公开(公告)号：US09941039B2

公开(公告)日：2018-04-10

申请号：US14737876

申请日：2015-06-12

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Daisuke Okamoto ,  Kiyotaka Onodera ,  Shinjiro Saigusa ,  Kohei Ishii ,  Masashi Ohtsubo ,  Junghwan Hwang ,  Masaaki Tani ,  Takeshi Hattori

IPC: H01F17/04 ,  H01F27/24 ,  H01F1/24 ,  H01F41/02 ,  H01F1/147 ,  H01F1/33 ,  B22F1/02 ,  C22C33/02 ,  H01F3/08 ,  H01F27/255

CPC classification number: H01F1/24 ,  B22F1/02 ,  B22F2998/10 ,  C22C33/0257 ,  C22C33/0264 ,  H01F1/14791 ,  H01F1/33 ,  H01F3/08 ,  H01F27/255 ,  H01F41/0246 ,  B22F2009/0828 ,  B22F9/08 ,  B22F9/04 ,  B22F3/02 ,  B22F3/10

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.

公开(公告)号：US10535454B2

公开(公告)日：2020-01-14

申请号：US15291350

申请日：2016-10-12

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Daisuke Okamoto ,  Toshimitsu Takahashi ,  Sinjiro Saigusa ,  Kohei Ishii ,  Naoki Iwata ,  Jung Hwan Hwang ,  Masashi Ohtsubo ,  Takeshi Hattori ,  Masashi Hara

IPC: H01F3/08 ,  H01F1/147 ,  H01F1/24 ,  H01F1/28 ,  H01F41/02

Abstract: Provided is a compressed powder core that can suppress a decrease in the inductance even when a high magnetic field (of greater than or equal to 40 kA/m) is applied to the compressed powder core while suppressing an iron loss and a decrease in the strength of the compressed powder core. The compressed powder core 1A has soft magnetic particles 11A and aluminum nitride layers 12A formed on the surface layers of the respective soft magnetic particles 11A. The compressed powder core 1A has a ratio of the first differential relative permeability μ′L to the second differential relative permeability μ′H satisfying a relationship of μ′L/μ′H≤6, and has a magnetic flux density of greater than or equal to 1.4 T when a magnetic field of 60 kA/m is applied. The soft magnetic particles of the compressed powder core 1A contain Si in the range of 1.0 to 3.0 mass % and have, when analyzed using XRD, a peak area ratio Sal/Sfe of greater than or equal to 4%, the peak area ratio Sal/Sfe being the ratio of the area Sal of a peak waveform derived from AlN to the area Sfe of a peak waveform derived from Fe.

公开(公告)号：US20190221340A1

公开(公告)日：2019-07-18

申请号：US16244518

申请日：2019-01-10

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Naoki IWATA ,  Shinjiro Saigusa ,  Masafumi Suzuki ,  Masaaki Nishiyama ,  Jung Hwan Hwang ,  Masashi Ohtsubo

IPC: H01F1/147 ,  H01F1/153 ,  H01F41/02 ,  B22F3/02

CPC classification number: H01F1/1475 ,  B22F3/02 ,  B22F2003/023 ,  H01F1/15366 ,  H01F41/02

Abstract: A method of manufacturing a pressed powder magnetic core disclosed herein may include: mixing soft magnetic metal particles, low-melting-point glass particles and lubricant and heating a mixture of the soft magnetic metal particles, the low-melting-point glass particles and the lubricant at a temperature that is higher than a melting point of the lubricant and is lower than a softening point of the low-melting-point glass particles so as to obtain powder of coated metal particles in which surfaces of the soft magnetic metal particles are coated by the lubricant and the low-melting-point glass particles are distributed in coating layers of the lubricant; filling a mold with the powder; press-molding the powder in the mold; and annealing the press-molded powder. In the pressed powder magnetic core, an amount of the low-melting-point glass particles may be 0.1 wt % to 5.0 wt % relative to an amount of the soft magnetic metal particles.