公开(公告)号：US09704627B2

公开(公告)日：2017-07-11

申请号：US14372974

申请日：2013-01-15

Applicant: HITACHI METALS, LTD.

Inventor： Tetsuro Kato ,  Shin Noguchi ,  Kazunori Nishimura

IPC: C22C33/02 ,  B32B5/16 ,  H01F1/153 ,  H01F1/28 ,  B22F1/02 ,  C22C45/02 ,  B22F9/00 ,  B22F9/04 ,  H01F3/08 ,  H01F41/02 ,  B22F1/00 ,  B22F3/02 ,  H01F1/22 ,  H01F1/24 ,  H01F1/33 ,  H01F27/255 ,  H01F27/28

CPC classification number: H01F1/15308 ,  B22F1/0059 ,  B22F1/02 ,  B22F3/02 ,  B22F9/002 ,  B22F9/04 ,  C22C33/02 ,  C22C33/0278 ,  C22C45/02 ,  H01F1/15333 ,  H01F1/1535 ,  H01F1/22 ,  H01F1/24 ,  H01F1/28 ,  H01F1/33 ,  H01F3/08 ,  H01F27/255 ,  H01F27/28 ,  H01F41/0246

Abstract: In a metal powder core constructed from soft magnetic material powder and a coil component employing this, a configuration suitable for reduction of a core loss is provided. The metal powder core constructed from soft magnetic material powder is characterized in that Cu is dispersed among the soft magnetic material powder. It is characterized in that, preferably, the soft magnetic material powder is pulverized powder of soft magnetic alloy ribbon and that Cu is dispersed among the pulverized powder of soft magnetic alloy ribbon. Further, it is characterized in that, preferably, the soft magnetic alloy ribbon is a Fe-based nano crystal alloy ribbon or a Fe-based alloy ribbon showing a Fe-based nano crystalline structure and that the pulverized powder has a nano crystalline structure.

公开(公告)号：US10586646B2

公开(公告)日：2020-03-10

申请号：US16333091

申请日：2017-09-15

Applicant: HITACHI METALS, LTD.

Inventor： Toshio Mihara ,  Tetsuroh Katoh ,  Kazunori Nishimura ,  Shin Noguchi

IPC: H01F27/29 ,  H01F27/24 ,  H01F1/055 ,  H01F27/28 ,  H01F1/33 ,  B22F1/00 ,  H01F37/00 ,  H01F27/255 ,  B22F1/02 ,  C22C38/00 ,  H01F1/24 ,  H01F1/147 ,  B22F3/00

Abstract: A magnetic core has a high initial permeability and a small core loss, reducing a core loss at high frequencies; and a coil component including the same. This magnetic core is formed by binding a plurality of Fe-based alloy particles containing Al via an oxide layer containing an Fe oxide. In an X-ray diffraction spectrum of the magnetic core measured using Cu-Kα characteristic X-rays, a peak intensity ratio (P1/P2) of peak intensity P1 of a diffraction peak derived from the Fe oxide having a corundum structure appearing in the vicinity of 2θ=33.2° to peak intensity P2 of a diffraction peak derived from the Fe-based alloy having a bcc structure appearing in the vicinity of 2θ=44.7° is 0.010 or less (excluding 0). A superlattice peak intensity of an Fe3Al ordered structure is at most a noise level within a range of 2θ=20° to 40°.

公开(公告)号：US10573441B2

公开(公告)日：2020-02-25

申请号：US15325741

申请日：2015-07-16

Applicant: HITACHI METALS, LTD.

Inventor： Shin Noguchi ,  Kazunori Nishimura ,  Toshio Mihara

IPC: H01F1/147 ,  H01F41/02 ,  B22F1/00 ,  C22C38/34 ,  C22C38/00 ,  H01F1/24 ,  C22C38/18 ,  B22F5/00 ,  C22C33/02 ,  C22C38/06 ,  B22F5/10 ,  B22F3/24

Abstract: There is provided a magnetic core having both high strength and high resistivity, a coil component produced with such a magnetic core, and a magnetic core manufacturing method capable of easily manufacturing a magnetic core with high strength and high resistivity. A method for manufacturing a magnetic core having a structure including dispersed Fe-based soft magnetic alloy particles includes: a first step including mixing a first Fe-based soft magnetic alloy powder containing Al and Cr, a second Fe-based soft magnetic alloy powder containing Cr and Si, and a binder; a second step including pressing the mixture obtained after the first step; and a third step including heat-treating the compact obtained after the second step, wherein the heat treatment forms an oxide layer on the surface of Fe-based soft magnetic alloy particles and bonds the Fe-based soft magnetic alloy particles together through the oxide layer.

公开(公告)号：US10468174B2

公开(公告)日：2019-11-05

申请号：US16333132

申请日：2017-09-15

Applicant: HITACHI METALS, LTD.

