Magnetic field sensitive member, method of manufacturing the same and use

Abstract

To provide an enhanced form or an alternate form with respect to the prior arts.SOLUTION: The present invention relates to a magnetic field sensitive member, and the magnetic field sensitive member includes particles of a soft magnetic material. Thus, a magnetic field sensitive member of which the coercive force is especially small, of which the saturation magnetic flux density is especially high and which is geometrically soft as further as possible can be realized. A structure of the magnetic field sensitive member reduces effective permeability, thereby advantageously improving a saturation magnetic field strength. Thus, satisfactory heat stability of the magnetic field sensitive member is provided as a whole. Further, the present invention also relates to a method of manufacturing a magnetic field sensitive member and use of a magnetic field sensitive member.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a magnetic field sensitive component, a method for producing the same and its use. In particular, the present invention relates to a magnetic field sensitive component comprising particles of soft magnetic material, a method for producing a magnetic field sensitive component using particles of soft magnetic material and the use of such a magnetic field sensitive component. [Background technology]

[0002] A magnetic field sensitive component can be characterized by its magnetic permeability, saturation magnetic flux density, saturation magnetic field strength, coercivity and / or remanence.

[0003] The soft magnetic field sensitive member has a relatively high saturation magnetic flux density and a relatively low coercive force compared to the hard magnetic component, and also has a higher magnetic permeability compared to the hard magnetic component.

[0004] In some applications, especially those where a relatively high saturation magnetic field strength is advantageous, soft magnetic field sensitive members with reduced effective magnetic permeability are particularly advantageous.

[0005] This type of application is known, inter alia, from the use of magnetically sensitive components having air gaps and / or having material properties modified by annealing, which not only increase the saturation field strength of the magnetically sensitive component but also reduce the permeability and flatten and linearize the hysteresis loop, without necessarily affecting the remanence and / or coercivity.

[0006] Due to the material requirements of soft magnetic field sensitive components, especially those with a relatively high saturation magnetic flux density, they are made by winding very flat strips, which creates geometrical boundary conditions for this type of magnetic field sensitive component, since winding can only produce certain shapes.

[0007] At most, the air gap can be introduced by mechanically reworking the magnetic field sensitive member after winding the component. Summary of the Invention [Problem to be solved by the invention]

[0008] The problem on which the present invention is based is to provide an improvement or alternative to the prior art. [Means for solving the problem]

[0009] According to a first aspect of the present invention, the problem is solved by a magnetic field sensitive component comprising particles of soft magnetic material.

[0010] In this regard, the following terms are explained.

[0011] First, it is expressly mentioned that within the scope of this patent application, indefinite articles and numerical indications such as "one", "two", etc. are generally to be understood as "minimum" indications, i.e. as "at least one", "at least two", etc., unless it is clear from the respective context or obvious to a person skilled in the art or technically necessary that they can only mean "exactly one", "exactly two", etc.

[0012] Within the scope of this patent application, the expression "in particular" is always to be understood as introducing optional and preferred features, and should not be understood in the sense of "and" and "i.e."

[0013] By "magnetic field sensitive component" is understood a component, in particular a ferromagnetic component, which reacts to a magnetic field by changing at least one state variable of the component. From the magnetic field sensitive component, in particular together with electrical conductors, inductors can be produced which can be used for electrical and / or electronic applications.

[0014] Preferably, a magnetic field sensitive component is understood to be a component made of soft magnetic material.

[0015] By "soft magnetic material" is understood a material that can be easily magnetized in a magnetic field. Preferably, the soft magnetic material has a coercivity of less than 1,000 A / m.

[0016] "Coercive force" is understood to be the strength of the magnetic field required to completely demagnetize a magnetic field sensitive member that has previously been charged to saturation magnetic flux density.

[0017] Preferably, the soft magnetic material, in particular the amorphous soft magnetic material, comprises an alloy containing iron, nickel and / or cobalt.

[0018] By "particles" is understood an object that is small relative to the magnetic field sensitive element. Preferably, particles are understood to be objects that extend in each spatial direction in the range between 3 μm and 200 μm.

