Sumitomo Electric Industries, Limited

Toda Kogyo Corporation

Toru Maeda

Haruhisa Toyoda

Naoto Igarashi

Kazuhiro Hirose

Kazuyuki Hayashi

Hiroko Morii

Yasushi Mochida

Seiji Ishitani

Asako Watanabe

Koji Mimura

Takao Nishioka

Hirokazu Kugai

Kazuyuki Maeda

Atsushi Sato

Kazuhiro Inaba

Kazushi Kusawake

Tomoyuki Ishimine

Toshihiro Sakamoto

Yoshiyuki Shimada

Naoto Sumitomo Electricic Ind Ltd Igarashi

Takao Sumitomo Electricic Ind Ltd Nishioka

Kazuhiro Sumitomo Electricic Ind Ltdnd Ltd Hirose

Haruhisa Sumitomo Electricic Ind Ltd Toyoda

The present invention provides a powder for a magnet which can form a rare earth magnet having excellent magnetic characteristics and which has excellent moldability, a method for producing the powder for a magnet, a powder compact, and a rare earth-iron-boron-based alloy material.

Powder for magnet

Provided are a method for producing powder for a magnet, and methods for producing a powder compact, a rare-earth-iron-based alloy material, and a rare-earth-iron-nitrogen-based alloy material. Magnetic particles constituting the powder each have a texture in which grains of a phase of a hydride of a rare-earth element are dispersed in a phase of an iron-containing material. The uniform presence of the phase of the iron-containing material in each magnetic particle results in powder having excellent formability, thereby providing a powder compact having high relative density. The powder is produced by heat-treating rare-earth-iron-based alloy powder in a hydrogen atmosphere to separate the rare-earth element and the iron-containing material and then forming a hydride of the rare-earth element. The powder is compacted. The powder compact is heat-treated in vacuum to form a rare-earth-iron-based alloy material. The rare-earth-iron-based alloy material is heat-treated in a nitrogen atmosphere to form a rare-earth-iron-nitrogen-based alloy material.

Method for producing powder for magnet

A reactorof the present invention includes a coiland a magnetic coredisposed inside and outside the coilto form a closed magnetic path. At least part of the magnetic coreis made of a composite material containing a magnetic substance powder and a resin containing the powder being dispersed therein. The magnetic substance powder contains powders respectively made of a plurality of materials differing in the relative permeability, representatively, a pure iron powder and an iron alloy powder. Thanks to provision of the magnetic coremade of the composite material containing magnetic substance powders made of different types of materials, the reactorachieves both a high saturation magnetic flux density and a low-loss characteristic.

Composite material, reactor-use core, reactor, converter, and power converter apparatus

The present invention provides a powder for a magnetic member being excellent in moldability and difficult to oxidize, a powder compact produced from the powder, and a magnetic member suitable for a raw material of a magnetic member such as a rare earth magnet. A powder for a magnetic member includes magnetic particleswhich constitute the powder for a magnetic member and each of which is composed of less than 40% by volume of a hydrogen compoundof a rare earth element, and the balance composed of an iron-containing materialwhich contains iron and an iron-boron alloy containing iron and boron. The hydrogen compoundof a rare earth element is dispersed in a phase of the iron-containing material. An antioxidant layerhaving a low-oxygen permeability coefficient is provided on the surface of each of the magnetic particles

Powder for magnetic member, powder compact, and magnetic member

Provided are a powder for a magnet, which provides a rare-earth magnet having excellent magnet properties and which has excellent formability, a method for producing the powder for a magnet, a powder compact, a rare-earth-iron-based alloy material, and a rare-earth-iron-nitrogen-based alloy material which are used as materials for the magnet, and methods for producing the powder compact and these alloy materials.

Rare-earth-iron-based alloy material

Provided are a powder for a magnet, which provides a rare-earth magnet having excellent magnet properties and which has excellent formability, a method for producing the powder for a magnet, a powder compact, a rare-earth-iron-based alloy material, and a rare-earth-iron-nitrogen-based alloy material which are used as materials for the magnet, and methods for producing the powder compact and these alloy materials. Magnetic particlesconstituting the powder for a magnet each have a texture in which grains of a phaseof a hydride of a rare-earth element are dispersed in a phaseof an iron-containing material, such as Fe. The uniform presence of the phaseof the iron-containing material in each magnetic particleresults in the powder having excellent formability, thereby providing a powder compacthaving a high relative density. The powder for a magnet is produced by heat-treating a rare-earth-iron-based alloy powder in a hydrogen atmosphere to separate the rare-earth element and the iron-containing material from each other and then forming a hydride of the rare-earth element. The powder for a magnet is subjected to compacting to form the powder compact. The powder compactis subjected to heat treatment in vacuum to form a rare-earth-iron-based alloy material. The rare-earth-iron-based alloy materialis subjected to heat treatment in a nitrogen atmosphere to form a rare-earth-iron-nitrogen-based alloy material

