Kabushiki Kaisha Toshiba

Tomohiro Suetsuna

Seiichi Suenaga

Hiroaki Kinouchi

Tomoko Eguchi

Kouichi Harada

Koichi Harada

Toshihide Takahashi

Maki Yonetsu

Takahiro Kawamoto

Yasuyuki Hotta

Naoyuki Sanada

Masaya Hagiwara

Naoyuki Nakagawa

Shinya Sakurada

Mutsuki Yamazaki

Fumihiko Aiga

Shinji Murai

Yasuhiro Goto

Makoto Higaki

Akihiro Tsujimura

Takayuki Fukasawa

Noritsugu Shiokawa

Mitsuru Ishibashi

Naoto Ito

A magnetic material of the embodiments is a magnetic material including: a plurality of flaky magnetic metal particles, each flaky magnetic metal particle having a flat surface; and an intercalated phase existing between the flaky magnetic metal particles and containing at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F), in which the magnetic material includes the intercalated phase at a volume ratio of from 4% to 17% and includes voids at a volume ratio of 30% or less, and an average angle of orientation between the flat surface and a plane of the magnetic material is 10° or less.

Magnetic material and rotating electric machine

A pressed powder material according to embodiments is a pressed powder material including first magnetic metal particles having a first magnetic metal phase containing Fe and Co; and second magnetic metal particles having a second magnetic metal phase containing Fe, in which when the amounts of Co with respect to the total amounts of Fe and Co of the first and second magnetic metal particles are designated as Co1 and Co2, respectively, the ratio of Co2 to Co1 (Co2/Co1) is from 0 to 0.5, the average value of the ratio of the major axis to the minor axis is 2 or greater for the first magnetic metal particles and 1 or greater for the second magnetic metal particles, the second magnetic metal particles are present between the particles of the first magnetic metal particles, and the average value of the major axis of the second magnetic metal particles is equal to or longer than the average value of the major axis of the first magnetic metal particles.

Pressed powder material and rotating electric machine

The magnetic composite material of the embodiments is a magnetic composite material that includes a magnetic material having a plane at the surface; and a plate-shaped reinforcing material, the magnetic material having a plurality of magnetic bodies having a planar structure and having a magnetic metal phase containing at least one first element selected from the group consisting of iron (Fe), cobalt (Co), and nickel (Ni), and principal surfaces; and an intercalated phase containing at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F). In the magnetic composite material, the principal surfaces are oriented to be approximately parallel to the plane and have the difference in coercivity on the basis of direction within the plane.

Magnetic composite material and rotating electric machine

Flaky magnetic metal particles of embodiments each have a flat surface and a magnetic metal phase containing iron (Fe), cobalt (Co), and silicon (Si). An amount of Co is from 0.001 at % to 80 at % with respect to the total amount of Fe and Co. An amount of Si is from 0.001 at % to 30 at % with respect to the total amount of the magnetic metal phase. The flaky magnetic metal particles have an average thickness of from 10 nm to 100 μm. An average value of the ratio of the average length in the flat surface with respect to a thickness in each of the flaky magnetic metal particles is fromto. The flaky magnetic metal particles have the difference in coercivity on the basis of direction within the flat surface.

Plurality of flaky magnetic metal particles, pressed powder material, and rotating electric machine

A plurality of flaky magnetic metal particles have an average thickness of 10 nm to 100 μm, each of the particles having a flat surface; a magnetic metal phase containing at least one element selected from the group consisting of Fe, Co, and Ni; and a difference in coercivity on the basis of direction within the surface, the average value of the ratio of the average length within the surface with respect to the thickness being from 5-10,000. The particles include a particle having at least one of a crack in a thickness direction having a depth equivalent to 10% or more of the thickness of the particle and a width shorter than the depth, and a crack in a direction parallel to the surface having a length equivalent to 10% or more of the thickness of the particle and a width shorter than the length.

A pressed powder material of the embodiments is a pressed powder material including: a plurality of flaky magnetic metal particles, each flaky magnetic metal particle having a flat surface and a magnetic metal phase containing at least one first element selected from the group consisting of Fe, Co, and Ni, the flaky magnetic metal particles having an average thickness of from 10 nm to 100 μm and an average value of the ratio of the average length in the flat surface to the thickness of from 5 to 10,000; and an intercalated phase existing between the flaky magnetic metal particles and containing at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F), in which the pressed powder material includes a plane, and in which the pressed powder material includes, in a predetermined cross-section perpendicular to the flat surfaces, a void site at the boundary part between the flat surface of a flaky magnetic metal particle and the intercalated phase in contact with the flat surface, and the ratio of the length of the void site is 20% or less with respect to the length of the flat surface.

Flaky magnetic metal particles of embodiments each have a flat surface and a magnetic metal phase containing iron (Fe), cobalt (Co), and silicon (Si). An amount of Co is from 0.001 at % to 80 at % with respect to the total amount of Fe and Co. An amount of Si is from 0.001 at % to 30 at % with respect to the total amount of the magnetic metal phase. The flaky magnetic metal particles have an average thickness of from 10 nm to 100 &#x3bc;m. An average value of the ratio of the average length in the flat surface with respect to a thickness in each of the flaky magnetic metal particles is from 5 to 10,000. The flaky magnetic metal particles have the difference in coercivity on the basis of direction within the flat surface.