[0019] Here, a magnetic field sensitive component is proposed which comprises particles of soft magnetic material.

[0020] At this time, the magnetic field sensitive member is initially formed using particles preferably made of a soft magnetic material.

[0021] For processing the particles of soft magnetic material into a magnetic field sensitive component, preferably powder metallurgy processes, in particular sintering of the magnetic field sensitive component made of particles of soft magnetic material, are conceivable.

[0022] Alternatively, it is conceivable that the magnetic field-sensitive component may have a matrix material in addition to particles of soft magnetic material. Here, it is conceivable, inter alia, to dissolve the particles in the matrix material and then harden the matrix material to form a solid magnetic field-sensitive component. In particular, a matrix material based on a base component and a hardener can be used.

[0023] It should be noted that all other molding methods are also suitable for producing the magnetic field sensitive components described herein.

[0024] By initially molding the magnetic field sensitive component using particles of soft magnetic material, it is advantageously possible to achieve almost any shape possible for the magnetic field sensitive component, thereby making it possible to accommodate the special boundary conditions of a specified application.

[0025] Furthermore, since magnetic field sensitive components with air gaps can be produced in this manner without the need for subsequent machining of the magnetic field sensitive component, the production of magnetic field sensitive components with reduced effective permeability can be greatly simplified.

[0026] According to a particularly suitable embodiment, it is conceivable to realize a magnetic component having pores between the individual particles by sintering the particles or by mixing the particles with a solvent, and the pores can then be filled with a surrounding medium or solvent. In this case, the solvent preferably comprises a matrix material. The pores have the effect of changing the magnetic flux between the individual particles, so that the effective magnetic permeability of the magnetic field-sensitive component is lower than that of a magnetic field-sensitive component made by winding a soft magnetic material.

[0027] In particular, in applications where the thermal stability of the magnetic field-sensitive component plays a role in determining the size, the saturation magnetic flux density, saturation magnetic field strength, and / or coercive force are sizing factors. The higher the saturation magnetic field strength and / or the lower the coercive force and / or the higher the saturation magnetic flux density of the magnetic field-sensitive component, the smaller the magnetic field-sensitive component can be in order to maintain thermal stability.

[0028] Here, by selecting the material of the particles, a magnetic field sensitive component is proposed that has a particularly low coercive force and a particularly high saturation magnetic flux density, and the structure of this magnetic field sensitive component reduces the effective magnetic permeability, thereby advantageously increasing the saturation magnetic field strength, in other words, a magnetic field sensitive component with advantageous magnetic shear can be realized.

[0029] Furthermore, advantageously, the magnetic field sensitive components proposed herein result in flexible shaping of the magnetic field sensitive components, which is independent of the boundary conditions of the ease of rolling of the starting material, allowing the shape of the magnetic field sensitive components to be adapted to the boundary conditions of the application.

[0030] Preferably, the magnetic field sensitive component contains particles of soft magnetic material in a proportion of 10% by weight or more, more preferably 20% by weight or more, particularly preferably 30% by weight or more.

[0031] Preferably, the magnetic field-sensitive component contains 40% by weight or more, preferably 50% by weight or more, and particularly preferably 60% by weight or more of soft magnetic material particles. Even more preferably, the magnetic field-sensitive component contains 70% by weight or more, preferably 80% by weight or more, and particularly preferably 90% by weight or more of soft magnetic material particles. Even more preferably, the magnetic field-sensitive component contains 95% by weight or more, preferably 97.5% by weight or more, and particularly preferably 99% by weight or more of soft magnetic material particles.

[0032] It is expressly noted that the above values ​​for the mass fraction of particles of soft magnetic material should not be understood as strict limits, but rather may be exceeded or exceeded on an engineering scale without departing from the described aspects of the invention. In short, the above values ​​provide a guide for the proposed magnitude of the mass fraction.

[0033] Particularly preferably, the magnetic field sensitive member has a coercive force of 10 A / m or less, more preferably a coercive force of 5 A / m or less, and particularly preferably a coercive force of 3 A / m or less.

