Taiyo Yuden Co., Ltd.

Yoko Orimo

Shinsuke Takeoka

Tomoo Kashiwa

Xinyu Li

Kenji Otake

Takayuki Arai

Atsushi Tanada

Minoru Ryu

Yoshiki Iwazaki

Hirotaro Seino

Kenji Takashima

Chengli He

One object is to provide a magnetic body having a high mechanical strength. A magnetic body according to one embodiments of the present invention includes: first particles of a first alloy containing Fe and Cr; second particles of a second alloy containing at least one of Al or Mn; and bonding portions containing at least one of Al oxide or Mn oxide, the bonding portions bonding the first particles to each other. The bonding portions containing at least one of Al oxide or Mn oxide increase the mechanical strength of the magnetic body.

Magnetic body, coil component including magnetic body, and method of manufacturing magnetic body

A magnetic body is constituted by grains of a soft magnetic alloy bonded together via an oxide layer, wherein: the soft magnetic alloy is an alloy containing Si by 1 to 5.5 percent by mass, and Cr and/or Al by 0.2 to 4 percent by mass in total, as constituent elements, with Fe and unavoidable impurities accounting for the remainder, wherein a content of Si is more than a content of Cr and Al in total; and the oxide layer contains Si, as well as at least one of Fe, Cr, and Al, where, among Fe, Si, Cr, and Al, Si is contained in the largest quantity based on mass. The magnetic body can have high magnetic permeability.

Coil component using magnetic body and circuit board carrying same

A magnetic base body according to an embodiment of the present invention includes a metal magnetic particle and an amorphous silicon oxide film provided on a surface of the metal magnetic particle, the amorphous silicon oxide film having a structural defect introduced therein.

Magnetic base body containing metal magnetic particles and electronic component including the same

A magnetic body is constituted by grains of a soft magnetic alloy bonded together via an oxide layer, wherein: the soft magnetic alloy is an alloy containing Si by 1 to 5.5 percent by mass, and Cr or Al by 0.2 to 4 percent by mass in total, as constituent elements, with Fe and unavoidable impurities accounting for the remainder; and the oxide layer contains Si, as well as at least one of Cr and Al, where, among Fe, Si, Cr, and Al, Si is contained in the largest quantity based on mass. The magnetic body can have high magnetic permeability.

Magnetic body and method for manufacturing same, as well as coil component using magnetic body and circuit board carrying same

A magnetic material includes a soft magnetic metal grain containing Fe, and a multilayer oxide film covering the surfaces of the soft magnetic metal grain. The multilayer oxide film has a first oxide layer of crystalline nature containing Fe, and a second oxide layer of amorphous nature containing Si. In an embodiment, the silicon oxide film of amorphous nature is formed by dripping, divided into multiple sessions, a treatment solution containing TEOS (tetraethoxy silane), ethanol, and water into a mixed solution containing the soft magnetic metal grain, ethanol, and ammonia water, to mix the solutions.

Magnetic material, electronic component, and method for manufacturing magnetic material

A metal magnetic powder is constituted by metal magnetic grains that each include: a metal phase where the mass percentage of Fe at its center part is lower than that at its contour part; and an oxide film covering the metal phase so as to allow the magnetic body resistant to magnetic saturation and low in iron loss.

Metal magnetic powder and method for manufacturing same, as well as coil component and circuit board

A metal magnetic powder is constituted by metal magnetic grains that each include: a metal phase where the percentage of Fe at its center part is 98 percent by mass or higher, while the mass percentage of Fe at its contour part is lower than that at the center part; and an oxide film covering the metal phase, so as to inhibit oxidation of Fe contained in the metal phase, despite the high content percentage of Fe in the metal phase.

A magnetic body of the coil component contains, as soft magnetic alloy grains, first grains whose alloy components are substantially Fe, Si, and Cr, and second grains which contain, as alloy components, Fe, Si, and an element other than Si or Cr that oxidizes more easily than Fe; the average grain size of the second grains is smaller than the average grain size of the first grains; the first grains have, on their surface, an amorphous oxide film containing Si and Cr; the second grains have, on their surface, a crystalline oxide layer containing the element other than Si or Cr that oxidizes more easily than Fe; and the crystalline oxide forms adhesion parts, each contacting a multiple number of the first grains via the amorphous oxide film thereof and coupling or bridging the multiple number of the first grains. The coil component can offer improved mechanical strength.

