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US-12618125-B2 - Soft magnetic alloy powder, magnetic core, magnetic component and electronic device

US12618125B2US 12618125 B2US12618125 B2US 12618125B2US-12618125-B2

Abstract

A soft magnetic alloy powder has a specific composition in which a Co content is large. A soft magnetic alloy powder has a glass transition point Tg and a melting point Tm, 900° C.≤Tm≤1200° C. is satisfied, or when coercivity when applying a pressure X P to a soft magnetic alloy powder is set as Y H , and a straight line obtained by linearly approximating a relationship between X P and Y H by a method of least squares is set as Y H =kX P +1, k (unit: Oe/MPa) satisfies 0≤k≤0.00100.

Inventors

  • Yoshiki KAJIURA
  • Akito HASEGAWA
  • Kazuhiro YOSHIDOME
  • Hiroyuki Matsumoto
  • Hironobu KUMAOKA

Assignees

  • TDK CORPORATION

Dates

Publication Date
20260505
Application Date
20201211
Priority Date
20191227

Claims (9)

  1. 1 . A soft magnetic alloy powder comprising: a main component having a composition formula of (Co (1−(α+β)) X 1 α X 2 β ) (1−(a+b+c+d+e+f)) M a B b P c Si d Cr e S f (atom number ratio), wherein X1 represents one or more selected from the group consisting of Fe and Ni, X2 represents one or more selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Bi, N, O, C, and rare-earth elements, M represents one or more selected from the group consisting of Nb, Hf, Zr, Ta, Mo, W, Ti, and V, 0.001≤a≤0.140, 0.180≤b≤0.220, 0.010≤c≤0.050, 0≤d≤0.250, 0≤e≤0.030, 0≤f≤0.010, 0.160≤b+c+d+e+f≤0.430, 0.500<1−(a+b+c+d+e+f)<0.840, α≥0, β≥0, and 0≤α+β<0.50 are satisfied, the soft magnetic alloy powder has a glass transition point Tg and a melting point Tm, 900° C.≤Tm≤1200° C. is satisfied, and a coercivity He of the soft magnetic alloy powder is 0.04 Oe or less.
  2. 2 . The soft magnetic alloy powder according to claim 1 , wherein average circularity of powder particles included in the soft magnetic alloy powder is 0.93 or greater, and a number percentage of the powder particles having a circularity of 0.50 or less is 2.0% or less.
  3. 3 . The soft magnetic alloy powder according to claim 1 , wherein average circularity of powder particles included in the soft magnetic alloy powder is 0.95 or greater, and a number percentage of the powder particles having a circularity of 0.50 or less is 1.5% or less.
  4. 4 . The soft magnetic alloy powder according to claim 1 , wherein a value obtained by dividing an atom number ratio of Co by an atom number ratio of B is greater than 2.000 and less than 5.000.
  5. 5 . The soft magnetic alloy powder according to claim 1 , further including an amorphous material.
  6. 6 . The soft magnetic alloy powder according to claim 1 , further including a nanocrystal material.
  7. 7 . A magnetic core comprising: the soft magnetic alloy powder according to claim 1 .
  8. 8 . A magnetic component comprising the soft magnetic alloy powder according to claim 1 .
  9. 9 . An electronic device comprising the soft magnetic alloy powder according to claim 1 .