[0034] Preferably, the magnetic field-sensitive component has a coercive force of 2 A / m or less, more preferably 1.5 A / m or less, and particularly preferably 1 A / m or less, and even more preferably 0.5 A / m or less, more preferably 0.1 A / m or less, and particularly preferably 0.05 A / m or less.

[0035] The above values ​​for the coercive force apply in a magnetic field oscillating at 50 Hz.

[0036] The low coercivity of the magnetic field sensitive component reduces dissipation within the magnetic field sensitive component, thereby further enhancing thermal stability, especially when applications are designated with magnetic field strengths that change polarity.

[0037] It is expressly noted that the above values ​​for the coercivity of the magnetic field sensitive component should not be understood as strict limits, but rather may be exceeded or exceeded on an engineering scale without departing from the described aspects of the invention. In short, the above values ​​provide a guide for the magnitude of the coercivity of the magnetic field sensitive component proposed herein.

[0038] Particularly expediently, the magnetic field-sensitive component has a residual magnetic field of less than 0.1 T, preferably less than 0.05 T, particularly preferably less than 0.02 T.

[0039] This advantageously allows for an additional reduction in dissipation occurring in the magnetic field sensitive component at magnetic field strengths of varying polarity.

[0040] Preferably, the magnetic field sensitive member has a saturation magnetic flux density of 1 T or more, more preferably 1.1 T or more, particularly preferably 1.2 T or more. Preferably, the magnetic field sensitive member has a saturation magnetic flux density of 1.3 T or more.

[0041] Increasing the saturation flux density advantageously allows for smaller dimensions of the magnetic field sensitive component for standard applications without thermal instability, especially since high saturation magnetic field strengths can also be achieved with high saturation flux densities.

[0042] It is expressly noted that the above values ​​for the saturation magnetic flux density of the magnetic field sensitive component should not be understood as strict limits, but rather may be exceeded or exceeded on an engineering scale without departing from the described aspects of the invention. In short, the above values ​​provide a guide for the magnitude of the saturation magnetic flux density of the magnetic field sensitive component proposed herein.

[0043] Preferentially, the particles have extensions of less than 200 μm, in particular extensions in the range from 3 μm to 200 μm, preferably extensions in the range from 4 μm to 100 μm, particularly preferably extensions in the range from 5 μm to 50 μm.

[0044] More preferably, the particles have extensions in the range of 7 μm to 40 μm, preferably 8 μm to 30 μm, and particularly preferably 10 μm to 20 μm.

[0045] The particle size proposed here interacts with the pore size that occurs between the particles, at least during the production of the magnetic field-sensitive component by a sintering process. The pore size interacts with the effective magnetic permeability, which in turn interacts with the thermal stability. Experiments have shown that particle sizes in the above ranges result in particularly advantageous magnetic field-sensitive components and / or are particularly easy to produce by grinding from the starting material.

[0046] It is understood that the above range limits may be combined in any manner without departing from this aspect of the invention.

[0047] According to a preferred embodiment, the soft magnetic material is a metallic glass. Preferably, the soft magnetic material is a magnetic amorphous metal.

[0048] In this regard, the following terms are explained.

[0049] By "metallic glass" is understood a metal-based alloy of matter that has an amorphous rather than a crystalline structure at the atomic level, but nevertheless has metallic conductivity as a property. Preferably, metallic glasses may also contain non-metallic alloying components in addition to the metal alloying components.

[0050] The amorphous atomic arrangement, which is highly unusual in metals, advantageously enables special physical material properties. In particular, the use of metallic glasses can advantageously reduce the coercivity and / or increase the magnetic permeability of magnetic field-sensitive components. Furthermore, metallic glasses can have high electrical resistivity, which can advantageously reduce eddy current losses caused by magnetic field-sensitive components in some applications.

[0051] Particularly preferably, the soft magnetic material has a nanocrystalline structure.

[0052] In this regard, the following terms are explained.

