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：US11508512B2

公开(公告)日：2022-11-22

申请号：US16430857

申请日：2019-06-04

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 ,  C22C33/02 ,  B22F1/16

Abstract: The invention provides a method 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：US20150332850A1

公开(公告)日：2015-11-19

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 ,  C22C38/06 ,  H01F1/147 ,  H01F1/22 ,  H01F27/255 ,  H01F27/28 ,  C22C38/18 ,  B22F3/16

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.

Abstract translation: 一种使用软磁性材料粉末制造粉末磁芯的方法，其中所述方法具有：将软磁性材料粉末与粘合剂混合的第一步骤，将通过第一步骤获得的混合物进行压力成形的第二步骤， 以及对通过第二步骤获得的成形体进行热处理的第三步骤。 软磁性材料粉末是包含Fe，Cr和Al的Fe-Cr-Al基合金粉末。 通过热处理在软磁性材料粉末的表面上形成氧化物层。 与粉末中的合金相相比，氧化物层的Al的质量比Fe，Cr和Al的总和高。

公开(公告)号：US20190355503A1

公开(公告)日：2019-11-21

申请号：US16430816

申请日：2019-06-04

Applicant: HITACHI METALS, LTD.

Inventor： Kazunori NISHIMURA ,  Shin Noguchi ,  Toshio Mihara

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

Abstract: The invention provides a powder magnetic core and a method 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. A method for manufacturing a powder magnetic core with a metallic soft magnetic material powder includes: 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：US10236110B2

公开(公告)日：2019-03-19

申请号：US15124550

申请日：2015-03-13

Applicant: Hitachi Metals, Ltd.

Inventor： Kazunori Nishimura ,  Toshio Mihara ,  Shin Noguchi

IPC: H01F27/25 ,  H01F27/255 ,  C22C38/00 ,  H01F3/08 ,  H01F41/02 ,  H01F1/26 ,  H01F1/33 ,  C22C38/02 ,  C22C38/06 ,  C22C38/12 ,  C22C38/14 ,  C22C38/18 ,  C22C33/02 ,  B22F3/02 ,  B22F3/24 ,  C21D8/12 ,  C21D9/40 ,  C22C38/28 ,  H01F1/147 ,  H01F1/20 ,  H01F1/24 ,  C21D6/00 ,  C21D1/26

Abstract: A magnetic core includes alloy phases 20 each made of Fe-based soft magnetic alloy grains including M1 (wherein M1 represents both elements of Al and Cr), Si, and R (wherein R represents at least one element selected from the group consisting of Y, Zr, Nb, La, Hf and Ta), and has a structure in which the alloy phases 20 are connected to each other through a grain boundary phase 30. In the grain boundary phase 30, an oxide region is produced. The oxide region includes Fe, M1, Si and R and further includes Al in a larger proportion by mass than the alloy phases 20.

公开(公告)号：US09734942B2

公开(公告)日：2017-08-15

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：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：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.