US4985089A
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Fe-base soft magnetic alloy powder and magnetic core thereof and method of producing same
Assignee: Proterial Ltd
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Filing: 1988-07-25
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Granted: 1991-01-15
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Expires: 2008-07-25
Abstract
Abstract Fe-base soft magnetic alloy powder and dust core having the composition represented by the general formula: (Fe.sub.1-a M.sub.a).sub.100-x-y-z-α-β-γ Cu.sub.x Si.sub.y B z M'.sub.α M".sub.β X.sub.γ wherein M is Co and/or Ni, M' is at least one element selected from the group consisting of Nb, W, Ta, Zr, Hf, Ti and Mo, M" is at least one element selected from the group consisting of V, Cr, Mn, Al, elements in the platinum group, Sc, Y, rare earth elements, Au, Zn, Sn and Re, X is at least one element selected from the group consisting of C, Ge, P, Ga, Sb, In, Be and As, and a, x, y, z, α, β and γ respectively satisfy 0≦a≦0.5, 0.1≦x≦3, 0≦y≦30, 0≦z≦25, 0≦y+z≦35, 0.1≦α≦30, 0≦β≦10 and 0≦γ≦10, at least 50% of the alloy structure being fine crystalline particles having an average particle size of 500 Å or less.
Inventors
- 👤 Yoshihito Yoshizawa
- 👤 Kiyotaka Yamauchi
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 21:15
CPC Classifications
H; H01; H01F; H01F1/00; H01F1/01; H01F1/03; H01F1/032; H01F1/12; H01F1/14; H01F1/147; H01F1/153; H01F1/15341; H01F1/1535; H01F1/15358; H01F1/15366; H01F1/20
Claims Analysis
Total Claims: 17
Claim 1
Independent Claim
140 words
Fe-base soft magnetic alloy powder having the composition represented by the general formula: (Fe.sub.1-a M.sub.a).sub.100-x-y-z-α-β-γ Cu.sub.x Si.sub.y B.sub.z M'.sub.α M".sub.β Xγ wherein M is Co and/or Ni, ' is at least one element selected from the group consisting of Nb, W" Ta, Zr, Hf, Ti and Mo, M" is at least one element selected from the group consisting of V, Cr, Mn, A±, elements in the platinum group, Sc, Y, rare earth elements, Au, Zn, Sn and Re, X is at least one element selected from the group consisting of C, Ge, P, Ga, Sb, In, Be and As, and a, x, y, z, α, β and γ respectively satisfy 0<a<0.5, 0.1<x<3, 0<y=<30, 0<z<25, 0<y+z<35, 0.1<α<30, 0<β<10 and 0<γ<10, at least 50% of the alloy structure being fine crystalline particles having an average particle size of 500 Å or less.
Claim 2
Dependent Claim
140 words
Fe-base soft magnetic alloy powder having the composition represented by the general formula: (Fe.sub.1-a M.sub.a).sub.100-x-y-z-α-β-γ Cu.sub.x Si.sub.y B.sub.z M'.sub.α M".sub.β Xγ wherein M is Co and/or Ni, ' is at least one element selected from the group consisting of Nb, W" Ta, Zr, Hf, Ti and Mo, M" is at least one element selected from the group consisting of V, Cr, Mn, A±, elements in the platinum group, Sc, Y, rare earth elements, Au, Zn, Sn and Re, X is at least one element selected from the group consisting of C, Ge, P, Ga, Sb, In, Be and As, and a, x, y, z, α, β and γ respectively satisfy 0<a<0.5, 0.1<x<3, 0<y=<30, 0<z<25, 0<y+z<35, 0.1<α<30, 0<β<10 and 0<γ<10, at least 50% of the alloy structure being fine crystalline particles having an average particle size of 500 Å or less.
Claim 3
Dependent Claim
31 words
The Fe-base soft magnetic alloy powder according to claim 1, wherein said a, x, y, z, α, β and γ respectively satisfy 0<a<0.3, 0.5<x<2, 10<y<25, 3≦z<12, 18≦+z<28, 2<α<8, β<8 and γ<5.
Claim 4
Dependent Claim
26 words
The Fe-base soft magnetic alloy powder according to claim 1, wherein said crystalline particles are substantially composed of an Fe solid solution having a bcc structure.