[0053] A material with a "nanocrystalline structure" is understood to be a polycrystalline solid with a nano-microstructure, where microstructure is understood to be the type, crystalline structure, number, shape and topological arrangement of point defects, dislocations, stacking faults and grain boundaries in a crystalline material.

[0054] The nanocrystalline structure can further improve the physical properties of the magnetic field sensitive component, in particular it can increase the permeability of the soft magnetic material and / or reduce the saturation of the soft magnetic material.

[0055] Preferably, the nanocrystalline material is produced from an amorphous material, and the crystal growth starting from the amorphous material is stimulated by the influence of thermal and / or magnetic effects.

[0056] Preferably, the magnetic field-sensitive component is made of a soft magnetic material having a nanocrystalline structure with a typical grain size in the range of 5 μm to 30 μm, more preferably a nanocrystalline soft magnetic material with a typical grain size in the range of 7 μm to 20 μm, and particularly preferably a nanocrystalline soft magnetic material with a typical grain size in the range of 8 μm to 15 μm, which allows achieving particularly advantageous physical properties of the magnetic field-sensitive component, in particular with regard to magnetic permeability and / or saturation magnetic field strength.

[0057] According to a particularly preferred embodiment, the soft magnetic material has the following atomic composition:

[0058]

number

[0059] where a≦0.3, 0.6≦x≦1.5, 10≦y≦17, 5≦z≦14, 2≦α≦6, β≦7, γ≦8, M′ is at least one of the elements V, Cr, Al, and Zn, and M″ is at least one of the elements C, Ge, P, Ga, Sb, In, and Be.

[0060] Experiments have shown that the above specifications for the soft magnetic material result in particularly advantageous material properties for the magnetic field sensitive component proposed here.

[0061] In particular, the above material specifications make it possible to achieve magnetic field-sensitive components with particularly low coercive forces and / or particularly high saturation flux densities.

[0062] Preferably, the soft magnetic material specified above comprises nickel, in particular a nickel content of 4.5% by weight or more, preferably a nickel content of 5% by weight or more, particularly preferably a nickel content of 5.5% by weight or more.

[0063] According to an alternative embodiment, the magnetic field sensitive component comprises a matrix material, in particular a resin-based matrix material.

[0064] In this regard, the following terms are explained.

[0065] "Matrix material" is understood to be a material in which particles of soft magnetic material can be dissolved, and which in turn supports the magnetic field-sensitive component and allows it to maintain its physical shape.

[0066] Dissolving particles of soft magnetic material in a matrix material is understood to mean transferring or having transferred the particles, while maintaining their material composition, into a mixture that is as homogeneous as possible in the technical sense, which mixture comprises, in addition to the particles, at least one solvent for the particles, in particular at least the matrix material, where the solvent surrounds the particles and the particles are bound to the solvent by adhesive interactions.

[0067] Preferably, the solvent also comprises a filler in addition to the matrix material, which can reduce the cost of the magnetic field-sensitive component and / or improve the chemical and / or physical properties of the magnetic field-sensitive component.

[0068] The matrix material may preferably be a liquid material, in particular a liquid material with dilatant or Newtonian or pseudoplastic or Bingham plastic or Casson plastic flow behavior.

[0069] According to an alternative embodiment, the matrix material is or has been hardened after dissolution of the particles, in particular by reaction of the matrix material with a hardener.

[0070] It should be noted that magnetically sensitive components are also proposed in which particles of soft magnetic material are not in a solid state, but rather dissolved in a liquid solvent, in which case the mixture of solvent and particles is surrounded by a shaped shell.

[0071] Preferably, this allows for the realization of a magnetic field-sensitive component in which the particles do not need to be in direct contact with each other, which further reduces the effective magnetic permeability of the magnetic field-sensitive component. The mixing ratio of the particles of soft magnetic material and the solvent advantageously allows for the setting of the pore size or, in general, the distance between the individual particles of the soft magnetic material, and thereby the effective permeability of the magnetic field-sensitive component in particular.

[0072] According to a particularly expedient embodiment, the magnetic field-sensitive element is sintered.