Description

BACKGROUND OF THE INVENTION The present invention relates to a soft magnetic alloy powder, a magnetic core, a magnetic component, and an electronic device. In recent, there has been a demand for low power consumption and high efficiency in electronic/information/communication devices, particularly, in electronic devices. In addition, the demand becomes stronger toward low-carbon society. Accordingly, in a power supply circuit of the electronic/information/communication devices and the like, particularly, the electronic devices, a reduction in energy loss and an improvement of power efficiency are also required. Here, for the reduction in energy loss and the improvement of power efficiency, it is required to obtain a soft magnetic alloy powder having excellent soft magnetic characteristics and an improved packing rate when used in a magnetic core. Patent Document 1 discloses a soft magnetic powder of which Wardell's spheroidicity is improved. In addition, it is also stated that an excellent power inductor can be manufactured by improving the spheroidicity. Patent Document 2 discloses a Co-based amorphous alloy ribbon. In addition, it is also described that permeability and squareness ratio are improved when the amount of S contained is set to 30 ppm or less, and the amount of Al contained is set to 40 ppm or less. In addition, as a method of packing the soft magnetic alloy powder in a high density, it is known that methods described in Patent Documents 3 and 4 are effective. In Patent Document 3, it is described that an inductor having excellent relative permeability can be manufactured by using a soft magnetic alloy powder with high spheroidicity. In Patent Document 4, it is described that when two kinds of particles having particle sizes different from each other, and a particle size ratio of the two kinds of particles is set within a specific range, particles are filled in a high density, and the relative permeability is improved. [Patent Document 1] JP 2016-25352 A[Patent Document 2] JP H3-173750 A[Patent Document 3] JP 2010-212442 A[Patent Document 4] JP 2011-192729 A BRIEF SUMMARY OF INVENTION An object of the invention is to provide a soft magnetic alloy powder to obtain a magnetic core having satisfactory permeability. In response to achieve the above object, a soft magnetic alloy powder of a first aspect of the present invention including a main component having a composition formula of (Co(1−(α+β))X1αX2β)(1−(a+b+c+d+e+f))MaBbPcSidCreSf(atom number ratio), X1 represents one or more selected from the group consisting of Fe and Ni,X2 represents one or more selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Bi, N, O, C, and rare-earth elements,M represents one or more selected from the group consisting of Nb, Hf, Zr, Ta, Mo, W, Ti, and V,0<a≤0.140,0.160<b≤0.250,0≤c≤0.200,0≤d≤0.250,0≤e≤0.030,0≤f≤0.010,0.160<b+c+d+e+f≤0.430,0.500<1−(a+b+c+d+e+f)<0.840,α≥0,β≥0, and0≤α+β<0.50 are satisfied,the soft magnetic alloy powder has a glass transition point Tg and a melting point Tm, and900° C.≤Tm≤1200° C. is satisfied. According to the soft magnetic alloy powder of the first aspect of the invention, average circularity of powder particles included in the soft magnetic alloy powder may be 0.93 or greater, and a cumulative number ratio from a site where circularity of the powder particles is lowest to a site where the circularity is 0.50 may be 2.0% or less. According to the soft magnetic alloy powder of the first aspect of the invention, average circularity of powder particles included in the soft magnetic alloy powder may be 0.95 or greater, and a cumulative number ratio from a site where circularity of the powder particles is lowest to a site where the circularity is 0.50 may be 1.5% or less. According to the soft magnetic alloy powder of the first aspect of the invention, a value obtained by dividing a content ratio of Co by a content ratio of B may be greater than 2.000 and less than 5.000. According to the soft magnetic alloy powder of the first aspect of the invention, the soft magnetic alloy powder may further include an amorphous material. According to the soft magnetic alloy powder of the first aspect of the invention, the soft magnetic alloy powder may further include a nanocrystal material. In response to achieve the above object, a soft magnetic alloy powder of a second aspect of the present invention including a main component having a composition formula of (Co(1−(α+β))X1αX3β)(1−(a+b+c+d+e+))MaBbPcSidCre(atom number ratio), X1 represents one or more selected from the group consisting of Fe and Ni,X3 represents one or more selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Bi, N, O, C, S, and rare-earth elements,M represents one or more selected from the group consisting of Nb, Hf, Zr, Ta, Mo, W, Ti, and V,0<a≤0.140,0.160<b≤0.250,0≤c≤0.200,0≤d≤0.250,0≤e≤0.030,0.160<b+c+d+e 0.430,0.500<1−(a+b+c+d+e)<0.840,α≥0,β≥0, and0≤α+β<0.50 are satisfied,wherein k (unit: Oe/MP