Claim 5
Dependent Claim
20 words
The Fe-base soft magnetic alloy powder according to claim 1, wherein the balance of said alloy structure is substantially amorphous.
Claim 6
Dependent Claim
20 words
The Fe-base soft magnetic alloy powder according to claim 1, wherein said alloy structure substantially consists of fine crystalline particles.
Claim 7
Dependent Claim
42 words
The Fe-base soft magnetic alloy powder according to claim 1, wherein said powder is in the form of a fine flake whose thickness is less than 100 μm and substantially uniform, and said powder has a particle size smaller than 4 mesh.
Claim 8
Dependent Claim
19 words
The Fe-base soft magnetic alloy powder according to claim 6, wherein said particle size is smaller than 10 mesh.
Claim 9
Dependent Claim
35 words
The Fe-base soft magnetic alloy powder according to claim 1, wherein said powder is substantially in the form of a sphere whose particle size is 200 μm or less when measured by its maximum size.
Claim 10
Dependent Claim
25 words
The Fe-base soft magnetic alloy powder according to claim 1, wherein said powder has an irregular shape having a maximum size less than 2 mm.
Claim 11
Dependent Claim
156 words
An Fe-base soft magnetic alloy dust core composed of compressed Fe-base soft magnetic alloy fine powder, said Fe-base soft magnetic alloy having the composition represented by the general formula: (Fe.sub.1-a M.sub.a).sub.100-x-y-z-α-β-γ Cu.sub.x Si.sub.y B.sub.z M'.sub.α M".sub.β M.sub.γ wherein M is Co and/or Ni, M' is at least one element selected from the group consisting of Nb, W, Ta, Zr, Hf, Ti and Mo, M" is at least one element selected from the group consisting of V, Cr, Mn, Al, elements in the platinum group, Sc, Y, rare earth elements, Au, Zn, Sn and Re, X is at least one element selected from the group consisting of C, Ge, P, Ga, Sb, In, Be and As, and a, x, y, z, α, β and Y respectively satisfy 0<a<0.5, 0.1<x<3, 0<y<30, 0<z<25, 0<y+z<35, 0.1<α<30, 0<β<10 and 0<γ<10, at least 50% of the alloy structure being fine crystalline particles having an average particle size of 500 Å or less.
Claim 12
Dependent Claim
156 words
An Fe-base soft magnetic alloy dust core composed of compressed Fe-base soft magnetic alloy fine powder, said Fe-base soft magnetic alloy having the composition represented by the general formula: (Fe.sub.1-a M.sub.a).sub.100-x-y-z-α-β-γ Cu.sub.x Si.sub.y B.sub.z M'.sub.α M".sub.β M.sub.γ wherein M is Co and/or Ni, M' is at least one element selected from the group consisting of Nb, W, Ta, Zr, Hf, Ti and Mo, M" is at least one element selected from the group consisting of V, Cr, Mn, Al, elements in the platinum group, Sc, Y, rare earth elements, Au, Zn, Sn and Re, X is at least one element selected from the group consisting of C, Ge, P, Ga, Sb, In, Be and As, and a, x, y, z, α, β and Y respectively satisfy 0<a<0.5, 0.1<x<3, 0<y<30, 0<z<25, 0<y+z<35, 0.1<α<30, 0<β<10 and 0<γ<10, at least 50% of the alloy structure being fine crystalline particles having an average particle size of 500 Å or less.
Claim 13
Dependent Claim
31 words
The Fe-base soft magnetic alloy dust core according to claim 10, wherein said a, x, y, z, α, β and γ respectively satisfy 0<a<0.3, 0.5<x<2, 10<y<25==3<=z<1=12, 2y+z<28, 2<c<8, β<8 and γ<10.
Claim 14
Dependent Claim
21 words
The Fe-base soft magnetic alloy dust core according to claim 10, wherein the balance of said alloy structure is substantially amorphous.
Claim 15
Dependent Claim
21 words
The Fe-base soft magnetic alloy dust core according to claim 10, wherein said alloy structure substantially consists of fine crystalline particles.
Claim 16
Dependent Claim
16 words
The Fe-base soft magnetic alloy dust core according to claim 10, wherein said ' is Nb.
Claim 17
Dependent Claim
34 words
The Fe-base soft magnetic alloy dust core according to claim 19, wherein M" is at least one element selected from the group consisting of Ru, Ph, Pd, Os, Ir, Pt, Au, Cr, and V.
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