[0073] In this regard, the following terms are explained.

[0074] "Sintering" is understood to be a process for producing or modifying a magnetic field-sensitive component, in which particles of soft magnetic material are heated but the temperature is kept below the melting temperature of the particles of soft magnetic material, so that the shape of the magnetic field-sensitive component is maintained. During sintering, a shrinkage of the dimensions of the magnetic field-sensitive component may occur, as the particles of soft magnetic material are compressed and the pore spaces are filled. Preferably, the particles of soft magnetic material are compressed before and / or during tempering. Sintering of the particles results in a material bond between the particles.

[0075] Advantageously, with a sintered magnetic field-sensitive component, it is achieved that the effective magnetic permeability matches the desired value particularly precisely.

[0076] The sintered magnetic field-sensitive component is advantageously robust and dimensionally stable even at application temperatures of 200° C. to 350° C. Overall, the sintered magnetic field-sensitive component has a particularly high thermal stability.

[0077] According to a second aspect of the present invention, the above problem is solved by a method for manufacturing a magnetic field sensitive component using particles of soft magnetic material, the method comprising the steps of: - forming a blank of a magnetic field sensitive component using particles of soft magnetic material; - tempering and / or hardening the blank to strengthen it into a magnetic field sensitive component; - demolding the magnetic field sensitive component; It is characterized by:

[0078] In this regard, the following terms are explained.

[0079] "Forming" is understood in this embodiment to mean finishing the shape of a blank for the magnetic field sensitive component.

[0080] Preferably, a blank made of particles of soft magnetic material can be finished in shape in a sintering tool, which is used as a negative mold.

[0081] However, other molding processes may preferably be considered in the molding.

[0082] In particular, it is also conceivable here to place a mixture containing a solvent, preferably a matrix material, and particles of a soft magnetic material into a negative mold, and to allow the mixture to harden in the negative mold and subsequently be demolded as a magnetic field-sensitive component.

[0083] It would also be conceivable to inject a mixture containing a solvent and particles of soft magnetic material into a sealable shell, thereby similarly producing a magnetic field-sensitive component, in which case temperature treatment and demolding to strengthen the magnetic field-sensitive component would not be necessary.

[0084] By "blank" is meant a molding material that is prepared for further processing, in particular by thermal treatment or chemical reaction. Preferably, blanks for sintering processes or blanks of magnetic field-sensitive components that are prepared for hardening by chemical reaction are considered. In other words, the molding blank is strengthened in downstream reprocessing steps.

[0085] "Tempering" is understood to mean a heat treatment of the blank or the magnetic field-sensitive component, in particular by chemical reaction of the constituents and / or by an external heat source.

[0086] "Hardening" is understood to be a chemical reaction of the blank or magnetic field-sensitive member, in particular a cross-linking reaction, which results in an increase in hardness and / or toughness and / or an increase in melting point and / or a decrease in solubility of the blank or magnetic field-sensitive member.

[0087] "De-molding" is understood to mean removing the magnetic field-sensitive element from the negative mold.

[0088] Here, a method for manufacturing a magnetic field sensitive component is proposed, in particular a method for manufacturing a magnetic field sensitive component according to a first aspect of the invention.

[0089] It is known that in the prior art, magnetic field sensitive components have been limited in terms of their shape due to boundary conditions resulting from known manufacturing processes. This drawback in the prior art can be overcome by the proposed manufacturing method, since the proposed method allows for almost any shape of magnetic field sensitive components, especially magnetic field sensitive components with air gaps.

[0090] It is clear that the advantages of the magnetic field sensitive component as described above extend to the method for manufacturing the magnetic field sensitive component.

[0091] Particularly preferably, the magnetic field sensitive component is sintered.

[0092] It is proposed here that the tempering of the plank is carried out by a sintering process.

[0093] This advantageously strengthens the particles of soft magnetic material into magnetic field sensitive components.

[0094] Expediently, the blank is compressed by applying an external force between forming and sintering and / or during sintering.

