公开(公告)号：US20090047519A1

公开(公告)日：2009-02-19

申请号：US12160079

申请日：2006-11-22

申请人： Toru Maeda ,  Naoto Igarashi ,  Haruhisa Toyoda ,  Seiji Ishitani ,  Hiroko Morii ,  Kazuyuki Hayashi

发明人： Toru Maeda ,  Naoto Igarashi ,  Haruhisa Toyoda ,  Seiji Ishitani ,  Hiroko Morii ,  Kazuyuki Hayashi

IPC分类号： B32B15/02 ,  B05D5/12

CPC分类号： H01F1/24 ,  B22F1/02 ,  B22F2998/10 ,  C22C33/02 ,  H01F1/26 ,  H01F3/08 ,  H01F41/0246 ,  Y10T428/2991 ,  Y10T428/2998 ,  B22F1/007 ,  B22F3/02 ,  B22F3/10

摘要： The soft magnetic material includes a plurality of composite magnetic particles having a metal magnetic particle and an insulating film surrounding the surface of the metal magnetic particle. The metal magnetic particle contains iron as the main component. The insulating film contains aluminum, silicon, phosphorus, and oxygen. The insulating film satisfies the relationship 0.4≦MAl/(MAl+MSi)≦0.9 and the relationship of 0.25≦(MAl+MSi)/MP≦1.0 in the case that molar amount of aluminum contained in the insulating film is represented by MAl, the sum of the molar amount of aluminum contained in the insulating film and the molar amount of silicon contained in the insulating film is represented by (MAl+MSi), and the molar amount of phosphorus contained in the insulating film is represented by MP.

摘要翻译： 软磁性材料包括具有金属磁性颗粒的多个复合磁性颗粒和围绕金属磁性颗粒表面的绝缘膜。 金属磁性粒子含有铁作为主要成分。 绝缘膜含有铝，硅，磷和氧。 在绝缘膜中含有的铝的摩尔量为绝对膜的情况下，绝缘膜满足关系0.4 <= MA1 /（MA1 + MSi）<= 0.9，0.25 <=（MA1 + MSi）/ MP < 由MA1表示，绝缘膜中所含的铝的摩尔量与绝缘膜中所含的硅的摩尔量之和表示为（MA1 + MSi），表示绝缘膜中所含的磷的摩尔量 由MP。

公开(公告)号：US07682695B2

公开(公告)日：2010-03-23

申请号：US10597197

申请日：2005-01-28

申请人： Hirokazu Kugai ,  Naoto Igarashi ,  Toru Maeda ,  Kazuhiro Hirose ,  Haruhisa Toyoda ,  Koji Mimura ,  Takao Nishioka

发明人： Hirokazu Kugai ,  Naoto Igarashi ,  Toru Maeda ,  Kazuhiro Hirose ,  Haruhisa Toyoda ,  Koji Mimura ,  Takao Nishioka

IPC分类号： B32B5/16 ,  B29C67/04

CPC分类号： H01F3/08 ,  H01F1/24 ,  H01F1/33 ,  H01F41/0246 ,  Y10T29/4902 ,  Y10T428/2991 ,  Y10T428/2993 ,  Y10T428/2995 ,  Y10T428/2996

摘要： The object of the present invention is to provide a powder core and method for making the same that is equipped with insulative coating having superior heat resistance, with the coating making it possible to adequately restrict the flow of eddy currents between particles.The powder core is equipped with a plurality of compound magnetic particles bonded to each other. Each of said plurality of composite magnetic particles includes: a metal magnetic particle 10; an insulative lower layer coating 20 surrounding a surface 10a of said metal magnetic particle 10; an upper layer coating 30 surrounding said lower layer coating 20 and containing silicon; and dispersed particles 50 containing a metal oxide compound and disposed in said lower layer coating 20 and/or said upper layer coating 30. A mean particle diameter R of the dispersed particles 50 meets the condition 10 nm

