IP Library Granted Patent US 9,941,039
Granted Patent B2
US 9,941,039 · App. 14/737,876 · Granted Apr 10, 2018

Soft magnetic member, reactor, powder for dust core, and method of producing dust core

Inventors: Daisuke Okamoto (Toyota, JP); Kiyotaka Onodera (Toyota, JP); Shinjiro Saigusa (Toyota, JP); Kohei Ishii (Nagoya, JP); Masashi Ohtsubo (Nagakute, JP); Junghwan Hwang (Nagakute, JP); Masaaki Tani (Nagakute, JP); Takeshi Hattori (Nagakute, JP)
Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
H01F1/24B22F1/02C22C33/0257C22C33/0264H01F1/14791H01F1/33H01F41/0246B22F2998/10H01F3/08H01F27/255
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Quick Facts
Patent No.
US 9,941,039
App. No.
14/737,876
Granted
Apr 10, 2018
Kind
B2
Abstract

A soft magnetic member is formed such that, when a differential relative permeability in an applied magnetic field of 100 A/m is represented by a first differential relative permeability μ′L, and when a differential relative permeability in an applied magnetic field of 40 kA/m is represented by a second differential relative permeability μ′H, a ratio of the first differential relative permeability μ′L to the second differential relative permeability μ′H satisfies a relationship of μ′L/μ′H≤10, and a magnetic flux density in an applied magnetic field of 60 kA/m is 1.15 T or higher.

Claims (11)

1. A dust core comprising

powder comprising soft magnetic particles each coated with an insulating film,

an average particle size of particles constituting the powder for the dust core is 20 μm to 450 μm,

the insulating film contains aluminum oxide as a major component,

the soft magnetic particles are formed of an iron-aluminum-silicon alloy,

in the iron-aluminum-silicon alloy, the Si content is 1 mass % to 7 mass %, the Al content is 1 mass % to 6 mass %, the total content of Si and Al is 1 mass % to 12 mass %, and the balance includes iron and unavoidable impurities, and

the insulating film has a Vickers hardness, which is 2.0 times or higher than that of the soft magnetic particles, and has a thickness of 150 nm to 2 μm,

wherein the dust core is formed such that, when a differential relative permeability in an applied magnetic field of 100 A/m is represented by a first differential relative permeability μ′L, and when a differential relative permeability in an applied magnetic field of 40 kA/m is represented by a second differential relative permeability μ′H, a ratio of the first differential relative permeability μ′L to the second differential relative permeability μ′H satisfies a relationship of μ′L/μ′H≤10, and a magnetic flux density in an applied magnetic field of 60 kA/m is 1.15 T or higher.

2. A reactor comprising:

a core formed of the dust core according to claim 1 ; and

a coil that is wound around the core.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 12, 2015
From: OKAMOTO, DAISUKE; ONODERA, KIYOTAKA; SAIGUSA, SHINJIRO; ISHII, KOHEI; OHTSUBO, MASASHI; HWANG, JUNGHWAN; TANI, MASAAKI; HATTORI, TAKESHI
To: TOYOTA JIDOSHA KABUSHIKI KAISHA
Reel/Frame 035828/0473 →
Priority Claims (1)
JP 2014-122429 · Jun 13, 2014 · national
Continuity (1)
Related Publication 20150364235A1 · Dec 17, 2015