[0095] The blank and / or magnetic field sensitive member can be compressed by applying an external force before and / or during sintering.

[0096] In the experiment, 120N / mm 2 More than 300N / mm 2 A pressure in the range of 150 N / mm 2 More than 250N / mm 2 A pressure in the range of 180 N / mm 2 More than 200N / mm 2 The following ranges of pressure have proven to be particularly advantageous:

[0097] This advantageously makes it possible to achieve a particularly robust sintered magnetic field sensitive component.

[0098] It is expressly noted here that the above values ​​for the pressing force should not be construed as strict limits, but rather may be exceeded or exceeded on an engineering scale without departing from the above-described aspects of the invention. Briefly, the above values ​​provide a guide to the magnitude of the proposed range of pressing force.

[0099] Preferably, the magnetic field sensitive component is sintered at a temperature in the range of 400°C to 650°C, more preferably in the range of 450°C to 620°C, and particularly preferably in the range of 500°C to 600°C.

[0100] When the sintering temperature was specified as above, particularly advantageous magnetic field-sensitive components were realized in experiments. In particular, the specified temperature value allowed the time and / or pressure during the sintering process to be reduced.

[0101] Furthermore, it is recommended that the magnetic field-sensitive component not be sintered at a temperature exceeding 700°C, preferably not exceeding 650°C, and particularly preferably not exceeding 600°C, since this advantageously prevents changes in the crystalline structure of the soft magnetic material, in particular preventing crystallization from the amorphous state. Preferably, this allows the impedance of the magnetic field-sensitive component to be maintained, and therefore the thermal stability of the magnetic field-sensitive component to be maintained as well.

[0102] It is recommended that the magnetic field-sensitive component not be sintered below 400°C, preferably not below 550°C, and particularly preferably not below 600°C, since this requires higher pressing forces during sintering and therefore increases, inter alia, tool costs.

[0103] More preferably, the magnetic field-sensitive component is sintered for a time period ranging from 15 seconds to 1,800 seconds, more preferably from 30 seconds to 900 seconds, and particularly preferably from 45 seconds to 600 seconds.

[0104] In particular, it is proposed to sinter the magnetic field sensitive component at 600° C. for a time period ranging from 15 to 180 seconds, preferably from 20 to 60 seconds.

[0105] Preferably, it is further proposed to sinter the magnetic field sensitive component at 500° C. for a time period ranging from 500 to 1,500 seconds, preferably from 750 to 1,100 seconds.

[0106] It is expressly noted that the above values ​​for temperature and / or sintering time should not be understood as strict limits, but rather may be exceeded or exceeded on an engineering scale without departing from the described aspects of the invention. Briefly, the above values ​​provide a guide for the magnitude of the temperatures and / or sintering times suggested herein.

[0107] According to an alternative embodiment, besides the particles of soft magnetic material, a matrix material, in particular a resin-based matrix material, is also used to form the blank.

[0108] Here, it is conceivable to dissolve particles of soft magnetic material in a solvent, preferably in a matrix material, which is then shaped together with the matrix material into a blank or a magnetic field-sensitive component.

[0109] Optionally, hardening is achieved by chemical reaction of the matrix material.

[0110] It is proposed here to add a hardening agent to the matrix material and the particles of soft magnetic material, the combination of which causes a chemical reaction that strengthens the magnetic field-sensitive component.

[0111] According to an expedient embodiment, the particles of soft magnetic material are obtained from a strip material.

[0112] Metallic glasses in particular are produced by rapid solidification of particularly thin layers of material, which allows the production of strips of soft magnetic material.

[0113] In particular, it is proposed that the particles are produced by chopping and / or grinding strip material, which allows the particles of soft magnetic material to be produced particularly cost-effectively.

[0114] It is expressly pointed out that the subject matter of the second aspect may be advantageously combined with the subject matter of the above aspects of the invention, both individually and cumulatively in any combination.

[0115] According to a third aspect of the present invention, the above object is achieved by a magnetic field sensitive component manufactured by the method according to the second aspect of the present invention.