Coil component and method for manufacturing same

A method for manufacturing magnetic alloy powder constituted by magnetic grains whose alloy phase is coated with an oxide film, includes: providing a material powder for magnetic alloy whose Fe content is 96.5 to 99 percent by mass and which also contains Si and at least one of non-Si elements (element M) that oxidize more easily than Fe; and heat-treating the material powder and thus forming an oxide film on a surface of each grain constituting the material powder, to obtain a magnetic alloy powder, wherein a content of Fe in the alloy phase is higher than in the material powder; and at a location in the oxide film where its content of Si is in element distributions in a film thickness direction is highest, the content of Si is higher than a content of Fe, and also higher than its content of element M, at the location.

Method for manufacturing magnetic alloy powder having certain element distributions in thickness direction

A soft magnetic alloy powder contains Fe, Si, and at least one of Cr and Al, as constituent elements, wherein, on the surface of each grain constituting the alloy powder, an oxide film is provided which is such that: it contains Si, as well as at least one of Cr and Al, as constituent elements; these elements are contained at higher percentages by mass than those in the alloy part inside the grain; and the content of Si, expressed in percentage by mass, is higher than the total content of Cr and Al. The soft magnetic metal powder can achieve a higher filling rate.

Soft magnetic alloy powder and method for manufacturing same, as well as coil component made from soft magnetic alloy powder and circuit board carrying same

In an exemplary embodiment, a magnetic alloy powder is constituted by magnetic grainswhose alloy phaseis coated with an oxide film, wherein: the alloy phasehas a Fe content of 98 percent by mass or higher and also contains Si and at least one type of non-Si element that oxidizes more easily than Fe (element M); and the oxide filmis such that, at the location where the content of Si as expressed in percentage by mass is the highest according to the element distributions in the direction of film thickness, this content of Si is higher than the content of Fe, and also higher than the content of element M, at this location. The magnetic alloy powder has a high Fe content and also offers excellent insulating property.

Magnetic alloy powder and method for manufacturing same, as well as coil component made of magnetic alloy powder and circuit board carrying same

A magnetic material has: multiple soft magnetic alloy grains that contain Fe, element L (where element L is Si, Zr, or Ti), and element M (where element M is not Si, Zr, or Ti, and oxidizes more easily than Fe); a first oxide film that contains element L and covers each of the multiple soft magnetic alloy grains; a second oxide film that contains element M and covers the first oxide film; a third oxide film that contains element L and covers the second oxide film; a fourth oxide film that contains Fe and covers the third oxide film; and bonds that are constituted by parts of the fourth oxide film and that bond the multiple soft magnetic alloy grains together.

Magnetic material and electronic component

In some embodiments, a magnetic bodyhas soft magnetic alloy grainsthat contain Fe, M (M is a metal element that oxidizes more easily than Fe), and S, as well as oxide filmsproduced by partial oxidization of the soft magnetic alloy grains, wherein the magnetic bodyhas its adjacent soft magnetic alloy grainsbonded together at least partially through the oxide films, and contains Fe by 92.5 to 96 percent by weight and S by 0.003 to 0.02 percent by weight. The magnetic body can have high levels of both magnetic permeability and volume resistivity, to meet the demand for smaller, higher-performance electronic components.

Magnetic body and electronic component comprising the same

In an embodiment, a magnetic body includes soft magnetic alloy grainscontaining Fe, element L, and element M (where element L is Si or Zr and element M is a metal element other than Si or Zr that oxidizes more easily than Fe), as well as oxide film produced from oxidization of part of these grains; wherein at least some of the bonds between adjacent soft magnetic alloy grainsare by way of the oxide film; the oxide film has an inner film, and an outer filmpositioned on the outer side of the inner film; and the inner filmcontains more of element L than element M, while the outer filmcontains more of element M than element L.

Growing community of inventors

Takasaki, Japan

Yoko Orimo