公开(公告)号：US11011305B2

公开(公告)日：2021-05-18

申请号：US15988209

申请日：2018-05-24

Applicant: HITACHI METALS, LTD.

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

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

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：US10354790B2

公开(公告)日：2019-07-16

申请号：US15124942

申请日：2015-03-12

Applicant: HITACHI METALS, LTD.

Inventor： Kazunori Nishimura ,  Shin Noguchi ,  Toshio Mihara

IPC: H01F7/06 ,  H01F27/255 ,  C22C38/00 ,  H01F1/26 ,  H01F41/02 ,  H01F1/147 ,  H01F1/22 ,  B22F1/02

Abstract: An object of the invention is to provide a method that is for manufacturing a powder magnetic core through simple compression molding and capable of manufacturing a complicatedly shaped powder magnetic core with reliable high strength and insulating properties. The invention is directed to a method for manufacturing a powder magnetic core with a metallic soft magnetic material powder, the method including: a first step including mixing a soft magnetic material powder and a binder; a second step including compression molding the mixture obtained after the first step; a third step including performing at least one of grinding and cutting on the compact obtained after the second step; and a fourth step including heat-treating the compact after the third step, wherein in the fourth step, the compact is heat-treated so that an oxide layer containing an element constituting the soft magnetic material powder is formed on the surface of the soft magnetic material powder.

公开(公告)号：US20190096553A1

公开(公告)日：2019-03-28

申请号：US16203187

申请日：2018-11-28

Applicant: Hitachi Metals, Ltd.

Inventor： Tetsuro Kato ,  Shin Noguchi ,  Kazunori Nishimura

IPC: H01F1/147 ,  H01F5/00 ,  H01F1/22 ,  H01F27/24 ,  B22F3/02

Abstract: Provided are: a metal powder core having a configuration suitable for core loss reduction and strength improvement; a coil component employing this; and a fabrication method for metal powder core. The metal powder core is obtained by dispersing Cu powder among soft magnetic material powder comprising pulverized powder of Fe-based soft magnetic alloy and atomized powder of Fe-based soft magnetic alloy and then by performing compaction. The fabrication method for metal powder core includes: a mixing step of mixing together soft magnetic material powder containing thin-leaf shaped pulverized powder of Fe-based soft magnetic alloy and atomized powder of Fe-based soft magnetic alloy, Cu powder, and a binder and thereby obtaining a mixture; a forming step of performing pressure forming on the mixture obtained at the mixing step; and a heat treatment step of annealing a formed article obtained at the forming step.

公开(公告)号：US10176912B2

公开(公告)日：2019-01-08

申请号：US15124584

申请日：2015-03-10

Applicant: HITACHI METALS, LTD.

Inventor： Kazunori Nishimura ,  Toshio Mihara ,  Shin Noguchi

IPC: H01F1/147 ,  C22C38/00 ,  H01F1/24 ,  H01F3/08 ,  H01F41/02 ,  H01F1/33 ,  C22C38/02 ,  C22C38/06 ,  C22C38/18 ,  C22C33/02 ,  B22F1/00 ,  B22F3/02 ,  B22F3/24 ,  C21D8/12 ,  C21D9/40 ,  C22C38/34 ,  H01F1/22 ,  H01F27/255 ,  H01F1/26 ,  C21D6/00 ,  C21D1/26

Abstract: A magnetic core has a structure in which alloy phases 20 each including Fe, Al, Cr and Si are dispersed and any adjacent two of the alloy phases 20 are connected to each other through a grain boundary phase 30. In this grain boundary phase 30, an oxide region is produced which includes Fe, Al, Cr and Si, and includes Al in a larger proportion by mass than the alloy phases 20. This magnetic core includes Al in a proportion of 3 to 10% both inclusive by mass, Cr in a proportion of 3 to 10% both inclusive by mass, and Si in a proportion more than 1% and 4% or less by mass provided that the sum of the quantities of Fe, Al, Cr and Si is regarded as being 100% by mass; and includes Fe and inevitable impurities as the balance of the core.