[0116] As mentioned above, it is self-evident that the advantages of the method for manufacturing a magnetic field sensitive component according to the second aspect of the present invention extend directly to a magnetic field sensitive component manufactured by the method according to the second aspect of the present invention.

[0117] It is expressly mentioned that the subject matter of the third aspect may be advantageously combined with the subject matter of the previous aspects of the invention, and may be combined individually or cumulatively in any combination.

[0118] According to a fourth aspect of the present invention, the above problem is solved by using a magnetic field sensitive component according to the first aspect of the present invention and / or according to the third aspect of the present invention in an electric choke.

[0119] In this regard, the following terms are explained.

[0120] By "choke" is understood an inductor, in particular an inductor for limiting the current in electrical wiring, in particular for spectral physical limiting, for intermediate storage of energy in the form of a magnetic field, for impedance matching and / or filtering.

[0121] As mentioned above, it is self-evident that the advantages of the magnetic field sensitive element according to the first aspect of the present invention and / or the third aspect of the present invention extend directly to the use of the magnetic field sensitive element according to the first aspect of the present invention and / or the third aspect of the present invention.

[0122] It is expressly mentioned that the subject matter of the fourth aspect may be advantageously combined with the subject matter of the above-mentioned aspects of the invention, and may be combined individually or cumulatively in any combination.

[0123] Further advantages, details and features of the invention will become apparent from the examples described below. [Brief explanation of the drawings]

[0124] [Figure 1]FIG. 2 is a schematic diagram of a magnetic field sensitive member. DETAILED DESCRIPTION OF THE INVENTION

[0125] In the following description, the same reference numerals indicate the same components or features, so that the description of components given in one figure is valid for the other figures to avoid repetition. Furthermore, individual features described in connection with one embodiment can also be used separately in other embodiments.

[0126] The magnetic field sensitive component 10 of FIG. 1 comprises particles of soft magnetic material.

[0127] According to the first embodiment, a powder metallurgy process is used to process particles of soft magnetic material into the magnetic field sensitive component 10, in particular the magnetic field sensitive component 10 made of particles of soft magnetic material is sintered under the action of pressure and temperature.

[0128] By initially shaping the magnetic field sensitive component 10 using particles of soft magnetic material, it is advantageously possible to achieve almost any shape possible for the magnetic field sensitive component 10. This allows the shaping of the magnetic field sensitive component 10 to accommodate the specific boundary conditions, particularly the geometric boundary conditions, of a given application.

[0129] The saturation magnetic flux density, saturation magnetic field strength, and / or coercive force are sizing factors, particularly in applications where the thermal stability of the magnetic field sensitive component 10 plays a role in determining the size. The higher the saturation magnetic field strength and / or the lower the coercive force and / or the higher the saturation magnetic flux density of the magnetic field sensitive component 10, the smaller the magnetic field sensitive component 10 can be in order to maintain thermal stability.

[0130] The magnetic field sensitive component 10 has a particularly low coercive force and a particularly high saturation induction due to the material selection of the particles. The pores between the particles that are generated during sintering result in a decrease in the effective magnetic permeability of the magnetic field sensitive component 10.

[0131] According to a second embodiment, the magnetic field-sensitive component 10 comprises, in addition to particles of soft magnetic material, a matrix material. Here, it is conceivable, inter alia, to dissolve the particles in the matrix material, which is then hardened to form the solid magnetic field-sensitive component 10. In particular, a matrix material based on a base component and a hardener can be used here.

[0132] According to the third embodiment, the magnetic field sensitive component 10 is manufactured by a different fabrication method.

[0133] According to the fourth embodiment, the magnetic field sensitive component 10 has an air gap (not shown). The air gap can be manufactured by the above-proposed manufacturing method of the magnetic field sensitive component 10, without the need for subsequent machining of the magnetic field sensitive component 10. This can greatly simplify the manufacturing of the magnetic field sensitive component 10 with reduced effective permeability. [Explanation of symbols]

[0134] 10 Magnetic field sensitive components

Claims

1. In the magnetic field sensitive member (10), The magnetic field sensitive member (10) is characterized in that it comprises particles of a soft magnetic material.