Provided is a plurality of flaky magnetic metal particles of embodiments, each flaky magnetic metal particle having a flat surface having either or both of a plurality of concavities and a plurality of convexities, the concavities or convexities being arranged in a first direction and each having a width of 0.1 &#x3bc;m or more, a length of 1 &#x3bc;m or more, and an aspect ratio of 2 or higher; and a magnetic metal phase containing at least one primary element selected from the group consisting of iron (Fe), cobalt (Co), and nickel (Ni). The flaky magnetic metal particles have an average thickness of between 10 nm and 100 &#x3bc;m inclusive, and the average value of the ratio of the average length within the flat surface with respect to the thickness is between 5 and 10,000 inclusive.

A rotating electric machine according to embodiments is a rotating electric machine including a rotor including a first core and being capable of rotating around a rotating shaft; and a stator disposed to face the rotor in the axial direction of the rotating shaft, the first core including a first pressed powder material having a plurality of first flaky magnetic metal particles and a first intercalated phase, the first flaky magnetic metal particles having an average thickness of from 10 nm to 100 &#x3bc;m, each first flaky magnetic metal particle having a first flat surface and a first magnetic metal phase including at least one first element selected from the group consisting of Fe, Co, and Ni, the average value of the ratio of the average length in the first flat surface with respect to the average thickness being from 5 to 10,000, the first intercalated phase existing between the first flaky magnetic metal particles and including at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F), wherein in the first pressed powder material, the first flat surfaces are oriented approximately in parallel with a first principal plane of the first pressed powder material and have the difference in magnetic permeability on the basis of direction within the first principal plane, and the first principal plane of the first pressed powder material is disposed to be approximately perpendicular to the radial direction of the rotating electric machine.

Rotating electric machine

Provided is a plurality of flaky magnetic metal particles of the embodiments, each flaky magnetic metal particle having a flat surface provided with either or both of a plurality of concavities and a plurality of convexities arranged in a first direction, each concavity or convexity having a width of 0.1 &#x3bc;m or more, a length of 1 &#x3bc;m or more, and an aspect ratio of 2 or higher; and at least one first element selected from the group consisting of iron (Fe), cobalt (Co), and nickel (Ni), the flaky magnetic metal particles having an average thickness of between 10 nm and 100 &#x3bc;m inclusive and an average aspect ratio of between 5 and 10,000 inclusive.

The magnetic wedge of embodiments is a magnetic wedge used for a rotating electrical machine and includes magnetic bodies having a planar structure having a principal plane. The principal planes of the magnetic bodies are disposed approximately perpendicularly to the air-gap surface between a stator and a rotor of a rotating electrical machine. The magnetic bodies have differences in the axial direction magnetic permeability in the axial direction of the rotating electrical machine, the rotational direction magnetic permeability in the direction of rotation, and the diametric direction magnetic permeability in the direction of the diameter.

Rotating electric machine having magnetic wedge with planes and having differences in magnetic permeability

The flaky magnetic metal particles of the embodiments include a plurality of flaky magnetic metal particles, each of the flaky magnetic metal particles including a first magnetic particle including a flat surface, at least one first element selected from the group consisting of Fe, Co and Ni, an average ratio between the maximum length and the minimum length in the flat surface being between 1 and 5 inclusive, an average thickness of the first magnetic particles being between 10 nm and 100 &#x3bc;m inclusive, an average aspect ratio of the first magnetic particles being between 5 and 10000 inclusive; and a plurality of second magnetic particles disposed on the flat surface, an average number of the second magnetic particles being five or more, an average diameter of the second magnetic particles being between 10 nm and 1 &#x3bc;m inclusive.

Flaky magnetic metal particles, pressed powder material, rotating electric machine, motor, and generator

Provided is a method for producing a magnetic material. The method includes preparing magnetic metal particles containing at least one magnetic metal selected from a first group consisting of Fe, Co and Ni, and at least one non-magnetic metal selected from a second group consisting of Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, Ba, Sr, Cr, Mo, Ag, Ga, Sc, V, Y, Nb, Pb, Cu, In, Sn and rare earth elements, pulverizing and reaggregating the magnetic metal particles, and thereby forming composite particles containing a magnetic metal phase and an interstitial phase, and heat-treating the composite particles at a temperature of from 50&#xb0; C. to 800&#xb0; C. The particle size distribution of the magnetic metal particles in the preparing magnetic metal particles has two or more peaks.

Method for producing magnetic material

The soft magnetic material of embodiments includes flattened magnetic metal particles including at least one magnetic metal selected from iron (Fe), cobalt (Co) and nickel (Ni), each of the flattened magnetic metal particles having a thickness of from 10 nm to 100 &#x3bc;m, an aspect ratio of from 5 to 10,000, and a lattice strain of from 0.01% to 10%, and being oriented with magnetic anisotropy in one direction within aligned flattened surface; and an interposed phase existing between the flattened magnetic metal particles and including at least one of oxygen (O), carbon (C), nitrogen (N) and fluorine (F).

Growing community of inventors

Kawasaki, Japan

Tomohiro Suetsuna