公开(公告)号：US11192183B2

公开(公告)日：2021-12-07

申请号：US15759550

申请日：2016-09-16

Applicant: HITACHI METALS, LTD.

Inventor： Tetsuroh Katoh ,  Kazunori Nishimura ,  Shin Noguchi

IPC: B22F3/24 ,  H01F41/02 ,  H01F1/147 ,  B22F1/02 ,  C22C38/18 ,  C22C38/06

Abstract: A powder magnetic core manufacturing method includes: a first step of mixing a binder with a soft magnetic material powder containing Fe-M (M: Al or Cr)-based alloy particles on which an insulating layer is formed; a second step of filling a pressing die with a mixture obtained through the first step, subjecting the mixture to pressing to obtain a green compact, and slidingly demolding the green compact from the pressing die; a third step of processing the green compact after the second step and removing expansion deformed matter of the alloy particles present in a region of pressing flaws formed on a surface of the green compact during the slidingly demolding; and a fourth step of subjecting the green compact after the third step to heat treatment to oxidize surfaces of the Fe-M (M: Al or Cr)-based alloy particles at high temperature, so that the oxide phase is formed.

公开(公告)号：US10453599B2

公开(公告)日：2019-10-22

申请号：US15326071

申请日：2015-07-16

Applicant: Hitachi Metals, Ltd.

Inventor： Shin Noguchi ,  Kazunori Nishimura ,  Toshio Mihara

IPC: H01F27/255 ,  H01F1/20 ,  H01F1/24 ,  H01F1/147 ,  H01F27/28 ,  H01F41/02 ,  H01F3/08 ,  H01F17/04 ,  H01F27/29

Abstract: There is provided a magnetic core having high manufacturability and high magnetic permeability, to provide a method for manufacturing such a magnetic core, and to provide a coil component having such a magnetic core. The invention is directed to a magnetic core including: Fe-based soft magnetic alloy particles; and an oxide phase existing between the Fe-based soft magnetic alloy particles, wherein the Fe-based soft magnetic alloy particles include Fe—Al—Cr alloy particles and Fe—Si—Al alloy particles.

公开(公告)号：US09773605B2

公开(公告)日：2017-09-26

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

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.

公开(公告)号：US09449752B2

公开(公告)日：2016-09-20

申请号：US14522162

申请日：2014-10-23

Applicant: Hitachi Metals, Ltd.

Inventor： Masami Taguchi ,  Shigeho Tanigawa ,  Shin Noguchi

IPC: H01F27/02 ,  H01F27/255 ,  B22F1/02 ,  H01F41/02 ,  H01F1/153 ,  B22F5/10

CPC classification number: H01F27/255 ,  B22F1/02 ,  B22F5/106 ,  B22F2998/10 ,  B22F2999/00 ,  C22C2200/02 ,  C22C2202/02 ,  H01F1/15308 ,  H01F27/02 ,  H01F41/0246 ,  B22F1/0059 ,  B22F3/02 ,  B22F2003/248 ,  B22F2202/05 ,  B22F2201/05

Abstract: It is an objective of the invention to provide a dust core made of an Fe-based amorphous metal powder having excellent magnetic properties, in which the dust core has a higher-than-conventional density, excellent magnetic properties and a high mechanical strength. There is provided a dust core including a mixture powder compacted, the mixture powder including: an Fe-based amorphous metal powder having a crystallization temperature Tx (unit: K), the Fe-based amorphous metal powder being plastically deformed, the plastically deformed metal Fe-based amorphous metal powder having a filling factor in the dust core higher than 80% and not higher than 99%; and a resin binder having a melting point Tm (unit: K), in which the Tx and Tm satisfy a relationship of “Tm/Tx≧0.70”.

Abstract translation: 本发明的目的是提供一种由具有优异的磁性能的Fe基非晶态金属粉末制成的防尘芯，其中该防尘芯具有高于常规密度，优异的磁性能和高的机械强度。 本发明提供一种压粉粉体，其特征在于，包括：具有结晶化温度Tx（单位：K）的Fe系非晶态金属粉末，所述Fe系非晶金属粉末发生塑性变形，所述塑性变形金属 在粉尘芯中具有填充因子的Fe基非晶金属粉末高于80％且不高于99％; 和具有熔点Tm（单位：K）的树脂粘合剂，其中Tx和Tm满足“Tm /Tx≥0.70”的关系。

公开(公告)号：US20160155549A1

公开(公告)日：2016-06-02

申请号：US14904022

申请日：2014-07-17

Applicant: HITACHI METALS, LTD.