Provided is a soft magnetic powder used for obtaining a dust core having a low hysteresis loss, in particular, in a high temperature range. A soft magnetic powder includes an aggregate of composite magnetic particles, each including a soft magnetic particle containing Fe, Si, and Al, and an insulating coating film disposed on the surface thereof, and satisfies the expressions (1) and (2) below: Expression (1) . . . 27&#x2266;2.5a+b&#x2266;29 and Expression (2) . . . 6&#x2266;b&#x2266;9, where a represents the Si content (mass %) and b represents the Al content (mass %). The soft magnetic powder is capable of reducing the hysteresis loss, in a high-temperature environment, of a dust core obtained using the soft magnetic powder.

Soft magnetic powder, granulated powder, dust core, electromagnetic component, and method for producing dust core

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 at least one of oxygen and carbon. The nonferrous metal has an affinity with the at least one of oxygen and carbon included in the upper film that is larger than such affinity of iron; or the nonferrous metal has a diffusion coefficient with respect to the at least one of oxygen and carbon included in the upper film that is smaller than such diffusion coefficient of iron. This configuration provides desirable magnetic properties.

Soft magnetic material, powder magnetic core and process for producing the same

The invention offers a method for producing a soft magnetic material. The method effectively produces a soft magnetic material having soft magnetic metallic particles each coated with a plurality of insulating layers. A soft magnetic material to be used as the material for a dust core is produced through the following steps: a step of preparing a material powder having composite magnetic particles produced by forming an insulating film containing hydrated water on each of the surfaces of soft magnetic metallic particles, a step of preparing a resin material containing silicone that cures through a hydrolysis-polycondensation reaction, and a step of mixing the material powder and the resin material in a heated atmosphere at 80&#xb0; C. to 150&#xb0; C. to form a silicone film on the surface of the insulating film.

Method for producing soft magnetic material and method for producing dust core

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.

Manufacturing method of soft magnetic material and manufacturing method of dust core

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

Soft magnetic material, powder magnetic core and method of manufacturing soft magnetic material

To provide a core for reactor capable of reducing the eddy current loss and improving the direct current superposition characteristics, a manufacturing method thereof, and a reactor. A core for reactor M is obtained by press molding metallic magnetic particles coated with an insulating coated film, and the metallic magnetic particles have the following compositions: (1) the mean particle size is 1 &#x3bc;m or more and 70 &#x3bc;m or less; (2) the variation coefficient Cv which is a ratio (&#x3c3;/&#x3bc;) of the standard deviation (&#x3c3;) of the particle size and the mean particle size (&#x3bc;) is 0.40 or less; and (3) the degree of circularity is 0.8 or more and 1.0 or less. On the outside of the insulating coated film, at least one of a heat-resistance imparting protective film and a flexible protective film is further provided as a outer coated film.

Core for reactors comprising press-molded metallic magnetic particles, its manufacturing method, and reactor

A soft magnetic material includes a plurality of composite magnetic particles () each including a metal magnetic particle () and an insulation coating () covering the surface of the metal magnetic particle (), wherein the insulation coating () contains Si (silicon), and 80% or more of Si contained in the insulation coating constitutes a silsesquioxane skeleton. Therefore, it is possible to effectively decrease a hysteresis loss while suppressing an increase in eddy-current loss.

Soft magnetic material, powder magnetic core, method for manufacturing soft magnetic material, and method for manufacturing powder magnetic core

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&#x2266;M/(M+M)&#x2266;0.9 and the relationship of 0.25&#x2266;(M+M)/M&#x2266;1.0 in the case that molar amount of aluminum contained in the insulating film is represented by M, 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 (M+M), and the molar amount of phosphorus contained in the insulating film is represented by M.

Soft magnetic material comprising an insulating layer containing aluminum, silicon, phosphorous and oxygen; dust magnetic core; process for producing soft magnetic material; and process for producing dust magnetic core

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Itami, Japan

Toru Maeda