摘要翻译： 本发明的目的是提供一种粉末芯及其制造方法，其具有耐热性优异的绝缘涂层，该涂层可以适当地限制颗粒之间的涡流的流动。 粉末芯配备有彼此结合的多个复合磁性颗粒。 所述多个复合磁性颗粒中的每一个包括：金属磁性颗粒10; 围绕所述金属磁性颗粒10的表面10a的绝缘性下层涂层20; 围绕所述下层涂层20并含有硅的上层涂层30; 和含有金属氧化物化合物的分散颗粒50，并且设置在所述下层涂层20和/或上层涂层30中。分散颗粒50的平均粒径R满足条件10nm

公开(公告)号：US07674342B2

公开(公告)日：2010-03-09

申请号：US10594961

申请日：2005-03-29

申请人： Toru Maeda ,  Naoto Igarashi ,  Kazuhiro Hirose ,  Haruhisa Toyoda

发明人： Toru Maeda ,  Naoto Igarashi ,  Kazuhiro Hirose ,  Haruhisa Toyoda

IPC分类号： H01F1/14

CPC分类号： C22C33/02 ,  B22F1/0088 ,  B22F2003/248 ,  B22F2998/10 ,  H01F1/24 ,  H01F1/26 ,  H01F41/0246 ,  B22F9/082 ,  B22F1/0085 ,  B22F1/02 ,  B22F1/0059 ,  B22F3/02 ,  B22F3/24

摘要： A method of producing a soft magnetic material includes the steps of preparing soft magnetic powder containing a plurality of soft magnetic particles etching the soft magnetic powder to remove surfaces of the soft magnetic particles and, after the etching step, heat-treating the soft magnetic powder in a finely divided state at a temperature of not less than 400° C. and not more than 900° C. By this method configured as above, desired magnetic characteristics can be obtained.

摘要翻译： 一种制造软磁性材料的方法包括以下步骤：制备含有多个软磁性颗粒的软磁性粉末，该软磁性粉末蚀刻软磁性粉末以去除软磁性颗粒的表面，并且在蚀刻步骤之后，对软磁性粉末进行热处理 在不低于400℃且不高于900℃的温度下处于细分状态。通过如上构造的方法，可以获得期望的磁特性。

公开(公告)号：US08323725B2

公开(公告)日：2012-12-04

申请号：US12816833

申请日：2010-06-16

申请人： Toru Maeda ,  Naoto Igarashi ,  Haruhisa Toyoda ,  Hirokazu Kugai ,  Kazuyuki Hayashi ,  Hiroko Morii ,  Seiji Ishitani

发明人： Toru Maeda ,  Naoto Igarashi ,  Haruhisa Toyoda ,  Hirokazu Kugai ,  Kazuyuki Hayashi ,  Hiroko Morii ,  Seiji Ishitani

IPC分类号： H01F1/20

CPC分类号： B22F1/02 ,  B22F2998/10 ,  H01F1/24 ,  H01F1/26 ,  H01F41/0246 ,  Y10T428/2991 ,  B22F3/02 ,  B22F3/24

摘要： A soft magnetic material is a soft magnetic material including a composite magnetic particle (30) having a metal magnetic particle (10) mainly composed of Fe and an insulating coating (20) covering metal magnetic particle (10), and insulating coating (20) contains an iron phosphate compound and an aluminum phosphate compound. The atomic ratio of Fe contained in a contact surface of insulating coating (20) in contact with metal magnetic particle (10) is larger than the atomic ratio of Fe contained in the surface of insulating coating (20). The atomic ratio of Al contained in the contact surface of insulating coating (20) in contact with metal magnetic particle (10) is smaller than the atomic ratio of Al contained in the surface of insulating coating (20). Thus, iron loss can be reduced.

