and wherein the second weight ratio R2, the first median diameter D1, the second median diameter D2, and the average median diameter DT satisfy following expressions (1) to (5): 0.4≤R2≤0.7 (1) 0.49≤(D1−D2)/D1≤0.6 (2) D1≤7 μm (3) 4.4 μm≤DT≤5.7 μm (4) D2≤3.9 μm (5). ### Claim 17 (depends on 16) The compression molded core according to claim 16, wherein the amorphous magnetic material includes an Fe-based amorphous alloy containing at least Fe, P, and C, and the crystalline magnetic material includes at least one of an Fe—Si—Cr alloy and an Fe—Ni alloy, and wherein the compression molded core further comprises: a resin-based binding component binding the first powder and the second powder to another material contained in the compression molded core. ### Claim 18 (depends on 17) The compression molded core according to claim 17, wherein the Fe-based amorphous alloy further contains at least Ni, B, and Cr. ### Claim 19 (depends on 16) An inductor comprising the compression molded core according to claim 16, a coil, and connection terminals connected to each of ends of the coil, wherein the compression molded core is disposed so as to be at least partially located in an inductive magnetic field generated by a current when the current flows in the coil through the connection terminals. ### Claim 20 (depends on 19) The inductor according to claim 19, wherein an initial permeability μ(0) measured at a condition of 1 MHz, a relative magnetic permeability μ(8) measured at a condition of 1 MHz when an external magnetic field is 8 kA/m, and an iron loss Pcv (unit: kW/m3) measured at a condition of applying a magnetic field having an effective maximum magnetic flux density of 15 mT at a frequency of 2 MHz satisfy a following expression (I): μ(0)×μ(8)/Pcv>3.2 kW−1m3 (I).