2. The magnetic field sensitive element (10) according to claim 1, characterized in that the particles of the soft magnetic material are present in an amount of 10% by weight or more, preferably 20% by weight or more, and particularly preferably 30% by weight or more.

3. The magnetic field sensitive element (10) according to claim 1 or 2, characterized in that it has a coercive force of 10 A / m or less, preferably a coercive force of 5 A / m or less, particularly preferably a coercive force of 3 A / m or less.

4. The magnetic field sensitive element (10) according to any one of claims 1 to 3, characterized in that it has a residual magnetic field of 0.1 T or less, preferably a residual magnetic field of 0.05 T or less, particularly preferably a residual magnetic field of 0.02 T or less.

5. The magnetic field sensitive element (10) according to any one of claims 1 to 4, characterized in that it has a saturation magnetic flux density of 1 T or more, preferably a saturation magnetic flux density of 1.1 T or more, and particularly preferably a saturation magnetic flux density of 1.2 T or more.

6. The magnetic field sensitive member (10) according to any one of claims 1 to 5, characterized in that the particles have an extension in the range of 3 μm to 200 μm, preferably in the range of 4 μm to 100 μm, particularly preferably in the range of 5 μm to 50 μm.

7. 7. The magnetic field sensitive element (10) according to any one of claims 1 to 6, characterized in that the soft magnetic material is a metallic glass.

8. The magnetic field sensitive component (10) according to claim 7, characterized in that the soft magnetic material has a nanocrystalline structure.

9. The soft magnetic material is [Equation 1] wherein a≦0.3, 0.6≦x≦1.5, 10≦y≦17, 5≦z≦14, 2≦α≦6, β≦7, γ≦8, M′ is at least one of the elements V, Cr, Al, and Zn, and M″ is at least one of the elements C, Ge, P, Ga, Sb, In, and Be; A magnetic field sensitive component (10) according to any one of claims 1 to 8, characterized in that it has an atomic composition.

10. 10. The magnetic field sensitive element (10) according to any one of claims 1 to 9, characterized in that the magnetic field sensitive element (10) comprises a matrix material, in particular a resin-based matrix material.

11. The magnetic field sensitive component (10) according to any one of claims 1 to 9, characterized in that the magnetic field sensitive component (10) is sintered.

12. A method for manufacturing a magnetic field sensitive component (10) using particles of soft magnetic material, comprising: - forming a blank of the magnetic field sensitive component (10) using said particles of said soft magnetic material; - tempering and / or hardening said blank to strengthen it into said magnetic field sensitive component (10); - demolding the magnetic field sensitive component (10); A method characterized by:

13. 13. The method of claim 12, wherein the magnetic field sensitive component (10) is sintered.

14. 14. The method according to claim 13, characterized in that the blank is pressed by applying an external force between the forming and the sintering and / or during the sintering.

15. 15. A method according to claim 13 or 14, characterized in that the magnetic field sensitive component (10) is sintered at a temperature in the range of 400°C to 650°C, preferably in the range of 450°C to 620°C, particularly preferably in the range of 500°C to 600°C.

16. 16. A method according to any one of claims 13 to 15, characterized in that the magnetic field sensitive component (10) is sintered over a time range of 15 seconds to 1,800 seconds, preferably over a time range of 30 seconds to 900 seconds, particularly preferably over a time range of 45 seconds to 600 seconds.

17. 13. The method according to claim 12, characterized in that besides the particles of the soft magnetic material, a matrix material, in particular a resin-based matrix material, is also used to form the blank.

18. 18. The method of claim 17, wherein the hardening is achieved by chemical reaction of the matrix material.

19. 19. A method according to any one of claims 12 to 18, characterized in that the particles of soft magnetic material are obtained from strip material.

20. A magnetic field sensitive component (10) manufactured by the method of any one of claims 12 to 19.

21. Use of a magnetic field sensitive element (10) according to any one of claims 1 to 12 and / or claim 20 for an electric choke.

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