US 12,251,760 B2
Magnetic core powder, magnetic core and coil device using it, and method for producing magnetic core powder
Tetsuro Kato, Tokyo (JP); Nobuhiko Chiwata, Tokyo (JP); and Motoki Ohta, Tokyo (JP)
Assigned to PROTERIAL, LTD., Tokyo (JP)
Appl. No. 17/266,281
Filed by PROTERIAL, LTD., Tokyo (JP)
PCT Filed Aug. 22, 2019, PCT No. PCT/JP2019/032807
§ 371(c)(1), (2) Date Feb. 5, 2021,
PCT Pub. No. WO2020/040250, PCT Pub. Date Feb. 27, 2020.
Claims priority of application No. 2018-156415 (JP), filed on Aug. 23, 2018.
Prior Publication US 2021/0313111 A1, Oct. 7, 2021
Int. Cl. H01F 1/153 (2006.01); B22F 1/052 (2022.01); B22F 1/08 (2022.01); B22F 5/10 (2006.01); H01F 3/08 (2006.01); H01F 27/255 (2006.01); H01F 41/02 (2006.01)
CPC B22F 5/106 (2013.01) [B22F 1/052 (2022.01); B22F 1/08 (2022.01); H01F 1/15308 (2013.01); H01F 3/08 (2013.01); H01F 27/255 (2013.01); H01F 41/0246 (2013.01); Y10T 428/115 (2015.01)] 5 Claims
OG exemplary drawing
 
1. A magnetic core powder comprising a granular powder A of an Fe-based, magnetic, crystalline metal material and a granular powder B of an Fe-based, magnetic, amorphous metal material;
said granular powder A having a composition of aFe bSi cCr dAl eC, wherein a=100−b−c−d−e, 0≤b≤12.0, 0≤c≤8.0, 0≤d<13.8, and 0≤e≤0.5, on a %-by-mass basis;
said granular powder B being an Fe—Si—B-based, amorphous, magnetic metal material having a composition of (Fe1-xCrx)a(Si1-yBy)100-a-bCb, wherein x and y meet 0<x≤0.06, and 0.3≤y≤0.7 by atomic ratio, and a and b meet 70≤a≤81, and 0<b≤2 by atomic %, and/or an Fe—P—C-based, magnetic, amorphous metal material having a composition of Fe100-x-yPxCy, wherein 6.8%≤x≤13.0%, and 2.2%≤y≤13.0% by atomic %;
the particle size d50A of said granular powder A at a cumulative frequency of 50% by volume being 0.5 μm or more and 7.0 μm or less, and the particle size d50B of said granular powder B at a cumulative frequency of 50% by volume being more than 15.0 μm, in a cumulative distribution curve showing the relation between a particle size and a cumulative frequency from the smaller particle size side, which is determined by a laser diffraction method; and
said magnetic core powder meeting (d90M−d10M)/d50M of 1.6 or more and 6.0 or less, wherein d10M represents the particle size of said magnetic core powder at a cumulative frequency of 10% by volume, d50M represents the particle size of said magnetic core powder at a cumulative frequency of 50% by volume, and d90M represents the particle size of said magnetic core powder at a cumulative frequency of 90% by volume,
wherein said granular powder A is present in a mixing ratio of 30% by mass to 70% by mass, wherein the mixing ratio is a ratio of the mass of said granular powder A to the sum of the mass of said granular powder A and the mass of said granular powder B.