SOFT MAGNETIC MATERIAL, POWDER MAGNETIC CORE AND METHOD FOR MANUFACTURING THE SAME
It is an object to provide a novel soft magnetic material that enables the fabrication of a powder magnetic core capable of suppressing degradation in performance due to a high-temperature treatment and achieving high core resistance and low loss. A soft magnetic material comprising: a core particle each having a soft magnetic particle comprising iron as a main component and an insulating film formed on a surface of the soft magnetic particle; and a coating layer formed on the core particle, wherein the coating layer comprises a metal complex having nonferrous central metal and at least one organic ligand.
1 . A soft magnetic material comprising:
a core particle having a soft magnetic particle comprising iron as a main component thereof and an insulating film formed on a surface of the soft magnetic particle; and
a coating layer formed on the core particle,
wherein the coating layer comprises a metal complex having a nonferrous central metal and at least one organic ligand.
2 . The soft magnetic material according to claim 1 ,
wherein at least one multidentate ligand is contained as the organic ligand.
3 . The soft magnetic material according to claim 1 ,
wherein the metal complex is a metal chelate complex.
4 . The soft magnetic material according to claim 1 ,
wherein the nonferrous central metal of the metal complex is contained in an amount from 0.001 to 1.0 mol % with respect to the iron contained in the core particle.
5 . The soft magnetic material according to claim 1 ,
wherein the nonferrous central metal is at least one type selected from the group consisting of Al, Mg, Mn, Ti, Co and Zr.
6 . The soft magnetic material according to claim 1 ,
wherein the soft magnetic particle contains 95% or more iron.
7 . A soft magnetic material obtainable by: applying a metal complex having a nonferrous central metal and at least one organic ligand onto a core particle having a soft magnetic particle containing iron as a main component and an insulating film formed on the soft magnetic particle; and thereby forming a coating layer.
8 . A method of manufacturing a powder magnetic core, comprising at least the steps of:
warm-compacting a mixture containing the soft magnetic material according to claim 1 and a lubricant; and
performing a heat treatment for a compact obtained after the warm-compaction.
9 . The method according to claim 8 ,
wherein in the step of warm-compaction, the compaction is carried out at a temperature from 80° C. to 200° C.
10 . The method according to claim 8 ,
wherein in the step of performing the heat treatment, the heat treatment is carried out at a temperature from 450° C. to 600° C.
11 . The method according to claim 8 ,
wherein in the step of performing the heat treatment, the heat treatment is carried out in an oxygen-containing atmosphere.
12 . A powder magnetic core fabricated by performing heat treatment for a compact that is obtainable by warm-compacting a mixture containing the soft magnetic material according to claim 1 and a lubricant.
13 . The powder magnetic core according to claim 12 ,
wherein a green density is 7.60 g/cm3 or higher.