摘要翻译： 软磁性材料是包括具有主要由Fe构成的金属磁性粒子（10）和覆盖金属磁性粒子（10）的绝缘涂层（20）的复合磁性体（30）和绝缘涂层（20）的软磁性材料， 含有磷酸铁化合物和磷酸铝化合物。 包含在与金属磁性颗粒（10）接触的绝缘涂层（20）的接触表面中的Fe的原子比大于绝缘涂层（20）表面中所含的Fe的原子比。 绝缘涂层（20）与金属磁性颗粒（10）接触的接触表面中所含的Al的原子比小于绝缘涂层（20）表面中的Al的原子比。 因此，可以减少铁损。

公开(公告)号：US20120164320A1

公开(公告)日：2012-06-28

申请号：US13409850

申请日：2012-03-01

申请人： Toru Maeda ,  Naoto Igarashi ,  Haruhisa Toyoda ,  Seiji Ishitani ,  Hiroko Morii ,  Kazuyuki Hayashi

发明人： Toru Maeda ,  Naoto Igarashi ,  Haruhisa Toyoda ,  Seiji Ishitani ,  Hiroko Morii ,  Kazuyuki Hayashi

IPC分类号： B05D5/12

CPC分类号： H01F1/24 ,  B22F1/02 ,  B22F2998/10 ,  C22C33/02 ,  H01F1/26 ,  H01F3/08 ,  H01F41/0246 ,  Y10T428/2991 ,  Y10T428/2998 ,  B22F1/007 ,  B22F3/02 ,  B22F3/10

摘要： A manufacturing method of a soft magnetic material has a step of preparing a metal magnetic particle containing iron as the main component, and a step of forming an insulating film surrounding the surface of the metal magnetic particle. The step of forming the insulating film includes a step of mixing and stirring the metal magnetic particle, aluminum alkoxide, silicon alkoxide, and phosphoric acid.

摘要翻译： 软磁性材料的制造方法具有制备以铁为主要成分的金属磁性体的工序，以及形成包围金属磁性体的表面的绝缘膜的工序。 形成绝缘膜的步骤包括混合和搅拌金属磁性颗粒，醇铝，硅烷氧化物和磷酸的步骤。

公开(公告)号：US08153256B2

公开(公告)日：2012-04-10

申请号：US12160079

申请日：2006-11-22

申请人： Toru Maeda ,  Naoto Igarashi ,  Haruhisa Toyoda ,  Seiji Ishitani ,  Hiroko Morii ,  Kazuyuki Hayashi

发明人： Toru Maeda ,  Naoto Igarashi ,  Haruhisa Toyoda ,  Seiji Ishitani ,  Hiroko Morii ,  Kazuyuki Hayashi

IPC分类号： B32B5/16 ,  H01F1/12 ,  H01F1/24

CPC分类号： H01F1/24 ,  B22F1/02 ,  B22F2998/10 ,  C22C33/02 ,  H01F1/26 ,  H01F3/08 ,  H01F41/0246 ,  Y10T428/2991 ,  Y10T428/2998 ,  B22F1/007 ,  B22F3/02 ,  B22F3/10

摘要： The soft magnetic material includes a plurality of composite magnetic particles having a metal magnetic particle and an insulating film surrounding the surface of the metal magnetic particle. The metal magnetic particle contains iron as the main component. The insulating film contains aluminum, silicon, phosphorus, and oxygen. The insulating film satisfies the relationship 0.4≦MAl/(MAl+MSi)≦0.9 and the relationship of 0.25≦(MAl+MSi)/MP≦1.0 in the case that molar amount of aluminum contained in the insulating film is represented by MAl, the sum of the molar amount of aluminum contained in the insulating film and the molar amount of silicon contained in the insulating film is represented by (MAl+MSi), and the molar amount of phosphorus contained in the insulating film is represented by MP.