Inventor： Toshio Mihara ,  Tetsuroh Katoh ,  Kazunori Nishimura ,  Shin Noguchi

IPC: H01F27/28 ,  H01F27/255 ,  B22F1/00 ,  C22C38/00 ,  H01F1/147 ,  H01F1/24 ,  H01F1/33 ,  H01F17/04

Abstract: Provided are a magnetic core having a high initial permeability and a coil component including the same. The magnetic core has an X-ray diffraction spectrum of the magnetic core measured using Cu-Kα characteristic X-rays, wherein a peak intensity ratio (P1/P2) of a peak intensity P1 of a diffraction peak of an Fe oxide having a corundum structure appearing in a vicinity of 2θ=33.2° to a peak intensity P2 of a diffraction peak of the Fe-based alloy having a bcc structure appearing in a vicinity of 2θ=44.7° is 0.015 or less; and in the X-ray diffraction spectrum, a peak intensity ratio (P3/P2) of a peak intensity P3 of a superlattice peak of an Fe3Al ordered structure appearing in a vicinity of 2θ=26.6° to the peak intensity P2 is 0.015 or more and 0.050 or less.

公开(公告)号：US10008324B2

公开(公告)日：2018-06-26

申请号：US14760964

申请日：2014-01-14

Applicant: Hitachi Metals Ltd.

Inventor： Yoshimasa Nishio ,  Shin Noguchi ,  Kazunori Nishimura ,  Tetsuroh Katoh ,  Toshio Mihara

IPC: H01F41/02 ,  B22F3/24 ,  H01F1/147 ,  B22F3/16 ,  H01F1/22 ,  H01F27/28 ,  B22F1/02 ,  C22C38/00 ,  H01F27/255 ,  C22C38/02 ,  C22C38/06 ,  C22C38/18 ,  C22C38/34 ,  H01F1/24 ,  H01F1/33 ,  B22F3/10 ,  C22C33/02

CPC classification number: H01F41/02 ,  B22F1/02 ,  B22F3/1039 ,  B22F3/16 ,  B22F2201/03 ,  B22F2201/05 ,  B22F2302/253 ,  B22F2304/10 ,  C22C33/02 ,  C22C38/00 ,  C22C38/002 ,  C22C38/02 ,  C22C38/06 ,  C22C38/18 ,  C22C38/34 ,  C22C2202/02 ,  H01F1/147 ,  H01F1/22 ,  H01F1/24 ,  H01F1/33 ,  H01F27/255 ,  H01F27/2823 ,  H01F41/0246

Abstract: A method for manufacturing a powder magnetic core using a soft magnetic material powder, wherein the method has: a first step of mixing the soft magnetic material powder with a binder, a second step of subjecting a mixture obtained through the first step to pressure forming, and a third step of subjecting a formed body obtained through the second step to heat treatment. The soft magnetic material powder is an Fe—Cr—Al based alloy powder comprising Fe, Cr and Al. An oxide layer is formed on a surface of the soft magnetic material powder by the heat treatment. The oxide layer has a higher ratio by mass of Al to the sum of Fe, Cr and Al than an alloy phase inside the powder.

公开(公告)号：US09805855B2

公开(公告)日：2017-10-31

申请号：US15111202

申请日：2015-01-14

Applicant: HITACHI METALS, LTD.

Inventor： Shin Noguchi ,  Kazunori Nishimura ,  Toshio Mihara

IPC: H01F27/28 ,  H01F27/255 ,  B22F1/00 ,  B22F1/02 ,  B22F3/14 ,  C22C33/02 ,  C22C38/00 ,  C22C38/06 ,  C22C38/18 ,  C22C45/02 ,  H01F1/24 ,  H01F41/02 ,  B22F3/03 ,  B22F3/04 ,  B22F3/24 ,  B22F9/04 ,  B22F9/08 ,  C22C38/02 ,  C22C38/04 ,  C22C38/08 ,  H01F1/33

CPC classification number: H01F27/255 ,  B22F1/00 ,  B22F1/0014 ,  B22F1/0062 ,  B22F1/02 ,  B22F3/03 ,  B22F3/04 ,  B22F3/14 ,  B22F3/24 ,  B22F9/04 ,  B22F9/082 ,  B22F2003/248 ,  B22F2009/0828 ,  B22F2998/10 ,  B22F2999/00 ,  C22C33/02 ,  C22C33/0257 ,  C22C33/0264 ,  C22C38/00 ,  C22C38/001 ,  C22C38/002 ,  C22C38/02 ,  C22C38/04 ,  C22C38/06 ,  C22C38/08 ,  C22C38/18 ,  C22C45/02 ,  H01F1/24 ,  H01F1/33 ,  H01F27/28 ,  H01F27/2823 ,  H01F41/0246 ,  B22F3/02 ,  B22F5/10 ,  B22F2207/07 ,  C22C2202/02 ,  B22F1/0059 ,  B22F1/0096 ,  B22F2003/023 ,  B22F2009/0824

Abstract: A magnetic core has a structure in which Fe-based soft magnetic alloy particles are connected via a grain boundary. The Fe-based soft magnetic alloy particles contain Al, Cr and Si. An oxide layer containing at least Fe, Al, Cr and Si is formed at the grain boundary that connects the neighboring Fe-based soft magnetic alloy particles. The oxide layer contains an amount of Al larger than that in Fe-based soft magnetic alloy particles, and includes a first region in which the ratio of Al is higher than the ratio of each of Fe, Cr and Si to the sum of Fe, Cr, Al and Si, and a second region in which the ratio of Fe is higher than the ratio of each of Al, Cr and Si to the sum of Fe, Cr, Al and Si. The first region is on the Fe-based soft magnetic alloy particle side.