Granted Patent B2

US 12,226,830 · App. 16/888,888 · Granted Feb 18, 2025

Inventors: Tetsuo Ito (Sendai, JP); Masakazu Abe (Sendai, JP)

Assignee: TOKIN CORPORATION

B22F5/006B22F1/05B22F1/065B22F1/102H01F1/16H01F41/0233B22F2304/10

Abstract

Claims (42)

1. A composite magnetic material, comprising:

spherical soft magnetic metal powder incorporated in the composite magnetic material in a dispersed manner;

a flame retardant powder incorporated in the composite magnetic material in a dispersed manner; and

a binder configured to bind the soft magnetic metal powder and the flame retardant,

wherein the composite magnetic material has a sheet shape,

wherein the composite magnetic material has a volume occupancy of the soft magnetic metal powder of 45 vol % or more and 68 vol % or less, and a volume occupancy of the flame retardant of 12 vol % or more and 20 vol % or less,

wherein the composite magnetic material has a thickness of at least 0.38 mm and not more than 1 mm,

wherein the flame retardant powder has a spherical shape with an average particle diameter of 2 μm or more, and

wherein the flame retardant is a nitrogen-based compound.

2. The composite magnetic material according to claim 1 , wherein the volume occupancy of the soft magnetic metal powder is 55 vol % or more and 68 vol % or less.

3. The composite magnetic material according to claim 1 , wherein the composite magnetic material is bendable.

4. The composite magnetic material according to claim 1 , wherein the volume occupancy of the flame retardant is 15 vol % or more and 20 vol % or less.

5. The composite magnetic material according to claim 1 , wherein the binder is an acrylic rubber.

6. The composite magnetic material according to claim 1 , wherein the soft magnetic metal powder has an average particle diameter of less than 10 um.

7. The composite magnetic material according to claim 6 , wherein the soft magnetic metal powder has an average particle diameter of 4 μm or more and 8 μm or less.

8. An electrical and electronic device, comprising the composite magnetic material of claim 1 .

9. The composite magnetic material according to claim 1 , wherein the composite magnetic material consists essentially of the spherical soft magnetic metal powder, the flame retardant, and the binder.

10. The composite magnetic material according to claim 1 , wherein the composite magnetic material consists of the spherical soft magnetic metal powder, the flame retardant, and the binder.

11. The composite magnetic material according to claim 1 , wherein the composite magnetic material has the volume occupancy of the soft magnetic metal powder of 45 vol % or more and 68 vol % or less, and the volume occupancy of the flame retardant of 12 vol % or more and 20 vol % or less, and wherein the balance of the composite magnetic material is the binder.

12. The composite magnetic material according to claim 1 , wherein the composite magnetic material has the volume occupancy of the soft magnetic metal powder of 45 vol % or more and 68 vol % or less, and the volume occupancy of the flame retardant of 12 vol % or more and 20 vol % or less, and wherein the balance of the composite magnetic material is the binder and an additive.

13. A composite magnetic material, comprising:

spherical soft magnetic metal powder incorporated in the composite magnetic material in a dispersed manner;

a flame retardant powder incorporated in the composite magnetic material in a dispersed manner; and

a binder configured to bind the soft magnetic metal powder and the flame retardant,

wherein the composite magnetic material has a sheet shape,

wherein the composite magnetic material has a volume occupancy of the soft magnetic metal powder of 45 vol % or more and 68 vol % or less, and a volume occupancy of the flame retardant of 12 vol % or more and 20 vol % or less, and wherein the balance of the composite magnetic material is the binder,

wherein the composite magnetic material has a thickness of at least 0.38 mm and not more than 1 mm,

wherein the flame retardant powder has a spherical shape with an average particle diameter of 2 μm or more, and

wherein the flame retardant is a nitrogen-based compound.

14. A composite magnetic material, consisting of:

spherical soft magnetic metal powder incorporated in the composite magnetic material in a dispersed manner;

a flame retardant powder incorporated in the composite magnetic material in a dispersed manner; and

a binder configured to bind the soft magnetic metal powder and the flame retardant,

wherein the composite magnetic material has a sheet shape,

wherein the composite magnetic material has a volume occupancy of the soft magnetic metal powder of 45 vol % or more and 68 vol % or less, and a volume occupancy of the flame retardant of 12 vol % or more and 20 vol % or less,

wherein the composite magnetic material has a thickness of at least 0.38 mm and not more than 1 mm,

wherein the flame retardant powder has a spherical shape with an average particle diameter of 2 μm or more, and

wherein the flame retardant is a nitrogen-based compound.

15. A method of manufacturing the composite magnetic material according to claim 1 , the method comprising:

kneading the spherical soft magnetic metal powder, the flame retardant, and the binder to produce a kneaded product;

forming the kneaded product into the sheet shape to produce a formed body; and

heating and pressing the formed body to produce the composite magnetic material having the volume occupancy of the soft magnetic metal powder of 45 vol % or more and 68 vol % or less, and the volume occupancy of the flame retardant of 12 vol % or more and 20 vol % or less, and having been formed and processed into the sheet shape.

Assignments (2)

Priority Claims (1)

Continuity (1)

References Cited (21)