Inventor： Tetsuro Kato ,  Shin Noguchi ,  Kazunori Nishimura

IPC: H01F1/147 ,  B22F3/02 ,  C22C45/02 ,  B22F1/00 ,  C21D9/00 ,  C22C9/02 ,  H01F1/22 ,  B22F9/04

CPC classification number: H01F1/147 ,  B22F1/0062 ,  B22F3/02 ,  B22F9/04 ,  B22F2301/10 ,  B22F2301/35 ,  B22F2302/45 ,  B22F2998/10 ,  B22F2999/00 ,  C21D9/0068 ,  C22C9/02 ,  C22C45/02 ,  C22C2202/02 ,  H01F1/15308 ,  H01F1/22 ,  H01F1/24 ,  H01F1/26 ,  H01F3/08 ,  H01F5/00 ,  H01F27/24 ,  B22F1/0003 ,  B22F2003/248 ,  B22F1/0048 ,  B22F9/082 ,  B22F1/0055

Abstract: Provided are: a metal powder core having a configuration suitable for core loss reduction and strength improvement; a coil component employing this; and a fabrication method for metal powder core. The metal powder core is obtained by dispersing Cu powder among soft magnetic material powder comprising pulverized powder of Fe-based soft magnetic alloy and atomized powder of Fe-based soft magnetic alloy and then by performing compaction. The fabrication method for metal powder core includes: a mixing step of mixing together soft magnetic material powder containing thin-leaf shaped pulverized powder of Fe-based soft magnetic alloy and atomized powder of Fe-based soft magnetic alloy, Cu powder, and a binder and thereby obtaining a mixture; a forming step of performing pressure forming on the mixture obtained at the mixing step; and a heat treatment step of annealing a formed article obtained at the forming step.

Abstract translation: 提供：具有适于铁损减小和强度提高的构造的金属粉末芯; 使用该线圈部件的线圈部件 以及金属粉末芯的制造方法。 通过将Fe粉末分散在由Fe系软磁合金的粉碎粉末和Fe系软磁性合金的雾化粉末构成的软磁性体粉末中，然后进行压实而获得金属粉末芯。 金属粉末芯的制造方法包括：将含有Fe系软磁合金的薄叶状粉碎粉末的软磁性体粉末与Fe系软磁性合金的粉末状粉末，Cu粉末和粘合剂混合的混合工序 从而获得混合物; 在混合步骤中获得的混合物上进行压力成形的成形步骤; 以及对在成形工序中得到的成形体进行退火的热处理工序。

公开(公告)号：US20150162118A1

公开(公告)日：2015-06-11

申请号：US14372974

申请日：2013-01-15

Applicant: HITACHI METALS, LTD.

Inventor： Tetsuro Kato ,  Shin Noguchi ,  Kazunori Nishimura

IPC: H01F1/153 ,  H01F1/24 ,  C22C33/02 ,  C22C45/02 ,  H01F27/255 ,  B22F1/02 ,  B22F3/02 ,  H01F1/33 ,  H01F27/28 ,  H01F1/22 ,  B22F1/00

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.

Abstract translation: 在由软磁性材料粉末构成的金属粉末芯和采用该磁性材料粉末的线圈组件中，提供了适于减少磁芯损耗的构造。 由软磁性材料粉末构成的金属粉末芯的特征在于，Cu分散在软磁性材料粉末中。 其特征在于，优选地，软磁性材料粉末是软磁性合金带的粉碎粉末，并且Cu分散在软磁性合金带的粉碎粉末中。 此外，其特征在于，优选地，软磁性合金带是Fe基纳米晶体合金带或Fe基纳米晶体结构的Fe基合金带，并且粉碎的粉末具有纳米晶体结构。