摘要翻译： 软磁性材料包括具有金属磁性颗粒的多个复合磁性颗粒和围绕金属磁性颗粒表面的绝缘膜。 金属磁性粒子含有铁作为主要成分。 绝缘膜含有铝，硅，磷和氧。 在绝缘膜中包含的铝的摩尔量表示的情况下，该绝缘膜满足关系0.4＆nlE; MA1 /（MA1 + MSi）＆nlE; 0.9以及0.25＆nlE;（MA1 + MSi）/MP_nlE1.0的关系 通过MA1，绝缘膜中所含的铝的摩尔量和绝缘膜中所含的硅的摩尔量之和由（MA1 + MSi）表示，绝缘膜中所含的磷的摩尔量由 MP。

公开(公告)号：US07998361B2

公开(公告)日：2011-08-16

申请号：US10599003

申请日：2005-03-29

申请人： Kazuhiro Hirose ,  Haruhisa Toyoda ,  Takao Nishioka ,  Naoto Igarashi ,  Toru Maeda ,  Yoshiyuki Shimada

发明人： Kazuhiro Hirose ,  Haruhisa Toyoda ,  Takao Nishioka ,  Naoto Igarashi ,  Toru Maeda ,  Yoshiyuki Shimada

IPC分类号： C04B35/00 ,  C09D5/23 ,  H01F1/00 ,  C01G49/08 ,  C04B35/26 ,  C04B35/64

CPC分类号： B22F1/02 ,  B22F2998/10 ,  H01F1/24 ,  H01F1/33 ,  H01F41/0246 ,  B22F3/02 ,  B22F3/24

摘要： A soft magnetic material includes: a plurality of composite magnetic particles formed from a metal magnetic particle and an insulative coating surrounding a surface of the metal magnetic particle and containing metallic salt phosphate and/or oxide; and a lubricant formed as fine particles added at a proportion of at least 0.001 percent by mass and no more than 0.1 percent by mass relative to the plurality of composite magnetic particles. With this structure, superior lubrication is provided during compacting and desired magnetic characteristics can be obtained after compacting.

摘要翻译： 软磁性材料包括：多个由金属磁性颗粒形成的复合磁性颗粒和围绕金属磁性颗粒的表面的包含金属盐磷酸盐和/或氧化物的绝缘涂层; 以及相对于多个复合磁性粒子以比例为0.001质量％以上0.1质量％以下的微粒子形成的润滑剂。 利用这种结构，在压实过程中提供了优异的润滑，并且在压实后可获得所需的磁特性。

公开(公告)号：US20080248245A1

公开(公告)日：2008-10-09

申请号：US11919704

申请日：2006-07-20

申请人： Toru Maeda ,  Haruhisa Toyoda ,  Naoto Igarashi ,  Kazuhiro Hirose ,  Seiji Ishitani ,  Hiroko Morii ,  Kazuyuki Hayashi

发明人： Toru Maeda ,  Haruhisa Toyoda ,  Naoto Igarashi ,  Kazuhiro Hirose ,  Seiji Ishitani ,  Hiroko Morii ,  Kazuyuki Hayashi

IPC分类号： B32B5/16 ,  B32B15/02 ,  B05D1/00 ,  C04B35/634

CPC分类号： H01F3/08 ,  B22F1/02 ,  B22F1/025 ,  B22F2998/10 ,  C22C33/02 ,  C22C2202/02 ,  H01F1/24 ,  H01F1/26 ,  H01F1/33 ,  H01F41/0246 ,  Y10T428/2438 ,  Y10T428/2991 ,  B22F1/0059 ,  B22F3/02

摘要： A soft magnetic material includes a plurality of composite magnetic particles. Each of the plurality of composite magnetic particles has a metal magnetic particle including iron, a lower film surrounding the surface of the metal magnetic particle and including a nonferrous metal, and an insulating upper film surrounding the surface of the lower film and including an inorganic compound. The inorganic compound contains at least one element of oxygen and carbon. The nonferrous metal has an affinity with at least one of oxygen and carbon that is larger than such affinity of iron. The nonferrous metal has a diffusion coefficient with respect to at least one of oxygen and carbon that is smaller than such diffusion coefficient of iron. Thus, a soft magnetic material that provides desirable magnetic properties, a method of manufacturing a soft magnetic material, a dust core, and a method of manufacturing a dust core are provided.

摘要翻译： 软磁性材料包括多个复合磁性颗粒。 多个复合磁性颗粒中的每一个具有包含铁的金属磁性颗粒，围绕金属磁性颗粒的表面的下部膜，并且包含有色金属，以及包围下部膜的表面的包含无机化合物的绝缘上层膜 。 无机化合物含有至少一种氧和碳元素。 有色金属与氧和碳中的至少一种具有比铁的这种亲和力更大的亲和力。 有色金属相对于氧和碳中的至少一种具有小于铁的扩散系数的扩散系数。 因此，提供了提供所需磁性的软磁性材料，软磁性材料的制造方法，防尘芯，以及制造防尘芯的方法。

公开(公告)号：US20080061264A1

公开(公告)日：2008-03-13

申请号：US11911657

申请日：2006-03-09

申请人： Toru Maeda ,  Naoto Igarashi ,  Haruhisa Toyoda

发明人： Toru Maeda ,  Naoto Igarashi ,  Haruhisa Toyoda

IPC分类号： H01F1/00

CPC分类号： H01F3/08 ,  B22F2003/248 ,  B22F2998/10 ,  B22F2999/00 ,  H01F1/20 ,  H01F1/24 ,  H01F41/0246 ,  B22F9/082 ,  B22F2201/10 ,  B22F1/007 ,  B22F1/0085 ,  B22F2202/17 ,  B22F1/0062 ,  B22F1/0059 ,  B22F1/0096 ,  B22F3/02 ,  B22F3/24 ,  B22F2009/0828 ,  B22F9/04

摘要： A soft magnetic material has a plurality of composite magnetic particles. Each of the plurality of composite magnetic particles has a metal magnetic particle and an insulating coating covering the metal magnetic particle. Each of the plurality of composite magnetic particles has a ratio of a maximum diameter to an equivalent circle diameter greater than 1.0 and at most 1.3, and a specific surface area of at least 0.10 m2/g.

摘要翻译： 软磁性材料具有多个复合磁性粒子。 多个复合磁性颗粒中的每一个具有金属磁性颗粒和覆盖金属磁性颗粒的绝缘涂层。 多个复合磁性颗粒中的每一个具有最大直径与当量圆直径之比大于1.0且至多为1.3，比表面积至少为0.10m 2 / g的比值。

公开(公告)号：US20080041496A1

公开(公告)日：2008-02-21

申请号：US10594961

申请日：2005-03-29

申请人： Toru Maeda ,  Naoto Igarashi ,  Kazuhiro Hirose ,  Haruhisa Toyoda

发明人： Toru Maeda ,  Naoto Igarashi ,  Kazuhiro Hirose ,  Haruhisa Toyoda

IPC分类号： H01F1/12 ,  B22F1/00

CPC分类号： C22C33/02 ,  B22F1/0088 ,  B22F2003/248 ,  B22F2998/10 ,  H01F1/24 ,  H01F1/26 ,  H01F41/0246 ,  B22F9/082 ,  B22F1/0085 ,  B22F1/02 ,  B22F1/0059 ,  B22F3/02 ,  B22F3/24

摘要： A method of producing a soft magnetic material includes the steps of preparing soft magnetic powder containing a plurality of soft magnetic particles etching the soft magnetic powder to remove surfaces of the soft magnetic particles and, after the etching step, heat-treating the soft magnetic powder in a finely divided state at a temperature of not less than 400° C. and not more than 900° C. By this method configured as above, desired magnetic characteristics can be obtained.

摘要翻译： 一种制造软磁性材料的方法包括以下步骤：制备含有多个软磁性颗粒的软磁性粉末，该软磁性粉末蚀刻软磁性粉末以去除软磁性颗粒的表面，并且在蚀刻步骤之后，对软磁性粉末进行热处理 在不低于400℃且不高于900℃的温度下处于细分状态。通过如上构造的方法，可以获得期望的磁特性。